Viessmann Vitomax HS M73 Operating And Service Instructions Download

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Operating and service instructions

for contractors

Viesmann

Vitomax HS
Type M73
Type M75
Type M93
Type M95

High pressure steam boiler

VITOMAX HS

5837984 GB

1/2019

Please keep safe.

Summary of Contents for Vitomax HS M73

Page 1: ...Operating and service instructions for contractors Viesmann Vitomax HS Type M73 Type M75 Type M93 Type M95 High pressure steam boiler VITOMAX HS 5837984 GB 1 2019 Please keep safe...

Page 2: ...ciations Safety instructions for working on the system Commissioning Note Unpleasant odours may develop during commission ing Ensure the installation room is well ventilated Before working on the syst...

Page 3: ...ystem Ventilate the installation site Draining hot water Please note The blow down and TDS water from boiler sys tems can reach temperatures of over 100 C Before draining water into the sewage system...

Page 4: ...fects that cannot be remedied locally must be reported to the manufacturer Protect all boiler parts and control equipment from rain water leaks and expelled steam Safety instructions Safety instructio...

Page 5: ...19 Top up water 19 Condensate return 19 Water treatment system 19 Saline boiler feedwater requirements 20 Organic substances 20 Conditioning 21 Sampling of water and steam 23 Sample analysis 23 Test e...

Page 6: ...Wearing parts Wearing parts and gaskets 52 Order forms 52 11 Checklist Recommendations for operation maintenance and testing in accord ance with EN 12953 6 55 Checklist for boiler system Steam boiler...

Page 7: ...dispose of component in domestic waste The steps in connection with commissioning inspec tion and maintenance are found in the Commission ing inspection and maintenance section and identified as follo...

Page 8: ...carried out Intended use also includes adherence to maintenance and inspection intervals Systems with operating temperatures 110 C Category IV boiler systems compliant with Pressure Equipment Directiv...

Page 9: ...trode LWL Lowest water level qT Conductivity electrode wP Safety valve number is country specific wQ Air vent shut off valve optional wW Steam shut off valve wE Feedwater shut off valve wR Feedwater c...

Page 10: ...rmation Self monitoring overfill protection comprising Level electrode Evaluation device Standard water level Electrode is not immersed in conducting boiler water Feedwater pump operation enabled Feed...

Page 11: ...m pressure increase until the SIV opens completely at maximum discharge PS 10 Closing pressure is PS 10 Testing checks Operating information Operating checks at regular intervals or in accordance with...

Page 12: ...jury Do not release the lever TDS unit wU and wI Function Continual checking and regulation of the salt content through temperature compensated conductivity elec trode Desalination via TDS valve Valve...

Page 13: ...pressure indica tor Regular operating check Observe country specific reg ulations Pressure limiter rW If maximum pressure is ex ceeded Protect the steam boiler against positive pres sure Checking wit...

Page 14: ...values in the operator s log pH value Residual hardness p value value to determine the free alkalinity m value value to determine the entire alkalinity Phosphate Sulphide Measure and document additio...

Page 15: ...boiler systems The type of preservation depends on the type and duration of the interruption in operation Type of preservation Effect Wet preservation Keeps oxygen away from the boiler system Dry pres...

Page 16: ...l with treated feedwater 2 Note To prevent oxygen corrosion mix oxygen binder e g sodium sulphite into the boiler water in accordance with the manufacturer s instructions Mix the oxygen binder thoroug...

Page 17: ...y filled boiler shell is maintained at a pressure of 0 1 to 0 2 bar using nitrogen specifically nitrogen 5 0 Please note Frost may cause damage to the boiler Do not use wet preservation if there is a...

Page 18: ...enance ensures trouble free efficient and environmentally responsible system operation Observe the specified maintenance intervals Only use authorised companies Viessmann Industrial Service see contac...

Page 19: ...for treating the boiler feedwater This records the amount of top up water added to the recy cled condensate It will also indirectly monitor the amount of steam removal Condensate return Where possible...

Page 20: ...ts Feedwater conductivity 30 S cm 30 S cm Permissible operating pressure bar 0 5 PS 20 PS 20 PS 0 5 General requirements Colourless clear free of undissolved substances pH value at 25 C 10 5 to 12 10...

Page 21: ...General comments Certain feedwater and boiler water characteristics must be improved conditioned through chemical treatment Aim of the conditioning Support for the formation of magnetic layers or oth...

Page 22: ...damage to the boiler Do not use film forming amines Stress corrosion cracking In case of damage evaporation can lead to a concen tration of the solute non volatile boiler water constitu ents salts sol...

Page 23: ...be calibrated Procedure A clean surface with water supply and drainage facility must be chosen to carry out the analysis The required equipment must also be kept in a cupboard at the workplace Note F...

Page 24: ...4 2 Silicic acid 6 Sodium ISO 9964 1 TOC 7 ISO 8245 Total hardness of calcium Ca magnesium Mg ISO 6059 6 There is currently no European or international standard available See for example DIN 38405 21...

Page 25: ...ccess to platforms and plinths Handrails and insulation Heating and ventilation Illumination Firefighting and first aid Turbulators if installed and removal of transport brackets Telephone system Comm...

Page 26: ...the feedwater valve to OPEN via the control ler and adjust the 100 point of the valve at the controller 5 Set the limit switch at the straight through feedwa ter valve for pump to OFF 6 Preset the sw...

Page 27: ...nse pressure of the safety valve Make the function check with a closed steam valve and by bypassing the pressure controller key switch or test button on the control panel The burner may be operated wi...

Page 28: ...ect condition 2 Commission the control panel circuit breaker ON 3 Commission the feed 4 Check the water level and the function of the water level indicator as well as that of the water level control 5...

Page 29: ...ting faults refer to the operating instructions The following highlights some aspects that are the result of general operating experi ence Immediately shut off any leaking steam pipes valves fittings...

Page 30: ...30 Contact details for Viessmann Industrial Service GmbH Telephone 49 180 3843776 Email industrialservice viessmann com Monitoring What to do in the event of operating faults cont 5837984 Operation...

Page 31: ...ing that it is safe to work in this area The same applies to pipes which are separated from the system to allow it to be shut down These required measures that depend on the individ ual system must be...

Page 32: ...being fed from an isolating transformer higher voltages of up to 380 V are permissible Extra low voltage ELV and isolating transformers must be located outside the steam boiler Inspections The type an...

Page 33: ...nsulation components and gaskets 38 12 Inserting turbulators if installed and closing boiler door s 38 13 Closing and securing the inspection ports 39 14 Checking the water chamber for deposits 39 15...

Page 34: ...ressure Version with integral ECO Manually activate the blow down valve to repeat edly initiate a feedwater flow through the ECO This will prevent steam hammer during heat up 15 Vent the boiler at the...

Page 35: ...if required A B Fig 4 1 Remove the fuel supply line 2 Undo screws A and remove the burner with burner plate B Please note The burner and burner plate can twist or tilt during removal This can cause d...

Page 36: ...over E 2 Flame tube entry Remove screws F and pivot cleaning door G open 3 ECO flue gas hood option Remove nuts H and cover K Removing and cleaning the turbulators if installed B A Fig 8 1 Without usi...

Page 37: ...n the heat exchanger surfaces through inspec tion port C e g with pressure lances or in cases of severe contamination with feedwater Note In the case of wet cleaning always ensure that the exchanger s...

Page 38: ...nto the 3rd flue Use tur bulator extractor B 2 Close the boiler door s 3 Tighten fittings evenly with approx 20 Nm until the boiler doors are flue gas tight all the way round Danger Leaks can result i...

Page 39: ...side connections for tightness Fill the boiler system with water Replace the gaskets every time the connections are opened 1 Clean the sealing face 2 Replace the gasket see installation instructions 3...

Page 40: ...ety and control equipment Checking the safety valve Information on the safety valve Checking the water quality Document the top up volume and overall hardness of the boiler water See chapter Standard...

Page 41: ...the flue gas collector To prevent vibrations and resonances Adjust the burner correctly Prevent Hard flame Carefully monitor the operation of the burner during the 1st year of operation Rectify opera...

Page 42: ...W factor f x nominal steam mass flow rate in kg h Example Nominal steam mass flow rate 10 000 kg h M75C 1 Operation with ECO 2 Factor f 0 689 results in combustion heating output 6890 kW curve A at 11...

Page 43: ...7 optional wear resist ant burner entry point c mm 240 240 290 290 320 370 370 420 470 Max flame head 7 standard version c mm Adjusted subject to burner Minimum flame head length e mm 315 360 Combust...

Page 44: ...ength e mm 360 Combustion chamber volume min values Flame tube m 1 94 2 34 2 62 3 08 3 90 4 61 5 64 6 58 Flame tube length and reversing chamber depth m 2 23 2 66 2 96 3 46 4 34 5 09 6 19 7 20 Pressur...

Page 45: ...hamber volume min values Flame tube m 7 8 9 1 10 3 11 8 13 6 15 0 17 0 18 5 Flame tube length and reversing chamber depth m 8 4 9 8 11 1 12 6 14 5 16 0 18 1 19 7 Pressure drop on the flue gas side wit...

Page 46: ...5 0 96 1 11 1 37 1 71 2 10 Flame tube length and reversing chamber depth m 0 80 0 94 1 18 1 35 1 65 2 01 2 44 Pressure drop on the flue gas side with natural gas For operating pressure With ECO 2 5 ba...

Page 47: ...10 8 46 9 70 Pressure drop on the flue gas side with natural gas For operating pressure With ECO 2 5 bar mbar 11 2 10 3 12 2 13 1 13 2 13 1 14 9 13 6 23 bar 10 mbar 12 3 11 4 13 5 14 4 14 6 14 5 16 6...

Page 48: ...l gas For operating pressure With ECO 2 5 bar mbar 13 2 14 2 14 5 15 3 16 4 15 7 15 9 16 5 23 bar 10 mbar 14 6 15 8 16 0 16 8 18 0 17 1 17 3 17 9 With ECO 1 5 bar mbar 12 5 13 5 13 5 14 3 15 3 14 7 15...

Page 49: ...e M73C Boiler size 3 4 5 6 7 8 9 Flue gas volume With ECO 2 m 1 28 1 47 1 79 2 03 2 48 3 29 3 97 With ECO 1 m 1 30 1 50 1 83 2 07 2 53 3 35 4 04 Without ECO m 1 24 1 43 1 74 1 97 2 41 3 19 3 85 Tab 21...

Page 50: ...e With ECO 2 m 6 3 7 5 8 5 9 7 12 1 14 7 17 2 20 5 With ECO 1 m 6 4 7 7 8 7 9 9 12 4 15 0 17 6 20 9 Without ECO m 6 1 7 3 8 3 9 4 11 8 14 3 16 7 19 9 Tab 25 Type M95B continued Boiler size 9 A B C D E...

Page 51: ...water alkalinity is too high Blow down boiler at regular intervals in stall a TDS unit where necessary treat water in accordance with the VdT V guidelines and notes from page 19 on wards drain downst...

Page 52: ...ity Quan tity Quan tity Quan tity Quan tity Quan tity 1 Packing per boiler door 2 Packing per boiler door 3 13 Insulation ring optional 4 13 Burner connection packing 5 13 Cleaning cover packing 6 13...

Page 53: ...225 x 325 mm Vitomax HS type M75 continued size 12 9 A B C D E F G Pos Component Quan tity Quan tity Quan tity Quan tity Quan tity Quan tity Quan tity Quanti ty 1 Packing per boiler door 2 Packing per...

Page 54: ...cking 5 13 Cleaning cover packing 6 13 Rear boiler floor packing 7 13 Packing per inspection port 8 Handhole gasket 100 x 150 mm Manhole gasket 325 x 425 mm 9 Seal ring set 10 Headhole gasket 225 x 32...

Page 55: ...and temperature indica tor pressure gauge O Comparison with limiters and controllers Pressure limiter O T Function check by increasing the pres sure up to the switching points Temperature limiter O T...

Page 56: ...rangements made with the system user the supervisory authority and the manufacturer Recommendation We recommend that the 6 monthly tests are conducted in accordance with the applicable regulations e g...

Page 57: ...ting pressure Safety valve Pressure regulator Pressure limiter Flue gas heat ex changer Flue gas damper Flame ap pearance Combustion system bar 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 58: ...mp T D S facili ty Blow down valve 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Comments faults Signatures Boiler techni cians Line manager Scope and interval of...

Page 59: ...ectrical conductivity at 25 C Temperature Appearance pH value at 25 C Residual oxygen Oxygen bind er Residual hardness S cm C mg l mg l mmol l 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 60: ...alue at 25 C Excess phosphate PO4 Acid capaci ty KS 8 2 mmol l S cm mmol l S cm mg l mmol l 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Comments faults Signatur...

Page 61: ...ance service Date By Commissioning Maintenance service Maintenance service Date By Commissioning Maintenance service Maintenance service Date By Commissioning Maintenance service Maintenance service D...

Page 62: ...Interruption in operation 3 15 16 Ion exchanger 23 L Low NOx burner 41 Hard flame 41 M Multi boiler system 25 Multi boiler system 17 N Nitrogen 15 17 NW electrode 11 O Operating check 13 Operating co...

Page 63: ...63 Water level limiter 26 Water quality 19 Water shortage 11 Water side closures 28 Water side connections 39 Water side preservation 17 Wet preservation 15 16 Keyword index Keyword index cont 5837984...

Page 64: ...r Chaussee 3 D 15479 Mittenwalde Telephone 49 33764 83 0 Telefax 49 33764 83 202 www viessmann com Represented by Viessmann Ltd Hortonwood 30 TF1 7YP Telford Telephone 441952 675000 Telefax 441952 675...

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