Viessmann VITOMAX 200-HS M73A Manuel utilisateur

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

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

5607 279 GB

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

5607 279 GB

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

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°

F1/2

90°

F1/2

CF1/2

F1/2

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

5607 279 GB

800

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

5607 279 GB

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

5607 279 GB

rZ6 2 wT wZ

qQqWqPqEqW wQ wW wP

rQrWrR rErR 1

Illustrative example. Order-specific deviations from the standard delivery are possi-

ble.

Connecting the boiler on the steam side (cont.)

5607 279 GB

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.)

5607 279 GB

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.)

5607 279 GB

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