Viessmann Vitomax HW Series Training manual

Operating and service instructions
for contractors
Viesmann
Vitomax HW
Type M70
Type M72
Type M74
Type M92
Type M94
Type M96
High pressure hot water boilers
VITOMAX HW
5784019 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
5784019

3
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.)
5784019

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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.)
5784019

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1. Information Symbols ................................................................................................. 6
Note ....................................................................................................... 6
Designation of boiler types .................................................................... 6
Intended use .......................................................................................... 7
2. Operating information Operating tips ........................................................................................ 8
■Required water properties .................................................................. 8
■Commissioning ................................................................................... 8
■Systems with operating temperatures > 110 °C .................................. 8
Shutdown and preservation ................................................................... 8
■Shutdown ............................................................................................ 8
■Brief interruption in operation ≤ 3 days ............................................... 9
■Interruption in operation > 3 days ....................................................... 9
■Treating the flue gas side ................................................................... 10
Information on maintenance .................................................................. 10
■Preventing excessive flue gas temperatures ...................................... 11
Standard values for water quality .......................................................... 11
■Flow temperatures ≤ 100 °C (VDI 2035 Part 1-2) ............................... 11
■Flow temperatures > 100 °C (VdTÜV MB 1466) ................................ 12
■Preventing water side corrosion ......................................................... 13
3. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 15
4. Wearing parts Wearing parts and gaskets .................................................................... 25
■Viessmann Industrial Service contact details ..................................... 28
5. Checklist Checklist for boiler system: Hot water boilers ........................................ 29
Recommendation regarding scope and interval of testing .................... 29
6. Appendix Steam and hot water boilers .................................................................. 30
■Inspection checklist ............................................................................ 30
Water treatment system ......................................................................... 32
■Inspection checklist ............................................................................ 32
7. Commissioning/service
reports
Records of commissioning, inspection and maintenance ...................... 34
8. Keyword index ................................................................................................................ 35
Index
Index
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6
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Note
All diagrams in this document are schematic, illustra-
tive examples.
Designation of boiler types
Capital letters indicate the respective stage of develop-
ment (version) of the boiler type.
Example M74B: Boiler type M74 version B
Information
Symbols
5784019
Information

7
The appliance is intended solely for installation and
operation in sealed unvented heating systems, with
due attention paid to the associated installation, serv-
ice and operating instructions. The appliance is inten-
ded exclusively for steam generation and for heating
water in accordance with EN 12953 and AGFW data-
sheet FW510 (VdTÜV datasheet TCh 1466).
Commercial or industrial use for a purpose other than
steam generation or the heating of water shall be
deemed inappropriate.
All other use is deemed inappropriate. Any resulting
losses are excluded from the manufacturer's liability.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Intended use presupposes that a permanent installa-
tion in conjunction with permissible components
designed for this purpose has been carried out.
Intended use also includes adherence to maintenance
and inspection intervals.
Information
Intended use
5784019
Information

8
Required water properties
The required water properties for the operation of
boiler and heating systems are specified in the "Stand-
ard values for water quality" chapter on page 11.
Commissioning
Note
When commissioning, ensure that the installation room
is well ventilated, as odour nuisance may occur.
Authorised to commission the boiler:
■Viessmann Industrial Service (for contact details see
page 28) or
■The system installer or
■An approved contractor or institution nominated by
the system installer
Required for commissioning:
■Presence of a competent expert authority
■Completion of a test report
■Required signatories:
–System installer
–Official expert authority
–System user
■The flue gas inspector (where applicable) should be
notified of the commissioning within 4 weeks.
Recommended operating conditions to prevent
damage to the boiler system
Never interrupt boiler operation, even if no heat is
being drawn off temporarily
Maintain the following at all times
■Water temperature: 70 °C
■Specified operating pressure
Multi boiler systems with a boiler on permanent
standby:
Changeovers between heating and standby should be
infrequent, for example with each annual inspection of
the overall system
Systems with operating temperatures > 110 °C
Category IV boiler systems compliant with Pressure Equipment Directive
Requirements for commissioning
■System installation has official approval.
■The system has been checked by an expert author-
ity.
■Commissioning of the control system is carried out
by a qualified organisation.
Requirements for operators
Only qualified personnel may operate, supervise and
service the system.
Requirements for operation without supervision
■Boiler system is equipped in accordance with EN
12953, Part 6.
■The system has received official approval for opera-
tion.
Checking system operation
Scope checks should be determined in accordance
with EN 12953-6
Shutdown and preservation
Shutdown
Shutdown means shutting down the system via the cir-
cuit breaker at the control panel. The duration of the
shutdown determines the preservation measures
described in this chapter.
A short-term shutdown is not recommended, as every
start-up process subjects the boiler to additional
stresses. For a period of up to 72 hours, for example
over a weekend, the boiler should be left to continue
operating.
Operating information
Operating tips
5784019
Operation

9
What preservation is for
A depressurised boiler system is at risk from idle-time
corrosion. Such corrosion can be prevented by preser-
vation.
Preservation measures are carried out in areas on the
flue gas side and on the water side of a boiler system.
The type of preservation depends on the type and
duration of the interruption in operation.
Type of preser-
vation
Effect
Wet preservation Keeps oxygen away from the boiler
system.
Dry preservation Keeps moisture in the boiler system
to a minimum.
Tab. 1
Interruption in operation
Duration Recommendation
≤ 3 days Maintain the positive pressure in the boil-
er system incl. all boiler-related equip-
ment (thermal water treatment, etc.).
> 3 days Select type of preservation.
Tab. 2
Basic rule
VdTÜV datasheet TC 1465 "Preserving the water side
of steam boilers"
Recommendation
If using preservation methods that include chemicals
other than those stated here, please consult the manu-
facturers of the chemicals.
Brief interruption in operation ≤ 3 days
Treatment for preservation of the water side
Operating
condition
Measures
The boiler is
switched off.
Add oxygen binder to the feedwater 1
hour before switching off. Dosing: 2
to 3 times the standard dose
The boiler re-
mains on.
Maintain the boiler system pressure
and temperature.
Tab. 3
Preserving agents: Ammonia or nitrogen
■A technically demanding form of preservation.
■Consult the chemical manufacturer before use.
■The operator must compile system-specific operating
instructions.
Treating the flue gas side
■Keep heating surfaces dry.
■Remove severe contamination as it binds moisture.
Interruption in operation > 3 days
Treatment for preservation of the water side
Dry preservation
Note
Restarting the system quickly is not possible.
Applications:
■Prolonged boiler idle periods
■Risk of frost
See the "Using antifreeze in boilers" chapter in
the technical guide
Application:
1. Drain hot water boilers at < 90 °C.
!Please note
Draining hot water into the sewage system
causes environmental pollution.
Therefore cool the water to < 35 °C before-
hand. If necessary, collect it in containers.
2. Open the water closures.
3. Dry the boiler system thoroughly.
4. Place desiccant (silica gel) in the boiler system in
accordance with the manufacturer's instructions.
Note
Ensure that the desiccant does not come into
direct contact with the boiler material.
5. Close the boiler system.
6. Check the effectiveness of the desiccant regularly.
Wet preservation
1. Fill the boiler system up to the highest possible
level with treated feedwater.
2. Mix oxygen binder, e.g. sodium sulphite, into the
boiler water in accordance with the manufacturer's
instructions. Mix it thoroughly with the boiler water
by means of thermal or mechanical circulation.
Oxygen binder inhibits oxygen corrosion.
Operating information
Shutdown and preservation (cont.)
5784019
Operation

10
3. Check the concentration of the oxygen binder reg-
ularly and at least every month; if necessary, add
more oxygen binder.
Preserving single boilers in a multi boiler system
The relevant boilers are kept at temperatures such that
water from the rest of the boiler system flows through
them.
Corrosion protection of a full boiler shell
A fully filled boiler shell is maintained at a pressure of
0.1 to 0.2 bar using nitrogen, specifically nitrogen 5.0.
!Please note
Frost may cause damage to the boiler.
Do not use wet preservation if there is a risk of
frost!
!Please note
Do not use layer-forming monoamines.
The use of film-forming polyamines must be
agreed with and approved by the boiler manu-
facturer.
Recommendation
Agree the steps for the preservation of the water side
with the manufacturer of the preserving agent.
Applicable regulations
Draining preserving solutions
■Conditions for draining waste water into sewer sys-
tems or the main discharge system
Use of preserving agents
■Working instructions and safety datasheets supplied
by the product manufacturer
Treating the flue gas side
1. Clean the heating surfaces on the flue gas side.
Maintain the alkaline balance of the water used for
cleaning at pH 8 to 9, or, in the case of ammonia,
pH 10.
2. Dry the heating surfaces on the flue gas side (allow
normal air flow).
3. Accelerate the ventilation process by means of a
fan heater. If necessary, open the flue gas shut-off
dampers, then close them again.
4. Spray preserving oil, e.g. graphite or varnish, onto
the flame tube walls and hot gas flues, or apply it
with a brush.
5. Keep the boiler door(s) open. Keep the boiler sur-
faces dry during idle periods.
6. Apply a desiccant (silica gel).
7. Use a dryer with a fan.
Recommendation for areas with high relative
humidity
Do not use dry preservation in areas with high relative
humidity (in the tropics, near the sea) due to the spe-
cial installation conditions that prevail in these areas.
Detailed information
■Operating instructions for preservation on the
water and hot gas side
■Datasheets of the VdTÜV, no. MB TECH
1466, dated 2014-01, and the VGB, no.
R116H, dated 2009
Information on maintenance
Correct maintenance ensures trouble-free, efficient
and environmentally responsible system operation:
■Observe the specified maintenance intervals
■Only use authorised companies:
–Viessmann Industrial Service (for contact details
see page 28)
–Other authorised contractors
Operating information
Shutdown and preservation (cont.)
5784019
Operation