Viessmann VITOMAX 200-HW User manual

VIESMANN
Installation instructions
for contractors
Vitomax 200-HW
Type M238
Oil/gas fired high pressure hot water boiler
Combustion output 4.0 to 18.2 MW
VITOMAX 200-HW
5592 830 GB 6/2007 Dispose after installation.

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas appliances must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
Workingonthesystem
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
Safety instructions
2
5592 830 GB

Product information
&Clearance dimensions ............................................................................. 4
Installation sequence
Boiler handling ........................................................................................... 6
Boiler positioning and adjustment ............................................................... 6
Heating water side connections .................................................................. 7
Fitting the test and control equipment.......................................................... 9
&Installing the intermediate flow piece........................................................ 9
&Fitting the electrode water level limiter ..................................................... 10
&Fitting the pressure limiting equipment ..................................................... 11
Connection on the flue gas side .................................................................. 11
Installing the combustion chamber sight glass............................................. 12
Burner installation....................................................................................... 13
Fuel............................................................................................................ 14
Burner adjustment ...................................................................................... 14
Commissioning and adjustment .................................................................. 16
Index
3
5592 830 GB

High pressure hot water boiler to
TRD, compliant with category IV of
the Steam Boiler Order [Germany] or
thePressureEquipmentDirective97/
23/EC.
For permissible flow temperatures in
excess of 120 °C.
Permiss. operating pressure (subject
to version) 6, 8, 10, 13, 16, 18, 20, 22
or 25 bar
Preparing for installation
Clearance dimensions
ABoiler BBurner
Note
Observe the given dimensions to
ensure easy installation and mainte-
nance.
Minimum clearances relate to the boil-
er.
These clearances must be checked in
accordance with the applicable code
of practice at the installation site, sub-
ject to the actual equipment level
(accessories).
Product information
4
5592 830 GB

Boilersize 1234567 8
Combustion
output to EN
12953-3 when
operating
with
Natural gas MW 4.00 5.10 6.80 9.05 11.30 13.55 15.75 18.20
Fuel oil MW 4.00 5.10 6.80 8.90 9.80 11.00 12.80 14.00
a mm 3300 3700 4300 4900 5400 5900 6350 6800
a min. mm 1400 1400 1500 1500 1700 1700 1900 2000
Dim. a: This clearance is recommended for boiler cleaning.
Dimension a
min.:
A bigger minimum dimension may be required because of the
actual burner dimensions.
Preparing for installation (cont.)
5
5592 830 GB

Note
Observe all relevant accident preven-
tion regulations.
Only use the marked lifting points.
1. Lifting the boiler
Use lifting eyes Aor lifting points
Con the boiler base.
2. Moving the boiler
Fitting steel castors underneath
foot rail C.
3. Secure the pulling means to pulling
eyes B.
Boiler positioning and adjustment
Level the boiler.
Note
We recommend the installation of the boiler on anti-vibration supports.
Boiler handling
6
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Danger
Opening the boiler connections
and openings whilst the boiler
is under pressure can lead to a
high risk of severe injury.
Only open the connections on
the water side after the boiler
has been fully depressurised.
Note
Install all pipe connections free of
load and torque stresses.
1. Thoroughly flush the system (espe-
cially when connecting the boiler to
an existing system).
2. Make all necessary line connec-
tions.
ABoiler flow (see table)
BIntermediate flow piece
CConnector for fitting assembly
(pressure regulator, pressure lim-
iter and pressure gauge)
D2 female connections R ½" for
additional control equipment
EBoiler return: see table
FSafety valve connector (2 pce.):
see table
GDrain: DN 40 PN 40
Heating water side connections
7
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Boilersize 1234 5 6 7 8
Combus-
tion output
to EN
12953-3
when oper-
ating with
Natural gas MW 4.00 5.10 6.80 9.05 11.30 13.55 15.75 18.20
Fuel oil MW 4.00 5.10 6.80 8.90 9.80 11.00 12.80 14.00
Boiler con-
nections
Boiler flow
and return at
rated output
and tem-
perature
spread
20 K DN 200 200 250 250 300 350 350 400
30 K DN 150 150 200 200 250 250 300 300
40 K DN 125 150 150 200 200 250 250 250
Safety valve
connector
for additional
operating
pressure
6 bar PN 40 DN 65 65 80 100 100 100 125 150
8 bar PN 40 DN 50 65 80 80 100 100 100 125
10 bar PN 40 DN 50 65 65 80 80 100 100 100
13 bar PN 40 DN 40 50 65 65 80 80 100 100
16bar PN40DN40505065658080 80
18bar PN40DN40405065656580 80
20bar PN40DN40405050656580 –
22bar PN40DN32405050 65 65 ––
25bar PN40DN32404050 ––– –
Heating water side connections (cont.)
8
5592 830 GB

Fit test and control equipment that is
pressure tested to the same level as
the operating pressure of the boiler
and that is suitable for the intended
operating mode (operation with or
without constant supervision). Agree
details with the responsible approval
body that should also approve them.
Note
Carry out the installation in accor-
dance with the instructions supplied
with the devices.
See the connection and wiring dia-
grams regarding the electrical con-
nection.
Installing the intermediate flow piece
AConnector DN 20 PN 40 for fitting
assembly with pressure limiting
equipment (pressure regulator,
pressure limiter and pressure
gauge)
BConnector DN 50 PN 40 for elec-
trode water level limiter
C5 female connections R ½" for
thermometer, sampling valve and
additional control equipment
a DN 125 150 200 250 300 350 400
b mm 500 500 500 550 550 600 600
Connect the intermediate flow piece
at the boiler flow connector.
Note
2 additional female connections R ½"
for test and control equipment are
available at the boiler return connec-
tor.
Seal all connectors that are not used
after fitting the test and control equip-
ment.
Fitting the test and control equipment
9
5592 830 GB

Fitting the electrode water level limiter
1. Insert the electrode into the
threaded flange.
2. Trim the electrode (175 mm).
Note
The electrode supplied by the boil-
er manufacturer is already trimmed
to size.
3. Fit the threaded flange with elec-
trode into the test connector.
Observe the fitting instructions
for the electrodes
Fitting the test and control equipment (cont.)
10
5592 830 GB

Fitting the pressure limiting equipment
Install the fitting assembly with the
pressure limiting equipment at the test
connector of the intermediate flow
piece.
Subject to system design, several
pressure limiting facilities may be
required.
Check with the certifying body.
Connection on the flue gas side
1. Connect the flue outlet with the
shortest possible run to the flue
gas system using slightly inclined
flue pipes.
Avoid sharp kinks.
2. Locate the test aperture (approx.
10 mm 7) at a distance of two to
three times the diameter of the flue
pipe behind the flue outlet.
3. Thermally insulate the flue pipe.
Fitting the test and control equipment (cont.)
11
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Boiler size 1 2 3 4 5 6 7 8
Flue gas
connection
External
7mm
510 610 650 760 810 910 1010 1110
Flue gas
connection
Internal
7mm
500 600 640 750 800 900 1000 1100
Danger
Risk of poisoning through
escaping flue gas.
Seal the drain connectors if
they are not used. When using
an ECO mounted on top and
when wet cleaning, these con-
nectors are designed for drain-
ing the cleaning water.
Installing the combustion chamber sight glass
Fit the combustion chamber sight
glass (inside the combustion cham-
ber) to the combustion chamber lid at
the back of the boiler.
Connection on the flue gas side (cont.)
12
5592 830 GB

Separate burner documenta-
tion.
1. Secure burner plate Afor the
burner installation together with
seal ring Cto boiler flange B.
Note
If the burner plate was not pre-
drilled at the factory, drill the burner
fixing holes into the burner plate
and cut out the flame tube hole.
For the max. flame tube diameter,
see the table.
2. Secure the burner to the burner
plate.
Boiler size 1 2 3 4 5 6 7 8
Burner connection dimensions
Minimum
flame tube
length
mm 360
Max. flame
tube diameter,
dimension e
7
mm
515 595 715 715 765 765 910 1015
3. Trim thermal insulation Din
accordance with the actual flame
tube diameter.
4. Seal the annular gap between the
flame tube and the thermal insula-
tion block with heat-resistant insu-
lation material E(supplied in the
combustion chamber pack).
5. Run the cable/leads and the fuel oil
line etc. in a loop. This enables the
cleaning door to be opened without
lines/cables/leads having to be
removed.
Burner installation
13
5592 830 GB

Systems with oil burner:
Fuel oil EL to DIN 51603
Systems with gas burner:
Natural gas in accordance with
DVGW Code of Practice G260/I and II
or in accordance with local regula-
tions.
Burner adjustment
For burner adjustments, see
the separate burner documen-
tation.
Adjust the highest oil or gas through-
put of the burner to the specified com-
bustion output of the boiler.
Boiler size 1 2 3 4 5 6 7 8
max. combustion output
Combus-
tion output
to EN
12953-3
when oper-
ating with
natural gas
MW 4.00 5.10 6.80 9.05 11.30 13.55 15.75 18.20
Flue gas
pressure
drop
mbar 12.00 11.50 13.50 9.10 10.60 11.70 13.30 15.80
Combus-
tion output
to EN
12953-3
when oper-
ating with
fuel oil
MW 4.00 5.10 6.80 8.90 9.80 11.00 12.80 14.00
Output por-
tion
% 100 100 100 98.3 86.7 81.2 81.3 76.9
Flue gas
pressure
drop
mbar 12.0 11.5 13.5 8.8 7.8 7.5 8.5 9.0
Fuel
14
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Flue gas pressure drop and flue gas temperature differential subject to the
boiler output
ABoiler size 8
BBoiler size 3
CBoiler size 7
DBoiler size 6
Burner adjustment (cont.)
15
5592 830 GB

EBoiler size 2
FBoiler size 5
GBoiler size 1
HBoiler size 4
KTemperature differential between
the flue gas temperature at the
boiler outlet and the boiler flow
temperature
Commissioning and adjustment
Service instructions for boiler
and boiler control unit and
separate burner documenta-
tion.
Burner adjustment (cont.)
16
Printed on environmentally friendly, chlorine-free bleached paper
5592 830 GB Subject to technical modifications.
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]