Viessmann VITOMAX 200-HW Schulungshandbuch

VIESMANN

Operating and service

instructions

for contractors

Vitomax 200-HW

Type M238

Oil/gas fired high pressure hot water boiler

Combustion output 4.0 to 18.2 MW

VITOMAX 200-HW

5592 548 GB 06/2007 Please keep safe.

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

designed for qualified personnel.

&Work on gas equipment must only

be carried out by a qualified gas fit-

ter.

&Work on electrical equipment must

only be carried out by a qualified

electrician.

&The system must be commissioned

by the system installer or a qualified

person authorised by the installer.

Regulations

Observe the following when working

on this system

&all legal instructions regarding the

prevention of accidents,

&all legal instructions regarding

environmental protection,

&theCodeofPracticeofrelevant

trade associations,

&all current safety regulations as

defined by DIN, EN, DVGW, TRGI,

TRF, VDE and all locally applicable

standards.

If you smell gas

Danger

Escaping gas can lead to

explosions which may result in

serious injury.

&Never smoke. Prevent naked

flames and sparks. Never

switch lights or electrical

appliances ON or OFF.

&Close the gas shut-off valve.

&Open windows and doors.

&Remove all people from the

danger zone.

&Notify your gas or electricity

supplier from outside the

building.

&Shut off the electricity supply

to the building from a safe

place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life-threa-

tening poisoning.

&Shut down the heating sys-

tem.

&Ventilate the boiler room.

&Closealldoorsleadingtothe

living space.

Safety instructions

5592 548 GB

Workingonthesystem

&When using gas as fuel, also close

the main gas shut-off valve and

safeguard against unauthorised

reopening.

&Isolate the system from the power

supply and check that it is no longer

'live', e.g. by removing a separate

fuse or by means of a main isolator.

&Safeguard the system against

unauthorised reconnection.

!Please note

Electronic modules can be

damaged by electro-static dis-

charges.

Touch earthed objects, such as

heating or water pipes, to dis-

charge static loads.

Repair work

!Please note

Repairing components which

fulfil a safety function can com-

promise the safe operation of

your heating system.

Replace faulty components

only with original Viessmann

spare parts.

Ancillary components, spare and

wearing parts

!Please note

Spare and wearing parts which

have not been tested together

with the heating system can

compromise its function. Instal-

ling non-authorised compo-

nents and non-approved

modifications/conversion can

compromise safety and may

invalidate our warranty.

For replacements, use only ori-

ginal spare parts from

Viessmann or those which are

approved by Viessmann.

Safety instructions (cont.)

Safety instructions

5592 548 GB

Operating information

Operating tips............................................................................................. 5

Operational checks..................................................................................... 5

Shutdown ................................................................................................... 6

Maintenance information............................................................................. 8

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance................................... 9

Further details regarding the individual steps .............................................. 11

Additional information

Standard values for water quality ............................................................... 20

Commissioning/service reports............................................................... 22

Keyword index .......................................................................................... 27

Index

5592 548 GB

According to the Pressure Equipment

Directive 97/23/EC, a steam boiler

category IV may only be taken into

use when the relevant authority has

granted permission for the installation

of the system, and an authorised

expert has tested the system.

The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer as well

the relevant expert.

Record all actual values in a commis-

sioning/service report. These values

must be confirmed by the expert and

the system user.

According to the Pressure Equipment

Directive 97/23/EC, hot water boilers

category IV may only be operated,

supervised and maintained by a

trained boilerman.

The relevant authority may grant,

upon application, permission to oper-

ate the boiler without permanent

supervision, subject to it being

equipped in accordance with EN

12953 part 6.

In systems comprising several boi-

lers,ofwhichoneisconstantlyused

as standby boiler, only change the

operation over in longer intervals, e.g.

during the annual inspection of the

total system.

We would recommend that you oper-

ate the boiler constantly at the

required operating pressure and tem-

perature.

The continued boiler operation is still

advantageous, even if no heat is

drawn off for a longer period of time.

Operational checks

Danger

Boiler components that are not

thermally insulated can be sub-

ject to high temperatures that

can result in burns.

Take care with hot surfaces.

Subject to the safety equipment fitted

and the details in the permit certifi-

cate, either monitor the correct boiler

operation constantly, every 24 hours

or every 72 hours.

Determine the extent of checks

required in accordance with TRD 601,

sh. 1, section 7 [or local regulations].

Test the chemical composition of the

boiler water and feedwater constantly

in accordance with EN 12953 part 10

and VdTÜV datasheet 1466 [or local

regulations].

Carry out the following checks daily

or every 72 hours, subject to boiler

version and the manufacturer's speci-

fication (see also TRD 601, sh. 1):

&Blow down the boiler (only for boi-

lers without automatic facility;

briefly open the valve two or three

times at operating pressure).

&Check the water level limiter.

&Check the feed and boiler water.

Operating tips

Operating information

5592 548 GB

Carry out the following checks

monthly:

&Check the function of the safety

valve.

&Check the function of all control and

safety equipment.

&Check all connections and closures

for leaks.

&Check the installation room ventila-

tion.

Have someone carry out the following

checks every six months (in accor-

dance with TRD 602 and 604):

&Check the safety equipment.

&Check the burner.

&Check the thermal insulation on the

hot gas side, i.e. on lids and doors.

Record the results of the daily,

monthly and biannual checks in a log.

Shutdown

To prevent corrosion setting in during idle periods, when the boiler is not pres-

surised, conserve 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 dif-

ferentiation between wet conservation (during which exposure to oxygen is to

be avoided) and dry conservation (during which moisture levels are to be mini-

mised).

Brief interruption of operation (1 to 2 days)

Water side

Recommendation: Maintain the boiler

pressure and temperature. Where that

is not possible and the boiler should

be depressurised for several days, we

would recommend the following:

To prevent oxygen corrosion, add an

oxygen binder with twice to three

times the standard dose to the feed-

water from approx. one hour before

the boiler is shut down.

Flue gas side

Keep the heating surfaces dry.

Remove severe contamination as it

binds moisture.

Operational checks (cont.)

Operating information

5592 548 GB

Longer interruptions of operation

Water side

Wet conservation, as long as there is no risk of frost

1. Fill the boiler up to the highest pos-

sible level with treated feedwater.

To prevent oxygen corrosion, add

an oxygen binder to the boiler water

(e.g. sodium sulphite) in accor-

dance with the manufacturer's

instructions. For this, ensure good

admixing with the boiler water

(thermal or mechanical agitation).

2. If, in multi-boiler systems, only

some boilers must be conserved,

these can be filled with desalinated

boiler water from the boilers that

remain in use, which will also main-

tain the temperature.

3. Maintaining pressure in a fully filled

boiler using nitrogen (preferably

nitrogen 5.0) of 0.1 to 0.2 bar can

prevent corrosion.

Dry conservation in case there is a risk of frost or in case of longer idle

periods

Drain the boiler at a temperature

between 120 and 140 °C, then open

the fittings on the water side.

Dry the boiler thoroughly and fill with

desiccant (e.g. silica gel) in accor-

dance with the manufacturer's details.

Ensure that the desiccant does not

come into contact with the boiler

material. Then close the boiler again.

Check in regular intervals whether the

desiccant is still able to absorb moist-

ure.

Flue gas side

Thoroughly clean and dry the sur-

faces on the flue gas side.

Maintain the alkaline balance of the

wash water (pH 8-9, in case of ammo-

nia pH 10).

After the surfaces have been dried

completely, conserve them with a thin

film of graphite or boiled oil.

Shutdown (cont.)

Operating information

5592 548 GB

Keep the surfaces dry during the idle

periods (by inserting desiccant (e.g.

silica gel) or by air changes from a

connected dryer).

Further details

For further details, see the operating

instructions for conservation on the

water and hot gas side or the VdTÜV

datasheets (no. 1465, Oct. 1978) and

the VGB (no. R116H, 1981) [or local

regulations].

Maintenance information

The maintenance of a high pressure

hot water boiler is specified by the

TRD [or local] regulations.

Danger

Boiler components that are not

thermally insulated can be sub-

ject to high temperatures that

can cause burns.

Take care with hot surfaces.

Shutdown (cont.)

Operating information

5592 548 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



••• 1. Starting the heating system .............................................. 11

•• 2. Shutting down the system ................................................. 12

•3. Removing the burner (if required) .................................. 13

•• 4. Opening the cleaning door(s)........................................... 13

•• 5. Opening the clean-out cover and combustion

chamber door ......................................................................... 14

•6. Extracting (if installed) and cleaning the

turbulators............................................................................... 14

•7. Cleaning the heating surface, the flue outlet and

flue pipe .................................................................................... 15

•• 8. Checking all seals/gaskets and packing cords on

thefluegasside

•• 9. Checking the thermal insulation parts.......................... 15

•• 10. Inserting turbulators (if appropriate) and closing

the cleaning doors................................................................ 16

•• 11. Securing the clean-out cover and the combustion

chamber door ......................................................................... 16

•12. Installing the burner............................................................. 17

•13. Checking all connections on the water and steam

side for leaks

•14. Checking the inspection ports for leaks ...................... 17

•15. Check the function of all safety equipment in

accordance with the log for steam boiler systems

category IV............................................................................... 18

•• 16. Cleaning the sight glass in the combustion

chamber doors....................................................................... 19

••17. Checking the water quality................................................ 19

••• 18. Checking the installation room ventilation

Steps - commissioning, inspection and maintenance

Commissioning, inspection, maintenance

5592 548 GB

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•• 19. Checking the flue pipe for soundness

••20. Adjusting the burner............................................................ 19

Steps - commissioning, inspection and . . . (cont.)

Commissioning, inspection, maintenance

5592 548 GB

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