Viessmann Vitomax HS M73 Training manual

Operating and service instructions
for contractors
Viesmann
Vitomax HS
Type M73
Type M75
Type M93
Type M95
High pressure steam boiler
VITOMAX HS
5837984 GB 1/2019 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations to be observed
■Pressure Equipment Directive
■Health and Safety at Work Act (BetrSichV) [Ger-
many] and extended technical rules for operational
safety (TRBS)
■Country-specific safety regulations for the installation
site
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
Safety instructions for working on the system
Commissioning
Note
Unpleasant odours may develop during commission-
ing. Ensure the installation room is well ventilated.
Before working on the system
■Close the fuel shut-off valve and secure against
unintentional reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer 'live'.
■Safeguard the system against reconnection.
Hot surfaces
Danger
Hot surfaces can lead to burns. Never touch hot
surfaces, e.g.
■Steam pipes
■Hot water pipes
■Cleaning apertures and closures on the boiler
system
■Boiler doors, as well as components behind
the doors
Observe occupational safety. Wear protective
clothing where necessary.
Electrostatic discharge
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Dismantling and disposal
When dismantling and disposing of thermal insulation
materials and gaskets on the gas side, observe the
applicable safety regulations.
The product and its components must be disposed of
according to local environmental regulations.
This applies in particular to the disposal of thermal
insulation materials and gaskets/seals on the gas side.
Safety instructions for operating the system
General
The materials included in the product pose no threat to
health during operation.
If you notice oil leaks or the smell of gas
Danger
Escaping fuel can lead to explosions which may
result in very serious injuries.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the quick-acting fuel valve and shut-off
valve.
■Ventilate the boiler house.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the system.
■Ventilate the installation site.
Draining hot water
!Please note
The blow-down and TDS water from boiler sys-
tems can reach temperatures of over 100 °C.
Before draining water into the sewage system,
allow it to cool to a temperature of < 35 °C. If
necessary, consult the local water board.
Draining condensate from the flue gas side
!Please note
When starting up the boiler system, or under
certain operating conditions, condensate may
build up in the flue passes, the flue gas collector
and the downstream flues, including the chim-
ney.
The condensate must be drained away safely by
means of suitable installation measures put in
place by the system installer.
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 body
responsible for issuing permits.
General information
Shut down the boiler immediately if there is any
safety-related damage.
Observe safety-related instructions.
After an accident, the condition of the system must not
be changed before the investigation takes place,
unless necessary in order to rescue people or prevent
further damage.
Only authorised personnel are permitted to enter the
boiler house.
Keep the boiler house clean at all times.
Do not store anything in the boiler house.
Keep exits clear.
Never use the boiler house or system components as
a drying area.
The operating personnel must log the following:
■Settings
■Readings
■Faults
■Replacement of spare parts
■Repairs
Any defects must be dealt with immediately by trained
personnel, e.g.:
■Abnormalities on weld seams
■Leaks
■Heavy corrosion
■Faulty instrument displays
■Noise in the boiler
Safety instructions
Safety instructions (cont.)
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Faults and defects that cannot be remedied locally
must be reported to the manufacturer. Protect all boiler
parts and control equipment from rain, water leaks and
expelled steam.
Safety instructions
Safety instructions (cont.)
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1. Information Symbols ................................................................................................. 7
Note ....................................................................................................... 7
Designation of boiler types .................................................................... 7
Intended use .......................................................................................... 8
Systems with operating temperatures > 110 °C ..................................... 8
2. Functions Installation overview .............................................................................. 9
Description of selected components in a steam boiler system .............. 10
■Level electrodes qP to qW ................................................................... 10
■Safety valve wP ................................................................................... 11
■Air vent shut-off valve wQ (optional) .................................................... 11
■Steam shut-off valve wW ...................................................................... 11
■Blow-down wT and wZ ......................................................................... 12
■TDS unit wU and wI ............................................................................ 12
■Water level indicator rP ...................................................................... 12
■Pressure monitoring unit rQ to rR ...................................................... 13
■Sample cooler rZ ............................................................................... 14
3. Shutdown and preserva-
tion
Shutdown ............................................................................................... 15
■Steps to shut down the boiler ............................................................. 15
■Brief interruption in operation ≤ 3 days ............................................... 15
■Interruption in operation > 3 days ....................................................... 16
Information on maintenance .................................................................. 18
■Preventing excessive flue gas temperatures ...................................... 18
4. Water quality Standard values for water quality .......................................................... 19
Raw water .............................................................................................. 19
Top-up water .......................................................................................... 19
Condensate return ................................................................................. 19
Water treatment system ......................................................................... 19
Saline boiler feedwater requirements .................................................... 20
■Organic substances ............................................................................ 20
■Conditioning ........................................................................................ 21
■Sampling of water and steam ............................................................. 23
■Sample analysis ................................................................................. 23
■Test equipment and standardised analysis procedures ...................... 23
5. Commissioning Recommendation for commissioning ..................................................... 25
Preparations for commissioning ............................................................ 25
Commissioning sequence ...................................................................... 25
■Commissioning the control panel ....................................................... 25
■Commissioning the feedwater pumps ................................................ 26
■Filling the boiler with feedwater .......................................................... 26
■Adjusting the water level control ......................................................... 26
■Checking the water level limiter .......................................................... 26
■Commissioning the burner .................................................................. 27
■Function check of the safety pressure limiter ..................................... 27
■Safety valve function check ................................................................ 27
■TDS controller adjustment .................................................................. 28
■Checking the closures on the water side ............................................ 28
Commissioning following boiler idle time ............................................... 28
Boilout .................................................................................................... 28
Report .................................................................................................... 28
Instructions ............................................................................................ 28
6. Monitoring Recommendation for monitoring ............................................................ 29
■Testing intervals .................................................................................. 29
Operator's log ........................................................................................ 29
What to do in the event of operating faults ............................................ 29
Index
Index
5837984