Viessmann Vitomax HW Series Bedienungsanleitung

Installation instructions

for contractors

Viesmann

Vitomax HW

Type M70

Type M72

Type M74

Type M92

Type M94

Type M96

High pressure hot water boilers

VITOMAX HW

5777858 GB 1/2019

Please follow these safety instructions closely to

prevent accidents and material 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 environmental pollution.

Note

Details identified by the word "Note" contain additional

information.

Target group

These instructions are exclusively intended for quali-

fied contractors.

■Work on gas installations must only be carried out by

a registered gas fitter.

■Work on electrical equipment may only be carried

out by a qualified electrician.

■The commissioning must only be carried out by

trained specialist personnel in accordance with the

Viessmann operating and service instructions.

Regulations to be observed

■Pressure Equipment Directive

■Health and Safety at Work Act (BetrSichV) [Ger-

many] and extended technical rules for operational

safety (TRBS)

■Country-specific safety regulations for the installation

site

■National installation regulations

■Statutory regulations for the prevention of accidents

■Statutory regulations for environmental protection

■Codes of practice of the relevant trade associations

Working on the system

■Close the fuel shut-off valve and secure against

unintentional reopening.

■Isolate the system from the power supply, 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 reconnection.

Safety instructions

5777858

1. Installation information Preparing for installation ........................................................................ 4

■Symbols .............................................................................................. 4

■Designation of boiler types ................................................................. 4

■Intended use ....................................................................................... 5

■Storing Viessmann shell boilers .......................................................... 5

■Transporting a shell boiler .................................................................. 6

2. Installation sequence Handling and levelling the boiler ............................................................ 7

■Recommended minimum clearances ................................................. 7

■Anti-vibration supports ........................................................................ 8

Boiler connections ................................................................................. 8

Installing the pipework ........................................................................... 11

Fitting the measuring and control equipment ......................................... 12

■Preparing for the control unit installation ............................................ 12

■Equipment for control and limitation ................................................... 12

Connections on the flue gas side ........................................................... 12

■Mounting the flue pipe ........................................................................ 12

Fitting the sight glass ............................................................................. 13

Installing the burner ............................................................................... 13

■Preparing the burner connection ........................................................ 13

■Fitting the burner plate (if delivered separately) ................................. 13

Adjusting the burner ............................................................................... 14

Commissioning and adjustment ............................................................. 21

Index

5777858

Symbols

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion point. Do not 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 follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Steps required during inspection

Not required during inspection

Steps required during maintenance

Not required during maintenance

Note

All diagrams in this document are schematic, illustra-

tive examples.

Designation of boiler types

Capital letters indicate the respective stage of develop-

ment (version) of the boiler type.

Example M74B: Boiler type M74 version B

Preparing for installation

5777858

Intended use

The appliance is intended solely for installation and

operation in sealed unvented heating systems, with

due attention paid to the associated installation, serv-

ice and operating instructions. The appliance is inten-

ded exclusively for steam generation and for heating

water in accordance with EN 12953 and AGFW data-

sheet FW510 (VdTÜV datasheet TCh 1466).

Commercial or industrial use for a purpose other than

steam generation or the heating of water shall be

deemed inappropriate.

All other use is deemed inappropriate. Any resulting

losses are excluded from the manufacturer's liability.

Any usage beyond this must be approved by the man-

ufacturer in each individual case.

Intended use presupposes that a permanent installa-

tion in conjunction with permissible components

designed for this purpose has been carried out.

Intended use also includes adherence to maintenance

and inspection intervals.

Storing Viessmann shell boilers

Recommendation for corrosion prevention

Please follow all instructions carefully.

Applicability of instructions

Storage of boilers until system installation.

General

■Store Viessmann shell boilers in closed rooms, pro-

tected from weather influences and under dry condi-

tions.

■The room temperature must not fall below 0 °C or

exceed 50 °C.

■Viessmann shell boilers are delivered equipped with

blank flanges or protective caps on the water side,

for protection against the ingress of foreign bodies.

■To prevent the formation of condensate on the boiler:

–Remove the transport packaging after delivery or

–Protect the boiler against moisture by using a des-

iccant.

Storage period > 4 weeks

■Protect the interior of the shell boiler against mois-

ture. Use a desiccant, e.g. silica gel, on the flue gas

and water side.

■Use the appropriate amount of desiccant for the vol-

ume of the boiler.

Note

Observe the desiccant manufacturer's instructions.

■Check the effectiveness of the desiccant at regular

intervals.

■Ensure that the desiccant does not come into contact

with the boiler material.

Recommendation

Fill suitable containers with desiccant. Suspend the

containers in the boiler body.

■Instead of extracting the moisture on the flue gas

side by means of a desiccant, a dryer with air circula-

tion can also be used.

■Coat the dry flue gas side of the shell boiler with a

thin film of graphite or varnish.

Preparing for installation (cont.)

5777858

Transporting a shell boiler

Danger

Inappropriate handling of the boiler may lead to

accidents. There is a risk of injury.

Only use the slinging points. Observe all the

applicable regulations on accident prevention.

F1/2 F1/2

90°

>45°

Fig. 1 Slinging points/tie-down options

A, BHoles for lifting gear (7 80 mm)

CBase rail (slinging points on boiler base)

1. Attach lifting gear to the boiler A.2. Move boiler.

■Place steel rollers underneath slinging points C.

■Secure traction mechanism to holes for lifting

gear B (7 80 mm).

Preparing for installation (cont.)

5777858

Recommended minimum clearances

y1/2

A B

Fig. 2

ABoiler

BBurner

CControl system and control panel

DAnti-vibration boiler supports

a Control panel not fitted

b Control panel depth

c Control panel fitted

d, e, f Other clearances

x1, y1 See tables of dimensions: Max. length, max.

width

a mm ≥1000

b mm Subject to the selected control

panel

c mm ≥800

d mm ≥500

e mm ≥300

f mm ≥500

Tab. 1

Recommendation for dimension f

Leave one boiler length (x1) of space in front of the

boiler door to extract the turbulators (if fitted) and for

cleaning.

Observe the stated dimensions to ensure straightfor-

ward installation and maintenance.

Observe the clearances with regard to the regulations

applicable at the installation site. Allow for equipment

and accessories.

The installation surface must be level. Level the boiler

horizontally.

M70A

Boiler size*1 1 2 3 4 5 6 7 8 9

x1 mm 2556 2707 3566 3636 3696 3766 3916 4316 4616

y1 mm 1575 1655 1675 1725 1825 1900 2000 2100 2225

Tab. 2

M72B

Boiler size*1 1 2 3 4 5 6 7 8 9 A B C

x1 mm 4110 4110 4370 4370 4730 4730 5200 5200 5790 5790 6508 6508

y1 mm 1925 1925 2010 2010 2150 2150 2280 2280 2400 2400 2670 2670

Tab. 3

M74B

Boiler size*1 1 2 3 4 5 6 7 8 9

x1 mm 6430 6680 6995 7545 8035 8525 8970 9410 9710

y1 mm 2700 2775 2875 3000 3175 3325 3450 3575 3650

Tab. 4

M92A

Boiler size*1 1 2 3 4 5 6 7

x1 mm 3970 4200 4460 4720 5070 5420 5780

y1 mm 2025 2100 2200 2325 2410 2485 2575

Tab. 5

*1 Last digit of type designation

Handling and levelling the boiler

5777858

M94B

Boiler size*1 1 2 3 4 5 6 7 8 9

x1 mm 6430 6680 6995 7545 8035 8525 8970 9410 9710

y1 mm 2850 2925 3025 3175 3300 3450 3525 3625 3675

Tab. 6

M96A

Boiler size*1 1 2 3 4 5 6 7 8 9

x1 mm 4820 5120 5490 5850 6550 7050 7620 8020 8480

y1 mm 2580 2675 2750 2890 3065 3250 3440 3550 3715

Tab. 7

Anti-vibration supports

Recommendation

Use to provide vibration isolation and minimise trans-

mission of structure-borne noise.

Installation of anti-vibration supports

Manufacturer's installation instructions

Boiler connections

M70A

Boiler size 1 2 3 4 5 6 7 8 9

Boiler flow*2

Temperature spread

For permiss. operat-

ing pressure 40 K DN 100 100 100 100 100 100 100 100 100

30 K DN 100 100 100 100 100 100 100 100 125

20 K DN 100 100 100 100 100 100 125 125 150

Boiler return*2

Temperature spread

For permiss. operat-

ing pressure 40 K DN 40*3 40*3 50 65 65 65 80 100 100

30 K DN 40*3 50 65 65 80 80 100 100 125

20 K DN 50 65 65 80 100 100 125 125 150

Safety valve

For permiss. operat-

ing pressure 6 bar PN40 DN 20 20 25 32 32 40 40 50 50

8 bar PN40 DN 20 20 25 25 32 32 40 40 50

10 bar PN40 DN 20 20 20 25 25 32 32 40 40

13 bar PN40 DN 20 20 20 20 25 25 32 32 40

16 bar PN40 DN 20 20 20 20 20 25 25 32 32

18 bar PN40 DN 20 20 20 20 20 20 25 32 32

20 bar PN40 DN 20 20 20 20 20 20 25 25 32

Tab. 8

*1 Last digit of type designation

*2 For boilers up to 10 bar, flange connectors are PN 16; from 13 to 18 bar they are PN 25; and at 20 bar they are PN 40

*3 All connectors < DN 50 are PN 40.

Handling and levelling the boiler (cont.)

5777858

M72B

Boiler size 1 2 3 4 5 6 7 8 9 A B C

Boiler flow and return

Temperature spread

For permiss. operating

pressure 6 and 10 bar 40 K PN16 DN 100 100 100 125 125 125 150 150 150 200 200 200

30 K PN16 DN 125 125 125 125 150 150 150 200 200 200 200 250

20 K PN16 DN 150 150 150 150 200 200 200 200 250 250 250 250

For permiss. operating

pressure 16 bar 40 K PN25 DN —————————200 200 200

PN40 DN 100 100 100 125 125 125 150 150 150 — — —

30 K PN25 DN ———————200 200 200 200 250

PN40 DN 125 125 125 125 150 150 150 ———— —

20 K PN25 DN ————200 200 200 200 250 250 250 250

PN40 DN 150 150 150 150 ——————— —

Safety valve

For permiss. operating

pressure

6 bar PN40 DN 50 50 50 65 65 65 65 80 80 80 100 100

10 bar PN40 DN 40 40 40 50 50 50 50 65 65 65 65 80

16 bar PN40 DN 32 32 32 40 40 40 40 50 50 50 65 65

Tab. 9

M74B

Boiler size 1 2 3 4 5 6 7 8 9

Boiler flow and return

For permiss. operating pressure

6, 10 bar

Temperature spread 40 K PN16 DN 200 200 200 250 250 250 300 300 300

30 K PN16 DN 200 250 250 250 300 300 350 350 350

20 K PN16 DN 250 250 300 300 350 400 400 400 450

For permiss. operating pressure

16 bar

Temperature spread 40 K PN25 DN 200 200 200 250 250 250 300 300 300

30 K PN25 DN 200 250 250 250 300 300 350 350 350

20 K PN25 DN 250 250 300 350 350 400 400 400 450

Safety valve connector

For permiss. operating

pressure

6 bar PN40 DN 100 100 100 100 125 125 150 150 150

10 bar PN40 DN 65 80 80 80 100 100 100 125 125

16 bar PN40 DN 65 65 65 65 80 80 80 100 100

Boiler connections (cont.)

5777858

M92A

Boiler size 1 2 3 4 5 6 7

Boiler flow and return

For permiss. operating pres-

sure 6, 10 bar PN16 DN 150 150 200 200 200 250 250

16 bar PN25 DN — — 200 200 200 250 250

16 bar PN40 DN 150 150 — — — — —

Safety valve

For permiss. operating pres-

sure

6 bar PN40 DN 50 50 50 65 65 65 80

10 bar PN40 DN 40 40 40 50 50 65 65

16 bar PN40 DN 32 32 32 40 40 50 50

Drain outlet

For permiss. operating pres-

sure

6-16 bar

PN40 DN 40 40 40 40 40 40 40

Tab. 10

M94B

Boiler size 1 2 3 4 5 6 7 8 9

Boiler flow and return

For permiss. operating pressure

6, 10 bar

Temperature spread 40 K PN16 DN 200 200 200 250 250 250 300 300 300

30 K PN16 DN 200 250 250 250 300 300 350 350 350

20 K PN16 DN 250 250 300 300 350 400 400 400 450

For permiss. operating pressure

16 bar

Temperature spread 40 K PN25 DN 200 200 200 250 250 250 300 300 300

30 K PN25 DN 200 250 250 250 300 300 350 350 350

20 K PN25 DN 250 250 300 350 350 400 400 400 450

Safety valve connector

For permiss. operating

pressure

6 bar PN40 DN 100 100 100 100 125 125 150 150 150

10 bar PN40 DN 65 80 80 80 100 100 100 125 125

16 bar PN40 DN 65 65 65 65 80 80 80 100 100

M96A

Boiler size 1 2 3 4 5 6 7 8 9

Boiler flow and return*4

Temperature spread

For permiss. operat-

ing pressure

40 K DN 125 150 150 200 200 200 250 250 250

30 K DN 150 150 200 250 250 250 250 300 300

20 K DN 200 200 250 250 250 300 350 350 400

Safety valve

For permiss. operat-

ing pressure

6 bar PN 40 DN 65 65 65 80 100 100 100 125 125

8 bar PN 40 DN 50 65 65 65 80 80 100 100 125

10 bar PN 40 DN 50 50 65 65 65 80 80 100 100

*4 For boilers up to 10 bar the flange connections are PN 16, from 13 to 18 bar they are PN 25 and from 20 to 25 bar they are

PN 40

Boiler connections (cont.)

5777858

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