Viessmann Vitomax 200-LW M64A Training manual

Operating and service
instructions
for contractors
VIESMANN
Vitomax 200-LW
Type M64A
Oil/gas low pressure hot water boilers
Rated output 8.0 to 20.0 MW
VITOMAX 200-LW
5727 529 GB 5/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
Viessmann Industrieservice, the sys-
tem installer or a qualified person
authorised by the installer.
Regulations
Observe the following when working on
this system
■ All legal instructions regarding the pre-
vention of accidents
■ All legal instructions regarding envi-
ronmental protection
■ Health and Safety at Work Act
(BetrSichV) [Germany]
■ The Code of Practice of relevant trade
associations
■ Directive 97/23/EC, as well as the rel-
evant safety regulations of the follow-
ing countries
dDVGW, TRGI, TRF and VDE,
TRD
aKG, ABV, LRG-K, LRV-K, DKBG
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS Directive
1942: LPG, part 2
If you notice oil leaks and the smell of
gas
Danger
Escaping fuel can lead to explo-
sions which may result in very
serious injuries.
■ Do not smoke. Prevent naked
flames and sparks. Do not
press any switches for lights or
electrical appliances.
■ Close the quick-acting fuel
valve and shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supply utility from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5727 529 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down system.
■ Ventilate boiler room.
Working on the system
■ Close the fuel shut-off valve and
secure against unintentional opening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as water
pipes, to discharge static loads.
Danger
Risk of burning from hot surfaces
so that
■ steam line,
■ hot water line,
■ cleaning cover and closures/
plugs at the boiler system,
■ boiler doors, as well as compo-
nents behind the doors,
can all become very hot. Observe
safety in the workplace!
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
making non-approved modifica-
tions or conversions can compro-
mise safety and may invalidate
our warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Draining hot water
!Please note
The blow-down and T.D.S. water
from boiler systems can reach
temperatures of up to and over
100 °C.
Set up the system in such a way
that this water is cooled to a tem-
perature of < 35 °C before being
channelled into the drainage sys-
tem. If necessary, consult the
local water board.
Safety instructions
Safety instructions (cont.)
5727 529 GB

4
Draining condensate from the flue
gas side
!Please note
When starting up the boiler sys-
tem, or under certain operating
conditions, condensate may build
up in the flue passes, the flue gas
collector and the downstream
flues, including the chimney.
The system user must provide
suitable installations to safely
drain such condensate.
Subject to the regulations in the country
concerned, this condensate may need to
be neutralised. In such cases, consult
the local water board or the relevant
authorities in the country of installation.
Technical safety information
Any damage to the boiler that could
lead to risks requires an immediate
boiler shutdown.
If the boiler or any vessels suffer large-
scale damage, notify the installation/
service company immediately before
carrying out any repairs.
Observe all technical safety instruc-
tions.
In the case of damage, nothing should
be altered before an inspection takes
place unless it is to prevent further dam-
age or to rescue somebody.
The boiler house must only be entered
by authorised personnel. Always keep
the boiler house clean, well lit and free
from all objects that do not belong there
and that might impair the operation. The
use of any part of the system as a drying
area is prohibited.
During operation, all required exits must
be left unlocked and free from obstruc-
tions. The operating personnel must log
all events, such as faults, adjustments,
consumption of spare parts and repairs.
A log must be maintained of all regular
readings of the control instruments.
Obvious signs at weld seams, leaking
damaged areas, severe corrosion,
unusual characteristics of operating
instruments and system components as
well as unusual noise inside the boiler
must be notified immediately. Faults and
defects on the system that cannot be
remedied by experts locally must be noti-
fied to the manufacturer. Protect all
boiler parts and control equipment from
rain, water leaks and expelled steam.
Any damage or leaks that occur should
be repaired without delay.
Apart from the relevant legal require-
ments, all practical instructions issued by
our technical personnel to the operating
personnel are applicable.
Safety instructions
Safety instructions (cont.)
5727 529 GB

5
It is impossible to clarify and describe all
potential cases of indicators and possi-
ble faults. After the system has been
operated for a certain time, the regula-
tions specified should therefore be sup-
plemented in the light of experience
gained.
Safety instructions
Technical safety information (cont.)
5727 529 GB

6
Operating instructions
Operating information
Operating tips....................................................................................................... 7
Shutdown............................................................................................................. 7
Maintenance information...................................................................................... 9
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 10
Further details regarding the individual steps....................................................... 11
Water quality requirements
Water quality requirements.................................................................................. 22
Using antifreeze in boilers.................................................................................... 24
Parts lists............................................................................................................ 26
Commissioning/service reports........................................................................ 28
Keyword index.................................................................................................... 29
Index
Index
5727 529 GB

7
The boiler and heating systems must
only be filled and operated with water
corresponding to the water quality
requirements (see chapter “Water qual-
ity requirements”). The system must be
commissioned by the system installer or
a qualified relevant expert authorised by
the installer.
Record all actual values in a test report.
These must be confirmed by the instal-
ler, commissioning expert and the sys-
tem user.
Within 4 weeks of the combustion equip-
ment being commissioned, the operator
must notify the local flue gas inspector
accordingly [check local regulations].
We recommend operating the boiler con-
stantly at a boiler water temperature of
70 °C and at the required operating pres-
sure. Even if no heat demand occurs for
a longer period of time, it is still better to
operate the boiler continuously.
In systems comprising several boilers, of
which one is constantly used as a
standby boiler, only change the opera-
tion over after longer intervals, e.g. dur-
ing the annual inspection of the total sys-
tem.
Operating instructions on pre-
serving the water and hot gas
sides
Shutdown
To prevent corrosion setting in, during idle periods when the boiler is not pressurised,
preserve the boiler surfaces on the flue gas and water sides, subject to the length of
the period during which the boiler is taken out of use. There is a differentiation
between wet preservation (during which exposure to oxygen is to be avoided) and
dry preservation (during which moisture levels are to be minimised).
Brief operational interruption
(1 to 2 days)
Water side
Recommendation: Maintain the boiler
pressure and temperature. If this is not
possible and the boiler needs to be dep-
ressurised for several days, we recom-
mend the following:
To prevent oxygen corrosion, approx.
one hour before shutting the boiler down,
add 2 to 3 times more oxygen binder
than usual to the feedwater until the
boiler is shut down.
Flue gas side
Keep the heating surfaces dry. Remove
severe contamination as it binds mois-
ture.
Operating information
Operating tips
5727 529 GB
Operation

8
Longer interruptions of operation
Water side
Wet preservation if no risk of frost*1
exists
1. Fill the boiler up to the highest possi-
ble level with treated feedwater. To
prevent oxygen corrosion, add an
oxygen binder to the boiler water (e.g.
sodium sulphite) in accordance with
the manufacturer's instructions. Test
the oxygen binder concentration at
least monthly and top up if required.
For this, ensure a good admixing with
the boiler water (thermal or mechani-
cal agitation).
2. In multi boiler systems if only some
boilers must be preserved, these can
be filled with desalinated boiler water
from the boilers that remain in use.
This will also maintain the tempera-
ture.
3. Maintaining pressure in a fully filled
boiler using nitrogen (preferably nitro-
gen 5.0) of 0.1 to 0.2 bar can prevent
corrosion.
Dry preservation if there is a risk of
frost*1 or prolonged idle period
Drain the boiler at 90 °C and then open
the water connections.
Dry the boiler thoroughly and fill with
dessicant (e.g. silica gel) in accordance
with the manufacturer's details.
Ensure that the dessicant does not come
into contact with the boiler material. Then
close the boiler again. Check in regular
intervals whether the dessicant is still
able to absorb moisture.
Flue gas side
Thoroughly clean and dry the surfaces
on the flue gas side.
Maintain the alkaline balance of the
wash water (pH 8-9, in the case of
ammonia pH 10).
After thoroughly drying the surfaces, pre-
serve them with a thin film of graphite or
varnish.
Keep the surfaces dry during the idle
periods (by adding a dessicant such as
silica gel or by air circulation via a con-
nected dryer).
Further details
For further details, see the operating
instructions for preservation on the water
and hot gas side or the VdTÜV data-
sheets (no. 1465, Oct. 1978) and the
VGB (no. R116H, 1981) [or local regula-
tions].
*1 See chapter "Using antifreeze in boilers"
Operating information
Shutdown (cont.)
5727 529 GB

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We recommend having the boiler system
serviced regularly to ensure fault-free,
efficient and environmentally responsi-
ble operation.
The boiler should be cleaned regularly to
prevent the flue gas temperature rising
with increasing contamination, which
leads to higher energy consumption.
We recommend the installation of a flue
gas thermometer. Monitoring the flue
gas temperature highlights incorrect
burner adjustment and the level of boiler
contamination.
Excessive flue gas temperatures
through contamination or altered burner
adjustment reduce efficiency. Where
necessary, clean the boiler or adjust the
burner settings.
Operating information
Maintenance information
5727 529 GB
Operation

10
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system........................................... 11
• • 2. Shutting down the system............................................. 12
•3. Removing the burner (if required)................................. 13
• • 4. Opening the boiler doors............................................... 13
• • 5. Opening the cleaning door and cleaning cover........... 14
•6. Cleaning the heating surfaces and flue gas collector. 14
••• 7. Checking all seals/gaskets and packing cords on the
flue gas side
• • 8. Cleaning the sight glass................................................ 14
••• 9. Checking thermal insulation parts and gaskets.......... 15
••• 10. Closing boiler doors....................................................... 16
••• 11. Fitting the cleaning door and cleaning cover.............. 16
• • 12. Installing the burner....................................................... 17
• • 13. Checking all water connections for leaks
• • 14. Checking the inspection ports for leaks...................... 17
•15. Checking the water chamber for deposits................... 19
••• 16. Checking the water level and system pressure
••• 17. Checking the safety and control equipment
••• 18. Checking the safety valve.............................................. 19
• • 19. Checking all water connections for leaks after the
boiler has been filled...................................................... 19
• • 20. Checking the water quality............................................ 20
• • 21. Checking the thermal insulation
••• 22. Checking the installation room ventilation
••• 23. Checking the flue pipe for tightness
• • 24. Adjusting the burner...................................................... 21
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5727 529 GB

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Commissioning the system
Details provided by the burner
manufacturer and regarding
accessories
01. Open the boiler doors and check
that the turbulators (if fitted) are fully
pushed into the hot gas flues.
02. Check that the installation room
ventilation is unobstructed.
03. Filling the heating system with water
and venting it.
!Please note
Unsuitable water quality can
damage the boiler body.
Fill and operate the heating
system with water that com-
plies with the "Water quality
guidelines" from page 22
onwards.
Note
Record the fill volume and total
hardness on page 20.
04. Check the system pressure.
05. Check all fitted components, such
as pipework, valves, controllers,
pumps etc. for function and leaks.
06. Check the fuel supply for leaks and
pressure.
07. Open the flue gas damper (if instal-
led).
08. Check that the cleaning aperture on
the flue outlet is closed.
09. Check that the dewatering line (if
installed) is correctly connected to
the condensate connection.
The condensate connection must
be sealed when not in use.
10. Open the shut-off valves in the oil
lines (at the oil tank and filter) or
open the gas shut-off valve.
11. Switch ON the main isolator, the
ON/OFF switch for the boiler drives
and burner in this order.
Burner manufacturer's oper-
ating instructions
12. Start the boiler at a low output (max.
30 %) and heat up to a temperature
of approx. 30 K below the operating
temperature.
The condensate drains must be
open and any condensate must be
correctly collected or drained.
13. After the required flow temperature
has been achieved, open the boiler
return valve, the feedwater valve if
required and then, very slowly, the
boiler flow valve.
14. Only then, enable the full burner
load.
15. While the system heats up, check
the correct function of all control and
safety equipment.
16. Observe the pressure and temper-
ature test equipment.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5727 529 GB
Service

12
17. Check the fittings for leaks and
tighten if required.
Closure Dimen-
sions
Torque
Hand-
hole
100 mm
x150 mm,
M16
100 Nm
18. After approx. 50 hours, check the
boiler doors and cleaning cover for
leaks and retighten all screws (tor-
que approx. 20 Nm).
Shutting down the system
Danger
Heating water escaping under
pressure will injure bystanders.
Only open connections and
inspection ports on the heating
water and flue gas side if the
boiler has been depressurised
and cooled.
!Please note
Draining the boiler with a suction
pump will create negative pres-
sure inside the boiler.
Only drain the boiler with a suc-
tion pump if the air vent valve is
open.
!Please note
Hot water can cause damage.
Never drain hot water into the
drainage system.
Ensure adequate cooling.
1. Shut down the burner.
2. Close the shut-off valves in the oil
lines (at the oil tank and filter) or the
gas shut-off valve.
3. Isolate the system from the power
supply.
4. Close all valves.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB

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Removing the burner (if required)
A
B
1. Remove the fuel supply line.
For pressure-jet gas burner:
Remove the gas supply pipe.
Danger
Escaping gas leads to a risk of
explosion.
Test the tightness of all gas
connections.
2. Undo screws A and remove burner
with burner plate B.
Opening the boiler doors
AB
Undo screws A on boiler doors B and
swing the doors open.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB
Service

14
Opening the cleaning door and cleaning cover
B
A
Undo nuts and remove cleaning cover
B. Open the cleaning door A.
Cleaning the heating surfaces and flue gas collector
A
B
1. Clean flues A, combustion chamber
B and reversing chamber with suit-
able cleaning equipment and remove
combustion residues.
2. Remove combustion residues from
the flue gas collector (back).
Cleaning the sight glass
Check the sight glass with gaskets A for
leaks and clean.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB

15
Checking thermal insulation parts and gaskets
A
Check thermal insulation parts A and
gaskets B.
Replace faulty parts.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB
Service

16
Closing boiler doors
1. Close boiler doors A.
2. Tighten boiler door screws evenly
(torque approx. 20 Nm).
Fitting the cleaning door and cleaning cover
B
A
1. Secure both cleaning covers B so
they seal.
2. Close cleaning door A and secure it
so it seals.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB

17
Installing the burner
ABC
1. Fit burner plate B with screws A to
burner flange C.
2. Seal annular gap (if present) between
burner head and insulation rings with
heat-resistant insulation material
(see parts list).
3. For pressure-jet gas burner:
Fit the gas supply pipe.
Danger
Escaping gas leads to a risk of
explosion.
Test the tightness of all gas
connections.
Checking the inspection ports for leaks
Danger
Boiler components that are not
thermally insulated can be sub-
ject to high temperatures that can
cause burns.
Take care with hot surfaces.
Note
Replace the gaskets every time the con-
nections and inspection ports are
opened.
Only use gaskets approved in accord-
ance with TRD 401, appendix 1, VdTÜV
[or local regulations].
Installation instructions of the
gasket manufacturer.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB
Service

18
Caution - hot surface
ACleaning apertures
BInspection port
CHandhole
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB

19
Checking the water chamber for deposits
1. Fully drain the boiler.
Danger
Heating water escaping under
pressure will injure bystand-
ers.
Only open connections and
inspection ports on the heat-
ing water and flue gas side if
the boiler has been depres-
surised and cooled.
!Please note
Draining the boiler with a suc-
tion pump will create negative
pressure inside the boiler.
Only drain the boiler with a
suction pump if the air vent
valve is open.
!Please note
Hot water can cause dam-
age.
Never drain hot water into the
drainage system.
Ensure adequate cooling.
2. Clean the water chamber (hose it out)
and remove deposits via the drain. In
case of harder deposits that cannot
be removed by hosing down, carry
out chemical cleaning using an
approved descaling agent.
3. Clean sealing surfaces of the hand-
hole cover and thread of the inspec-
tion port and replace the gaskets.
Seal the thread using hemp.
Retighten new gaskets after commis-
sioning and check again after 24
hours run.
Checking the safety valve
Manufacturer's details
Checking all water connections for leaks after the boiler has
been filled
Replace the gaskets every time a con-
nection has been opened.
1. Clean the sealing face.
2. Replace the gasket.
3. Retighten all closures after commis-
sioning.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB
Service

20
Checking the water quality
Enter the amount of top-up water and the total hardness of the boiler water into the
table.
For water quality requirements, see page 22.
Fill
wa-
ter
Top-up
water
Meter
read-
ing
Total
water
volume
Total hard-
ness
pH
val-
ue
Water treat-
ment
Date
m3 m3 m3 m3
Feed-
water
Boil-
er
wa-
ter
Boil-
er
wa-
ter
Medi-
um
Meter-
ing vol-
ume
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
The total hardness must not exceed 0.02 mol/m3 (0.11 °dH).
The pH value should be between 9.0 and 10.5.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5727 529 GB