User Manual - Vitomax 200
Contents
1. For further information regarding the individual steps see the page indicated Commissioning steps Inspection steps Di 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 0400 5 13 5 Opening the clean out cover and combustion chamber door 14 6 Extracting if installed and cleaning the turbulators arras nio 14 7 Cleaning the heating surface the flue outlet and flue pipers ai ie 15 8 Checking all seals gaskets and packing cords on the flue gas side 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 categorvIV et a ee 18 16 Cleaning the sight glass in the combustion chamber doors 19 17 Checking the water quality 19 18 Checking the installation room ventilation Commissioning inspection maintenance Steps commissioning inspection and cont Commissioning steps Inspection steps Maintenance steps Page Q Q 19 Checking the flue pipe for soundness Q Q2. 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 Operational checks A 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 Operating information 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 of which one is constantly used 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 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
3. Further details regarding the individual steps cont ie or Eat i 1 ef 6 o Check the function of all safety equipment in accordance with the log for steam boiler systems category IV Check the safety valves plus the tem perature and pressure limiters in accordance with manufacturer s details 18 5592 548 GB 5592 548 GB Commissioning inspection maintenance Further details regarding the individual steps cont Cleaning the sight glass in the combustion chamber doors Check the sight glass with gaskets 4 for leaks and clean Checking the water quality For standard values see page 20 Adjusting the burner By the burner manufacturer or authorised heating contractor 19 Additional information Standard values for water quality According to the EN 12953 part 10 and the VdTUV datasheet 1466 regarding the water quality for hot water boilers in heating systems the following details apply to heating sys tems operated with flow temperatures in excess of 100 C Operation with circulating water with low salt content Only use water with a low salt content Systems using mixed condensate as fill or top up water such as desali generally create water with low salt nated water permeate or condensate content if no boiler water is fed into the system for putrefaction by alka lies Operation with
4. after the supply boiler has been completely de pressurised 4 Close all valves 5592 548 GB 12 5592 548 GB Commissioning inspection maintenance Further details regarding the individual steps cont Removing the burner if required 1 Remove the fuel supply line 2 Undo screws A and remove burn er with burner plate 6 Undo screws A at cleaning door s and open the cleaning door s 13 Commissioning inspection maintenance Further details regarding the individual steps cont Opening the clean out cover and combustion chamber door 1 Remove clean out cover 6 2 Open combustion chamber door Extracting if installed and cleaning the turbulators For this use the turbulator extractor 14 Remove turbulators A without force that is part of the cleaning equipment 5592 548 GB 5592 548 GB Commissioning inspection maintenance Further details regarding the individual steps cont Cleaning the heating surface the flue outlet and flue pipe 1 Clean flues combustion cham ber and reversing chamber with the brush and remove combustion residues 2 Remove combustion residues from the flue pipe and the flue outlet Checking the thermal insulation parts 1 Checking the thermal insulation parts of combustion chamber door 2 Check the thermal insulation parts on the clean out doors the com ae bustion chamber entry the clean out cover and check inside th
5. gradually open the boiler return valve and possibly the feedwater valve as well as the boiler flow valve Only then enable the full burner load When heating the system from cold also when restarting after maintenance and cleaning work prevent all heat transfer to consu mers to clear the dew point range as quickly as possible After the operating temperature has been reached sequentially switch on the heat consumers and change over to automatic mode 11 Commissioning inspection maintenance Further details regarding the individual steps cont 17 Check the fittings for leaks priorto 18 Check the boiler door s and and during the heat up phase and clean out cover after approx 50 retighten where required hours for leaks and retighten all Retighten all fittings at max per screws missible operating pressure Tor que values under cold and hot conditions Closure Dimen Torque sions Hand hole 100 x 150 100 Nm M16 Head hole 220 x 320 200 Nm M20 Manhole 320 x 420 350 Nm M24 Shutting down the system Danger 1 Close the shut off valves in the oil Opening the boiler connections lines at the oil tank and filter or and openings whilst the boiler the gas shut off valve is under pressure can lead to a high risk of severe injury 2 Switch OFF the burner Only open the connections on the water and steam side and 3 Isolate the system from the power inspection apertures
6. serious injury m Never smoke Prevent naked flames and sparks Never switch lights or electrical appliances ON or OFF m Close the gas shut off valve m Open windows and doors m 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 A Danger Flue gas can lead to life threa tening poisoning m Shut down the heating sys tem m Ventilate the boiler room m Close all doors leading to the living space 5592 548 GB 5592 548 GB Safety instructions cont Working on the system m When using gas as fuel also close the main gas shut off valve and safeguard against unauthorised reopening m 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 m Safeguard the system against unauthorised reconnection I 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 Safety instructions 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 n
7. 20 Adjusting the burner 10 5592 548 GB 5592 548 GB Commissioning inspection maintenance Further details regarding the individual steps Starting the heating system R Check that the turbulators if 10 Details provided by the burner manufacturer and regarding accessories installed are fully pushed into the hot gas flues open the cleaning door s Check that the installation room ventilation is open Check the function of the water treatment system Fill the boiler with water and venti late it Note The water in hot water boilers must comply with EN 12953 part 10 see also Standard values for water quality on page 20 Check all fitted components such as pipework valves regulators pumps etc for function and leaks Check the system pressure Check the fuel oil level or the gas supply pressure Open the flue gas damper if installed Check that the cleaning aperture s on the flue outlet is are closed Open the gas or oil supply line shut off valves 11 12 13 14 15 16 Switch ON the main isolator the switch for the boiler drives and the burner control switch in this order observe the burner manu facturer s operating instructions Start the boiler at a low output max 30 and gradually heat up to a temperature of approx 30 K below operating temperature After the required flow tempera ture has been reached
8. EN 12953 part 10 and VdTUV 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 m Check the feed and boiler water Operating information Operational checks cont Carry out the following checks monthly m Check the function of the safety valve m Check the function of all control and safety equipment m Check all connections and closures for leaks m Check the installation room ventila tion Shutdown Have someone carry out the following checks every six months in accor dance with TRD 602 and 604 m Check the safety equipment m Check the burner m 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 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 Br
9. Operating and service VIE2MANN 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 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses Safety instructions explained A 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 m Work on electrical equipment must only be carried out by a qualified electrician m 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 m all legal instructions regarding the prevention of accidents m all legal instructions regarding environmental protection m the Code of Practice of relevant trade associations m 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
10. e reversing chamber 15 Commissioning inspection maintenance Further details regarding the individual steps cont Inserting turbulators if appropriate and closing the clean ing doors 1 Insert turbulators only in the 3rd flue as far as they will go 2 Close the clean out doors 3 Tighten the screws on the clean w out doors A evenly and diagon ally Securing the clean out cover and the combustion chamber door 1 Tighten down both clean out cov ers 8 so they seal 2 Close combustion chamber door Q and tighten it down so it seals 16 5592 548 GB 5592 548 GB Commissioning inspection maintenance Further details regarding the individual steps cont Installing the burner 1 Secure burner plate 8 with screws A to burner flange 2 For pressure jet gas burner Fit the gas supply pipe Danger gt xj ae Escaping gas leads to a risk a of explosion E Test the soundness of all A gas connections Checking the inspection ports for leaks Danger Note Boiler components that are not Replace the gaskets every time a con thermally insulated can be sub nection has been opened ject to high temperatures that Insert only gaskets approved in accor can result in burns dance with TRD 401 appendix 1 Take care with hot surfaces VdTUV or local regulations Installation instructions of the gasket manufacturer 17 Commissioning inspection maintenance
11. ief 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 Flue gas side Keep the heating surfaces dry Remove severe contamination as it binds moisture 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 5592 548 GB 5592 548 GB Shutdown cont Operating information 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 temperat
12. nt Tu i A e T Boiler type amp ES VIE Ki 1E g 8 lt 10 e E e B Q 5592 548 GB Keyword index B Burner installation 17 Burner removal 13 C Cleaning door opening 13 Clean out cover opening 14 Clean out cover securing 16 Combustion chamber door opening ae ee pad E Cei a 14 F Fill and top up water 20 Flue outlet and flue pipe cleaning 15 Flue supply line 0 13 M Maintenance information 8 Keyword index O Operational checks 5 S Safety valve checking 6 Saline water 20 Shutdown eee 6 12 Sight glass cleaning 19 Starting the heating system 11 T Thermal insulation parts checking 15 Turbulators extracting 14 Turbulators inserting 16 Ww Water quality 20 Water with a low salt content 20 27 28 Viessmann Werke GmbH amp Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Tele
13. ote 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 Index Index Operating information Operating tips cast sie dati alia a lin deeds ana aio 5 Operational checks 5 Shutdown ae riali riali iatale ada EL Alpi al 6 Maintenance information eens 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 cece eee eeeeeeeeeeeaaeeeeeeeaaneeees 22 Keyword iNdeX sicir ies RIO ante IAA AEREE 27 5592 548 GB 5592 548 GB Operating tips 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
14. phone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Subject to technical modifications 5592 548 GB Printed on environmentally friendly chlorine free bleached paper M
15. saline water Where possible use water with a low salt content that is at least free from alkaline earths softened as fill or top up water with low salt content saline El conductivity at 25 C uS cm 10 to 30 gt 30 to 100 gt 100 to 1 500 General requirements Clear with Clear with Clear without out sedi out sedi sediments ments ments pH value at 25 C 9 10 9 10 5 9 10 5 pH value according to the lt 9 5 lt 9 5 lt 9 5 Drinking Water Order Drinking Water Treat ment Order or local reg ulations Oxygen 02 mg lt 0 1 lt 0 05 lt 0 02 1 values for constant op litre eration are generally sig nificantly lower 1The oxygen concentration in the re circulated water may be up to 0 1 mg litre if suitable inorganic corrosion inhibitors are used 20 5592 548 GB 5592 548 GB Standard values for water quality cont Additional information with low salt content saline Alkaline earths Ca Mg mmol lt 0 02 lt 0 02 lt 0 02 litre Phosphate PO4 mg lt 5 lt 10 lt 15 litre Phosphate PO4 accord mg lt 7 lt 7 lt 7 ing to the Drinking Water litre Order Drinking Water Treatment Order or local regulations Phosphate PO4 for mg lt 2 5 lt 5 lt 15 Viessmann hot water boi litre lers When using oxygen bin ders Sodium sulphite mg lt 10 Na2S03 litre When using other suita ble products observe the respective guidelines is sued by
16. the relevant sup plier The VAT V datasheet 1466 advises that further oxygen binders are offered as chemicals that may have the following active ingredients m Ascorbic acid Carbohydrazide m Diethyl hydroxylamine DEHA m Hydroquinone m Tannic acid These must be used with care how ever as they can give rise to oxida tion cleavage and transformation products under boiler operating condi tions Please refer to the above guide lines for further information Methyl ethyl ketoxime Meko 21 Commissioning service reports Commissioning service reports Commissioning Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by 22 5592 548 GB 5592 548 GB Commissioning service reports Vitomax 200 HW spare parts Note When ordering spare parts please quote the serial number and the boiler type see type plate Tick the required spare parts and state the number required Obtain standard parts from your local supplier Serial number Boiler type 23 Commissioning service reports Vitomax 200 HW spare parts cont 0009 Serial number Boiler type 24 5592 548 GB Vitomax 200 HW spare parts co
17. ure 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 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 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 After the surfaces have been dried completely conserve them with a thin film of graphite or boiled oil Operating information Shutdown cont 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 VAT V 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 5592 548 GB 5592 548 GB Commissioning inspection maintenance Steps commissioning inspection and maintenance
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