User Manual - Vitomax 200
Contents
1. 55 5607 288 GB Commissioning inspection maintenance Further details regarding the individual steps Commissioning the system 5607 288 GB Details provided by the burner 9 manufacturer and regarding accessories 10 1 Check that the turbulators if instal led are fully pushed into the hot gas flues open the boiler doors Check that the boiler doors and cleaning apertures atthe back ofthe boiler are closed 11 Check that the installation room ventilation is unobstructed Check the function of the water treatment system Fill the steam boiler with treated water higher than the low water indi cator level 12 Note In accordance with the TRD 61 1 only suitable water must be used with the steam boiler For water quality guidelines see from page 22 Check all fitted components such as pipework valves controllers 13 pumps etc for function and tight ness Check the fuel pressure 14 Open the flue gas damper if instal led Open the shut off valves in the oil or gas line Switch ON the mains isolator the Switch for the equipment required for the boiler system and the burner control switch in this order observe the burner manufacturer s operating instructions Start the boiler at a low heating out put and gradually heat up to a pres sure of approx 3 bar below operat ing pressure Version with integral economi2. 16 5607 288 GB 5607 288 GB Functions cont Sampling cooler Function Operating information Operating information Removal of water samples to carry out comparative tests Shutting down the system For short interruptions lt 3 days maintain the positive pressure in the boiler system incl all boiler related drives thermal water treatment etc See also page 38 Preservation The procedures listed in the following should be considered as preservation options Further procedures with alter native chemicals should be agreed with their manufacturer The basis of these instructions is the VdT V datasheet TC1465 Preserving the water side of steam boilers Germany Values to be checked in accordance with country specific regulations and to be recorded in the boiler log m pH value m Residual hardness m p value value to determine the free alka linity m m value value to determine the entire alkalinity m Phosphate m Sulphite For longer interruptions see chapter Preservation To prevent corrosion setting in during idle periods when the boiler is not pres surised preserve 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 preservation during which exposure to oxygen is to be avoided and dry preservation during which moisture levels are to be mini mise
3. Note See also country specific regulations 12 5607 288 GB 5607 288 GB Functions cont Operating information Level monitoring water level too low NW electrode 12 Level electrode to safeguard against minimum water levels Function Operating condi tion Operating informa tion Self monitoring low water indicator comprising m Two level electrodes m The associated evaluating devices Standard water level Water level too low The minimum boiler water content is achieved again Electrode is immersed into the conducting boiler water and regis ters a low resistance Safety chain closed Burner operation ena bled Electrode is out of the boiler water and regis ters a high resistance Safety chain and burner operation con stantly interrupted Re enable safety chain Burner block lifted Safety valve Function m Physical protection of the boiler against pressures in excess of the max permissible operating pressure P1 m Valve response pressure max per missible steam boiler operating pres sure Testing checks m Valve discharge capacity gt max steam output boiler m Pressure increase max P1 plus 10 with max blow off rating m Closing pressure at P1 minus 10 96 Operating information Operating checks in regular intervals or in accordance with country specific regulations Regular checking by an authorised con tractor or test bo
4. c 2 S o o Operating information Functions cont 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 Platform Control panel See separate documentation Integral economiser Connection line between econo miser and boiler Feedwater pump module Burner Level electrode WR water level control Level electrode HW maximum water level Level electrode NW minimum water level Accessory flanged connection DN 100 Accessory flanged connection DN 100 Conductivity electrode Safety valve eee ee eo eoo 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 10 665690 98 8 8 60 8 8 8 Air vent shut off valve Steam shut off valve Feedwater shut off valve Feedwater non return valve Blow down shut off valve Blow down valve T D S shut off valve T D S valve Mating flange DN 20 Air vent valve for economiser Water level indicator Pressure gauge Maximum pressure limiter Pressure transducer Straight through shut off valve with cap option Dial thermometer Sampling cooler 5607 288 GB 5607 288 GB Functions cont Level electrodes 19 to 12 Permanently modu
5. The water column rises quickly to the correct level Open valve on the water side When the water column rises slowly check that there are no blockages 15 c m S o 9 Operating information Functions cont Pressure monitoring facility to Component Function Operating information The pressure moni toring unit is directly connected to the boiler via the fitting assembly and com prises m Pressure gauge m Pressure limiter m Pressure trans ducer 83 m Straight through shut off valve with cap Operating pressure indicator Operating checks at regular intervals or in accordance with country specific regulations Protection of the boiler against over pressure when the maximum pressure is exceeded Checking with a calibrated test pres sure gauge by an authorised contrac tor or test body Safety chain opened by opening a contact in the pressure limiter Burner stops Safety chain reset by means of the appropriate key in the control panel Reduce the boiler pressure via the air vent valve or the main steam valve by approx 1 bar below the switching point of the max pressure limiter and reset the max pressure limiter Burner starts again Load dependent reg ulation of the boiler combustion subject to the operating pres sure Enables the replace ment of faulty com ponents Exclusively by authorised contractors
6. lowing steps m Close the steam valve m Bypass the pressure regulator key Switch or test button at the control panel m Bypass the safety pressure limiter in the control panel m Set the burner to full load Commissioning The safety valve must open when the set pressure has been reached this must be equal to or lower than the maximum per missible operating pressure of the boiler The boiler pressure can rise up to 10 96 above the permissible operating pres sure before the safety valve opens If the pressure inside the boiler remains below this value then the valve functions cor rectly and the boiler can be shut down The function check must only be carried out with a trained supervisor For this ensure that the boiler can be shut down immediately and at any time via the EMERGENCY STOP TDS controller adjustment This adjustment must also be made in accordance with the manufacturer s instructions The maximum permissible boiler water conductivity is specified in the water standards e g EN 12953 part 10 or page 23 these may differ The max value must not exceed 6000 uS cm to 20 bar Agree the control value with the user Test the limit value switch function regarding the max con ductivity by reducing the set value Boilout For technical or safety reasons a boilout prior to commissioning the boiler is not required for shell boilers Plugs closures on the water side During commissioning check all plugs c
7. Areas that must be accessed for control and maintenance of the steam boiler system must offer a head clearance of at least 2 m and a clear width of at least 1 m Individual boiler fittings may restrict the clear width to 0 8 m In all other areas a passage width of 0 5 m will suffice In the case of cylindrical boiler bodies the passage width on one side can be reduced to 0 3 m Access to boiler rooms The boiler room must not include instal lations to which personnel require access who are not charged with work ing on the steam boiler system or who might prevent the boilerman from carry ing out his work Rescue routes emergency exits Rapid unhindered access to and from the steam boiler rooms must be ensured at all times through the number location type and condition of escape routes Escape routes must lead away from the danger area by a short and direct route Exits must be identified Boiler rooms should have two exits opposite each other one of which should be designed as an emergency exit Escape routes and their exit points must have a clear width of at least 0 6 m and a clear head height of at least 2 m they must always be kept free and unobstruc ted 32 The clearance between the boiler top and the ceiling above must be at least 0 75 m when access to that area is required for operation and mainte nance All inspection apertures of the steam boiler system must be freely accessible or must be able t
8. Observe that both limiters must respond Commissioning the burner Commission the burner in accordance with the operating instructions issued by the burner manufacturer A prerequisite for commissioning is that the fuel supply is enabled and that when operating with oil the quick acting oil shut off valve at the tank operates correctly In the case of gas combustion a healthy gas supply from the local gas supply util ity must be enabled and the gas line inside the boiler house must be tested and certified in writing by the system installer as suitable prior to commission ing The quick acting gas shut off valve at the entry into the building must func tion correctly Any required gas warning equipment must function correctly 36 No unauthorised personnel should be in the boiler house when the burner is being commissioned Once the combustion is steady raise the operating pressure under partial burner load or to burner stage 1 to an operating pressure of approx 3 bar After that value has been reached the burner load is enabled up to rated output Now slowly open the steam valve and close the air vent valve Clean the steam lines in accordance with the specification provided by the user blow through Ensure the adequate drainage of the steam systems Subject to a steady steam draw off the combustion can be finely adjusted Agree the operating pressure subject to the safety pressure with the system user Functio
9. lt 0 2 uS cm phos phate injection is not required alternatively the AVT method conditioning with volatile alkalization agents pH value of the feedwater gt 9 2 and pH value of the boiler water gt 8 0 can be applied In such cases the conductivity downstream of a severely acidic cation exchanger must be lt 5 uS cm Standard adjustment of the pH value through injection of Na3PO additional NaOH injection only if the pH value is 10 23 Water quality Water quality for steam boiler systems cont Feedwater conductivity gt Feedwater conduc 30 uS cm tivity lt 30 uS cm Permiss oper bar gt 0 5 to 20 gt 20 gt 0 5 ating pressure Phosphate mg l 10 to 20 10 to 20 6 to 15 POs Silicic acid mg l Pressure dependent see the diagrams on SiO pages 25 and 26 Note The addition of phosphate is recommended but is not always essential Conversion 1 mol m 5 6 dH 1 dH 0 179 mol m 1 mval kg 2 8 dH Operation with salt free boiler feedwater is also possible as an alternative to operation with saline boiler feedwater If phosphate is used higher PO concentrations are permissible subject to con sideration of all other values e g with balanced or coordinated phosphate treat ment See section Conditioning 24 5607 288 GB 5607 288 GB Water quality Water quality for steam boiler systems cont Maximum permissible direct boiler water conductivity subject to
10. Ajejes s Jojeoipur on4 Lve sBum u s A eA s ul Syeo uoneiedo s pue 8Jojs onJ 9vt uoneiedo S Aye onus en SYE uols eJnsseJd 1e pue Em eui esind ay jo uondnaeju 1 ejdsip euinjo einssaud Jr vre syeq eoA 6 uej Jie Buiooo Jo pue uoniuBi a Jamod jo JejsueJ Buluuni jeini d s ugy Jie uonsnquuoo eve jen pue are 10 sjojouoAJes nl uogesado Ionuoo Jauing eve Jedwep y jo Buiuedo ai pue Buiso o 3 UOS uui siodtuep seb eid bye fay oor jo uanennoy r dayew upao jo ssejBui BuipieB i eee s Jeje JeJioq Buuioliuoui 104 seoieg LL9 AHL 9 25e Buysa Joje Jo ioq Buuoyuoui jeonApeue uBnoiu L X pue J9jeMpoee 4 cet uonejedo ejeujeyje eu L S Sene uone noJr pue J9jeMpee Jj Vete 60 5607 288 GB Keyword index A Access to boiler rooms 32 Adjusting the water level control 35 Air vent shut off valve 14 B BlOW dOWR esit tton 14 Boiler log riot tenis 40 BOM OU bcc 5n irte tuo teer rRERS 37 C Checking the water level limiting equip menu oriee oe e o 36 Clearances for operation and mainte NANCE L E u ATTE 32 Commissioning preparations 33 Commissioning the burner 36 Commissioning the control panel 35 Commissioning the feed pumps 35 Conditioning eee 26 D Dry preservation eessss 20 E Entering the steam boiler 43 Esca
11. TRD 604 Sheet 1 Germany Stages of the work m Commissioning the chemical water treatment system in accordance with the manufacturer s operating instruc tions adjustment of the safety equip ment for monitoring the required water quality m Filling the feedwater tank with treated water and flushing the feedwater lines m Commissioning the dosing equipment for feedwater conditioning m Commissioning the control panel See page 35 34 m Testing the lighting system m Checking the availability of fire fighting and First Aid equipment m Opening the front cleaning apertures of the boiler and checking the turbula tors if part of the standard delivery and removing shipping brackets m Operational telephone system m Commissioning the feed pumps See also the commissioning instruc tions of the pump manufacturer with reference to the required operating conditions See page 35 m Filling the boiler with feedwater until the water level is visible in the sight glass See page 35 m Adjusting the water level control See page 35 m Checking the water level limiting equipment See page 36 m Burner commissioning See page 36 m Function check of the safety pressure limiter See page 36 m Safety valve function check See page 37 m TDS controller adjustment See page 37 5607 288 GB 5607 288 GB Commissioning cont m Boilout See page 37 m Plugs closures on the water side See page 37 Commissioning the control pa
12. bar gt 0 5 lt 20 gt 20 pressure Total alkaline earths mmolllitre 0 01 0 01 Ca Mg Oxygen O mg l 0 05 0 02 Bound carbon dioxide mg l 25 25 CO Iron total Fe mg l lt 0 2 lt 0 1 Copper total Cu mg l lt 0 05 lt 0 01 Oxidability Mn VII mg l 10 10 Mn Il as KMnO Oil grease mg l 1 lt 1 Organic substances See comment Table 2 Boiler water requirements Feedwater conductivity gt Feedwater conduc 30 pS cm tivity x 30 uS cm Permiss oper bar gt 0 5 to 20 gt 20 gt 0 5 ating pressure General require Colourless clear and free of undissolved substan ments ces pH value at 10 5 to 12 10 5to 11 8 10 to 11 25 C Acid capacity mmol litre 1 to 12 1to 10 0 1 to 1 0 Ks 8 2 Conductivity at uS cm lt 6000 See Fig 1 lt 1500 25 C page 25 n general organic substances are mixtures of different compounds The consti tution of such mixtures and the characteristics of their components when subjected to boiler operating conditions are hard to predict Organic substances can decom pose into carbon dioxide and other acidic products that would increase the con ductivity and result in corrosion and deposits They can also lead to the formation of foam and or coatings that must be kept to the minimum levels possible The TOC content Total Organic Carbon should also be kept to a minimum When using demineralised water with a mixed bed quality LF
13. countries DVGW TRGI TRF and VDE TRD A5 KG ABV LRG K LRV K DKBG GH SEV SUVA SVGW SVTI SWKI VKF and EKAS guideline 1942 LPG part 2 If you notice oil leaks and the smell of gas A Danger Escaping fuel can lead to explo sions which may result in very serious injuries m Do not smoke Prevent naked flames and sparks Do not switch lights or electrical appli ances on or off m Close the quick acting fuel valve and shut off valve m Open windows and doors m Remove all people from the danger zone m Notify your gas or electricity supplier from outside the build ing m Shut off the electricity supply to the building from a safe place outside the building 5607 288 GB 5607 288 GB Safety instructions cont If you smell flue gas Danger Flue gas can lead to life threat ening poisoning m Shutdown system m Ventilate boiler room Working on the system m Close the fuel shut off valve and secure against unintentional opening m 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 m Safeguard the system against unau thorised reconnection Please note a 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 m steam line m
14. from the chemical wet preserva tion physical technical methods may also be applied With the wet preserva tion the rapid boiler availability is an advantage Preservation with sodium sulphite For steam boilers add the sodium sul phite in soluble form to the completely drained steam boiler via the feedwater pump Fill the steam boiler completely Also fill any installed economisers The pH value should be between 11 and 12 Keep all valves closed during the pres ervation process The preservation sol ution should be circulated weekly Ini tially check the sulphite excess fre quently then at least once monthly When the content drops and falls below the specified standard values recircu late again and add agent as required 5607 288 GB 5607 288 GB Preservation cont Sodium sulphite excess Operating information Idle time Sodium sulphite con Additional sodium sul tent in the preserva phite tion solution mg Without Crystal Na Soyll water g m lised g m Fill water for steam boilers m Water of low salt 1 week 20 50 20 50 40 100 content m Fully desalinated 1 month 100 200 100 200 200 400 water m Condensate Longer 200 500 200 500 500 1000 than 1 month m Water with salt content e g fully softened 1 week 40 100 40 100 80 100 water or boiler water Longer 400 1000 400 1000 800 2000 than 1 week When using cold prepared water which has not been de
15. hot water line m cleaning cover and closures plugs at the boiler system m boiler doors as well as compo nents behind the doors can all become very hot Observe safety in the workplace Safety instructions Repair work Please note n 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 5 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 n 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 lt 35 C prior to it entering the sewer sys tem Where necessary refer to the local water authority Safety instructions Safety instructions cont 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
16. out by Viessmann Industrieservice the sys tem installer or a contractor authorised by them Commissioning preparations Prior to commissioning the boiler the fol lowing steps are a minimum requirement and are the installer s responsibility Commissioning Walk on platforms or boiler covers higher than 1 m above floor level and stairs with more than five steps require a handrail Access and working platforms and simi lar must not restrict the ventilation in the boiler room Emergency lighting must be provided for the escape routes and their exits The lighting installation must be maintained in good working order at all times 33 Commissioning Commissioning cont m Checking the pipework depending on version e g retainers expansion joints drainage systems emptying venting m Checking the fittings valves for correct selection and installation e g correct pressure stage and materials flow direction controls correct flange con nection m Ensuring the safe operation of all boiler house facilities equipment working and access platforms hand rails insulation heating ventilation Starting the boiler The commissioning steps are subject to the respective boiler equipment andthe type of ancillary systems The specific sequences must be deter mined individually for each specific case The following details a sample sequence for a system requiring no supervision for 72 hours according to
17. pressure Feedwater conductivity gt 30 uS cm 10000 8000 4000 2000 Direct conductivity in uS cm 1000 0 10 20 30 40 Operating pressure in bar 25 Water quality Water quality for steam boiler systems cont Maximum permissible boiler water silicic acid content SiO subject to pres sure N eo 0 10 Operating pressure in bar Conditioning Ks g2 value in mmol l Certain feedwater and boiler water char acteristics must be improved through chemical treatment This conditioning can contribute to m Support for the formation of magnetic layers or other protective oxidisation layers m A reduction of corrosion through opti misation of the pH value m Stabilising the hardness and prevent ing or reducing scaling and deposits m Achieving chemical binding of residual oxygen 26 20 30 40 This level of alkalinity is no longer permissible gt 20 bar Conventional conditioning agents may for example contain sodium and potas sium hydroxide sodium phosphate sodium sulphite ammonia and diamide Note In some countries or production pro cesses the use of some of these chem icals may be restricted 5607 288 GB 5607 288 GB Water quality Water quality for steam boiler systems cont General information regarding conditioning m Conductivity Saline This means feedwater with electrical conductivity of
18. 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 c 2 S o 9 Operating information Operating tips cont 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 5607 288 GB 5607 288 GB Operating information Functions Installation drawing Illustrative example Order specific deviations from the standard delivery are possi 9
19. tions Keep the surfaces dry during idle periods by adding a desiccant such as silica gel or by air circulation via a connected dryer A dry preservation is not recommended under special installation conditions in areas with high relative humidity in the tropics near the sea 5607 288 GB 5607 288 GB Operating information Preservation cont Further details For further details see the VdT V data sheets no 1465 Oct 1978 and the VGB no R116H 1981 or local regula tions Maintenance instructions The TRD regulation specifies the main tenance of a steam boiler system which can be carried out by the Viessmann Industrieservice or by an authorised con tractor You can contact Viessmann Industrie service on Tel 49 0 30 6602 389 Fax 49 0 30 6602 136 Email Industrieser vice viessmann com Internet www viessmann industriekes sel de Industrieservice 21 c 2 S o 9 Water quality Water quality for steam boiler systems Steam boilers In its natural state most untreated water will be unsuitable as boiler feedwater The type of boiler feedwater treatment should be matched to the raw water quality As its quality may change regu lar checks are required The water feed pipe downstream of the boiler feedwater treatment should be equipped with a suitable water meter to record the volume of top up water added to the return condensate this also pro vides an indi
20. Operating and service instructions for contractors 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 VIESMANN 5607 288 GB 9 2011 Please keep safe Safety instructions Safety instructions 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 m Work on gas installations must only be carried out by a registered gas fitter m Work on electrical equipment must only be carried out by a qualified elec trician m 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 m All legal instructions regarding the pre vention of accidents m All legal instructions regarding envi ronmental protection m Health and Safety at Work Act Betr SichV Germany m The Code of Practice of relevant trade associations m Directive 97 23 EC as well as the rel evant safety regulations of the follow ing
21. aerated add an additional 80 g without water or 160 g crystallised sodium sulphite per m Preservation with film forming amines A wet preservation with film forming amines is not permissible Note m Observe all conditions for draining waste water into sewer systems or into the main discharge system when draining the preserving solution m When using the preserving agents observe the working instructions and safety datasheets supplied by the product manufacturer m Also agree the steps for the preserva tion of the water side with the manu facturer of the preserving agent Preservation through physical tech nical measures The following preservation steps through physical technical processes are also possible such as m Maintaining a positive steam pressure in the boiler m Flow preservation of steam boilers These processes require system spe cific equipment valves pipework pumps and should be taken into con sideration when designing the system 19 c o S o 9 Operating information Preservation cont Dry preservation Note This method is used when longer idle periods are expected and to ensure pro tection against frost This method means that a quick return of the system into use is not possible Complete drying out After cooling down in the idle stage the boiler will be quickly drained at a pres sure of approx 3 bar Observe the max imum permissible temperat
22. d 17 c 2 S o 9 Operating information Preservation cont Wet preservation 1 Fill the boiler incl economiser if installed up to the highest possible level with treated feedwater To pre ventoxygen corrosion add an oxygen binder to the boiler water e g sodium sulphite in accordance with the man ufacturer s instructions For this ensure good admixing with the boiler water thermal or mechanical agita tion 2 In multi boiler systems if only some boilers must be preserved these can be filled with desalinated boiler water from the boilers that remain in use This will also maintain the tempera ture Ensure that the temperature remains constant 3 Maintaining pressure in a fully filled boiler using nitrogen preferably nitro gen 5 0 of 0 1 to 0 2 bar can prevent boiler corrosion Chemical wet preservation chemically binds the oxygen thereby protecting the boiler material against corrosion The chemical wet preservation can be imple mented when steam boilers are taken out of use for short or longer periods An adequate amount of oxygen binders corresponding putrefaction by alkalis a thorough mixing of the preservation sol ution and complete filling of the boiler or System effectively prevent corrosion due to idle periods whilst giving a great deal of security with a reasonable amount of effort and cost 18 Never use this procedure where there is a risk of frost Apart
23. der nega tive pressure that this state has been secured and a person authorised by the user has checked the implementation of this measure and has certified in writing that the area of work is safe This also applies if line sections have been isola ted for the purpose of a shutdown These required measures that depend on the individual system must be laid down in writing by the user in the form of operating instructions 5607 288 GB 5607 288 GB Inspection Entering the steam boiler Prior to entering the steam boiler pipe connections steam feed and drain facilities to the operational boiler must be securely and visibly separated by means of adequately strong dummy flanges or by removing pipe sections If on pipework with welded in or seal wel ded fittings the break is made by in line shut off facilities the intermediate con necting device that connects to the out door air must be opened These shut off devices must be locked and secured against unauthorised activation Remov ing the hand wheels from these shut off devices is not enough Warning signs Danger Persons inside the steam boiler must be affixed to the shut off devices in a clearly visible location so that the signs cannot be easily removed Removing the warning signs is only per mitted with the agreement of the works manager Steam boiler and flues must be well ventilated The entry into the steam boiler must be explicitly requested by the person
24. ders Carbon dioxide and oxygen are expel led from the feedwater through full thermal deaeration The use of oxygen binders is required if it proves impos sible in practical use e g through repeated idle periods to keep the oxy gen content of the feedwater below the permissible values This correcting chemical is admixed with the feedwa ter through the dosing facility Please note Amines that form a film are not oxygen binders Note In case of damage evaporation can lead to a concentration of the solute non vol atile boiler water constituents salts solid conditioning agents Such condi tions can lead to local alkali concentra tions that result in stress fracture corro sion As a result sodium hydroxide as alkalization agent is only permissible in slightly buffered feedwater with conduc tivity of 30 uS cm if the recommended pH range cannot be achieved with sodium phosphate alone With this method sudden fluctuations in pH value result in low sodium hydroxide content 27 Water quality Water quality for steam boiler systems cont Deviation during conditioning Actual values deviating during constant operation from those specified may be the result of the following m Inadequate treatment of the top up water m Inadequate feedwater conditioning m Advancing corrosion on some system components m Water contamination through ingress of contaminants from other systems e g condensate tank heat
25. dy Briefly cracking open by lifting the lever Do not release the lever Note the manufacturer s operating instruc tions Never remove the lead seal 13 c 2 S o 9 Operating information Functions cont Air vent shut off valve Q1 Function Venting the boiler during filling or after a new sys tem start from atmospheric pressure Operation During heat up open the valve and close it again as Soon as visible steam is expelled Operating information Air steam must be able to be routed away safely Steam shut off valve 2 Function Operation Operating information Main boiler shut Enable steam or Open slowly to prevent water hammer off towards the close boiler with steam mains damper valves Blow down and Function m Periodic removal of sludge deposits Method of operation Operating information Automatic blow down via programma The programmable switch opens via the ble valve at regular intervals control valve of the blow down valve and briefly drains off boiler water The vacuum force thus created removes the sludge from the boiler Manual activation possible at any time Manual blow down at regular intervals Push the locking lever of the blow down or in accordance with country specific valve to the side regulations Push down on the activating lever of the blow down valve for two to three seconds Please note When acting manually be mindf
26. e TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Subject to technical modifications 5607 288 GB Printed on environmentally friendly chlorine free bleached paper M
27. er 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 m 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 m The amount of desiccant depends on the boiler volume 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 m Check the effectiveness of the desic cant regularly See the details provi ded by the desiccant manufacturer m Ensure that the desiccant does not come into contact with the boiler mate rial e g through suspended fixing m Preserve the dry flue gas side with a thin film of graphite or boiled oil m 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 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
28. er quality For water quality guidelines see from page 22 Adjusting the burner By the burner manufacturer or author ised heating contractor Gasket manufacturer s installa tion instructions 55 Spare parts Wearing parts gaskets Note When ordering spare parts please quote the serial number and the boiler type see type plate Quote required number of spare parts Obtain standard parts from your local trade supplier 56 5607 288 GB 5607 288 GB Wearing parts gaskets cont Spare parts 57 Spare parts Wearing parts gaskets cont 58 5607 288 GB Appendix Operating maintenance and inspection tasks 92IAJOS uonenpe Ag S suy jejog SCE uoyennoe Ag vd 3 e SQ pue ueq vee s9 julod oJez s BneB inss id sjojeoipur ainssaid Jo eunje1eduje L LLIS Ze 1939ujouueu UOISI9981d YIM Bulysayo shay 1S9 d d T anjen yes u Bueuo xd S Jeyuuj eunsseJd JO eunjejeduie EL OL Ze S9 eAneJeduuoo yno Aeg xd S S9U9 IMS eJnssaud 10 jejsouueu L ZLEZE JeonpeJ MOJ Jejiui AO 4 LTE od BUREIMS O Jejuul 9 9 194e Y uononpei 10 ufnouui Mog xd uiua SAS JEM gee uone4edo pue yBnoiu mojg xd S Jej 03juoo A 197e M STE oBessed 1eo o pue uonejed
29. escribed in chap ter Utilisation and operation m For one hour after starting the boiler the system should be supervised by an operator only applicable to systems without temporary supervision 5607 288 GB 5607 288 GB Commissioning Commissioning cont The length of the shutdown period also determines the preservation measures described in chapter Preservation A short term shutdown is not recommen ded as every start up process subjects the boiler to additional stresses For a period of up to 24 hours or over a week end the boiler should continue in oper ation If pressure can be reduced via an additional pressure regulator or via the PLC then the boiler can be operated with reduced pressure approx 2 bar Only close the steam valve downstream of the thermal water treatment TWA outlet Note For this ensure that the thermal water treatment plant is not closed off by damper valves i e that it is not isolated from the system pressure Keep the ther mal water treatment plant and the boiler under pressure during short shutdown periods Steps to take the boiler out of use m Shut down combustion and close the fuel valve m Feed the boiler up to the controlled water level m Close the steam see information regarding the thermal water treatment plant above and feed valves m Switch off the circuit breaker 39 Utilisation and operation Monitoring Utilisation and operation The supe
30. eversing chamber with pneumatic cleaner and remove combustion res idues Remove combustion residues from the flue pipe and the flue outlet 1 Remove combustion residues via cleaning aperture or drain clean ing water via drain connector B on the flue gas collector 2 Clean heat exchanger surfaces through cleaning aperture C with pressure lances or in the case of severe contamination with feedwater In the case of wet cleaning always ensure that the exchanger surfaces are at almost identical temperatures to the feedwater to prevent thermal stresses and thermal shocks 49 Commissioning inspection maintenance Further details regarding the individual steps cont Cleaning the sight glass in the cleaning aperture H ww em O Sight glass with gaskets A should be checked for tightness and cleaned 50 5607 288 GB 5607 288 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking thermal insulation components and gaskets 51 Commissioning inspection maintenance Further details regarding the individual steps cont 8 amp c 8 9 B Check all gaskets seals A and
31. exchang ers Conditioning Warranty Please note The warranty will be void m If film forming amines are used Carry out immediate changes to rein state the correct operation For example feeding in returned condensate must not influence the feedwater quality and may have to be treated The chemical composition of the boiler water can be monitored both by dosing specific chemicals and by continuous or intermittent blow down of a part of the water volume This must be done in such a way that solute as well as suspended contaminants can be removed m f dosing agents are used that are not listed in the guidelines Sampling Sampling of water and steam from the boiler system should comply with ISO 5667 1 and the treatment and han dling of samples should comply with ISO 5667 3 Samples are taken by means of a sam pling cooler This cools down the water sample to a temperature of approx 25 C To be able to draw off a useful sample flush the sampling line for an appropriate time Sampling points Provide sampling points at representa tive positions in the system Typical sampling points are 28 The sample should be analysed imme diately after drawing as values might change as a result of prolonged settling Opaque or contaminated sample water should be filtered prior to testing For this see also the Operating instruc tions of the sample cooler m Boiler feedwater entry valve m Boiler water from a d
32. fety information on page 4 Generally the operating instructions should be observed regarding action in case of operating faults The following highlights some aspects that are the result of general operating experience If steam lines fittings valves and other operating equipment on the steam boiler system leak and these leaks cannot be remedied immediately limit their effect identify and monitor them Areas at risk should only be entered if this is requested by the authorised per sonand the safety measures required for work inside the areas at risk have been implemented System parts that have been shut down as aresult of a fault must only be started following the instructions of the person with the appropriate responsibility once the cause for the shutdown has been removed and the system components have been tested locally prior to the new start Immediately shut down the steam boiler system and inform the supervisor as quickly as possible if a boiler condition is suspected that could cause a dangerous condition This applies particularly if for example m A boiler wall shows signs of glowing red hot or of a deformation anywhere m The safety valve cannot be made to respond correctly m A correct operation of the controllers the limiters or flame monitors cannot be ensured m A fuel leak is recognised m Irregularities in the combustion opera tion or a deflagration have has occur red m Medium is leaking fr
33. gt 30 yu S cm e g downstream of softening plants Low salt content This means feedwater with electrical conductivity of 0 2 30 uS cm e g downstream of desalination plants Free of salt This means feedwater with electrical conductivity of 0 2 uS cm and a sili cic acid concentration of 0 02 mg l as well as condensate with electrical conductivity 5 uS cm e g down stream of full desalination plants with mixed bed quality m Acid capacity Ks 8 2 A higher acid capacity in feedwater would indicate an excess of bound car bon dioxide This results in a higher putrefaction by alkalis of the boiler water which leads to an increased risk of corrosion on the steam boiler and also on the steam network down stream ofthe boiler through separation of vapour volatile carbon dioxide m Adjusting the alkalinity The selection of the alkalising agent depends amongst other things on the use of the steam the steam pressure and the type of water treatment There are solid and volatile alkalising agents A balanced conditioning with phosphate or its derivatives can also be beneficial through regulating the pH value of the boiler water However organic condi tioning agents have also been in use for years If organic conditioning agents are used the amounts and processes to be used as well as the required analyses must be specified by the supplier of these chem ical products m Oxygen and carbon dioxide or oxy gen bin
34. hut down the burner 46 18 Checkthe boiler doors and cleaning covers for leaks after approx 50 hours and retighten all screws tor que approx 5 to 10 Nm Close the shut off valves in the oil lines at the tank and filter or the gas shut off valve Isolate the system from the power supply Close all valves 5607 288 GB 5607 288 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 and remove burner with burner plate A Please note a Ensure the burner and burner plate are not twisted on removal Use a suitable tool lifting apparatus Undo screws and open boiler door 47 Commissioning inspection maintenance Further details regarding the individual steps cont Opening the cleaning cover 1 Flue gas collector m Remove nuts A and cleaning cover B 2 Flame tube entry m Remove screws C and pivot open cleaning door D 3 Economiser m Remove nuts E and cover F Removing and cleaning turbulators if installed Extract turbulators A without using force using turbulator extractor and clean them 48 5607 288 GB 5607 288 GB Commissioning inspection maintenance Further details regarding the individual steps cont Cleaning heating surface and flue gas collector 1 Clean flues A flame tube B and r
35. insulat ing parts for damage and a firm seat Note Only undamaged and properly fixed materials protect against the egress of gas and overheating and consequently against material damage and injury 52 5607 288 GB 5607 288 GB Commissioning inspection maintenance Further details regarding the individual steps cont Inserting turbulators if appropriate and closing the boiler doors 1 Push turbulators A using turbulator extractor as far as they will go 2 Close boiler door C tighten screws D evenly and diagonally torque approx 20 Nm 53 Commissioning inspection maintenance Further details regarding the individual steps cont Securing the cleaning cover Fitting in reverse order as described on page 48 1 Secure burner plate A with screws to the burner flange 2 Thermally insulate the space between the flame head burner and the burner opening boiler 3 For pressure jet gas burners fit the gas supply pipe Danger Escaping gas leads to a risk of explosion Check all gas connections for tightness 5607 288 GB 5607 288 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking the inspection ports for leaks Note Replace the gaskets every time a con nection has been opened Only use gaskets approved in accord ance with TRD 401 appendix 1 or VdT V or local regulations Checking the wat
36. lating level monitoring Operating information Level electrode for continual and load dependent boiler filling Function Method of opera tion Operating information Continual water level con trol comprising m A level electrode m An associated level controller Continual control of the boiler water level via the feedwater control valve Water level below or exceeds the selec ted set value The controller issues a pulse to the feedwater control valve Boiler is filled continually and sub ject to load 11 c 2 S o 9 Operating information Functions cont Level monitoring water level too high HW electrode G Level electrode to safeguard against maximum water levels Function Operating condi tion Operating informa tion Self monitoring overfill protection comprising m A level electrode m The associated evaluating device Standard water level Water level too high Electrode is not immersed in the con ducting boiler water and registers a high resistance Feedwater pump oper ation enabled Feedwater pump runs Boiler is filled continu ally and subject to load Electrode is immersed into the boiler water and registers a low resist ance The feedwater pump is stopped via the pump relay Feedwater supply to the boiler interrupted The level drops again Feedwater pump can start subject to demand
37. losures and flanges on the water side for tightness and retighten in accordance with page 46 point 17 37 Commissioning Commissioning cont Verification Create a first commissioning report where the established and set values are recorded This report must be signed by the customer Instructions Instruct the operating personnel after the first commissioning Create a report regarding these instructions Returning the boiler into use after idle periods Generally it would be the local operators who would return the boiler into use after an idle period Starting the boiler from the external control room is not permis sible The boiler must be returned into use in the following sequence m Walk around the system to visually check its correct condition m Control panel commissioning Circuit breaker ON m Commissioning the feed m Checking the water level and the func tion of the water level indicator as well as that of the water level control m Commissioning the combustion with a closed steam valve Shutdown Shutdown means shutting down the sys tem via the circuit breaker at the control panel 38 m Controlling the output to partial load or stage 1 m Check the water level and upon reaching high water reduce the water level by means of a blow down m When the boiler pressure has risen to 3 bar below the permissible operating pressure slowly open the steam valve m Further checks as d
38. n check of the safety pressure limiter Adjust the safety pressure limiter so that before the safety valve responds it switches the boiler to fault status The setting pressure depends on the individ ual system and must be adjusted with reference to the safety and operating pressures It must lie below the response pressure of the safety valve Make the function check with a closed steam valve and by bypassing the pres sure controller key switch or test button on the control panel The burner may be operated with partial load 5607 288 GB 5607 288 GB Commissioning cont Once the safety pressure limiter has responded and a fault shutdown of the boiler has been carried out the safety pressure limiter should be reset after a pressure drop in the boiler and the boiler should be started again in standard mode After a successful function check the safety pressure limiter must be sealed to protect it against unauthorised adjust ment Safety valve function check This function check serves to check the set pressure and to verify that the safety valve is capable of blowing off the amount of steam occurring at full load Priorto implementing the function check verify that the discharge pipe has been correctly routed and secured that the dewatering line has been connected to the safety valve and that its outlet is unobstructed and that no personnel are anywhere near this area To check the safety valve take the fol
39. nd inspection It must be supplemented and specifically adapted in accordance with country specific regulations In addition any instructions for the equipment and auxiliary systems that are part of the boiler system must be incorporated into the manual supplied with the system Only technically trained and instructed personnel may operate this system Installation Requirements for structural systems are always subject to the regulations appli cable in country of installation The fol lowing represent some fundamental requirements Installation requirements Steam boiler systems must be installed so that all parts can be correctly oper ated maintained repaired and moni tored The health and safety at work of employees must be safeguarded at all times Steam boilers and ancillary equipment that form part of the steam boiler system must be installed with regard to the pre vention of shock vibrations and sound emissions as well as the protection against any other risks so that the sys tems are compliant with all technical safety aspects Commissioning Valves and fittings of the steam boiler and the steam boiler system together with any safety and pressure relief facili ties fitted to them must be installed so thatthese can safely discharge or can be safely activated and that the relief proc ess can be clearly recognised 31 Commissioning Installation cont Clearances for operation and maintenance
40. nel m Visual inspection m Switch ON the mains isolator m Setting the individual control MCBs m Checking individual functions m Checking the display indicator func tions m Checking the rotational direction of motors and actuators m Function test EMERGENCY STOP Commissioning the feed pumps m Filling the pumps with medium m Starting the pumps and checking the rotational direction m Adjusting the operating pressure ofthe pumps during the first filling of the boiler m Supply pressure must be lower than the max operating pressure m Checking whether the boil dry protec tion device is active and operates Filling the boiler with feedwater Check the following m Is the drain blow down valve closed m Is the TDS valve in its CLOSED posi tion m Is the air vent valve open m Is the steam valve closed m Are all inspection ports in the water area watertight Replace gaskets if required Commissioning m When installing an economiser are the air vent valve and drain closed m Are the water level glasses open Flush on the DHW side if required Adjusting the water level control m 1 Staged control Checking the switching points for pump ON and pump OFF via the water level indicator m 2 Constant control After the water level has reached the low water indicator adjust the zero point Fill the boiler up to the top edge of the sight glass and adjust the 100 96 point at the controller Se
41. o 3 illoe Buiiduues vct SA91 0EM Pelee S 9 9 19 EM 9joulo Ajoaulp ay uy ejds p jo uosuedwog s eee oway ETE Jeq ze gt d uim z n sajog 10 pue uBnoug moja ad 4 jueuudinbe e dsip o 9 J9 eAA ZTE Ju9A ad S sanen jgjes Vete S13 S 2 239g 3 8 3 z lt 6 9 95 2 Jed siseysuoroedsui pue S2 s duuex sjse jo d L P a eoueueojureui uonejedo Bursuduuoo syse L GYL 01 uonoedsur AjyJUOW xis 3e 4 S9 uonound 4 uono dsul jensiA S 49 10q 193e JOU pue uueejs uu s s JeJIoq WeS S e JO SIPYOOUD xipueddy uonejedo L09 CYL e6 g peBueuoun ege eunr enss AI 4063429 sJe ioq uieejs 104 SUJejs S 1 l ioq uueejs JO SJesn JO suononujsul EJeuec Wed suu s s Jo loq ueejs jo uonejedo 89 88c 09S 59 Appendix Operating maintenance and inspection tasks cont 89 88c 2095 y yms dojs K oueBjeul3 LZVVE seni pue me J SJequieuo uonsnquioo jo jueuissessv WYE S uonsnquuoo jo jueuissessv S re Josues y Buue oo uBnoiul s Jolluouu ewes vVvt xd S uone ueA ELTE S uoniub V uoneanoy S U93AS dojs oueBjeul3 We eoue 1euJnq y Burjjnd m aunq eu BuhoAld yms wuj Jeuung Ove BAIEA JUBA il ojeipeuuejul JO w s ill9eJ Buryoayo sseujui evt eui uunjei y ur osje syea uonejedo S uoneJedo Jnou z e 104 jeuunq eu jo uue nsdn eve illoe yo nus
42. o be made accessible easily Unauthorised personnel must not be given access to the steam boiler system Affix prohibition notices on all entries to the boiler room so that they are clearly legible at any time The boiler user must determine the authorised circle of per sonnel Doors in the way of escape routes must be able to be opened easily from the inside and must open in the direction of escape The boiler room must be able to be ade quately ventilated For this openings must be provided at suitable points If the combustion air is drawn from the boiler room ensure that the boiler room is never subjected to more than 0 5 mbar negative pressure 5607 288 GB 5607 288 GB Installation cont Platforms and handrails To be able to safely operate fittings valves that must be activated or tested daily or every three days provide steps lean to ladders with platform and pro truding handrails or platforms with steps fixed ladders or lean to ladders Observe German Health amp Safety at Work Act UVV Ladders and steps Flue gas routing Flue gases from steam boiler systems must be routed so that they represent no risk to personnel and third parties Lighting Adequate lighting is required for the steam boiler system in particular in the area of valves fittings controls and safety equipment as well as in access and escape routes Commissioning First commissioning Generally commissioning is carried
43. o help remedy the problem Parameters must be checked in accord ance with the following standards Acid capacity EN ISO 9963 1 Conductivity ISO 7888 Copper ISO 8288 Iron ISO 6332 Oxygen ISO 5814 pH value ISO 10523 Phosphate ISO 6878 1 Potassium ISO 9964 2 Silicic acid Sodium ISO 9964 1 TOC ISO 8245 Total hardness as ISO 6059 Ca Mg DIN 38405 21 standardised German procedure for water waste water and sludge examination anions group D photometric determination of solute silicic acid D 21 6 As an alternative the permanganate index can be checked in accordance with ISO 8467 if these values are specified 29 Water quality Water quality for steam boiler systems cont Measure the acid conductivity in the form of the hydrogen ion concentration con tinuously in the same manner as the con ductivity in hydrogen form after the sam ple has gone through a severely acidic ion exchanger with a volume of 1 5 I The exchanger is inserted into a cylinder with a diameter height ratio of 1 3 orless whereby the exchanger medium takes up at least three quarters of the cylinder volume Regenerate the ion exchanger when it has been exhausted by two thirds This can be recognised when using an exchanger with colour indicator and transparent cylinder 30 5607 288 GB 5607 288 GB Preamble This manual contains general informa tion regarding the installation commis sioning operation maintenance a
44. of spare parts and repairs A log must be maintained of all regular readings of the control instruments 5607 288 GB 5607 288 GB Safety instructions Technical safety information cont 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 Itis 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 Index Index Operating instructions Operating information Storage of Vitomax boilers prior to installation as part of the system 7 Operating tips me 7 gie ten 9 Shutting down the system nm 44 Presenation ace yt u un erem deed ted ortu eaa 17 Maintenance instructions LULU ee exer ten sasaqa sassa assqa saq waka aaa 21 Service instructions Water quality Water
45. om the pressure part of the boiler If dangerous conditions for boilers exist shut off such conditions from boilers con nected in parallel If emergency operation should be ena bled for operational reasons agree the required measures with the approved inspection body and the manufacturer 41 Repairs and inspection Repairs General requirements Repair work may only commence after the person responsible for such repairs has determined the required safety measures has inspected their imple mentation and has declared the place of work to be safe to proceed Following the completion of the work safety measures may only be removed on the instruction of the person whose responsibility they are Keep all gaskets in the closure systems clean and dry Additives such as sealing compounds or separating agents must generally not be used Exceptions require the agreement of the gasket manufacturer Only use gaskets in their original condition and in accordance with the manufacturer s installation and oper ating instructions Working on hot pressurised medium Work by personnel on systems or parts of systems that carry hot pressurised medium e g valves in steam lines is not permitted if during such work the risk of releasing the medium cannot be totally excluded 42 Work in areas at risk may only com mence if the system or parts of the sys tem have previously been reliably dep ressurised and are also not un
46. on steps b Maintenance steps Page O o Oa P OQ N a 11 12 13 14 15 16 17 18 19 20 Commissioning the system 45 Shutting down the system 46 Removing the burner if required 47 Opening the boiler doors 47 Opening the cleaning cover 48 Removing and cleaning turbulators if installed 48 Cleaning heating surface and flue gas collector 49 Cleaning the economiser heating surfaces 49 Checking all gaskets seals and packing cords on the flue gas side Cleaning the sight glass in the cleaning aperture 50 Checking thermal insulation components and gaskets 2 eee Db cedere Ri eate 51 Inserting turbulators if appropriate and closing the boil r dOOrsS ree ert inris 53 Securing the cleaning cover 54 Mounting the burner 54 Checking all connections on the water and steam side for leaks Checking the inspection ports for leaks 55 Checking the water quality 55 Checking the installation room ventilation Checking the flue pipe for tightness Adjusting the burner
47. ownpipe or a con tinuous TDS line 5607 288 GB 5607 288 GB Water quality Water quality for steam boiler systems cont m Top up water downstream of the top up water treatment system or the stor age tanks m Condensate at the condensate tank outlet if installed otherwise draw the sample off as near to the feedwater tank as possible Analysis General information Verify compliance with the values speci fied in table 1 page 22 and table 2 page 23 through analyses If the analyses are carried out in accord ance with different standards or by indi rect means calibrate such methods A clean surface with water supply and drainage facility should be made availa ble for carrying out the analyses The required equipment should also be kept in a cupboard at the workplace Note For some types of water the amount of solute matter can be estimated by means of the conductivity In addition there is a correlation between the pH value and both conductivities Viessmann offers components for water analysis to aid continual monitoring of the O and pH values as well as water hardness levels There is currently no European or international standard see for example Analysis procedure test equipment In continuous boiler operation the boiler values can be checked adequately with the test equipment In the case of severe deviations confirm the actual values through correspondingly standardised analysis procedures t
48. pe routes emergency exits 32 F Filling the boiler with feedwater 35 Flue gas routing s 33 Function check of the safety pressure MME Fo Pm 36 I Inspections oon 43 Installation drawing 9 Keyword index Installation requirements 31 InStFUCtlOns iicet 38 L Level monitoring ss 11 Lighting nes 33 P Platforms and handrails 33 Plugs closures on the water side 37 Preserving the hot gas side 20 Pressure monitoring facility 16 R Returning the boiler into use after idle Berlods eu au un ttr o saan 38 s Safety valve II uuu 13 Safety valve function check 37 Sampling cooler 17 ShutaoWHis iie toic eese 38 Starting the boiler 34 Steam shut off valve 14 T ERA uu u rine ubus asua 15 TDS controller adjustment 37 U Utilisation and operation 40 w Water level indicator 15 Wet preservation ssss 18 What to do in case of operating faults41 61 89 887 7098 62 89 882 4098 63 64 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 Shropshir
49. quality for steam boiler systems ssee 22 Commissioning Preamble tean ae uu a Su eed iion d ebat c Le iet e rein 31 Installation we OT COMMISSIONING Ne uu Rid 6a Eo ete Sie a ei 33 Utilisation and operation Menem kaq 40 What to do in case of operating faults u u u u uuu 41 Repairs and inspection I36p llS 2 2 5 dco en i ette tutte de tiefen tus ier aufer tue eto esee see Inspection Commissioning inspection maintenance Steps commissioning inspection and maintenance a 44 Further details regarding the individual steps 45 Spare parts Wearing parts gaskets LULU ener htt asas potete iE needle eska eie 56 Appendix Operating maintenance and inspection tasks see 59 Keyword index u eo ed ete ertet ad Ed E a asla 61 5607 288 GB 5607 288 GB Operating information Storage of Vitomax boilers prior to installation as part of the system 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 matt
50. rect check on the steam draw off volume It is always advisable to return as much condensate as possible to the feedwater tank The condensate may also have to be treated so it conforms to the require ments of the boiler feedwater according to table 1 These requirements plus those of the boiler water according to table 2 mean that according to the raw water condi tion and the top up water volume at the very least a suitable chemical or thermal water treatment system must be instal led and there should be a facility for add ing oxygen binders possibly alkalines and phosphates into the feedwater tank supply line The requirements are monitored by measurements made by suitable pref erably uncomplicated devices either every 24 hor 72 hor in line with national requirements subject to operating mode These test values the volume of top up water the chemical consumption and the required maintenance should be entered into a boiler log to enable the operating conditions to be checked at any time Table 1 Saline boiler feedwater requirements Permiss operating bar gt 0 5 lt 20 gt 20 pressure General requirements Colourless clear and free of undissolved sub stances pH value at 25 C gt 9 gt 9 Conductivity at25 C wS cm Only standard values applicable to boiler water 22 5607 288 GB 5607 288 GB Water quality for steam boiler systems cont Water quality Permiss operating
51. rvision intervals are subject to the user specification and the national regulations applicable in the country of installation The operating maintenance and checking tasks as listed from page 59 are suggested by the opera tor These tasks are suggested as mini mum requirements Checks are differentiated according to Per shift day week month Carried out by the operator s The period Day for systems with operation for 72 hours without supervision means every three days Every 6 months 12 months These checks should be carried out by a spe cialist contractor e g the Viessmann Industrie service or the manufacturers of the boiler sys tem combustion equipment or water treat ment All checks and their results must be recorded with traceability Boiler log This boiler log should be presented to m Result of the regular water checks car the authorised supervisory body during ried out as part of standard operation every inspection Make the following m All fault cases and special findings dur entries in the boiler log ing inspections and maintenance of m Signed confirmation by the boilerman the steam boiler system of the inspection tasks carried out m Confirmation by a trained person regarding the inspection and mainte nance work carried out at the control and limiting equipment every six months 40 5607 288 GB 5607 288 GB Utilisation and operation What to do in case of operating faults Note See technical sa
52. ser To prevent steam hammer during heat up initiate a feedwater flow through the economiser several times for example by manually acti vating the blow down valve Vent the boiler at the air vent valve during heat up until steam is expel led Then close the valve Danger Expelled medium can lead to scalding Ensure the medium is drained off safely Slowly open the steam valve after the required steam pressure has been reached otherwise there is a risk of steam hammer While the system heats up check the correct function of all control and safety equipment 45 Commissioning inspection maintenance Further details regarding the individual steps cont 15 Observe the pressure and temper ature test equipment 16 If required drain and vent the con nection lines 17 Check the plugs closures for leaks and retighten if required Retighten all plugs closures again at max permissible operating pres sure Torque values under cold and hot conditions Cover Dimensions Torque Hand 100 x 150 100 Nm hole M16 Head 220 x 320 200 Nm hole M20 Manhole 320 x 420 350 Nm M24 Shutting down the system N Danger Opening the boiler connections and openings whilst the boiler is under pressure can lead to a high risk of severe personal injury Only open the connections on the water and steam side and inspec tion apertures after the boiler has been completely depressurised 1 S
53. t the feedwater valve to CLOSED via the controller and adjust the zero point of the valve at the controller Setthe feedwater valve to OPEN via the controller and adjust the 100 point of the valve at the controller Set the limit switch at the straight through feedwater valve for pump OFF Presetthe switching points for pump ON and pump OFF at the controller whilstthe boiler starts with the steam valve closed Set feed pump switch to automatic at the control panel and check the function of the water level control m Repeat this process after burner com missioning and when the boiler has been pressurised As the boiler water heats up and consequently expands check the low and high water indicator levels again 35 Commissioning Commissioning cont m Let the water level return to the zero point by opening the blow down valve and readjust at the controller m Bring the boiler to the required water level and adjust at the controller Checking the water level limiting equipment m When the low water indicator level LWL has been reached reset the water level limiter in the control panel by resetting the boiler safety chain m Check the response of the water level limiter under operating conditions in accordance with the manufacturer s operating instructions For this take the feed system out of use and reduce the water level in the boiler to the low water level by drawing steam or by means of a blow down
54. to safely drain such condensate 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 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 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
55. ul of the lever kickback Please note When acting manually be mind ful of the lever kickback 14 5607 288 GB 5607 288 GB Functions cont T D S unit and Function m Continual checking and regulation of the salt content through temperature compensated conductivity electrode m Desalination via the TDS valve m Maintenance of specified limits by opening and closing the valve Operating information Method of operation Conductivity drops Conductivity value exceeds the selec ted set value Conductivity exceeds the highest value Water level indicator Function m Visual and direct water level indication Operating information Flow rate is reduced Valve is opened further Safety chain is opened Burner stops Method of operation Operating information Visual water level check Valve on the steam and water side shut off device OPEN When there are no personnel present Carry out operating checks at regular intervals or in accordance with country specific regulations Flushing valve shut off device CLOSED Keep valve CLOSED Close the valve on the water and steam side Open blow down valve drain and check the valve for tightness Open the valve on the water side check for discharge noise Close valve on the water side Open the valve on the steam side check for discharge noise Leave the valve on the steam side open Close the flushing valve
56. ure for drain ing into the public sewage system Where required catch the water in a col lecting tank and drain it after it has cooled down sufficiently Flush steam boilers with a high salt con tent in their boiler water gt 5 000 uS cm once more on the water side Afterwards open all man head and hand holes Preserving the hot gas side Flue gas side After the boiler has been taken out of use clean the heating surfaces on their hot gas side The normal draught ensures that the heating surfaces on the hot gas side are adequately dried Accel erate the process by means of a fan heater if required open the flue gas shut off dampers for this process and then close again It is recommended to treat the combus tion chamber and the hot gas flues with preserving oil graphite or boiled oil This can be sprayed on or applied with a brush The boiler doors remain open 20 Dry out components such as econo misers separately Position desiccants e g silica gel blue gel in shallow bowls inside the open and drying boiler or hang them inside the boiler so that any contact with the boiler material is safely prevented Then close the boiler Check the desiccants at least monthly They should be replaced as and when required Preservation with ammonia or nitro gen These methods require extensive tech nical and technological effort When using these preserving methods formu late system specific operating instruc
57. with the appropriate authority The entry must be supervised Prior to the safety meas ures being removed a person with appropriate authority must ensure that no one is left inside the above parts of the system Repairs and inspection During the entry into the steam boiler and flues electrical equipment may only be used if including its cables and leads it complies with the relevant safety reg ulations and has been provided by the user or their agents for work inside the steam boiler Lamps must only be oper ated at safety voltages of up to 42 V The same regulation applies to electrical tools These may however be operated with higher voltages of up to 380 V sub ject to their supply being routed through anisolating transformer LV and isolating transformers must be located outside the steam boiler Inspections The type and interval of inspections depends on the regulations that apply in the country of installation The following periods are suggested in the declaration of conformity External inspec tion of the system annually Internal inspection of the system Repeated pres sure test every three years every nine years max test pressure in accordance with the initial pressure test 43 Commissioning inspection maintenance Steps commissioning inspection and maintenance For further information regarding the individual steps see the page indicated 44 Commissioning steps Inspecti
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