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
5592 830 GB

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
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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
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