Viessmann VITOMAX 200-HS Schulungshandbuch
Operating and service
instructions
for contractors
VIESMANN
Vitomax 200-HS
Type M73A
Oil/gas high pressure steam boiler
With or without economiser
Rated steam output 0.5 to 4.0 t/h
VITOMAX 200-HS
5607 288 GB 9/2011 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 personnel.
■ 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 (Betr-
SichV) [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 guideline
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
switch lights or electrical appli-
ances on or off.
■ 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
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5607 288 GB
3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shutdown 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 modules can be dam-
aged 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 system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
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 100 °C and
higher.
Set up the system so that this
water is cooled down to < 35 °C
prior to it entering the sewer sys-
tem. Where necessary, refer to
the local water authority.
Safety instructions
Safety instructions (cont.)
5607 288 GB
4
Draining condensate from the flue
gas side
!Please note
When the boiler system starts or
under certain conditions, conden-
sate can form in the flues, the flue
gas collector and downstream in
the flue or 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 authority or the relevant
body responsible for issuing permits.
Technical safety information
Any damage to the boiler that could
lead to risks requires an immediate
boiler shutdown.
If major damage occurs at the boiler or
vessels, notify the authorising supervi-
sory body without delay prior to carrying
out repairs.
Observe all technical safety instructions.
Steam generators require local permits
both for their installation and their oper-
ation. This permit must be available prior
to commissioning.
In the case of explosions, the user must
immediately notify the authorising super-
visory body, irrespective of whether any-
one was injured or not. Prior to the official
investigation, the status created by the
accident must not be changed apart from
what is necessary to prevent further
damage or as required for rescuing per-
sonnel.
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.
Safety instructions
Safety instructions (cont.)
5607 288 GB
5
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.
Immediately repair all damage and
leaks.
Apart from the relevant legal require-
ments, all practical instructions issued by
our technical personnel to the operating
personnel are applicable.
It is impossible to clarify and describe all
potential cases of indicators and possi-
ble faults. These guidelines should
therefore, after a reasonable time in
operation, be supplemented based on
the experiences gained up to that point.
Safety instructions
Technical safety information (cont.)
5607 288 GB
6
Operating instructions
Operating information
Storage of Vitomax boilers prior to installation as part of the system................... 7
Operating tips....................................................................................................... 7
Functions.............................................................................................................. 9
Shutting down the system.................................................................................... 17
Preservation......................................................................................................... 17
Maintenance instructions...................................................................................... 21
Service instructions
Water quality
Water quality for steam boiler systems................................................................ 22
Commissioning
Preamble.............................................................................................................. 31
Installation............................................................................................................ 31
Commissioning..................................................................................................... 33
Utilisation and operation
Monitoring............................................................................................................. 40
What to do in case of operating faults.................................................................. 41
Repairs and inspection
Repairs................................................................................................................. 42
Inspection............................................................................................................. 43
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 44
Further details regarding the individual steps....................................................... 45
Spare parts
Wearing parts, gaskets......................................................................................... 56
Appendix
Operating, maintenance and inspection tasks..................................................... 59
Keyword index.................................................................................................... 61
Index
Index
5607 288 GB
7
Please note:
This information applies to the storage prior to the system installation.
1. Vitomax boilers must be stored in
enclosed rooms, free from weather
influences under dry conditions.
2. The room temperature must not fall
below 0 °C nor exceed +50 °C.
3. In its delivered condition the boiler is
protected as standard on the water
side with dummy flanges or caps
against the ingress of foreign matter.
4. Remove the shipping packaging to
prevent the formation of condensate.
To prevent corrosion in the non-pressur-
ised state, observe the following if the
boiler is stored for longer than 4 weeks:
■ Protect the interior of the boiler against
moisture on the flue gas side and on
the DHW side with a desiccant, e.g.
silica gel.
■ The amount of desiccant depends on
the boiler volume.
■ Check the effectiveness of the desic-
cant regularly. See the details provi-
ded by the desiccant manufacturer.
■ Ensure that the desiccant does not
come into contact with the boiler mate-
rial (e.g. through suspended fixing).
■ Preserve the dry flue gas side with a
thin film of graphite or boiled oil.
■ Instead of the moisture extraction on
the flue gas side by means of a desic-
cant; a dryer with air circulation can
also be connected.
Operating tips
According to the Steam Boiler Order
[Germany], a steam boiler category IV
may only be taken into use when the rel-
evant authority has granted permission
for the installation of the system, and an
authorised expert has tested the sys-
tem.
According to the Steam Boiler Order
[Germany], steam boilers category IV
may only be operated, supervised and
maintained by a trained boilerman.
The approved inspection body may
grant, upon application, permission to
operate the boiler without supervision
subject to it being equipped in accord-
ance with the TRD 604.
The system must be commissioned by
the Viessmann Industrieservice, the sys-
tem installer or a qualified person author-
ised by the installer as well as the rele-
vant expert.
Within 4 weeks of the combustion equip-
ment being commissioned, the operator
must notify the local flue gas inspector
accordingly [check local regulations].
Operating information
Storage of Vitomax boilers prior to installation as part of the system
5607 288 GB
Operation
8
Record all actual values in a test report.
These must be confirmed by the instal-
ler, the relevant expert and the system
operator.
We would recommend that you operate
the boiler constantly at the required oper-
ating pressure. The operation of the
boiler at pressure will still be beneficial,
even if no heat demand occurs for a lon-
ger period of time.
In systems comprising several boilers, of
which one is constantly used as standby
boiler, only change the operation over
after longer intervals, e.g. during the
annual inspection of the total system.
Operating information
Operating tips (cont.)
5607 288 GB
9
Installation drawing
rZ6 2 wT wZ
wO
wU
qT
rP
wI
qQqWqPqEqW wQ wW wP
rT
4
eQ
3
5
rQrWrR rErR 1
wE
wR
qR
Illustrative example. Order-specific deviations from the standard delivery are possi-
Operating information
Functions
5607 288 GB
Operation
10
ble.
Note
Illustration of the fitting assembly refers to modulating operation. Provide two further
pressure regulators for stepped operation; the pressure transducer for the burner
control will then not be required.
1Platform
2Control panel
See separate documentation
3Integral economiser
4Connection line between econo-
miser and boiler
5Feedwater pump (module)
6Burner
qP Level electrode
(WR – water level control)
qQ Level electrode
(HW – maximum water level)
qW Level electrode
(NW – minimum water level)
qE Accessory, flanged connection
DN 100
qR Accessory, flanged connection
DN 100
qT Conductivity electrode
wP Safety valve
wQ Air vent shut-off valve
wW Steam shut-off valve
wE Feedwater shut-off valve
wR Feedwater non-return valve
wT Blow-down shut-off valve
wZ Blow-down valve
wU T.D.S. shut-off valve
wI T.D.S. valve
wO Mating flange DN 20
eQ Air vent valve for economiser
rP Water level indicator
rQ Pressure gauge
rW Maximum pressure limiter
rE Pressure transducer
rR Straight-through shut-off valve with
cap (option)
rT Dial thermometer
rZ Sampling cooler
In the following, selected components of
a steam boiler system are described. For
details, see the documentation provided
by the manufacturer of the individual
components.
Operating information
Functions (cont.)
5607 288 GB
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