Installation Instructions for use by heating contractor Please file in Service Binder Vitodens 200-W, WB2B Series Models 19, 26, 35 Wall-mounted, gas-fired condensing boiler For operation with natural gas and liquid propane gas Heating input 31 to 125 MBH 9 to 37 kW VITODENS 200-W IMPORTANT Read and save these instructions for future reference. 5369 297 v1.6 12/2011 This trademark is registered with the U.S. Patent and Trademark Office.
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. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
Table of Contents Page General Information ........................... 5 About these Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Applicability 8 Important Regulatory and Installation Requirements ........................................................................................................... ...........................................................................................
Table of Contents Control Connections Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of electrical connections and plug-in connectors . . . . . . . . . . . . . Connecting the Power/Pump module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power/Pump module electrical connectors . .
General Information Important Regulatory and Installation Requirements Codes The installation of this unit shall be in accordance with local codes or, in the absence of local codes, use CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning Appliances for Canada. For U.S. installations use the National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes. In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S.
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)
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. WARNING Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.
General Information Applicability CAUTION The boiler serial number must be provided when ordering replacement parts. Some replacement parts are not reverse compatible with previous versions of the Vitodens 200-W WB2B boiler. IMPORTANT When ordering replacement parts, provide either the 16-digit boiler serial number (on the bar code label) or the 12-digit ASME/NB serial number, located as shown underneath boiler front enclosure panel.
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. Whenever possible, install the boiler near an outside wall so that it is easy to duct the venting system to the boiler.
Set-up Before Set-up Before placing boiler in its installation location, ensure all necessary accessories are installed. CAUTION The boiler must be installed in such a way that gas ignition system components are protected from water (spraying, splashing, etc.) during boiler operation and service. Minimum Clearances Recommended minimum service clearances Side 12”/305 mm Top Front 12”/305 mm Back 0”/mm 28”/700 mm Side 0”/mm Fig. 2 Recommended min.
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. PRV PG EXT EXT CD BD BS GC BR 5369 297 v1.6 Fig.
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. 17¾” / 450 mm 12” / 305 mm 6¼” / 158 mm 55/8” / 143 mm 2¾” / 70 mm IMPORTANT 33½” / 850 mm The maximum ambient temperature must not exceed 104ºF / 40ºC.
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 a 1. 3/ ”/10 8 mm 2. Following are the installation instructions for the mounting bracket on each material. Skip to the installation instructions applicable to your installation requirements. CAUTION b*1 Fig. 5 Whichever mounting method is used, ensure that the bracket is tightly and securely fastened to wall.
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. 6. a Fig. 6 General installation of mounting bracket Install mounting bracket on wood studs as per Fig. 7. Drill 3/16” pilot holes to insert mounting bolts. Ensure that holes are located in the center of each wood stud.
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; do not remove completely. 4. 3. Remove front enclosure panel (lift up and pull towards you). 3. For installation of the mounting bracket, see “Wall mounting” on page 14 of this manual. 4.
Boiler Connections Connections Connecting the power supply See Power/Pump Module Installation Instructions The Vitodens 200-W boiler is shipped with a Power/Pump module, which requires a 120 VAC power supply from a wall receptacle. The module contains a 120/230 VAC step-up transformer for 230 VAC operation. Refer to the Installation Instructions shipped with the module or those contained in this manual for wiring details (see page 52).
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 on: – pipe length – number of fittings – type of gas – maximum input requirements of all gas appliances in the residence. IMPORTANT Design piping layout in such a way that piping does not interfere with serviceable components. Fig.
Boiler Connections Connections (continued) Gas piping pressure test When performing the gas piping pressure test, ensure the following requirements are met. WARNING Never check for gas leaks with an open flame. WARNING Exposing boiler gas pressure regulator and gas valve to extreme pressures renders warranty null and void. IMPORTANT ½ psig = 14 ”w.c. 1.
Boiler Connections Connections (continued) Heating water connections 1. Thoroughly flush heating system (particularly before connecting the boiler to an existing system). 2. Connect boiler to the heating system. Max. operating pressure . . . . . . . . . . . . . . . . . . . . . . . . 3 bar / 45 psig Test pressure . . . . . . . . . . . . . . 4 bar / 60 psig IMPORTANT Damage resulting from pressure exceeding those values stated is not covered by Viessmann warranty. AV PRV BF BD BWS BWR Fig.
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. See Vitodens 200-W WB2B Start-up/Service Instructions for applicable system coding information. Making the DHW connections 1.
Boiler Connections Connections (continued) Making the DHW connections (continued) 1. With a Vitocell 100 DHW storage tank: Insert DHW tank temperature sensor into sensor well as shown. With a Vitocell 300 DHW storage tank: Refer to the Vitocell 300 Installation Instructions shipped with the DHW storage tank for details. 1. 5 IMPORTANT Follow the Installation Instructions supplied with the Viessmann DHW storage tank when mounting and securing DHW tank temperature sensor .
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. 3. Fold down the control unit. 4. Release locking tabs as shown. 2. 2x 5. Remove cover. 1. CAUTION When running and securing connecting cables on site, ensure that the maximum permissible temperatures of the cables are not exceeded. 5. 6.
Boiler Connections Connections (continued) Connecting DHW sensor 1.Attach the DHW sensor to the quick connect plugs provided from the boiler control board (see page 22). Install DHW tank temperature sensor as described in the Vitocell Installation Instructions supplied with the DHW storage tank. Field Connection X9 Connector (boiler control board) Fig. 18 High altitudes setting In the factory default setting, the boiler is equipped to operate in altitudes of up to 5,000 ft. / 1,500 m.
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. The drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493.
Boiler Connections Safety Connections and Pressure Testing Installing boiler safety devices 1. Remove loosely pre-assembled combination pressure relief valve and drain valve assembly. 2. Apply sufficient amount of pipe sealant to both ends of all pipe fittings , , and , and install onto tees and . Fig. 21 Legend Extension, 2¼”x ¾” Tee, ¾” Brass nipple, length 3” x ¾” Tee, ¾” Drain valve connection, ¾” Brass nipple, length 2” x ¾” Pressure relief valve, ¾” NPT 3. Install pressure relief valve tighten.
Boiler Connections Safety Connections and Pressure Testing (continued) Performing a boiler pressure test The boiler must be leak tested before being placed in operation. Before boiler is connected to piping or electrical power supply, it must be hydrostatically pressure tested. 1. After installing safety devices (see previous page), install temporary cap on ¾” x 2” nipple. 2. Cap supply and return connections. 3.
Installation Examples General The schematics on the following pages are to be seen as guidelines only. They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local Viessmann sales representative office. Clearances A minimum of 2” / 51 mm circumferential clearance from non-insulated hot water pipes to combustible construction must be maintained.
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. 23 7 19.7 6 16.4 5 13.1 4 9.8 3 6.6 2 3.3 1 0 0 Fig. 22 m 8 Supply head pressure (ft. water) ft. 26 Pressure drop (primary circuit) for Vitodens 200-W, WB2B 19, 26, 35 For sizing an on-site circulation system. Max. flow rate 6.2 USGPM/1400 L/h 0 0 500 2.2 1000 4.4 1500 6.6 2000 L/h 8.
Boiler Connections Installation Examples (continued) System layout 1 Vitodens 200-W, WB2B with a direct-connected heating circuit 1 B C A L D AV G PRV TPV E J H 5 M K F I Fig. 23 5369 297 v1.
Boiler Connections Installation Examples (continued) System layout 2 Vitodens 200-W, WB2B with a direct-connected heating circuit and low-loss header 1 B C A L D AV G PRV TPV 5 H J P E N 5 O K M F Legend AV Air vent (models WB2B 19, 26, 35) PRV Pressure relief valve TPV Temperature and pressure relief valve Vitodens 200-W WB2B boiler with Vitotronic 200, HO1 outdoor reset control Outdoor temperature sensor Remote control Vitotrol 300 (optional) Heating circuit Boiler pump sÖ* DHW circulatin
Boiler Connections Installation Examples (continued) System layout 3 Vitodens 200-W, WB2B with... – DHW storage tank – one heating circuit with mixing valve and system separation 1 AV N 2 PRV Y F1 J TPV PRV Y Y F2 P 5 O M I Fig. 25 5369 297 v1.
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 B 1 O A I D G C E 2 AV TPV J 5 PRV V M F N L R P H Q M K Fig. 26 * See pages 52 and 56.
Boiler Connections Installation Examples (continued) 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 B 1 O C A I D G E 2 AV TPV J PRV 5 M F N F1 T L P 5 S Q H M R Fig. 27 5369 297 v1.
Boiler Connections Installation Examples (continued) System layout 6 Vitodens 200-W, WB2B with...
Boiler Connections Installation Examples (continued) System layout 7 Vitodens 200-W, WB2B with... – direct-connected heating circuit – one heating circuit with system separation B1 R D C E 2 A J AV TPV 5 K PRV V N G O S M P Q I F N L Fig. 29 5369 297 v1.
Boiler Connections Installation Examples (continued) System layout 8 Vitodens 200-W, WB2B with... – DHW storage tank – low-loss header – multiple heating circuits with mixing valves D B 1 P A H H H AV 2 E 2 E 2 E M PRV TPV F L F F 5 Q O C 5 I G G G J K Fig. 30 N When designing a system as illustrated above, please contact your local Viessmann Sales Representative for assistance.
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 function must be programmed in the Start-up/Service Instructions. . 1 2 TPV 5 PRV M 5 * Alternative location of the expansion tank * 5369 297 v1.6 Fig.
Boiler Connections Installation Examples (continued) Boiler in heating/cooling application The boiler, when used in connection with a refrigeration system, must be installed ensuring the chilled medium is piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler. See illustration on the left. v2 v1 Fig.
Boiler Connections Installation Examples (continued) Boiler with low water cut-off (remote-mounted, field supplied) Hi-Vent LWCO Vitodens 200-W Hi-Vent LWCO Vitodens 200-W A low water cut-off may be required by 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. Do not install an isolation valve between boiler and low water cut-off.
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.
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. IMPORTANT 1. It is essential to route cables as illustrated to ensure freedom of movement of control unit.
Control Connections Electrical Connections (continued) Power/Pump module electrical connectors Power/Pump Module 123 123 123 143 120/230 Transformer L L2 L1 G N N L N L N L N L 144 145 N 40 20A 21 20 50 40 20A 21 20 50 143 144 145 123 123 123 28 LG N Fig. 36 See Vitodens 200-W WB2B Start-up/Service Instructions for applicable system coding information. 42 5369 297 v1.
Control Connections Electrical Connections (continued) Boiler control board GC 130 electrical connections X3 LON LON X4 7 654 321 20 40 1234 A8 A8 Boiler Control Board GC 130 Fig. 37 5369 297 v1.
Control Connections Electrical Connections (continued) Connection between the Power/Pump module and boiler Power/Pump module 123 123 123 LOW WATER CUT--OFF SAFETY DEVICE --TYPICAL MAIN POWER SUPPLY 120V, 60HZ, 12A NGL 143 MAIN DISCONNECT SWITCH L 120/230 Transformer L2 L1 P1 P2 A N 40 L N L 20A N L 21 N L 20 L2 L1G N 40 20A 21 143 145 144 1 2 3 145 1 2 3 28 LG N 50 20 145 N 50 1 2 3 120VAC WALL RECEPTACLE 144 20 L N 230 VAC 1.
Control Connections Electrical Connections (continued) Accessories electrical connections See the following pages for connection to the individual accessories.
Control Connections Electrical Connections (continued) Accessing the X3 plug 1. Remove the control unit cover (see page 23). 3. 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. 1. 3. Reinstall the control cover. X3 2. Fig. 40 Connecting the low-loss header sensor 1. Connect the low-loss header sensor (if used) to terminals X3.4/X3.5 on the boiler control board. 7 6 5 4 3 2 1 1.
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). 1. 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. In case of a multi-storey building, mount outdoor temperature sensor in the upper half of the second floor.
Control Connections Electrical Connections (continued) External switching of heating program/External heat demand / External blocking 1 2 3 1 2 3 1 2 3 143 144 145 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 address ‘91’ Power/Pump module 143 144 145 1 2 3 1 2 3 1 2 3 See Start-up/Service Instructions with regard to changing the cod
Control Connections Electrical Connections (continued) Connecting the LON communication module Installing the LON module to the Vitotronic 200-H, HK1M mixing valve controller 2. 1. Remove the Vitotronic 200-H, HK1M front cover. 2. Insert the LON module into the Vitotronic 200-H, HK1M control board. 1. 3. Connect the LON connector cable to the LON module (see page 50). See the Vitotronic 200-H, HK1M Installation Instructions. 3. Fig.
Control Connections Electrical Connections (continued) Connecting the LON communication module (continued) Vitotronic 200-H HK1M LON L LON X1 LON X2 X 7 X4 7 6 5 4 3 2 1 100 35 20 96 1 40 X3 X 8 X 9 Boiler Control Board GC130 X11 LON KMK Fig. 48 5369 297 v1.6 See the Vitotronic 200-H, HK1M Installation Instructions.
Control Connections Electrical Connections (continued) Accessory kit connections for heating circuit with mixing valve part no. 7133392 (old version) Mixing Valve Controller 1 2 ON 3 4 S1 141 Dip Switch Setting 2 17 145 145 1 2 3 145 L 1 LON X1 LON X2 X 7 X4 7654 321 100 35 20 96 40 X3 X 8 Boiler Control Board GC130 X 9 X11 LON KMK 5369 297 v1.6 Fig. 49 See the Mixing Valve Controller Kit for one heating circuit with mixing valve Installation Instructions.
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.
Control Connections Electrical Connections (continued) Wiring diagram for the boiler / Power/Pump module X9.3 X9.
Control Connections Installing the Programming Unit of the Control Closing the control unit and inserting the programming unit 1.Install the cover onto the control board. 1. 2.Flip the control board back into position. 3.Secure the locking tabs as shown. 3. 2. 4.Install the Vitotronic, programming unit. 5. 5.Close control unit cover. 4. Fig. 51 Reinstalling the front enclosure panel 1. 1. Set front enclosure panel on the guide rails and push in place. 2. Tighten screws at the bottom.
Additional Information Technical Data Table 4 Boiler Model Model No. WB2B Natural gas / Liquid propane gas CSA input CSA output/DOE *1 heating capacity MBH kW MBH kW Net I=B=R rating *2 MBH Heat exchanger surface area ft.2 m2 19 26 35 31-67 9-20 28-61 8-18 31-93 9-27 28-85 8-25 31-125 9-37 28-114 8-33 53 74 99 10.23 0.95 10.23 0.95 10.23 0.95 Min. gas supply pressure Natural gas Liquid propane gas “w.c. “w.c. 4 10 4 10 4 10 Max.
Additional Information Technical Data (continued) Table 4 (continued) Boiler Model Model No.
Additional Information Wiring Diagram Complete system wiring diagram 99oC 210oF X1 X2 LON LON X1 X2 X8.15 PWM X8.13 HALL X8.12 GND X8.9 X8.8 X6.1 X2.2 X2.1 X9.9 X9.8 X8.1 X8.2 X8.3 X8.4 X9.10 X9.11 K4 A7 A8 INTERNAL CONNECTIONS OR X8.1 X9.1 GC130 BURNER IGNITION MODULE X9.3 KMK1KMK2 X8.11 X1 X8.10 X9.4 A8 WARNING! DISCONNECT POWER BEFORE SERVICING BOILER. CAUTION! LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.
Additional Information Wiring Diagram (continued) Complete system wiring diagram (continued) Legend 1 Outside Temperature Sensor Fixed High Limit A1 Main PCB (GC130 Ignition Module) 2 Flow Temperature Sensor/Low Loss Header Fault Alarm Output A2 Internal Power Supply Unit 3 Boiler Water Temperature Sensor Ignition Transformer A3 Optolink 5 DHW Temperature Sensor Power Supply Accessory (Not Used) A4 Burner Control Unit 11 Ionization Electrode Fan Motor A5 Programming Unit 15 Flue Gas
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. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
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 Total max. output current 8A T3.5A -X3 300VA boiler power supply 230 VAC -K1, -K2, -K3, -K4, -K5 operating contacts -F1, -F2 fuses (slow blow) -T transformer H1 communication board 5369 297 v1.6 Fig.
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Printed on environmentally friendly (recycled and recyclable) paper. Technical information subject to change without notice. 64 Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario • N2V 2G5 • Canada Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann.ca • info@viessmann.ca 5369 297 v1.6 Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island • 02886 • USA Tel. (401) 732-0667 • Fax (401) 732-0590 www.viessmann-us.com • info@viessmann-us.
