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Installation Instructions
for use by heating contractor
Vitodens 200
WB2 Series
Wall-mounted, gas-fired condensing boiler
For natural gas and liquid propane
Heating input NG 55 to 230 MBH
16 to
Heating input LP
55 to 214 MBH
16 to
VITODENS 200
5285 960 v1.2 10/2007
67 kW
63 kW
Vitodens 200, WB2-44/60
(with preinstalled vent pipe adaptor)
IMPORTANT
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Summary of Contents for Viessmann Vitodens 200 WB2 11-44
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Page 1: Installation Instructions
Installation Instructions for use by heating contractor Vitodens 200 WB2 Series Wall-mounted, gas-fired condensing boiler For natural gas and liquid propane Heating input NG 55 to 230 MBH 16 to 67 kW Heating input LP 55 to 214 MBH 16 to 63 kW VITODENS 200 Vitodens 200, WB2-44/60... - 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 Index Page Safety Important Regulatory and Installation Requirements ......General Information About these Installation Instructions .
- Page 4 Index Control Connections Electrical Connections ..................Overview of electrical connections and plug-in connectors .
- Page 5 Contact CAN/CSA-B149.1 or .2 Installation Viessmann for additional copies. Codes for Gas Burning Appliances for Canada. For U.S. installations use the This product comes with several National Fuel Gas Code ANSI Z223.1.
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Page 6: Safety Important Regulatory And Installation Requirements
- Operating Instructions and User’s Information Manual This product comes with several - System Design Guidelines safety instruction labels attached. - Instructions of other Viessmann Do not remove! products utilized and installed Contact Viessmann immediately if - Installation codes mentioned replacement labels are required. -
Page 7: General Information
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 8: Applicability
The Vitodens 200 comes factory set for operation with natural gas, with the option of conversion to liquid propane using a field conversion kit. (When planning on fuel converting the Vitodens 200 boiler, contact Viessmann to order the required conversion kit.) Boiler model must be selected based on an accurate heat loss calculation of the building. -
Page 9: Mechanical Room
(spraying, splashing, etc.) during boiler operation and service. Minimum Clearances Recommended minimum service clearances Side For typical Vitodens installations, Viessmann 12”/305 mm recommends installing the boiler with the clearances shown in the illustration on the left. 12”/305 mm Front Back 28”/700 mm... -
Page 10: Boiler Connections Preparing The Connections
Boiler Connections Preparing the Connections Use an approved pipe sealant or teflon tape when connecting the following installation fittings. Connections overview This section constitutes an overview only! Refer to subsequent sections for detailed information on individual piping connections. Piping connections for Vitodens 200, WB2 11-44 and 15-60 *These adapters are factory supplied. - Page 11 Boiler Connections Preparing the Connections When preparing gas, water and electrical connections in the field, see section entitled “Wall Mounting” on page 12 24”/600 mm 22”/550 mm of this manual for information regarding the installation of the wall mounting bracket. IMPORTANT The maximum ambient temperature must not exceed 95 ºF/35 ºC.
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Page 12: Wall Mounting
Boiler Connections Wall Mounting Wall mounting bracket installation The Vitodens 200 can be wall-mounted H a brick/concrete wall H wood studs H metal studs Following are the installation instructions for the mounting bracket on each material. Skip to the installation instructions applicable to your installation requirements. - Page 13 Boiler Connections Wall Mounting (continued) Mounting bracket installation (continued) Installation of mounting bracket on wood and metal studs To mount the Vitodens 200 boiler on wood or metal studs, install mounting bracket on wall as shown in Fig. . Refer to Figs. and below for more detailed installation information.
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Page 14: Mounting Vitodens 200 Boiler
Boiler Connections Boiler Connections Wall Mounting (continued) Mounting Vitodens 200 boiler 1. Open hinged cover of the control unit (by exerting slight pressure with fingertip). 2. Unlock enclosure panel by loosening screw as illustrated. 3. Remove front enclosure panel (lift up and pull towards you). -
Page 15: Proper Piping Practice
Boiler Connections Connections (continued) Proper piping practice 2 imperfect threads Use moderate amount of dope Support piping by proper suspension method. Piping must not rest on or be supported by boiler. Thread pipe right length Leave 2 end threads bare Gas connection and piping 1. - Page 16 Boiler Connections Connections (continued) Gas connection and piping (continued) 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 –...
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Page 17: 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 18: Heating Water Connections
............IMPORTANT Damage resulting from pressure exceeding those values stated is not covered by Viessmann warranty. Air vent Boiler Drain BWR Boiler water return... -
Page 19: Dhw Production Kit Installation
Boiler Connections DHW Production Kit Installation Product information The DHW Production Kit is required when using a stand-alone DHW storage tank with the Vitodens 200 heating boiler. It comprises all components required for the connection of a stand-alone tank. See Vitodens 200 Start-up/Service Instructions for applicable system coding information. - Page 20 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...
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Page 21: Electrical Connection
Boiler Connections DHW Production Kit Installation (continued) Electrical connection 1. Insert plug ”X7” of the DHW tank temperature sensor into terminal ”X7” of the control unit. Condensate connection The Vitodens 200 boiler comes with a 1. Install the condensate drain pipe built-in condensate trap. -
Page 22: Safety Connections And Pressure Testing
Boiler Connections Safety Connections and Pressure Testing Installing safety devices on the boiler 1. Remove loosely preassembled Minimum connection diameters: combination pressure relief valve and Pressure relief valve ¾“ ......drain valve assembly. -
Page 23: Performing Pressure Test On The Boiler
Specific system layouts may maintained. In cases where the pipes be further discussed with the local are insulated with pipe insulation of Viessmann sales representative office. appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0” (refer to local gas codes). - Page 24 Use standard friction loss method for pipe sizing. Observe boiler maximum flow rate limitations. If system flow rate exceeds boiler maximum flow rate or if system flow rate is unknown, Viessmann strongly recommends the installation of a low-loss header. See low-loss header Installation Instructions for details.
- Page 25 Boiler Connections Installation Examples (continued) Vitodens 200 (model WB2 11-44 and up) with DHW storage tank and one direct-connected heating circuit Installation example and corresponding plug-in connection example do not follow same alphabetical designation of components. AV Air vent Installation of ... The low-loss header is available as PRV Pressure relief valve H radiator heating circuit (high temperature...
- Page 26 Boiler Connections Installation Examples (continued) Plug-in connections Vitodens 200 (model WB2 11-44 and up) with DHW storage tank and one direct-connected heating circuit Vitodens 200 plug-in connections Vitodens 200 pump junction box Outdoor temperature sensor Remote control WS/RS (optional) Wall-mount base when using the programming unit as remote control (optional) Power connection cable to...
- Page 27 Boiler Connections Installation Examples (continued) Vitodens 200 (model WB2 11-44 and up) with DHW storage tank, one heating circuit with mixing valve and system separation AV Air vent DHW storage tank The use of a low-loss header is strongly PRV Pressure relief valve DHW tank temperature sensor recommended if the maximum water flow TPV Temperature and pressure relief...
- Page 28 Boiler Connections Installation Examples (continued) Plug-in connections Vitodens 200 (model WB2 11-44 and up) with DHW storage tank, one heating circuit with mixing valve and system separation Vitodens 200 plug-in connections Vitodens 200 pump junction box Outdoor temperature sensor Remote control WS/RS (optional) Wall-mount base when using the programming unit as remote control (optional)
- Page 29 Boiler Connections Installation Examples (continued) Vitodens 200 (model WB2 11-44 and up) with DHW storage tank, low-loss header, one heating circuit with mixing valve and one heating circuit without mixing valve Alternate locations of expansion tank Model No. Max. flow rate (GPM/ltr/h) Vitodens 200, AV Air vent...
- Page 30 Boiler Connections Installation Examples (continued) Plug-in connections Vitodens 200 (model WB2 11-44 and up) with DHW storage tank, low-loss header, one heating circuit with mixing valve and heating circuit without mixing valve Vitodens 200 plug-in connections Vitodens 200 pump junction box Outdoor temperature sensor Remote control WS/RS (optional) Wall-mount base when using...
- Page 31 Vitodens 200 boiler (see weather-responsive operation and Low-loss header following table). Viessmann 2-wire BUS extension DHW circulating pump (field supplied) module DHW tank temperature sensor Outdoor temperature sensor of Model No.
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Page 32: Boiler In Heating/Cooling Application
IMPORTANT Spring-loaded flow check valve chiller manufacturer carefully for Circulation pump additional requirements. Safety header Viessmann strongly suggests that the with automatic air vent and valves pictured above be labelled “v1” Cooling season starts: pressure relief valve and “v2”. Close valve v1 and open valve v2. -
Page 33: Boiler With Low Water Cut-Off
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 34: Venting Connection
Boiler Connections Boiler Connections Installation Examples (continued) Boiler with optional low water cut-off (boiler-mounted, factory supplied) Viessmann offers an optional boiler mounted low water cut-off (LWCO) connection kit, Part No.: 7134609. support for piping / component WARNING These fittings are not designed to support any accessories installed. -
Page 35: Overview Of Electrical Connections And Plug-In Connectors
(230 VAC, 60 Hz) External switching of heating External burner disable Not used program/External heat demand Outdoor temperature sensor Alarm output An expansion board is required for connection purposes. Direct connection is not permitted. Please contact Viessmann to order an expansion board (optional). -
Page 36: Control Connections Electrical Connections
Control Connections Electrical Connections (continued) Overview of electrical connections and plug-in connectors (continued) Power supply connection of accessories The power supply connection of 2-wire cabling required for: accessories can be made directly at the H outdoor temperature sensor control. The connection is activated H Vitotronic 050/Dekamatik-HK1 and deactivated with the system on/off H extension kit for heating circuit with... -
Page 37: Routing Of Connecting Cables
Control Connections Electrical Connections (continued) Routing of connecting cables CAUTION When running and securing connecting cables on site, ensure that the maximum permissible temperatures of the cables are not exceeded. 1. Secure cables coming from the power/pump module to the control mounting bracket with cable ties. - Page 38 Control Connections Electrical Connections (continued) Routing of connecting cables (continued) 5. Loosen and remove junction box cover. Installation Instructions Power/Pump Module 6. Break off required number of tabs for external cables to be connected (see page 35). 7. Insert necessary bushings. 8.
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Page 39: Outdoor Temperature Sensor
Control Connections Electrical Connections (continued) 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 40: Dhw Tank Temperature Sensor
Control Connections Electrical Connections (continued) DHW tank temperature sensor Accessory Install DHW tank temperature sensor as described in the Vitocell Installation Instructions supplied with the DHW storage tank. 1. Insert plug-in connector ”X7” of the DHW tank temperature sensor into terminal ”X7”. -
Page 41: External Switching Of Heating Program/External Heat Demand
Control Connections Electrical Connections (continued) External switching of heating program/External heat demand IMPORTANT Load capacity of the connection is 10 mA at 24 V–. For external call for heat function: See Start-up/Service Instructions with regard to changing the coding addresses. 1. -
Page 42: Power/Pump Module Installation
Control Connections Power/Pump Module Installation 1. Remove cover of power/pump module. Using the four screws supplied, mount power module base as shown next to Vitodens boiler. IMPORTANT Mount power/pump module in vertical or horizontal position only. DO NOT mount module on the ceiling or where it can be exposed to splashing water. -
Page 43: Power Supply Connection
See boiler wiring diagram on the inside of the boiler IMPORTANT enclosure panel. Viessmann recommends the installation of a disconnect switch to the 120 VAC power supply outside the boiler room. Technical data Power supply Pump outputs... -
Page 44: Product Information (Expansion Board)
Control Connections Power/Pump Module Installation (continued) Product information (expansion board) The installation of an expansion board allows for failure alarm output. Expansion board installation (optional) 1. Remove cover of power/pump module by loosening the two Philips screws on either side, and insert the four standoffs into provided holes located within the marked boundaries of the expansion board. -
Page 45: Technical Data
Control Connections Power/Pump Module Installation (continued) Expansion board installation (continued) 6. Remove and discard plug X4 (pink) from boiler control console and insert cable plug X4 into corresponding socket. IMPORTANT Move all wires connected to plug X4 (if previously installed) to cable plug X4. 7. -
Page 46: Installing The Programming Unit Of The Control Unit
Control Connections Installing the Programming Unit of the Control Unit Please note: The control unit comes packaged separately. 1. Slide control unit onto rails on both sides of the electrical connections unit and snap into place. IMPORTANT Electrical connections of individual components of the programming unit are made automatically upon insertion of the programming unit... -
Page 47: Start-Up And Adjustments
Appendix Start-up Information Start-up and adjustments See Vitodens 200 1. File all Parts Lists, Operating and 2. Install a protective hanging case near Start-up/Service Instructions Service Instructions in the Service the boiler and store the Service for details on start-up, Binder. -
Page 49: Lighting And Operating Instructions
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 50: Ladder Diagram
Appendix Ladder Diagram Legend Rast-5 terminal, power supply 120 VAC Rast-5 terminal, power supply for pumps 120 VAC, 10 FLA total X4.1, .G, .2 Rast-5 terminal, power supply for pumps 120 VAC, 10 FLA total F1, F2A Fuses (slow blow) R1, R2, R3 Operating contacts Transformer... - Page 52 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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