Viessmann VITOMAX 200-HS M73A User manual

Installation instructions
for contractors
VIESMANN
Vitomax 200-HS
Type M73A
Oil/gas high pressure steam boiler
With or without economiser
Rated steam output 0.5 to 4.0 t/h
VITOMAX 200-HS
5607 279 GB 9/2011

2
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.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed 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.
Regulations
Observe the following when working on
this system
■ All legal instructions regarding the pre-
vention of accidents
■ All legal instructions regarding envi-
ronmental protection,
■ Health and Safety at Work Act (Betr-
SichV) [Germany]
■ 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
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
Safety instructions
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Storage of Vitomax boilers prior to installation as part of the system......... 4
Preparing for installation
Handling the boiler............................................................................................... 5
Clearance dimensions.......................................................................................... 6
Installation sequence
Boiler positioning and levelling............................................................................. 7
Connecting the boiler on the steam side.............................................................. 7
Fitting the test and control equipment.................................................................. 11
■ Installing the fitting assembly............................................................................ 12
■ Fitting the water level limiter and the water level controller electrodes............. 13
Connections on the flue gas side......................................................................... 15
■ Fitting a flue gas hood to the economiser (when supplied separately)............. 15
■ Fitting a flue pipe............................................................................................... 15
Installing the sight glass....................................................................................... 16
Mounting the burner............................................................................................. 16
Adjusting the burner............................................................................................. 17
Commissioning and adjustment........................................................................... 21
Index
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Please note:
This information applies to the storage prior to the system installation.
1. Vitomax boilers must be stored in
enclosed rooms, free from weather
influences under dry conditions.
2. The room temperature must not fall
below 0 °C nor exceed +50 °C.
3. In its delivered condition the boiler is
protected as standard on the water
side with dummy flanges or caps
against the ingress of foreign matter.
4. 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 longer than 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. See the details provi-
ded by the desiccant manufacturer.
■ Ensure that the desiccant does not
come into contact with the boiler mate-
rial (e.g. through suspended fixing).
■ 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 system
5607 279 GB

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Note
Observe all relevant accident prevention
regulations.
Only use the marked fixing points.
1. Lifting the boiler
Use lifting eyes A or lifting area D
on the boiler support.
2. Moving the boiler
For this, fit steel rollers underneath
base rail C.
3. Secure the pulling equipment to the
tie-down points B.
45°
45°
F1/2
90°
A
B
F1/2
CF1/2
F1/2
DD
Lifting eyes A:7 80
Tie-down points B for IPB
120:
7 ≤60
Note
Boiler shown with an optional integral
economiser.
Handling the boiler
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6
800
LG
500
BG
BG
500
500
300
1000
A BC
Illustrative example
ABoiler
BBurner
CRegulating and control system
Note
Observe the given dimensions to ensure
easy installation and maintenance.
Minimum clearances relate to the
boiler.
Subject to equipment level (accesso-
ries), check the minimum clearances to
TRD 403.
Boiler
size
1 2 3 4 5 6 7 8 9
Without economiser
LG mm 2550 2700 2910 3110 3330 3545 3755 4110 4445
BG mm 1575 1655 1730 1800 1890 1975 2060 2190 2300
With economiser
LG mm 3010 3160 3370 3595 3815 4175 4385 4740 5075
BG mm 1575 1655 1730 1800 1890 1975 2060 2190 2300
Clearance dimensions
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Level the boiler horizontally. Note
We recommend installing the boiler on
anti-vibration supports. The boiler sup-
ports should be distributed evenly across
the length and centre under the base
rails. Observe the information provided.
Connecting the boiler on the steam side
Danger
Opening the boiler connections
and openings whilst the boiler is
under pressure can lead to a high
risk of severe personal injury.
Only open the connections on the
water and steam side and inspec-
tion apertures after the boiler has
been completely de-pressurised.
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 connections.
3. Install a feedwater line between the
outlet connector on the economiser
and the feedwater connector on the
boiler*1.
4. Thermally insulate the feedwater line
with the insulation material sup-
plied*1.
5. Fit the thermometer to the female
connection and the drain valve to the
connector*1.
*1 If the boiler is equipped with an optional integral economiser.
Boiler positioning and levelling
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rZ6 2 wT wZ
wO
wU
qT
rP
wI
qQqWqPqEqW wQ wW wP
rT
4
eQ
3
5
rQrWrR rErR 1
wE
wR
qR
Illustrative example. Order-specific deviations from the standard delivery are possi-
ble.
Connecting the boiler on the steam side (cont.)
5607 279 GB

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Note
Illustration of the fitting assembly refers to modulating operation. Provide two further
pressure regulators for stepped operation; the pressure transducer for the burner
control will then not be required.
1Platform
2Control panel
See separate documentation
3Integral economiser
4Connection line between econo-
miser and boiler
5Feedwater pump (module)
6Burner
qP Level electrode
(WR – water level control)
qQ Level electrode
(HW – maximum water level)
qW Level electrode
(NW – minimum water level)
qE Accessory, flanged connection
DN 100
qR Accessory, flanged connection
DN 100
qT Conductivity electrode
wP Safety valve
wQ Air vent shut-off valve
wW Steam shut-off valve
wE Feedwater shut-off valve
wR Feedwater non-return valve
wT Blow-down shut-off valve
wZ Blow-down valve
wU T.D.S. shut-off valve
wI T.D.S. valve
wO Mating flange DN 20
eQ Air vent valve for Economiser
rP Water level indicator
rQ Pressure gauge
rW Maximum pressure limiter
rE Pressure transducer
rR Straight-through shut-off valve with
cap (option)
rT Dial thermometer
rZ Sampling cooler
Connecting the boiler on the steam side (cont.)
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Boiler connections
Boiler size 1 2 3 4 5
Steam connector
for permiss. operating pressure
6 bar PN 16 DN 65 65 80 100 100
8 bar PN 16 DN 50 65 65 80 100
10 bar PN 16 DN — 50 65 65 80
PN 40 DN 40 — — — —
13 bar PN 40 DN 32 40 50 65 65
16 bar PN 40 DN 32 40 50 50 65
18 bar PN 40 DN 32 32 50 50 65
20 bar PN 40 DN 32 32 40 50 50
22 bar PN 40 DN 32 32 40 50 50
25 bar PN 40 DN 32 32 32 40 50
Safety valve connector
for permiss. operating pressure
6 bar PN 40 DN 20 20 25 32 32
8 bar PN 40 DN 20 20 25 25 32
10 bar PN 40 DN 20 20 20 25 25
13 bar PN 40 DN 20 20 20 20 25
16 bar PN 40 DN 20 20 20 20 20
18 bar PN 40 DN 20 20 20 20 20
20 bar PN 40 DN 20 20 20 20 20
22 bar PN 40 DN 20 20 20 20 20
25 bar PN 40 DN 20 20 20 20 20
Feedwater connector
for permiss. operating pressure
6-25 bar PN 40 DN 25 25 25 32 32
Connecting the boiler on the steam side (cont.)
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Boiler connections (cont.)
Boiler size 6 7 8 9
Steam connector
for permiss. operating pressure
6 bar PN 16 DN 125 125 150 150
8 bar PN 16 DN 100 100 125 150
10 bar PN 16 DN 80 100 125 125
PN 40 DN — — — —
13 bar PN 40 DN 80 80 100 100
16 bar PN 40 DN 65 80 80 100
18 bar PN 40 DN 65 65 80 100
20 bar PN 40 DN 65 65 80 80
22 bar PN 40 DN 65 65 65 80
25 bar PN 40 DN 50 65 65 80
Safety valve connector
for permiss. operating pressure
6 bar PN 40 DN 40 40 50 50
8 bar PN 40 DN 32 40 40 50
10 bar PN 40 DN 32 32 40 40
13 bar PN 40 DN 25 32 32 40
16 bar PN 40 DN 25 25 32 32
18 bar PN 40 DN 20 25 32 32
20 bar PN 40 DN 20 25 25 32
22 bar PN 40 DN 20 25 25 32
25 bar PN 40 DN 20 20 25 25
Feedwater connector
for permiss. operating pressure
6-25 bar PN 40 DN 32 32 32 32
Fitting the test and control equipment
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, which should
also approve them.
Note
Carry out the installation in accordance
with the instructions supplied with the
equipment.
For the electrical connection, see the
connection and wiring diagrams provi-
ded.
Connecting the boiler on the steam side (cont.)
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Installing the fitting assembly
Note
Illustration of the fitting assembly refers
to staged operation.
For modulating operation, two pressure
regulators are replaced by one pressure
transducer.
Fill the U-bend of fitting assembly E
with water and mount on the boiler front
panel.
The fitting assembly offers the following
connections:
■1 or 2 pressure regulators A (option-
ally with cap valve)
■1 maximum pressure limiter C
(optionally with cap valve)
■1 pressure gauge B with test valve
and 1 drain valve
■1 additional connection D.
Fitting the test and control equipment (cont.)
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Fitting the water level limiter and the water level controller elec-
trodes
Connector for water level limiter
a
d
AMax. water level limiter electrode
BMin. water level limiter electrode
CMinimum water level (NW)
Connector for water level controller
and limiter
a
b
c
d
BMin. water level limiter electrode
CMinimum water level (NW)
DWater level controller electrode
Note
Example showing the electrode heads.
Fit the water level controller and water
level limiter electrodes:
Installation instructions for the
electrodes
Fitting the test and control equipment (cont.)
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Note
Match or adjust the electrodes to the
switching points listed in the table.
The electrodes provided are matched at
the factory to the relevant boiler.
In each connector, only one electrode
can be fitted for limiting the water level.
However, the water level controller and
limiter can be combined.
Ensure the electrodes of multi boiler sys-
tems are not interchanged.
Boiler size Permiss. operating pressure up to 13 bar
Reference
electrode to
low water
level
Pump on Pump off Maximum
water level
HW
Dimension a Dimension b Dimension c Dimension d
mm mm mm mm
1 502 462 422 357
2 527 487 447 382
3 540 500 460 395
4 551 511 471 406
5 585 545 505 440
6 608 568 528 463
7 618 578 538 473
8 622 582 542 477
9 625 585 545 480
Boiler size Permiss. operating pressure from 16 bar
Reference
electrode to
low water
level
Pump on Pump off Maximum
water level
HW
Dimension a Dimension b Dimension c Dimension d
mm mm mm mm
1 492 452 412 357
2 517 477 437 382
3 530 490 450 395
4 541 501 461 406
5 575 535 495 440
6 598 558 518 463
7 608 568 528 473
8 612 572 532 477
9 615 575 535 480
Fitting the test and control equipment (cont.)
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Fitting a flue gas hood to the economiser (when supplied sepa-
rately)
A
B
1. Mount flue gas hood A on econo-
miser B and align centrally.
2. Weld the flue gas hood gas-tight (fillet
weld a ≥5 mm).
3. Stuff the empty space between the
thermal insulation of the hood and the
economiser with thermal insulation
mats.
4. Fit the thermal insulation panels.
Note
The thermal insulation mats and pan-
els are part of the standard delivery.
Fitting a flue pipe
A
Ø10
D
2-3 x D
1. Connect the flue outlet with the short-
est possible run to the flue system
using slightly inclined flue pipes.
Avoid sharp bends.
2. Provide a 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. Insulate the flue pipe.
Note
Option: flue gas flange with mating
flange.
Connections on the flue gas side
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Boiler size 1 2 3 4 5 6 7 8 9
Flue outlet*2 Inter-
nal7
mm
152 192 216 242 272 307 346 392 442
Danger
Risk of poisoning through escap-
ing flue gas.
Seal the condensate drain con-
nectors A if they are not used.
They are designed for draining
the water from the flue gas col-
lector that may accumulate when
cleaning the economiser or for
draining any condensate collec-
ted in the start-up condition.
Installing the sight glass
Fit sight glass (inside the flame tube) to
the cleaning door on the back of the
boiler.
Mounting the burner
Separate burner documentation.
*2 Internal diameter, for external diameter +8 mm.
Connections on the flue gas side (cont.)
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Note
If the burner plate was not pre-drilled at
the factory, drill the burner fixing holes
into the burner plate and cut the flame
head hole out with an oxy-acetylene
torch.
For max. flame head diameter, see table
on page 19.
Ø f
315
1. For the burner connection, secure the
burner plate to the boiler flange.
2. Secure the burner to the burner
plate.
3. For different dimensions, adjust the
cut-out in the thermal insulation
according to the flame head diame-
ter.
4. After fitting the burner, seal the annu-
lar gap between the flame head and
the thermal insulation block with
heat-resistant insulation (supplied in
the flame tube pack).
5. Insert the turbulators (if available) as
far as they will go.
6. Close the boiler doors and cleaning
aperture at the back of the boiler.
Adjusting the burner
For burner adjustment, see the
separate burner documentation.
Mounting the burner (cont.)
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a b
f
315
Ø c
Ø d Ø e
Boiler size 1 2 3 4 5
Steam output*3
(for 102 °C feedwater temperature)
t/h 0.5 0.7 1.0 1.3 1.65
Max. permissible combustion
heating output
MW 0.380 0.530 0.760 0.985 1.250
■Natural gas
Max. flue gas pressure drop without
ECO
mbar 4.2 4.7 6.4 7.9 10.4
Max. flue gas pressure drop with
ECO 100
mbar 4.6 5.3 7.2 8.9 11.4
Max. flue gas pressure drop with
ECO 200
mbar 4.8 5.5 7.9 9.9 11.9
■Fuel oil EL
Max. flue gas pressure drop without
ECO
mbar 3.8 4.2 5.8 7.1 9.3
Max. flue gas pressure drop with
ECO 100
mbar 4.2 4.8 6.6 8.1 10.3
Max. flue gas pressure drop with
ECO 200
mbar 4.4 5.0 7.3 9.1 10.8
Combustion chamber dimensions
Length
Flame tube Dimen-
sion a
mm 1350 1500 1710 1910 2130
*3 The permissible steam output varies depending on the required emission values.
Adjusting the burner (cont.)
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Boiler size 1 2 3 4 5
Reversing chamber Dimen-
sion b
mm 250 250 250 250 250
Diameter
Internal smooth tube
min.
Dimen-
sion c
mm 468 508 549 582 620
Internal smooth tube
max.
Dimen-
sion c
mm 486 524 569 602 642
Corrugated pipe, aver-
age
Dimen-
sion d
mm — — — — —
Corrugated pipe, inter-
nal
Dimen-
sion e
mm — — — — —
Burner connection dimensions
Min. flame head length mm 315 315 315 315 315
Max. flame head diame-
ter
Dimen-
sion f
mm 240 240 290 290 320
Combustion chamber volume (average)
Flame tube m30.24 0.31 0.42 0.53 0.67
Flame tube and reversing chamber
depth
m30.29 0.37 0.48 0.59 0.74
Adjusting the burner (cont.)
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Boiler size 6 7 8 9
Steam output*3
(for 102 °C feedwater temperature)
t/h 2.0 2.5 3.2 4.0
Max. permissible combustion heating
output
MW 1.510 1.890 2.415 3.020
■Natural gas
Max. flue gas pressure drop without ECO mbar 10.5 10.9 10.9 12.5
Max. flue gas pressure drop with ECO 100 mbar 11.5 12.4 12.4 14.0
Max. flue gas pressure drop with ECO 200 mbar 12.0 13.4 13.4 15.5
■Fuel oil EL
Max. flue gas pressure drop without ECO mbar 9.4 9.8 9.9 11.1
Max. flue gas pressure drop with ECO 100 mbar 10.4 11.3 11.4 12.6
Max. flue gas pressure drop with ECO 200 mbar 10.9 12.3 12.4 14.1
Combustion chamber dimensions
Length
Flame tube Dimen-
sion a
mm 2325 2535 2850 3185
Reversing chamber Dimen-
sion b
mm 250 250 250 250
Diameter
Internal smooth tube min. Dimen-
sion c
mm 653 696 746 791
Internal smooth tube max. Dimen-
sion c
mm 675 720 768 813
Corrugated pipe, average Dimen-
sion d
mm — — 790 835
Corrugated pipe, internal Dimen-
sion e
mm — — 740 785
Burner connection dimensions
Min. flame head length mm 315 315 315 315
Max. flame head diameter Dimen-
sion f
mm 320 370 420 420
Combustion chamber volume (average)
Flame tube m30.81 1.00 1.28 1.61
Flame tube and reversing chamber depth m30.89 1.10 1.40 1.74
Note
Details regarding diameter refer to the maximum depth of corrugations and the
smallest internal diameter. The type of flame tube depends on the pressure stages
employed. Product-specific tolerances are possible.
*3 The permissible steam output varies depending on the required emission values.
Adjusting the burner (cont.)
5607 279 GB