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

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Installation Instructions
for use by heating contractor
Vitodens 200-W, WB2B Series
Models 80, 105
Multiple boiler installations for gas-fired condensing boilers
For operation with natural gas and liquid propane gas
Heating input
104 to 370 MBH
30 to 108 kW
VITODENS 200-W
5441 444 v1.3 11/2011
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 80, 105 Multiple boiler installations for gas-fired condensing boilers For operation with natural gas and liquid propane gas Heating input 104 to 370 MBH 30 to 108 kW VITODENS 200-W ...
  • Page 2 Failure 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 Advice to owner before commencing installation. Store...

  • Page 3: Table Of Contents

    Table of Contents Page General Information Important Regulatory and Installation Requirements ......About these Installation Instructions .
  • Page 4 Table of Contents Control Connections Electrical Connections ..................Connecting the Power/Pump module .

  • 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 fuel conversion to liquid propane gas no conversion kit is required.

  • Page 9: 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 10: Set-Up

    This b” clearance is only required to Note: be able to remove the boiler’s front cover and view The Vitodens 200-W, WB2B boiler has passed the zero inches the rating plate attached to it, if needed. vent clearance to combustibles testing requirements dictated by This reduced clearance is also used in Vitodens the boiler Harmonized Standard ANSI Z21.13.

  • Page 11: Boiler Connections

    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. Fig. 3 Piping connections for Vitodens 200-W, WB2B 80, 105 Legend BWR Boiler Water Return, 1¼” NPTF BWS Boiler Water Supply, 1¼”...
  • Page 12 9½” / 240mm 21” / 530mm 6½” / 15¾” / 165mm 400mm Front view Side view Fig. 4 Piping connections for Vitodens 200-W, WB2B 80, 105 Legend Pressure Gauge Reference point for top of boiler Vitodens 200-W boiler Finished floor level Recommendation...

  • 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 Boiler Drain Boiler Fill...

  • Page 20: Making The Dhw Connections

    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 21: 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 22: High Altitudes Setting

    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 23: 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 24: 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 25: 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 26: 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 27: 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) 33.5 10.2 Pressure drop (primary circuit) for 30.1 9.2 Vitodens 200-W, WB2B 80, 105 For sizing an on-site circulation system.

  • Page 28: System Layout

    Boiler Connections Installation Examples (continued) System layout 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 Supply...

  • Page 29: 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 30 Control Connections Electrical Connections 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, shipped with the module or those Power/Pump Module which requires a 120 VAC power contained in this manual for wiring supply from a wall receptacle.
  • Page 31 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 32 Control Connections Electrical Connections (continued) Power/Pump module electrical connectors Legend - Power supply sÖ - Boiler pump Power/Pump module - Fault alarm output MAIN POWER SUPPLY 120V, 60HZ, 12A - KM BUS to boiler MAIN control board DISCONNECT SWITCH - Cascade 120/230 communication Transformer...
  • Page 33 Control Connections Electrical Connections (continued) Connecting the Cascade Communication Module A The cascade communication module The wires from the BUS cables are commutable. 3 2 1 A Plug aVG to the Vitotronic 300 B 2-core cable A Vitotronic 300 (cable cross-section 2 x 0.5 mm B KMK-BUS total length 164 ft.
  • Page 34 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 35 Additional Information Technical Data Table 4 Boiler Model Model No. WB2B Natural gas / Liquid propane gas 104-285 104-370 CSA input 30-83 30-108 95-260 98-350 CSA output/DOE 28-76 29-103 heating capacity Net I=B=R rating 28.88 28.88 Heat exchanger surface area 2.68 2.68 Min.
  • Page 36 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 37 Additional Information 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 NOT USED DISCONNECTION WHEN SERVICING CONTROLS.
  • Page 38 Additional Information Wiring Diagram (continued) Complete system wiring diagram (continued) Legend Fixed High Limit A1 Main PCB (GC131 Ignition Module) Boiler Water Temperature Sensor A2 Internal Power Supply Unit Ionization Electrode Fault Alarm Output Flue Gas Temperature Sensor Ignition Transformer A3 Optolink Boiler Pump A4 Burner Control Unit...
  • Page 39 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 40 Additional Information Ladder Diagram Legend -X1 [40] power supply 120 VAC -X1 [21] pump DHW tank (not used) -X1 [20] pump boiler 120 VAC -X1 [20A] heating circuit pump (not used) -X1 [50] fault alarm 120 VAC -X2 [28] pump, DHW recirculation, 120 VAC (not used) IMPORTANT Total max.
  • Page 41 5441 444 v1.3...
  • Page 42 5441 444 v1.3...
  • Page 43 5441 444 v1.3...
  • Page 44 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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