Installation instructionsfor contractors

VIESMANN

Vitomax 300-LWType M82AOil/gas low pressure hot water boiler Heating output 2.1 to 6.0 MW

VITOMAX 300-LW

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Please follow these safety instructions closely to prevent accidents and mate-rial losses.

Safety instructions explained

DangerThis symbol warns against therisk of injury.

! Please noteThis symbol warns against therisk of material losses and envi-ronmental pollution.

NoteDetails 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 inaccordance with Viessmann regula-tions. We recommend the system iscommissioned by Viessmann Industri-eservice.

Regulations

Observe the following when working onthis 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 tradeassociations

■ Directive 97/23/EC, as well as the rel-evant safety regulations of the follow-ing countries:

d DVGW, TRGI, TRF and VDE, TRDa KG, ABV, LRG-K, LRV-K, DKBGc SEV, SUVA, SVGW, SVTI, SWKI,

VKF and EKAS guideline 1942:LPG, part 2

Working on the system

■ Close the fuel shut-off valve andsecure against unintentional reopen-ing.

■ Isolate the system from the power sup-ply (e.g. by removing the separate fuseor by means of a mains isolator) andcheck 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 sequenceHandling and installing the boiler......................................................................... 6■ Recommended minimum clearances................................................................ 6Connecting the pipework...................................................................................... 7Fitting the measuring and control equipment....................................................... 9■ Preparing the control unit installation................................................................ 9■ Equipment for control and limitation.................................................................. 9Connecting the flue gas side................................................................................ 9■ Fitting a flue pipe............................................................................................... 10Mounting the sight glass....................................................................................... 11Fuels..................................................................................................................... 11Mounting the burner............................................................................................. 12Adjusting the burner............................................................................................. 13

Commissioning and adjustment....................................................................... 14

Index57

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Please noteThis information applies to boiler storage prior to installation as part of the plant andmust be observed.

■ Vitomax boilers must be stored inenclosed rooms, free from weatherinfluences under dry conditions.

■ The room temperature must not fallbelow 0 °C or exceed +50 °C.

■ In its delivered condition the boiler isprotected against the ingress of for-eign matter on the water side withdummy flanges or caps.

■ Remove the shipping packaging toprevent the formation of condensate.

To prevent corrosion in the non-pressur-ised state, observe the following if theboiler is stored for > 4 weeks:■ Protect the interior of the boiler against

moisture on the flue gas side and onthe DHW side with a desiccant, e.g.silica gel.

■ The amount of desiccant depends onthe boiler volume.

■ Check the effectiveness of the desic-cant regularly.

NoteObserve the desiccant manufacturer'sinstructions.

■ Ensure that the desiccant does notcome into contact with the boiler mate-rial (e.g. by suspended fixings).

■ Preserve the dry flue gas side with athin film of graphite or boiled oil.

■ Instead of the moisture extraction onthe flue gas side by means of a desic-cant, a dryer with air circulation canalso 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

DangerInappropriate handling of theboiler can result in serious healthrisks for the personnel engagedin the handling.

Observe all relevant accident preventionregulations.Only use the marked fixing points.

F1/2 F1/290° >45°

Fig. 1

1. Lifting the boilerUse 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 installation57

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Recommended minimum clearancesc o2

f

o4/2d e

a

C

D

A B

b

o4

Fig. 2

A BoilerB BurnerC Regulating and control systemD Anti-vibration boiler supports

(option)

a Control panel not fittedb Control panel depthc Control panel fittedd,e,f Remaining clearanceso2, o4 Max. length, max. width

Tab. 1a/b/c mm ≥1000/≥500/≥800d/e/f*1 mm ≥500/≥300/≥500

Observe the given dimensions to ensureeasy installation and maintenance.Level the boiler horizontally. Observerisk warning in chapter "Handling theboiler".

We recommendyou position the boiler onto anti-vibrationboiler supports. For this, distribute sup-ports evenly over the length and centrallyunderneath the base rails. Observe theinformation provided.

Tab. 2Boiler size 1 2 3 4 5 6 7o2 mm 3970 4200 4460 4720 5070 5420 5780o4 mm 2025 2100 2200 2325 2410 2485 2575*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 installing the boiler

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DangerOpening the boiler connectionson the water and steam sidewhilst the boiler is under pressurecan lead to a high risk of severeinjury.Only open the connections on thewater and steam side after theboiler has been completely dep-ressurised.

! Please noteUnsuitable water quality candamage the boiler shell.Only fill the boiler with water thatcomplies with the "Water qualityguidelines" (see service instruc-tions).

NoteInstall all pipe connections free of loadand torque stress.

1. Thoroughly flush the system (espe-cially when connecting the boiler toan existing system).

2. Make all necessary connections.

Connecting the pipework57

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Fig. 3 - Illustrative example. Order-specific deviations from the standard delivery arepossible.

A Boiler return connector B Boiler flow connector C Safety valve connectorD Fem. connection for high limit

safety cut-outR ½

E Fem. connection for temper-ature controller

R ½

F Fem. connection for addition-al control equipment

R ½

G Drain connector H Drilled hole for 7 13 mm

equipotential bond-ing

Connecting the pipework (cont.)

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Fit measuring and control equipmentthat is pressure tested to the same levelas the operating pressure of the boilerand that is suitable for the intended oper-ating mode (operation with or withoutconstant supervision). Agree details withthe responsible approval body, whichshould also approve them.

NoteCarry out the installation in accordancewith the instructions supplied with theequipment.

Power supplyConnection and wiring diagramssupplied

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

DangerThe gases created inside theboiler may be poisonous and canresult in severe health risks if theyare allowed to escapeunchecked.Close unused boiler aperturestightly and check gas lines fortightness.

Fitting the measuring and control equipment57

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Fitting a flue pipe

ØD

Ø10

2-3xØD

Fig. 4

1. Connect the flue outlet with the fluesystem using a flue pipe with favour-able flow characteristics.

2. Locate the test port (approx. 10 mm7) at a distance of two to three timesthe diameter of the flue pipe down-stream of the flue outlet.

3. Seal flue pipe.

4. Insulate the flue pipe.

OptionalFlue gas flange with mating flange.

Tab. 3 - Flue outlet D*2

Boiler size 1 2 3 4 5 6 7D 7mm 346 392 392 440 490 550 620

Note■ Prevent the return of condensate cre-

ated inside the flue system by suitableon-site measures (condensate trap).

■ Close the condensate drain connec-tors if they are not used. They aredesigned to drain any condensate col-lected in the start-up phase.

NoteConnect all flue pipes free of load andtorque stress. Flue pipe joints must begas-tight.

*2 Internal diameter, for external diameter for size 1 to 3: + 8 mm, for size 4 to 7: +10 mm

Connecting the flue gas side (cont.)

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Fig. 5

Mount the sight glass (supplied with theflame tube) into the cleaning apertureclosure 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, differentoutput data (heating output, flue gastemperature, efficiency) may result.

Gas■ Natural gas and LPG in accordance

with DVGW Code of Practice G 260/Iand II or in accordance with local reg-ulations.

Alternative fuel■ On request

Mounting the sight glass57

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Ø c

ee

Fig. 6

c Max. flame head diametere Minimum flame head length (table 4)

Separate burner instructions,connection and wiring schemesas well as operating and serviceinstructions.

1. For the burner connection, secure theburner plate to the boiler flange withscrews.

NoteIf the burner plate was not pre-drilledat the factory, drill the burner fixingholes into the burner plate and cut outthe flame head aperture.

2. Secure the burner to the burner platewith screws.

NoteFor different dimensions, adjust thecut-out in the thermal insulationaccording to the flame head diame-ter.

3. After mounting the burner, seal theannular gap between the flame headand the thermal insulation block withheat-resistant insulation material.

NoteThermal insulation blocks and loosethermal insulation are supplied eitherinside the reversing chambers of theboiler doors or inside the flame tube.

4. Close the boiler doors and cleaningaperture at the back of the boiler.

NoteCheck for gas tightness.

Mounting the burner

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c

e

d1

d1 d2

a b

Fig. 7

a Flame tube lengthb Reversing chamber depthc Max. flame head diameterd1 Smooth pipe, internal diameter,

min.

d1 Corrugated pipe, internal diameterd2 Corrugated pipe, average diametere Minimum flame head length

Tab. 4 - Burner connection dimensionsBoiler size 1 2 3 4 5 6 7c 7mm 520 520 590 590 590 718 718e mm 360

NoteThe type of flame tube depends on thepressure stage employed. Product-spe-cific tolerances are possible.

Separate burner documentation.

NoteAdjust the highest oil or gas throughputof the burner to the specified maximumcombustion heating output of the boiler.

Adjusting the burner57

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Service instructions of the boilerand separate documentation.

Commissioning and adjustment

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Viessmann LimitedHortonwood 30, TelfordShropshire, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040E-mail: info-uk@viessmann.com

Viessmann Werke GmbH&Co KGD-35107 AllendorfTelephone: +49 6452 70-0Fax: +49 6452 70-2780www.viessmann.com

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