User Manual - Vitomax 200
Contents
1. Ax A Caution hot surface Service B Inspection port R Cleaning aperture HL Handhole 17 Commissioning inspection maintenance Further details regarding the individual steps cont Checking the water chamber for deposits 1 Fully drain the boiler 3 Clean sealing surfaces of the hand hole cover and thread of the inspec I Please note tion port and replace the gaskets a Hot water can cause dam Seal the thread using hemp age Retighten new gaskets after commis Never drain hot water into the sioning and check again after 24 drainage system hours run Ensure adequate cooling 2 Clean the water chamber hose it out and remove deposits via the drain In case of harder deposits that cannot be removed by hosing down carry out chemical cleaning using an approved descaling agent Checking the safety valve Do Manufacturer s details Checking all water connections for leaks after the boiler has been filled Replace the gaskets every time a con 2 Replace the gasket nection has been opened 3 Retighten all closures after commis 1 Clean the sealing face sioning 5592 607 GB 18 5592 607 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking the water quality Enter the amount of top up water and the total hardness of the boiler water into the table For water quality guidelines see2. Inserting the turbulators if fitted and closing the boiler doors 1 Insert turbulators only in the 3rd flue as far as they will go using the turbulator extractor A to do so 2 Close boiler doors 3 Tighten boiler door screws evenly torque approx 5 to 10 Nm 15 Service Commissioning inspection maintenance Further details regarding the individual steps cont Securing the cleaning cover 1 Secure both cleaning covers so they seal 2 Position cleaning cover A over cen tering pin and tighten evenly and diagonally torque approx 10 Nm 1 Fit burner plate with screws to burner flange 2 For pressure jet gas burner Fit the gas supply pipe Danger Escaping gas leads to a risk of explosion Test the tightness of all gas connections 5592 607 GB 16 5592 607 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking the inspection ports for leaks Danger Installation instructions of the Boiler components that are not gasket manufacturer thermally insulated can be sub ject to high temperatures that can cause burns Take care with hot surfaces Note Replace the gaskets every time the con nections and inspection ports are opened Insert only gaskets approved in accord ance with TRD 401 appendix 1 VdTUV or local regulations
3. Operating and service VI EMAN N instructions for contractors Vitomax 200 LW Type M62A Oil gas low pressure hot water boilers Rated output 2 3 to 6 0 MW VITOMAX 200 LW 5592 607 GB 3 2009 Please keep safe Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate rial 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 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 equipment must only be carried out by a qualified gas fitter m Work on electrical equipment must only be carried out by a qualified elec trician m The system must be commissioned by the system installer or a qualified per son 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 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 m Gas Safety Installation amp Use Regu lations the appropriat
4. 14 Inserting the turbulators if fitted and closing the boiler COOS iieis eaa na 15 Securing the cleaning cover 16 Installing the burner cccececceeeeeeeeeeteeeeeeeteeteee 16 Checking all water connections for leaks Checking the inspection ports for leaks 17 Checking the water chamber for deposits 18 Checking the water level and system pressure Checking the safety and control equipment Checking the safety valve nenene 18 Checking all water connections for leaks after the boiler has been filled eeeeeeeeeeenneeeeeeeees 18 Checking the water Quality eeeeeeeeeeees 19 Checking the thermal insulation Checking the installation room ventilation Service Commissioning inspection maintenance Steps commissioning inspection and cont Commissioning steps Inspection steps po Maintenance steps Page on en Ne 24 Checking the flue pipe for tightness e 25 Adjusting the burner eset eeeeeneeeeeeeee 20 5592 607 GB Commissioning inspection maintenance Further details regarding the individual steps Commissioning the heating system 5592 607 GB led Check that the cleaning aperture on the flue outlet is closed ature test equipment Details provided by the burner 9 Check that the dewatering line i
5. 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 Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Subject to technical modifications 5592 607 GB Printed on environmentally friendly chlorine free bleached paper M
6. from page 21 onwards Fill Top up Meter Total wate water read water r ing volume m m m m Total hard ness Feed water Water treat ment Medi Meter um ing vol ume Date Service 19 Commissioning inspection maintenance Further details regarding the individual steps cont Adjusting the burner Do Burner manufacturer s details Adjust to the maximum oil or gas throughput of the burner to the rated boiler output Rated output Hot gas pressure drop MW Pa mbar 2 3 750 7 5 2 8 850 8 5 3 5 1000 10 0 4 5 1050 10 5 6 0 1400 14 0 To protect the system against dew point corrosion the full load must be set to the rated boiler output and must not be switched off during the summer months full load at constant standby The minimum boiler water temperature is 70 C Adjust the return temperature raising facility to a minimum temperature of 50 C operation with oil or to 55 C operation with gas 20 5592 607 GB 5592 607 GB Standard values for water quality Standard values for water quality The service life of any boiler as well as that of the complete heating system is influ enced by the quality of the water The cost of a water treatment facility is certainly less than the cost of repairing damage to the boiler system Maintaining the following requirements is
7. necessary to safeguard your warranty rights The manufacturer s warranty excludes damage due to corrosion and scal ing The following is a summary of essential water qualities A chemical water treatment can be ordered from Viessmann for filling Heating systems with rated operating temperatures up to 100 C VDI 2035 Prevent excessive scale build up cal cium carbonate on the heating surfaces For heating systems with operating tem peratures up to 100 C the VDI Directive 2035 Sheet 1 Prevention of heating sys tem damage scaling in DHW and hot water heating systems applies in Ger many together with the following stand ard values see also the full explanations in the original Directive Total output in kW gt 600 lt 0 02 Total alkaline earths mol m Total hardness in dH lt 0 11 The standard values assume the follow ing m The volume of fill and top up water of the heating system during its service life will not exceed three times the water content of the heating system m The specific system volume is less than 20 I kW output In multi boiler sys tems apply the output of the smallest boiler m All measures to prevent corrosion on the water side in accordance with VDI 2035 Sheet 2 have been implemented Soften the fill amp top up water in heating systems operating under the following conditions m The total of alkaline earths in the fill amp top up water exceeds the sta
8. with the Water quality guidelines see page 21 onwards The system must be commissioned by the system installer or a qualified rele vant expert authorised by the installer Record all actual values in a commis sioning service report These must be confirmed by the installer commission ing expert and the system user Within 4 weeks of the combustion equip ment being commissioned the operator must notify the local flue gas inspector accordingly check local regulations We would recommend that you operate the boiler constantly at the required oper ating pressure Even if no heat demand occurs for a longer period of time it is still better to operate the boiler continu ously Shutdown Control unit operating instruc tions Maintenance information We recommend that your boiler system is maintained regularly to ensure a fault free energy conscious and environmen tally responsible operation of your heat ing system The boiler must be cleaned at regular intervals otherwise the flue gas temper ature can rise with increasing contami nation resulting in higher energy losses In systems comprising several boilers of which one is constantly used as a standby boiler only change the opera tion over after longer intervals e g dur ing the annual inspection of the total sys tem Operating instructions on pre serving the water and hot gas sides Operation Operating instructions on pre serving the water a
9. 18 Chemicals for corrosion protection 25 Cleaning the flue gas collector 13 Cleaning the heating surfaces 13 Cleaning the sight glaSS 13 Cleaning the turbulators 12 Closing the boiler doors 15 COMMISSIONINQ i 5 Commissioning the heating system 9 COrrosion s aaa 24 Corrosion on the water side 24 D Diaphragm expansion vessel 24 E Expansion vessel 24 F Fill and top up water 19 Filling the heating system with water 9 Flow temperature uuuiin 23 Keyword index I Inserting the turbulators 15 Installing the bUrner 16 M Maintenance information 5 0 Opening the boiler doors 11 Opening the cleaning cover 12 S Saline WALGER oriire 23 Securing the cleaning cover 16 SNUTdOWN inien ara 5 Shutting down the system 10 x Total alkaline earthS 9 Total boiler water hardness 9 Total hardness of the boiler water 19 V Venting the heating system 9 Ww Water Quality uisinacianiaa 19 Water quality standard values 21 Water treatmMent i 25 Water with a low salt content 23 29 32
10. a corrosion resistant heat exchanger 5592 607 GB 5592 607 GB Standard values for water quality Standard values for water quality cont No further anti corrosion measures are required for sealed hot water heating systems subject to the above points being observed However take additional precautions where there is a risk of oxygen ingress for example by adding oxygen binder sodium sulphite 5 10 mg litre into the excess The heating water should have a pH value between 8 2 and 9 5 Different conditions apply to systems that contain aluminium components Where chemicals are used as part of the corrosion protection we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler mate rials and the materials of the other heat ing equipment components We recommend you refer questions of water treatment to an appropriate spe cialist Further details can be found in VDI Directive 2035 2 and EN 14868 25 Service Parts lists Parts lists When ordering spare parts Obtain standard parts from your local Please enter the serial number and type supplier as well as the number of articles required Boiler size Dec o1 02 03 04 0_5 Pos Component Quan Quan Quan Quan Quan tity tity tity tity tity Profiled gasket per boiler door 25 Pack per boiler door 3 Insu
11. cteristic blackening of the water after some time in use indicates that free oxygen is no longer present The technical rules and in particular VDI Directive 2035 2 therefore recommend that heating systems are designed and operated so that a constant ingress of oxygen into the heating water is preven ted Opportunities for oxygen ingress during the operation m Through overflowing open expansion vessels m Through negative pressure in the sys tem m Through gas permeable components 24 Sealed systems e g systems with a diaphragm expansion vessel offer good protection against the ingress of airborne oxygen into the system if they are correctly sized and operate at the correct pressure At every part of the heating system even at the suction side of the pump and under all operating conditions the system pressure should be above ambient atmospheric pressure The pre charge pressure of the dia phragm expansion vessel should be checked at least during the annual serv ice Also see chapter General design information for information regarding pressure maintenance systems and cor rosion The use of permeable components e g plastic pipes that are permeable to gas in underfloor heating systems should be avoided Provide system separation if such components are nevertheless used This must separate the water flow ing through the plastic pipes from other heating circuits e g from the boiler by the provision of
12. d if these instructions are observed Any lime deposits that have formed because the requirements to VDI Guide line 2035 were not observed will in most cases already have caused a reduction in the service life of the boilers installed Removing the lime deposits is one option to restore the operational viability This measure must be carried out by the Viessmann industrial services or a spe cialist company Inspect the heating sys tem for possible damage prior to return ing it into use Itis essential that the faulty operating parameters are corrected to prevent renewed formation of excessive scale deposits 5592 607 GB 5592 607 GB Standard values for water quality Standard values for water quality cont Heating systems with permissible flow temperatures in excess of 100 C VdTUV MB 1466 Operation with circulating water with low salt content Only use water with a low salt content as fill or top up water such as desalinated water permeate or condensate Systems using mixed condensate gen erally create water with low salt content if no boiler water is fed into the system Operation with 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 for putrefaction by alkalis Low salt content With salt content El conductivity at 25 C uS cem 10 to 30 gt 30 to 100 gt 100 to 1500 G
13. e Building Regulation either the Building regulations the Building Regulation Scotland Building Regulations Northern Ire land the Water Fittings Regulation or Water Bylaws in Scotland the current E E Wiring Regula tions If you smell gas A Danger Escaping gas can lead to explo sions which may result in serious injury m Never smoke Prevent naked flames and sparks Never switch lights or electrical appli ances ON or OFF m Close the gas 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 5592 607 GB 5592 607 GB Safety instructions cont If you smell flue gas A Danger Flue gas can lead to life threat ening poisoning m Shut down the heating system m Ventilate the boiler room m Close all doors leading to the living space 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 sup ply 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 unau thorised reconnection Please note Electronic modules can be dam aged by electro static dis charges Touch earthed objects such a
14. e correct function of all control and pressure safety equipment Open the flue gas damper if instal 16 Observe the pressure and temper Commissioning inspection maintenance Further details regarding the individual steps cont 17 Checkthe fittings for leaks and 18 Checkthe boiler doors and cleaning tighten if required cover for leaks after approx 50 hours run and retighten all screws Closure Dimensions Torque torque approx 5 to 10 Nm Handhole 100 x 150 100 Nm M16 Shutting down the system A Danger 1 Shut down the burner Heating water escaping under pressure will injure bystanders 2 Close the shut off valves in the oil Only open connections and lines at the oil tank and filter or the inspection ports on the heating gas shut off valve water side if the boiler has been depressurised 3 Isolate the system from the power supply Please note Draining the boiler with a suction 4 Close all valves pump will create negative pres sure inside the boiler Only drain the boiler with a suc tion pump if the air vent valve is open Please note Hot water can cause damage Never drain hot water into the drainage system Ensure adequate cooling 5592 607 GB 10 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 burner with burn
15. eneral requirements clear with clear with clear with out sedi out sedi out sedi ments ments ments pH value at 25 C 9 10 9 10 5 9 10 5 According to the potable lt 9 5 lt 9 5 lt 9 5 water order potable water treatment order Oxygen 03 mg litre lt 0 1 lt 0 05 lt 0 02 values for constant opera tion are generally significantly lower Alkaline earths Ca Mg mmol litre lt 0 02 lt 0 02 lt 0 02 co Phosphate PO mg litre lt 5 lt 10 lt 15 S According to the potable mg litre lt 7 lt 7 lt 7 D N water order potable water treatment order For Viessmann hot water mg litre lt 25 lt 5 lt 15 boilers 1 The oxygen concentration in the re circulated water may be up to 0 1mg itre if suitable inorganic corrosion inhibitors are used 23 Standard values for water quality Standard values for water quality cont When using oxygen binders Sodium sulphite Na S03 When using other suitable products observe the respective guidelines issued by the supplier mg litre With salt content Low salt content Prevention of damage through corrosion on the water side The corrosion resistance of materials used on the heating water side of heating systems and boilers depends on the absence of oxygen in the heating water The oxygen introduced into the heating system with the first fill and the top up water reacts with the system materials without causing damage The chara
16. er plate Opening the boiler doors Undo screws A and swing open boiler doors 8 Service 5592 607 GB 11 Commissioning inspection maintenance Further details regarding the individual steps cont Opening the cleaning cover Undo nuts and remove cleaning covers K SO and Removing and cleaning the turbulators if fitted Remove turbulators without applying force to do so use the turbulator extrac tor 8 supplied 5592 607 GB 12 Commissioning inspection maintenance Further details regarding the individual steps cont Cleaning the heating surfaces and flue gas collector 1 Clean flues combustion chamber and reversing chamber with suit able cleaning equipment and remove combustion residues 2 Remove combustion residues from the flue gas collector back Cleaning the sight glass Check the sight glass with gaskets A for leaks and clean Service 5592 607 GB 13 Commissioning inspection maintenance Further details regarding the individual steps cont Checking thermal insulation parts and gaskets Check thermal insulation parts A and gaskets 8 Replace faulty parts 5592 607 GB 14 5592 607 GB Commissioning inspection maintenance Further details regarding the individual steps cont
17. f manufacturer and regarding installed is correctly connected to accessories the condensate drain Open the boiler doors and check 10 Open the shut off valves in the oil that the turbulators if fitted are fully lines at the oil tank and filter or pushed into the hot gas flues open the gas shut off valve Check that the installation room 11 Switch ON the main isolator the ventilation is unobstructed ON OFF switch for the boiler drives and burner in this order Fill the heating system with water and vent it Burner manufacturer s oper ating instructions Please note n Unsuitable water quality can 12 Startthe boiler at a low output max damage the boiler body 30 and heat up to a temperature Fill and operate the heating of approx 30 K below the operating system with water that com temperature plies with the Water quality The condensate drains must be guidelines from page 21 open and the condensate correctly onwards collected or drained Note 13 After the required flow temperature Record the fill volume and total has been achieved open the boiler hardness on page 19 return valve and if required the feed water valve and the boiler flow valve Check the system pressure very slowly Q 3 Check all fitted components such 14 Only then enable the full burner gt as pipework valves regulators load D pumps etc for function and leaks 15 While the system heats up check Check the fuel supply for leaks and th
18. lation mat per boiler door 4 Insulation ring 52 Burner connection pack 62 Cleaning cover pack T Rear boiler floor pack 872 Pack per cleaning aper ture 9 Hand hole gasket 100 x 150 10 Seal ring set Please order individual parts from Viessmann Industrie Service Tel 0049 30 6602 389 Email industrieservice viessmann com Internet www viessmann industriekessel de 2 A corresponding amount of installation adhesive is provided 26 5592 607 GB Parts lists Parts lists cont CAIN EIS ad 209 Z69S 27 Commissioning service reports Commissioning service reports Commissioning Service Service date Service Service Service date Service Service Service date Service Service Service date by Service Service Service date 28 5592 607 GB 5592 607 GB Keyword index A Adjusting the burner 20 Anti corrosion measures 25 B Burner reMOVal 11 Cc Checking gaskets 14 Checking the inspection ports 17 Checking thermal insulation parts 14 Checking the safety valve 18 Checking the water chamber 18 Checking water connections
19. nd hot gas sides We recommend the installation of a flue gas thermometer Monitoring the flue gas temperature highlights incorrect burner settings and the level of boiler contamination Operating information Maintenance information cont Excessive flue gas temperatures through boiler contamination or incorrect burner setting reduce the system effi ciency Where necessary clean the boiler or adjust the burner settings 5592 607 GB 5592 607 GB Commissioning inspection maintenance Steps commissioning inspection and maintenance For further information regarding the individual steps see the page indicated Commissioning steps Inspection steps po Maintenance steps Page O N Oa AsaU N 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Commissioning the heating system 9 Shutting down the system eerren 10 Removing the burner if required 11 Opening the boiler doors 11 Opening the cleaning coveri 12 Removing and cleaning the turbulators if fitted 12 Cleaning the heating surfaces and flue gas collector 13 Checking all seals gaskets and packing cords on the flue gas side Cleaning the sight glass eenen eenn rrenen 13 Checking thermal insulation parts and gaskets
20. ndard value m Higher fill amp top up water volumes are expected 21 Service Standard values for water quality Standard values for water quality cont When engineering the system observe the following m Install shut off valves in different sec tions This prevents the need for drain ing the entire heating water in case of repairs or system expansion m Install a water meter to record the amount of the fill amp top up water Enter the volume of water filled and the water hardness into the boiler service instructions Operating information m Bring the system into use step by step starting with the lowest boiler output and a high heating water flow rate This prevents a localised concentra tion of lime deposits on the boiler heat ing surfaces m During expansion or repair work only drain the necessary sections m Where water treatment is required treat even the first fill of the heating systems prior to commissioning This also applies to any subsequent filling e g when adding top up water or after a repair or after system expansion m Filters dirt traps and other blow down or separating facilities in the heating water circuit must be checked cleaned and activated more frequently after commissioning or recommission ing and later on as required subject to the water treatment applied e g water softening 22 The build up of lime deposits on the heating surfaces will be minimise
21. s heating or water pipes to dis charge static loads Repair work I Please note n Repairing components which ful fil a safety function can compro mise the safe operation of your heating system Replace faulty components only with original Viessmann spare parts Safety instructions Ancillary components spare and wearing parts Please note Spare and wearing parts which have not been tested together with the heating system can com promise its function Installing non authorised components and non approved modifications con version can compromise safety and may invalidate our warranty For replacements use only orig inal spare parts from Viessmann or those which are approved by Viessmann Index Index Operating instructions Operating information Notes on commissioning and operation SNUtdOWN sisii oini seisine 5 Maintenance information 5 Service instructions Commissioning inspection maintenance Steps commissioning inspection and maintenance i 7 Further details regarding the individual StepS i 9 Standard values for water Quality i 21 Parts lists iaia 26 Commissioning service reports i 28 Keyword Nd n a eae eaa a EAA N SNS 29 5592 607 GB 5592 607 GB Operating information Notes on commissioning and operation Only fill and operate boilers and heating systems with water that complies
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