Viessmann VITODENS 200-W Installation Instructions Manual
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Viessmann VITODENS 200-W Installation Instructions Manual

Viessmann vitodens 200-w, wb2b series wall-mounted, gas-fired condensing boiler
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Installation Instructions
for use by heating contractor
Vitodens 200-W, WB2B Series
Models 45, 60
Wall-mounted, gas-fired condensing boiler
For operation with natural gas and liquid propane gas
Heating input
60 to 212 MBH
17 to 62 kW
VITODENS 200-W
5418 909 v1.6 12/2011
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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Summary of Contents for Viessmann VITODENS 200-W

  • Page 1 Installation Instructions  for use by heating contractor Vitodens 200-W, WB2B Series Models 45, 60 Wall-mounted, gas-fired condensing boiler For operation with natural gas and liquid propane gas Heating input 60 to 212 MBH 17 to 62 kW VITODENS 200-W ...
  • Page 2 Installation Instructions. formation of carbon monoxide, please to do so renders warranty see the Installation Instructions of the null and void. Vitodens 200-W Venting System. Product documentation WARNING Read all applicable documentation before commencing installation. Store Installers must follow local...

  • Page 3: Table Of Contents

    ....................Vitodens 200-W, WB2B (alternate DHW connection) .
  • Page 4 Table of Contents 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 (continued) For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply: Excerpt from 248 CMR 5-08: 2(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 decks and porches, the following requirements shall be satisfied:...

  • Page 7: 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 8: Applicability

    (DHW) production. The Vitodens 200-W, WB2B series boiler comes factory set for operation with natural gas. For a fuel conversion to liquid propane gas no conversion kit is required.

  • Page 9: Mechnical 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 10: Set-Up

    Note: the boiler connection, then this clearance can be The Vitodens 200-W, WB2B boiler has passed the zero inches reduced to b”. This b” clearance is only required to vent clearance to combustibles testing requirements dictated by be able to remove the boiler’s front cover and view...

  • Page 11: Boiler Connections

    BWR Boiler Water Return, 1¼” NPTF BWS Boiler Water Supply, 1¼” NPTF Boiler Drain Condensate Discharge tubing,1” Gas Connection, 1” NPTM Pressure Relief Valve Boiler Fill * G 1½” to 1¼” NPT adaptor and gasket Fig. 3 Piping connections for Vitodens 200-W, WB2B 45, 60...
  • Page 12 165 mm 400 mm 15” / 380 mm Front view Side view Fig. 4 Piping connections for Vitodens 200-W, WB2B 45, 60 Legend Air Vent (inside the boiler) Pressure Gauge Reference point for top of boiler Vitodens 200-W boiler Finished floor level...

  • Page 13: 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 14 (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. 6. Fig. 6 General installation of mounting bracket Install mounting bracket on wood studs as per Fig.

  • Page 15: 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 16: 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 17: Gas Connection And Piping

    No noticeable gas pressure drop in the gas line must occur when any unit (or combination See Vitodens 200-W WB2B of units) lights or runs. Start-up/Service Instructions for applicable system coding information.

  • Page 18: 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 19: 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 Air Vent (inside boiler) Boiler Drain...

  • Page 20: Dhw Storage Tank Information

    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 21 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 22: 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 23: 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 24: Condensate Connection

    If the condensate outlet of the Vitodens 200-W WB2B boiler is lower than the drain, a condensate pump must be installed. Select a pump which is approved for condensing boiler applications. To avoid condensate spillage, select a pump with an overflow switch.

  • Page 25: 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 26: 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 27: 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 28: Waterside Flow (Primary Circuit)

    Boiler Connections Installation Examples (continued) Waterside flow (primary circuit) The Vitodens 200-W, WB2B is designed for closed loop, forced circulation hot water heating systems only. H(ft.) H(m) 20.1 6.1 Pressure drop (primary circuit) for Vitodens 200-W, WB2B 45, 60 16.7 5.1 For sizing an on-site circulation system.

  • Page 29: 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 AV Air vent (models WB2B 45, 60) H DHW production PRV Pressure relief valve ...

  • Page 30: System Layout 2

    Boiler Connections Installation Examples (continued) System layout 2 Vitodens 200-W, WB2B with a direct-connected heating circuit and low-loss header Fig. 24 P Heating circuit pump Legend IMPORTANT AV Air vent (models WB2B 45, 60) PRV Pressure relief valve * See pages 53 and 57.

  • Page 31: System Layout 3

    TPV Temperature and pressure relief valve DHW circulating pump I must pump into H DHW production Vitodens 200-W WB2B boiler with the Vitodens 200-W WB2B boiler (as ... with the following flow conditions: Vitotronic 200, HO1 outdoor reset illustrated). The flow rate of the heating circuit is less...

  • Page 32: System Layout 4

    DHW circulating pump Q must pump into circuits is less than the maximum possible Accessory kit for heating circuit with the Vitodens 200-W WB2B boiler (as water flow rate of the Vitodens 200-W mixing valve WB2B boiler (see page 28 for max. water illustrated).

  • Page 33: System Layout 5

    H under floor heating circuit with 3-way Remote control Vitotrol 300 (optional) DHW circulating pump Q must pump into mixing valve (low-temp. circuit) Under floor heating circuit the Vitodens 200-W WB2B boiler (as H DHW production Radiator heating circuit illustrated)..with the following flow conditions:...

  • Page 34: System Layout 6

    DHW circulating pump S must pump into The 3-way mixing valve, built-in to achieve Expansion tank the low-temperature level of the under floor the Vitodens 200-W WB2B boiler (as Optional purge tee (field supplied) for heating circuit, is controlled by an accessory illustrated).

  • Page 35: System Layout 7

    Remote control Vitotrol 300 (optional) circuits is less than the maximum possible Under floor heating circuit IMPORTANT water flow rate of the Vitodens 200-W Heating circuit pump WB2B boiler (see page 28 for maximum Plate heat exchanger for system DHW circulating pump Q must pump into water flow rate of boiler).

  • Page 36: 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 37: System Layout 9

    Boiler Connections Installation Examples (continued) System layout 9 Multiple (up to four) Vitodens 200-W, models WB2B 45 to 105 with... – multiple heating circuits with mixing valves – low-loss header Vitocontrol-S Boiler 1 Boiler 2 Boiler 3 Boiler 4 Common...

  • Page 38: Vitodens 200-W, Wb2B (Alternate Dhw Connection)

    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 function must be programmed in the Start-up/Service Instructions. .

  • Page 39: Boiler In Heating/Cooling Application

    Heating season starts: Water chiller Close valve v2 and open valve v1. 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 40: Boiler With Low Water Cut-Off (Remote-Mounted, Field Supplied)

    Fig. 34 Boiler below radiation Fig. 35 Boiler above radiation Venting Connection Vitodens 200-W, WB2B CAUTION Installation Instructions Venting System Under certain climatic conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces.
  • Page 41 Please note that only one accessory part or switch contact can be connected to the contacts of a plug at a time. Connecting the Power/Pump module The Vitodens 200-W WB2B boiler is Refer to the Installation Instructions Installation Instructions shipped with a Power/Pump Module,...
  • Page 42 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 43 1-2 The allocation of the function “external heating program changeover” is set via coding address ’91’ - External 0-10V signal - KM BUS to boiler control board See Vitodens 200-W WB2B Start-up/Service Instructions for applicable system coding information.
  • Page 44 Control Connections Electrical Connections (continued) Boiler control board GC 130 electrical connections Boiler Control Board GC 130 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 45 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 46 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 47 Control Connections Electrical Connections (continued) Accessing the X3 plug 1. Remove the control unit cover (see page 23). 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 48 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 49 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 50 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 51 Control Connections Electrical Connections (continued) Connecting the LON communication module (continued) Boiler Control Board GC130 Fig. 49 See the Vitotronic 200-H, HK1M Installation Instructions.
  • Page 52 Control Connections Electrical Connections (continued) Accessory kit connections for heating circuit with mixing valve part no. 7133392 (old version) Mixing Valve Controller Dip Switch Setting Boiler Control Board GC130 Fig. 50 See the Mixing Valve Controller Kit for one heating circuit with mixing valve Installation Instructions.
  • Page 53 Control Connections Electrical Connections (continued) Accessory kit connections for heating circuit with mixing valve part no. 7837524 (new version) The mixing valve controller kit can only be used with wall-mounted gas-fired hot water heating boilers and a weather-responsive control; it can be used as an alternative for a Vitotronic 050/Dekamatik-HK1 control.
  • Page 54 Control Connections Electrical Connections (continued) Wiring diagram for the boiler / Power/Pump module X9.3 X9.4 GC130 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 Additional Information Technical Data Table 4 Boiler Model Model No. WB2B Natural gas / liquid propane gas 60-160 60-212 CSA input 17-47 17-62 55-146 55-194 CSA output/DOE 16-43 16-57 heating capacity Net I=B=R rating 15.76 15.76 Heat exchanger surface area 1.46 1.46 Min.
  • Page 57 Requires 1” / 25 mm tubing. See Vitodens 200-W Installation Instructions for details. For side wall vent installations (coaxial system): Do not exceed max. equivalent length specified in the Venting Installation Instructions of the Vitodens 200-W, WB2B Venting System. A maximum of five elbows may be installed in the vent system.
  • Page 58 Additional Information Wiring Diagram Complete system wiring diagram 99 C 210 F X1 X2 INTERNAL CONNECTIONS X8.1 X8.10 X8.11 X9.1 GC130 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 Additional Information Wiring Diagram (continued) Complete system wiring diagram (continued) Legend Outside Temperature Sensor Fixed High Limit A1 Main PCB (GC130 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 Additional Information 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 Additional Information 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 120 VAC -X1 [50] fault alarm 120 VAC -X2 [28] pump, DHW recirculation, 120 VAC IMPORTANT...
  • Page 62 5418 909 v1.6...
  • Page 63 5418 909 v1.6...
  • 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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Wb2b 45Wb2b 60

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