Viessmann Vitodens 200-W Series Installation Instructions Manual
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Viessmann Vitodens 200-W Series Installation Instructions Manual

Viessmann Vitodens 200-W Series Installation Instructions Manual

Models 80, 105 wall-mounted, gas-fired condensing boiler
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Installation Instructions

for use by heating contractor
Vitodens 200-W, WB2B Series
Models 80, 105
Wall-mounted, gas-fired condensing boiler
For natural gas only
Heating input
104 to 370 MBH
30 to 108 kW
VITODENS 200-W
5418 910 v1.0 b1 08/2009
IMPORTANT
Read and save these instructions
for future reference.
 This trademark is registered with the U.S. Patent and Trademark Office.

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  • Page 1: Installation Instructions

    Installation Instructions  for use by heating contractor Vitodens 200-W, WB2B Series Models 80, 105 Wall-mounted, gas-fired condensing boiler For natural gas only Heating input 104 to 370 MBH 30 to 108 kW VITODENS 200-W  IMPORTANT Read and save these instructions for future reference.
  • Page 2 Safety, Installation and Warranty Requirements Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.

  • Page 3: Table Of Contents

    Index Page General Information Important Regulatory and Installation Requirements ......About these Installation Instructions .
  • Page 4 Index Control Connections Electrical Connections ..................Overview of electrical connections and plug-in connectors .

  • Page 5: General Information

    - Start-up/Service Instructions Viessmann for additional copies. - Operating Instructions and User’s Information Manual This product comes with several - Instructions of other Viessmann safety instruction labels attached. products utilized and installed Do not remove! - Installation codes mentioned Contact Viessmann immediately if in this manual replacement labels are required.

  • Page 6: General Information Important Regulatory And Installation Requirements

    General Information Important Regulatory and Installation Requirements (continued) Special Requirements for Side-Wall Vented Appliances In the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to...
  • Page 7 General Information Important Regulatory and Installation Requirements (continued) Special Requirements for Side-Wall Vented Appliances In the Commonwealth of Massachusetts (continued) (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side-wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies ”special venting systems”, the following requirements shall be satisfied by the manufacturer: 1.

  • Page 8: About These Installation Instructions

    General Information About these Installation Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below. Warnings draw your attention to the WARNING presence of potential hazards or important product information.

  • Page 9: Applicability

    General Information General Information Applicability CAUTION The boiler serial number must be 12-digit ASME/NB serial number provided when ordering replacement (located on metallic plate riveted parts. Some replacement parts are to the heat exchanger) not reverse compatible with previous versions of the Vitodens 200-W WB2B boiler.

  • Page 10: Mechanical Room

    General Information Mechanical Room During the early stages of designing a new home, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to the gas- or oil-fired heating equipment and domestic hot water storage tank(s). The boiler must be located in a heated indoor area, near a floor drain, and as close as possible to a wall.

  • Page 11: Set-Up

    (spraying, splashing, etc.) during boiler operation and service. Minimum Clearances Recommended minimum service clearances Side 12”/305 mm For typical Vitodens installations, Viessmann recommends installing the boiler with the clearances Top 15¾”/ shown in the illustration on the left. Front 400 mm Back 0”/mm...

  • Page 12: Boiler Connections

    Boiler Connections Preparing the Connections Connections overview Use an approved pipe sealant or teflon tape when connecting the following installation fittings. This section constitutes an overview only! Refer to subsequent sections for detailed information on individual piping connections. Legend BWR Boiler Water Return, 1¼” NPTF BWS Boiler Water Supply, 1¼”...
  • Page 13 Boiler Connections Preparing the Connections (continued) Connections overview (continued) Use an approved pipe sealant or teflon tape when connecting the following installation fittings. This section constitutes an overview only! Refer to subsequent sections for detailed information on individual piping connections. 480mm/ When preparing gas, water 19”...

  • Page 14: Wall Mounting

    Boiler Connections Wall Mounting Installing the wall mounting bracket The Vitodens 200-W WB2B can be wall-mounted on H a brick/concrete wall H wood studs H metal studs ”/10 mm Following are the installation instructions for the mounting bracket on each material. Skip to the installation instructions applicable to your installation requirements.
  • Page 15 Boiler Connections Wall Mounting (continued) Installing the wall mounting bracket (continued) Installation of mounting bracket on wood and metal studs a = 16”/407 mm To mount the Vitodens 200-W WB2B boiler on wood or metal studs, install mounting bracket on wall as shown in Fig.

  • Page 16: Mounting The Boiler

    Boiler Connections Wall Mounting (continued) Mounting the boiler 1. To open hinged cover, lift cover A and pivot control unit flap B down. All boiler controls are located behind the control unit flap. 2. Loosen the screws at the bottom of the boiler;...

  • Page 17: Connections

    Boiler Connections Connections Connecting the power supply The Vitodens 200-W boiler is shipped Refer to the Installation Instructions See Power/Pump with a Power/Pump module, which shipped with the module or those Module Installation requires a 120 VAC power supply contained in this manual for wiring Instructions from a wall receptacle.

  • Page 18: Gas Connection And Piping

    Boiler Connections Connections (continued) Gas connection and piping 1. Refer to current CAN/CSA B149.1 and .2 or National Fuel Gas Code ANSI Z223.1/NFPA 54, as well as local codes for gas piping requirements and sizing. Pipe size to the boiler must be determined based –...

  • Page 19: Gas Piping Pressure Test

    Boiler Connections Connections (continued) Gas piping pressure test When performing the gas piping pressure test, ensure the following requirements are met. 1. Isolate the boiler from the gas supply WARNING piping system using the individual manual shutoff valve during pressure Never check for gas leaks with an tests equal to or less than ½...

  • Page 20: Heating Water Connections

    6 bar / 90 psig ....IMPORTANT Damage resulting from pressure exceeding those values stated is not covered by Viessmann warranty. Fig. 14 Legend Boiler Drain Boiler Fill...

  • Page 21: Dhw Storage Tank Information

    Boiler Connections Connections (continued) DHW storage tank information The DHW water tank sensor is required when using a stand-alone DHW storage tank with the Vitodens 200-W WB2B heating boiler. It comprises the sensor only required for the connection of a stand-alone tank. All other required piping connections are field supplied.
  • Page 22 Refer to the Vitocell 300 Installation Instructions shipped with the DHW storage tank for details. IMPORTANT Follow the Installation Instructions supplied with the Viessmann DHW storage tank when mounting and securing DHW tank temperature sensor WARNING IF A DHW STORAGE TANK OTHER...

  • Page 23: Accessing The Control Unit Cables

    Boiler Connections Connections (continued) Accessing the control unit cables 1. To open hinged cover, lift cover and pivot control unit flap down. 2. Release the hinged hooks located on both sides of the control unit. 3. Fold down the control unit. 4.

  • Page 24: Connecting Dhw Sensor

    See table 2 or the Viessmann Price List for order information. 1.Pull out the existing coding card, cut and remove it from the cable tie.

  • Page 25: Condensate Connection

    Boiler Connections Connections (continued) Condensate connection The Vitodens 200-W WB2B boiler comes with a built-in condensate trap. An external trap is not required when connecting the field drain to flexible discharge tubing. Discharge tubing (field supplied) must be of 1” diameter. Use CPVC, PVC or other material approved by codes listed below.

  • Page 26: Safety Connections And Pressure Testing

    Boiler Connections Safety Connections and Pressure Testing Installing boiler safety devices 1. Remove loosely pre-assembled Minimum connection diameters: combination pressure relief valve and Pressure relief valve ¾“ ......drain valve assembly.

  • Page 27: Performing Boiler Pressure Test

    Boiler Connections Safety Connections and Pressure Testing (continued) Performing a boiler pressure test The boiler must be leak tested before Max. operating pressure being placed in operation. Before boiler 4 bar/60 psig ........... is connected to piping or electrical Testing pressure power supply, it must be...

  • Page 28: Installation Examples

    If a DHW storage tank other than a The examples on the following pages DHW supply and return piping between Viessmann Vitocell 100 or 300 tank depict possible piping layouts of the boiler DHW connections and the is used, the installer must verify...

  • Page 29: Waterside Flow (Primary Circuit)

    (as stated above), falls below the minimum flow rate or if system flow rate is unknown, Viessmann strongly recommends the installation of a low-loss header. Table 3. Typical System Flow Rates Model...

  • Page 30: System Layout 1

    Boiler Connections Installation Examples (continued) System layout 1 Vitodens 200-W, WB2B with a direct-connected heating circuit Fig. 23 Legend Installation of ... H radiator heating circuit (high-temp. circuit) IMPORTANT PRV Pressure relief valve H DHW production TPV Temperature and pressure relief valve ...

  • Page 31: System Layout 2

    Flow check valve system flow rates are unknown. DHW recirculation pump sK* The low-loss header is available as Power/Pump Module accessory part. M Low-loss header N Optional purge tee (field supplied) O Viessmann temperature sensor for low-loss header P Heating circuit pump...

  • Page 32: System Layout 3

    System separation is required of underfloor and/or improper operation of the boiler. N Power/Pump module heating systems employing non-oxygen Viessmann STRONGLY recommends using a O Optional purge tee (field supplied) diffusion barrier tubing. low-loss header and a boiler pump in this...

  • Page 33: System Layout 4

    Boiler Connections Installation Examples (continued) System layout 4 Vitodens 200-W, WB2B with... – DHW storage tank – one direct-connected heating circuit – one heating circuit with a mixing valve Fig. 26 Legend * See pages 54 and 58. See following pages for additional PRV Pressure relief valve installation examples with a low-loss Installation of different heating circuits...

  • Page 34: System Layout 5

    Vitodens 200-W, WB2B with... – DHW storage tank – one heating circuit with mixing valve – one heating circuit without mixing valve and with low-loss header Fig. 27 S Viessmann temperature sensor for Legend IMPORTANT low-loss header PRV Pressure relief valve...

  • Page 35: System Layout 6

    Vitodens 200-W, WB2B with... – DHW storage tank – two heating circuits with a mixing valve and low-loss header Fig. 28 Contact your local Viessmann Technical Legend * See pages 54 and 58. Sales Representative for details. PRV Pressure relief valve TPV Temperature and pressure relief valve Installation of different heating circuits...

  • Page 36: System Layout 7

    Boiler Connections Installation Examples (continued) System layout 7 Vitodens 200-W, WB2B with... – direct-connected heating circuit – one heating circuit with system separation Fig. 29 Legend IMPORTANT Installation of different heating circuits... PRV Pressure relief valve H radiator heating circuit (high-temp. circuit) TPV Temperature and pressure relief valve H under floor heating circuit with 3-way Vitodens 200-W WB2B boiler with...

  • Page 37: System Layout 8

    Vitodens 200-W, WB2B with... – DHW storage tank – low-loss header – multiple heating circuits with mixing valves Fig. 30 When designing a system as illustrated above, please contact your local Viessmann Sales Representative for assistance. DHW storage tank Legend IMPORTANT Expansion tank...

  • Page 38: System Layout 9

    Low-Loss Header Fig. 31 When designing a multiple Vitodens system as shown above, please reference applicable multiple Vitodens technical documentation, and contact your local Viessmann Sales Representative for further assistance. IMPORTANT WARNING If a DHW storage tank other than a...

  • Page 39: Vitodens 200-W, Wb2B (Alternate Dhw Connection)

    Boiler Connections Installation Examples (continued) Vitodens 200-W, WB2B (alternate DHW connection) The following piping diagram reflects an alternative connection for the DHW tank only and applies to system layouts 2, 5, 6 and 8. The boiler control pump logic funtion must be programmed in the Start-up/Service Instructions. . Alternative location of the expansion tank...

  • Page 40: Boiler In Heating/Cooling Application

    Expansion tank Close valve v2 and open valve v1. Water chiller Boiler circuit pump (field supplied) IMPORTANT Viessmann strongly suggests that the valves pictured above be labelled “v1” and “v2”. IMPORTANT In the above system, the circulating pump must be operated from a separate on/off switch, not from the pump aquastat on the boiler control.

  • Page 41: Boiler With Low Water Cut-Off (Remote-Mounted, Field Supplied)

    Boiler Connections Boiler Connections Installation Examples (continued) Boiler with low water cut-off (remote-mounted, field supplied) A low water cut-off may be required by Hi-Vent Hi-Vent local codes. If boiler is installed above radiation level, a low water cut-off device of approved type (field supplied) must be installed in all instances at the highest point of the piping system.
  • Page 42 Control Connections Electrical Connections Overview of electrical connections and plug-in connectors Power supply connection of accessories The power supply connection of accessories can be made directly at the control. The connection is activated and deactivated with the system on/off switch. The Vitotronic 200-H, HK1M mixing valve control, the mixing valve accessory kit and the Solartrol control require a separate 120 VAC power supply from the wall receptacle.
  • Page 43 Control Connections Electrical Connections (continued) Connecting the Power/Pump module (continued) 1. Remove the cover of the power pump module. Using the four screws supplied, mount the module base on the wall next to the Vitodens boiler. 2. Secure the connecting cables to the wall using the supplied conduit holding clips.
  • Page 44 Control Connections Electrical Connections (continued) Power/Pump module electrical connectors Power/Pump module 1 2 3 1 2 3 1 2 3 120/230 Transformer 1 2 3 1 2 3 1 2 3 L1G N L G N Fig. 37 Legend - Power supply - System pump - DHW pump sÖ...
  • Page 45 Control Connections Electrical Connections (continued) Boiler control board GC 131 electrical connections KMK1 KMK2 X8.10 X8.11 Boiler Control Board GC131 Fig. 38 Legend - Power supply sÖ - Boiler pump - LON/cascade communication module - Terminal block (low-loss header sensor, outdoor sensor and KM BUS connection) - KM-BUS connection to the Power/Pump module...
  • Page 46 Control Connections Electrical Connections (continued) Connection between the Power/Pump module and boiler Power/Pump module MAIN POWER SUPPLY 120V, 60HZ, 12A MAIN DISCONNECT SWITCH 120/230 Transformer 1 2 3 1 2 3 L1G N L G N 120VAC WALL RECEPTACLE 1. Remove and discard the green factory test lead plug 230 VAC equipped) from the boiler control...
  • Page 47 Control Connections Electrical Connections (continued) Accessories electrical connections See the following pages for connection to the individual accessories. Power/Pump module MAIN POWER SUPPLY 120V, 60HZ, 12A MAIN DISCONNECT SWITCH 120/230 Transformer 1 2 3 1 2 3 1 2 3 120VAC L1 G N L G N...
  • Page 48 Control Connections Electrical Connections (continued) Accessing the X3 plug 1. Remove the control unit cover (see page 21). 2. Remove the X3 plug from the control board. Attach sensors and/or KM-BUS and/or accessories and reinsert the X3 plug. Refer to the following sensor information.

  • Page 49: Connecting The Outdoor Temperature Sensor

    Control Connections Electrical Connections (continued) Connecting the outdoor temperature sensor 1. Remove cover of outdoor temperature sensor. 2. Mount wall-mount base (cable entry must point downward). IMPORTANT The outdoor temperature sensor should be mounted 6.6 to 8.2 ft./ 2 to 2.5 m above ground level on the north or northwest wall of the building.
  • Page 50 Control Connections Electrical Connections (continued) External switching of heating program/External heat demand / External blocking aVD - External blocking terminals 2-3 External demand terminals 1-2 External heating program changeover terminals 1-2 The allocation of the function “external heating program changeover” is set via coding Power/Pump module address ‘91’...
  • Page 51 Control Connections Electrical Connections (continued) Connecting the LON communication module Installing the LON module to the Vitotronic 200-H, HK1M mixing valve controller 1. Remove the Vitotronic 200-H, HK1M front cover. 2. Insert the LON module into the Vitotronic 200-H, HK1M control board.
  • Page 52 Control Connections Electrical Connections (continued) Connecting the LON communication module (continued) Boiler Control Board GC131 Fig. 49 See the Vitotronic 200-H, HK1M Installation Instructions.
  • Page 53 Control Connections Electrical Connections (continued) Accessory kit connections for heating circuit with mixing valve Mixing Valve Controller Dip Switch Setting Boiler Control Board GC131 Fig. 50 See the Mixing Valve Controller Kit for one heating circuit with mixing valve Installation Instructions.
  • Page 54 Control Connections Electrical Connections (continued) Wiring diagram for the boiler / Power/Pump module X8.10 X8.11 GC131 BOILER/BURNER CONTROL MODULE KM--BUS Accessories Conduit WH GN b -- MAIN POWER SUPPLY 5 - - 120V, 60HZ, 12A N G L MAIN 2 - - DISCONNECT SWITCH POWER/PUMP MODULE...
  • Page 55 2. Tighten screws at the bottom. IMPORTANT Read and follow, where applicable, the safety instructions of all labels and stickers attached to boiler surfaces. Do not remove any of these instructions. Contact Viessmann if any replacement labels are required Fig. 53...
  • Page 56 Appendix Technical Data Table 4 Boiler Model Model No. WB2B 30-80 30-105 Natural gas NG only NG only 104-285 104-370 CSA input 30-83 30-108 95-260 98-350 CSA output/DOE 29-76 29-103 heating capacity Net I=B=R rating 28.88 28.88 Heat exchanger surface area 2.68 2.68 Min.
  • Page 57 Do not attempt to common-vent Vitodens 200-W WB2B with any other appliance. Venting material to be supplied by Viessmann only; side wall vent installation must include Viessmann protective screen! For details refer to the venting section starting on page 29 or the Installation Instructions for the Vitodens 200-W, WB2B Venting System.
  • Page 58 Appendix Wiring Diagram Complete system wiring diagram 99 C 210 F 190A X1 X2 INTERNAL CONNECTIONS X8.1 X8.10 X8.11 X9.1 GC131 BURNER IGNITION MODULE X9.3 X9.4 WARNING! DISCONNECT POWER BEFORE SERVICING BOILER. CAUTION! LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND 1 2 3 4 5 6 7 DANGEROUS OPERATION.
  • Page 59 Appendix Wiring Diagram (continued) Complete system wiring diagram (continued) Legend Outside Temperature Sensor Fixed High Limit A1 Main PCB (GC131 Ignition Module) Flow Temperature Sensor/Low Loss Header Fault Alarm Output A2 Internal Power Supply Unit Ignition Transformer Boiler Water Temperature Sensor A3 Optolink DHW Temperature Sensor Power Supply Accessory (Not Used)

  • Page 60: For Your Safety Read Before Operating

    Appendix Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 61 Appendix Ladder Diagram Legend -X1 [40] power supply 120 VAC -X1 [20A] pump, HTG system w/o mixing valve, 120 VAC -X1 [21] pump DHW tank 120 VAC -X1 [20] pump boiler tank 120 VAC -X1 [50] fault alarm 120 VAC -X2 [28] pump, DHW recirculation, 120 VAC IMPORTANT...
  • Page 62 5418 910 v1.0 b1...
  • Page 63 5418 910 v1.0 b1...
  • Page 64 Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc. 45 Access Road 750 McMurray Road Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada Tel. (401) 732-0667 • Fax (401) 732-0590 Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann-us.com •...

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