Viessmann VITOMAX 200-LW User manual

Installation instructions
for contractors
VIESMANN
Vitomax 200-LW
Type M64A
Oil/gas low pressure hot water boiler
Heating output 8.0 to 20.0 MW
VITOMAX 200-LW
5727 521 GB 1/2013

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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 inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ Commissioning must be carried out in
accordance with Viessmann regula-
tions. We recommend the system is
commissioned by Viessmann Industri-
eservice.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Health and Safety at Work Act [Ger-
many]
■ The Code of Practice of relevant trade
associations
■ Directive 97/23/EC, as well as the rel-
evant safety regulations of the follow-
ing countries:
dDVGW, TRGI, TRF and VDE, TRD
aKG, ABV, LRG-K, LRV-K, DKBG
cSEV, SUVA, SVGW, SVTI, SWKI,
VKF and EKAS guideline 1942:
LPG, part 2
Working on the system
■ Close the fuel shut-off valve and
secure against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
■ Safeguard the system against recon-
nection.
Safety instructions
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Storage of Vitomax boilers prior to installation as part of the overall plant 4
Preparing for installation................................................................................... 5
Installation sequence
Handling and siting the boiler............................................................................... 6
■Recommended minimum clearances................................................................ 6
Connecting the pipework...................................................................................... 7
Fitting the measuring and control equipment....................................................... 9
■Preparing the control unit installation................................................................ 9
■Equipment for control and limitation.................................................................. 9
Connecting the flue gas side................................................................................ 9
■Fitting a flue pipe............................................................................................... 10
Mounting the sight glass....................................................................................... 11
Fuels..................................................................................................................... 11
Mounting the burner............................................................................................. 12
Adjusting the burner............................................................................................. 13
Commissioning and adjustment....................................................................... 14
Index
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Please note
This information applies to boiler storage prior to installation as part of the plant and
must be observed.
■ Vitomax boilers must be stored in
enclosed rooms, free from weather
influences under dry conditions.
■ The room temperature must not fall
below 0 °C or exceed +50 °C.
■ In its delivered condition the boiler is
protected against the ingress of for-
eign matter on the water side with
dummy flanges or caps.
■ 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 > 4 weeks:
■ 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.
■ The amount of desiccant depends on
the boiler volume.
■ Check the effectiveness of the desic-
cant regularly.
Note
Observe the desiccant manufacturer's
instructions.
■ Ensure that the desiccant does not
come into contact with the boiler mate-
rial (e.g. by suspended fixings).
■ Preserve the dry flue gas side with a
thin film of graphite or boiled oil.
■ 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.
Storage of Vitomax boilers prior to installation as part of the overall plant
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Note
All diagrams in this document are schematic diagrams.
Handling the boiler
Danger
Inappropriate handling of the
boiler can result in serious health
risks for the personnel engaged
in the handling.
Observe all relevant accident prevention
regulations.
Only use the marked fixing points.
F1/2 F1/2
90°
>45°
Fig. 1
1. Lifting the boiler
Use lifting eyes A (7 80 mm) or lift-
ing points C on the boiler base.
2. Moving the boiler
■ Place steel rollers underneath
base rail C.
■ Secure the pulling equipment to tie-
down points B (7 80 mm).
Preparing for installation
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Recommended minimum clearances
c
o2
f
o4/2
d
e
a
C
D
A B
b
o4
Fig. 2
ABoiler
BBurner
CRegulating and control system
DAnti-vibration boiler supports
(option)
a Control panel not fitted
b Control panel depth
c Control panel fitted
d,e,f Remaining clearances
o2, o4 Max. length, max. width
Tab. 1
a/b/c mm ≥1000/≥500/≥800
d/e/f*1 mm ≥500/≥300/≥500
Observe the given dimensions to ensure
easy installation and maintenance.
Level the boiler horizontally. Observe
risk warning in chapter "Handling the
boiler".
We recommend
you position the boiler onto anti-vibration
boiler supports. For this, distribute sup-
ports evenly over the length and centrally
underneath the base rails. Observe the
information provided.
Tab. 2
Boiler size 1 2 3 4 5 6
o2 mm 6516 7056 7596 8116 8656 9416
o4 mm 2670 2840 2985 3200 3475 3650
*1 We recommend: Leave one boiler length (o2) of space clear in front of
the boiler door to facilitate the extraction of turbulators (if fitted) and cleaning.
Handling and siting the boiler
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Danger
Opening the boiler connections
on the water and steam side
whilst the boiler is under pressure
can lead to a high risk of severe
injury.
Only open the connections on the
water and steam side after the
boiler has been completely dep-
ressurised.
!Please note
Unsuitable water quality can
damage the boiler shell.
Only fill the boiler with water that
meets the "Water quality guide-
lines" (see service instructions).
Note
Install all pipe connections free of load
and torque stress.
1. Thoroughly flush the system (espe-
cially when connecting the boiler to
an existing system).
2. Make all necessary connections.
Connecting the pipework
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Fig. 3 - Illustrative example. Order-specific deviations from the standard delivery are
possible.
ABoiler return connector
BBoiler flow connector
CSafety valve connector
DFem. connection for high limit
safety cut-out
R ½
EFem. connection for temper-
ature controller
R ½
FFem. connection for addition-
al control equipment
R ½
GDrain connector
HDrilled hole for 7 13 mm
equipotential bond-
ing
Connecting the pipework (cont.)
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Fit measuring 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 oper-
ating mode (operation with or without
constant supervision). Agree details with
the responsible approval body, which
should also approve them.
Note
Carry out the installation in accordance
with the instructions supplied with the
equipment.
Power supply
Connection and wiring diagrams
supplied
Preparing the control unit installation
Vitotronic or Vitocontrol as an accessory:
Separate documentation
Equipment for control and limitation
For boilers with a Vitotronic control unit or Vitocontrol control panel:
Separate documentation
Connecting the flue gas side
Danger
The gases created inside the
boiler may be poisonous and can
result in severe health risks if they
are allowed to escape
unchecked.
Close unused boiler apertures
tightly and check gas lines for
tightness.
Fitting the measuring and control equipment
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Fitting a flue pipe
ØD
Ø10
2-3xØD
Fig. 4
1. Connect the flue outlet with the flue
system using a flue pipe with favour-
able flow characteristics.
2. Locate the test port (approx. 10 mm
7) at a distance of two to three times
the diameter of the flue pipe down-
stream of the flue outlet.
3. Seal flue pipe.
4. Insulate the flue pipe.
Optional
Flue gas flange with mating flange.
Tab. 3 - Flue outlet D*2
Boiler size 1 2 3 4 5 6
D7mm 700 800 850 950 1000 1100
Note
■ Prevent the return of condensate cre-
ated inside the flue system by suitable
on-site measures (condensate trap).
■ Close the condensate drain connec-
tors if they are not used. They are
designed to drain any condensate col-
lected in the start-up phase.
Note
Connect all flue pipes free of load and
torque stress. Flue pipe joints must be
gas-tight.
*2 Internal diameter, for external diameter: + 10 mm
Connecting the flue gas side (cont.)
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Fig. 5
Mount the sight glass (supplied with the
flame tube) into the cleaning aperture
closure at the back of the boiler.
Fuels
Oil
■ Fuel oil EL to DIN 51603, part 1.
■ Fuel oil S or SA to DIN 51603 part 3,
5. When using fuel oil S or SA, different
output data (heating output, flue gas
temperature, efficiency) may result.
Gas
■ Natural gas and LPG in accordance
with DVGW Code of Practice G 260/I
and II or in accordance with local reg-
ulations.
Alternative fuel
■ On request
Mounting the sight glass
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Ø c
ee
Fig. 6
c Max. flame head diameter
e Minimum flame head length (table 4)
Separate burner instructions,
connection and wiring schemes
as well as operating and service
instructions.
1. For the burner connection, secure the
burner plate to the boiler flange with
screws.
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 head aperture.
2. Secure the burner to the burner plate
with screws.
Note
For different dimensions, adjust the
cut-out in the thermal insulation
according to the flame head diame-
ter.
3. After mounting the burner, seal the
annular gap between the flame head
and the thermal insulation block with
heat-resistant insulation material.
Note
Thermal insulation blocks and loose
thermal insulation are supplied either
inside the reversing chambers of the
boiler doors or inside the flame tube.
4. Close the boiler doors and cleaning
aperture at the back of the boiler.
Note
Check for gas tightness.
Mounting the burner
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c
e
d1
d1
d2
ab
Fig. 7
a Flame tube length
b Reversing chamber depth
c Max. flame head diameter
d1 Smooth pipe, internal diameter,
min.
d1 Corrugated pipe, internal diameter
d2 Corrugated pipe, average diameter
e Minimum flame head length
Tab. 4 - Burner connection dimensions
Boiler size 1 2 3 4 5 6
c7mm 718 718 818 918 1018 1118
e mm 360
Note
The type of flame tube depends on the
pressure stage employed. Product-spe-
cific tolerances are possible.
Separate burner documentation.
Note
Adjust the highest oil or gas throughput
of the burner to the specified maximum
combustion heating output of the boiler.
Adjusting the burner
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Service instructions of the boiler
and separate documentation.
Commissioning and adjustment
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Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
5727 521 GB Subject to technical modifications.