Viessmann Vitodens 200-W System User manual

VITODENS 200-W
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 W


Read and save these instructions
for future reference.
IMP RTANT
This trademar is registered with the U.S. Patent and Trademar Office.
Please file in Service Binder
5441 444 v1.3 11/2011

Safety, Installation and Warranty Requirements
2
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).
Licensed professional heating
contractor
The installation, service, and
maintenance of this equipment must
be performed by a licensed
professional heating contractor.
"
Please see section
entitled “Important
Regulatory and
Installation
Requirements” in the
Installation Instructions.
Product documentation
Read all applicable documentation
before commencing installation. Store
documentation near boiler in a readily
accessible location for reference in
the future by service personnel.
"
For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and
Installation Requirements”
in the Installation Instructions.
Carbon monoxide
Improper installation, service and/or
maintenance can cause flue products
to flow into living space. Flue
products contain poisonous carbon
monoxide gas.
"
For information
pertaining to the proper
installation, service and
maintenance of this
equipment to avoid
formation of carbon monoxide, please
see the Installation Instructions of the
Vitodens 00-W Venting System.
Equipment venting
Never operate boiler without an
installed venting system. An improper
venting system can cause carbon
monoxide poisoning.
Warranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
Advice to owner
Once the installation wor is
complete, the heating contractor
must familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before
the heating season begins.
Warning
This boiler requires fresh air for safe operation and must be installed with provisions for adequate combustion and
ventilation air (in accordance with local codes and regulations of authorities having jurisdiction).
Do not operate this boiler in areas with contaminated combustion air. High levels of contaminants such as dust, lint or
chemicals can be found at construction sites, home renovations, in garages, wor shops, in dry cleaning/laundry facilities,
near swimming pools and in manufacturing facilities.
Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe personal injury
and/or loss of life. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in
accordance with the Start-up/Service Instructions of the boiler.
perating and Service Documentation
It is recommended that all product documentation such as parts lists, operating and service instructions be handed over to
the system user for storage. Documentation is to be stored near boiler in a readily accessible location for reference by
service personnel.
5441 444 v1.3
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Table of Contents
3
Page
General Information Important Regulatory and Installation Requirements 5
...........................
About these Installation Instructions 7 ...........................................................
Applicability 8 ...........................................................................................................
Product Information 8 ...........................................................................................
Mechanical Room 9 ................................................................................................
Set-up Before Set-up 10
.........................................................................................................
Minimum Clearances 10 ...........................................................................................
Boiler Connections Preparing the Connections 11
..............................................................................
Connections overview 11 ........................................................................................
Wall Mounting 13 ......................................................................................................
Installing the wall mounting brac et 13 ...........................................................
Mounting the boiler 15 .............................................................................................
Connections 16 ...........................................................................................................
Connecting the power supply 16 .........................................................................
Boiler venting 16 ........................................................................................................
Proper piping practice 16 .........................................................................................
Gas shut-off valve connection 16 ......................................................................
Gas connection and piping 17 ..............................................................................
Gas piping pressure test 18 ...................................................................................
Heating water connections 19 .............................................................................
Ma ing the DHW connections 20 ........................................................................
Accessing the control unit cables 21 ................................................................
High altitudes setting 22 .........................................................................................
Condensate connection 23 .....................................................................................
Safety Connections and Pressure Testing 24 .................................................
Installing boiler safety devices 24 ......................................................................
Performing boiler pressure test 25 ......................................................................
Installation Examples 26 .........................................................................................
Waterside flow (primary circuit) 27 ....................................................................
System layout 28 ......................................................................................................
Boiler with low water cut-off (remote-mounted, field supplied) 29 ......
Venting Connection 29 ............................................................................................
5441 444 v1.3

Table of Contents
4
Control Connections Electrical Connections 30
.......................................................................................
Connecting the Power/Pump module 30 .........................................................
Power/Pump module electrical connectors 32 ..............................................
Connecting the Cascade Communication Module 33 ................................
Installing the Programming Unit of the Control Unit 34 ............................
Closing the control unit and inserting the programming unit 34 ...........
Reinstalling the front enclosure panel 34 .........................................................
Additional Information Technical Data 35
......................................................................................................
Wiring Diagram 37 ......................................................................................................
Complete system wiring diagram 37 ..................................................................
Lighting and perating Instructions 39 ............................................................
Ladder Diagram 40 ....................................................................................................
5441 444 v1.3

General Information
5
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. use the
National Electrical Code ANSI/NFPA
70. The heating contractor must also
comply with both the Standard for
Controls and Safety Devices for
Automatically Fired Boilers,
ANSI/ASME CSD-1, and the Installation
Code for Hydronic Heating Systems,
CSA B214-01, where required by the
authority having jurisdiction.
Instructing the system user
The installer of the system is
responsible to ensure the system
operator/ultimate owner is made
familiar with the system functioning,
its activation, and its shut-down.
Initial start-up
Initial start-up must be performed by a
qualified heating contractor. Proper
completion of the Maintenance Record
by the heating contractor is also
required.
Working on the equipment
The installation, adjustment, service,
and maintenance of this boiler must be
done by a licensed professional heating
contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water boilers.
There are no user serviceable parts on
the boiler, burners, or control.
The following topics must be
covered:
Proper system operation sequence.
Explain the equipment.
Demonstrate an emergency
shut-down, what to do and what not.
Explain that there is no substitute for
proper maintenance to help ensure
safe operation.
The Maintenance Record is located in
the Start-up and Service Instructions.
Please carefully read this manual prior
to attempting start-up, maintenance
or service. Any warranty is null and
void if these instructions are not
followed.
For information regarding other
Viessmann System Technology
componentry, please reference
documentation of the respective
product.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main gas supply valve. Ta e
precautions in all instances to avoid
accidental activation of power during
service wor .
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include low
water cut-offs, flow switches (if used),
staging controls, pumps, motorized
valves, air vents, thermostats, etc.
Technical literature
Literature for the Vitodens boiler:
- Technical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of other Viessmann
products utilized and installed
- Installation codes mentioned
in this manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
This product comes with several
safety instruction labels attached.
Do not remove!
Contact Viessmann immediately if
replacement labels are required.
5441 444 v1.3

General Information
6
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 dec s and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal
vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide
detector with an alarm and battery bac -up is installed on the floor level where the gas equipment is to be
installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served
by the side-wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professional for the installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic,
the hard-wired carbon monoxide detector with alarm and battery bac -up may be installed on the next adjacent
floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally
vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch
in size, ”GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate
from the dwelling, building or structure used in whole or in part for residential purposes.
5441 444 v1.3

General Information
7
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”, ”CAUTI N”, and ”IMP RTANT”. See below.
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation,
operation or maintenance which
pertain to the product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
5441 444 v1.3
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTI N
IMP RTANT

General InformationGeneral Information
8
Applicability
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. Refer to page 15
for instructions on how to remove front
enclosure panel.
NG and LPG
Model No. WB2B 80
Serial No. 7424193 jjjjjjjjj
Model No. WB2B 105
Serial No. 7424194 jjjjjjjjj
NG only
Model No. WB2B 80
Serial No. 7374868 jjjjjjjjj
Model No. WB2B 105
Serial No. 7374869 jjjjjjjjj
Product Information
Natural/Liquid propane gas-fired wall-mounted condensing heating boiler for
weather-responsive operation in closed loop, forced circulation hot water heating
systems for space heating and domestic hot water (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 it is
required.
Boiler model must be selected based on an accurate heat loss calculation of the
building. Ensure boiler model is compatible with connected radiation.
Vitodens 200-W, WB2B series boilers are factory-tested and calibrated. Further
gas valve adjustments are not typically required during field start-up.
See the Vitodens 00-W, WB B
Start-up/Service Instructions.
.
5441 444 v1.3
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.
CAUTI N
IMP RTANT
Fig. 1 Locating boiler serial numbers for ordering replacement parts
1 -digit ASME/NB serial number
(located on metallic plate riveted
to the heat exchanger)
16-digit boiler serial number
on white bar code label
labelled “Boiler Serial Number”
is also located on the bottom
of the boiler.
Stainless steel Inox-Radial
heat exchanger
5441 444 v1.3

General Information
9
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 tan (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.
Locate the boiler on a wall capable of supporting the weight of the boiler filled with water (see section entitled “Technical
Data” on page 55 for information required for total boiler weight calculation). Ensure that the boiler location does not
interfere with the proper circulation of combustion and ventilation air of other fuel burning equipment within the mechanical
room (if applicable).
The maximum room temperature of the mechanical room where the boiler is located must not exceed 104ºF / 40ºC.
Installation area conditions
Ensure ambient temperatures are
higher than 32°F / 0°C and lower
than 104°F / 40°C.
Prevent the air from becoming
contaminated by halogenated
hydrocarbons (e.g. as contained in
paint solvents or cleaning fluids) and
excessive dust (e.g. through grinding
or polishing wor ). Combustion air for
the heating process, and ventilation
of the boiler room must be free of
corrosive contaminants. To that end,
any boiler must be installed in an area
that has no chemical exposure. The
list to the right indicates the main,
currently nown sources.
Avoid continuously high levels of
humidity (e.g. through frequent
drying of laundry).
Never close existing ventilation
openings.
Sources of combustion and ventilation
air contaminants
Areas likely to contain contaminants:
New building construction
Swimming pools
Remodelling areas, hobby rooms
Garages with wor shops
Furniture refinishing areas
Dry cleaning/laundry areas and
establishments
Auto body shops
Refrigeration repair shops
Metal fabrication plants
Plastic manufacturing plants
Photo processing plants
Beauty salons
Products containing contaminants:
Chlorine-type bleaches, detergents
and cleaning solvents found in
household laundry rooms
Paint and varnish removers
Hydrochloric acid, muriatic acid
Chlorine-based swimming pool
chemicals
Spray cans containing
chlorofluorocarbons
Chlorinated waxes and cleaners
Cements and glues
Refrigerant lea s
Calcium chloride used for thawing
Sodium chloride used for water
softening salt
Permanent wave solutions
Adhesives used to fasten building
products and other similar items
Antistatic fabric softeners used in
clothes dryers
Boiler operation in marine environments
(damp, salty coastal areas)
The service life of the boiler’s exposed
metallic surfaces, such as the casing
and fan housing, is directly influenced
by proximity to damp and salty marine
environments. In such areas, higher
concentration levels of chlorides from
sea spray, coupled with relative
humidity, can lead to degradation of
the exposed metallic surfaces
mentioned above. Therefore, it is
imperative that boilers installed in such
environments not be installed using
direct vent systems which draw
outdoor air for combustion. Such
boilers must be installed using room air
dependent vent systems; i.e. using
room air for combustion. The indoor air
will have a much lower relative
humidity and, hence, potential
corrosion will be minimized.
5441 444 v1.3
Incorrect ambient conditions can lead
to damage to the heating system and
put safe operation at risk.
WARNING
If you notice fire coming from the
appliance, call the fire department
immediately! Do not attempt to
extinguish the fire unless qualified to
do so.
WARNING
Fire causes a risk of burns and
explosion!
H
HH
HShut down the boiler
H
HH
HClose fuel shut-off valves
H
HH
HUse a tested fire extinguisher,
class ABC.
WARNING
IMP RTANT

Set-up
10
Before Set-up
Before placing boiler in its installation
location, ensure all necessary
accessories are installed.
Minimum Clearances
Recommended minimum service clearances
For typical Vitodens installations, Viessmann
recommends installing the boiler with the clearances
shown in the illustration on the left.
Note:
The 12” (305 mm) side clearance specified is only
recommended to be able to view the boiler certified
rating plate, decal and also accomodate the PRV
installation it.
If the pressure relief valve is rotated 90º facing
forward by using an extension between the tee and
the boiler connection, then this clearance can be
reduced to b”. This b” clearance is only required to
be able to remove the boiler’s front cover and view
the rating plate attached to it, if needed.
This reduced clearance is also used in Vitodens
multiple boiler installation system as described in
the multiple boiler installation instructions.
The Vitodens 200-W, WB2B boiler is approved for
closet and alcove installation with the following
clearances to combustibles.
Table 1. Clearances
Top Front Rear Left Right Vent pipe
0 0 AL, CL 0 0 0 0
AL = Alcove
CL = Closet
See Vitodens 00-W WB B
Venting System Installation Instructions
for details.
5441 444 v1.3
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.
CAUTI N
Front
12”/305 mm
0”/mm
28”/700 mm
Side
0”/mm
Bac
Side
Fig. Recommended min. service clearances
Top15¾”/
400 mm
Note:
The Vitodens 200-W, WB2B boiler has passed the zero inches
vent clearance to combustibles testing requirements dictated by
the boiler Harmonized Standard ANSI Z21.13. CSA 4.9.2007
and therefore is listed for zero clearance to combustibles when
vented with a single-wall special venting system (AL-29-4C ma-
terial) or UL/ULC-listed CPVC gas vent material. The zero inches
vent clearance to combustibles for the Vitodens 200-W, WB2B
boiler supercedes the clearance to combustibles listing that ap-
pears on the special venting system label.

Boiler Connections
11
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” NPTF
BD Boiler Drain
CD Condensate Discharge tubing,1”
GC Gas Connection, 1” NPTM
PRV Pressure Relief Valve
BF Boiler Fill
* G 1½” to 1¼” NPT adaptor
and gasket
5441 444 v1.3
BWS BWR
CD
PRV
BD
} }
**
GC
BF
Fig. 3 Piping connections for Vitodens 00-W, WB B 80, 105

Boiler Connections
12
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.
Legend
PG Pressure Gauge
Reference point for top of
boiler
Vitodens 200-W boiler
Finished floor level
*1Recommendation
When preparing gas, water
and electrical connections in
the field, see section entitled
“Wall Mounting” on page 13
of this manual for information
regarding the installation of
the wall mounting bracket.
The maximum ambient temperature
must not exceed 104ºF / 40ºC.
1. Heating water connections and gas
connection to be made in the field.
See illustration to the left and
connection-specific section for
details.
2. See subsection entitled “Power
supply connection” for details
regarding power supply to the
Vitodens 200-W WB2B boiler.
5441 444 v1.3
78” / 1975 mm
for single boiler
installation
*1
Fig. 4 Piping connections for Vitodens 00-W, WB B 80, 105
Front view Side view
19” /
480mm
9½”/
240mm
11 5/8“ / 295mm
for WB2B 80-105
using the coaxial
vent system
4¼” /
108mm
33½” / 850mm
43” / 1090mm
3” / 80mm
9½” / 240mm
15¾” /
400mm
6½” /
165mm
9½” /
240mm
PG
9½”./
236mm
4” / 102mm
21” / 530mm
15¾”/
400mm
IMP RTANT

Boiler Connections
13
Wall Mounting
Installing the wall mounting bracket
Legend
Reference point for top of boiler
Mounting template
Finished floor level
Dimensions
a 19” / 483 mm
b 78” / 1975 mm
*1Recommendation
The Vitodens 200-W WB2B can be
wall-mounted on
Ha bric /concrete wall
Hwood studs
Hmetal studs
Following are the installation
instructions for the mounting brac et
on each material. S ip to the
installation instructions applicable to
your installation requirements.
Installation of mounting bracket on
brick/concrete wall:
1. Drill holes (Ø 3/8” / 10 mm), using
mounting template supplied with the
boiler.
2. Align wall mounting brac et and
attach to wall with the screws and
bolts supplied.
5441 444 v1.3
a
b*1
3
/
8
”/10 mm
2.
1.
Fig. 5
Whichever mounting method is used,
ensure that the bracket is tightly and
securely fastened to wall. Failure to
secure boiler properly could cause
boiler to loosen, posing a severe
safety hazard.
CAUTI N

Boiler Connections
Fig. 6 General installation of mounting bracket
a
a = 16”/407 mm
Fig. 7 Installation of mounting bracket on wood studs
16”/407 mm
3/16”
2x
Fig. 8 Installation of mounting bracket on metal studs
5/8”
2x
16”/407 mm
14
Wall Mounting (continued)
Installing the wall mounting bracket (continued)
Installation of mounting bracket on
wood and metal studs
To mount the Vitodens 200-W WB2B
boiler on wood or metal studs, install
mounting brac et on wall as shown in
Fig. 6.
Install mounting brac et 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.
Install mounting brac et on metal studs
as per Fig. 8.
Drill 5/8” pilot holes to insert mounting
bolts.
Ensure that holes are located in the
center of each metal stud.
Secure mounting brac et with bolts to
metal studs as shown below.
5441 444 v1.3

Boiler Connections
15
Wall Mounting (continued)
Mounting the boiler
1. To open hinged cover, lift cover A
and pivot control unit flap Bdown.
All boiler controls are located behind
the control unit flap.
2. Loosen the screws at the bottom of
the boiler; do not remove
completely.
3. Remove front enclosure panel (lift up
and pull towards you).
For installation of the
mounting bracket, see
“Wall mounting” on
page 13
of this manual.
4. Mount boiler onto the mounting
brac et and connect boiler to the
installation fittings.
5441 444 v1.3
2x
4.
3.
2.
Fig. 9
1.

Boiler Connections
16
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 53).
Boiler venting
The Vitodens 200-W WB2B boiler
comes with a pre-installed vent pipe
adaptor (as shown in fig. 10).
Run venting system, single-wall or
coaxial, through the side wall or the
roof, ta ing the shortest possible route
and at a rising angle (min. 3º).
See Installation Instructions
WB B Venting System for
details.
Proper piping practice
Support piping by proper suspension
method. Piping must not rest on or be
supported by boiler.
Gas shut-off valve connection
1.Ma e gas connections in accordance
with codes CAN/CSA B149.1 and .2
or National Fuel Gas Code ANSI
Z223.1/NFPA 54,as well as local
codes.
2. Connect gas shutoff valve to the
boiler gas connection.
3. Once connected close gas shutoff
valve on boiler.
See following page for details on gas
connection and piping.
5441 444 v1.3
Fig. 10
Use moderate amount of dope
Leave 2 end threads bare
2 imperfect threads
Fig. 11 Pipe threads
Fig. 1 Gas valve connection
Gas
connection

Boiler Connections
17
Connections (continued)
Gas connection and piping
Legend
Gas connection ∅1“ (NPT)
Accessible manual gas
shutoff valve
Ground joint union
Drip leg
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.
Design piping layout in such a way that
piping does not interfere with
serviceable components.
2. Before connecting boiler to gas line,
install ground joint union, capped
drip leg and a manual equipment
shutoff valve as shown. Valves must
be listed by a nationally recognized
testing agency. Ma e boiler gas
connection as shown in Fig. 13.
3. Perform gas piping pressure test as
described in the following
subsection.
Max. gas supply pressure: 14 “w.c.
4. Identify shutoff valves as such with
a tab and familiarize
operator/ultimate owner of boiler
with these valves.
See Vitodens 00-W WB B
Start-up/Service Instructions
for applicable system coding
information.
5441 444 v1.3
Fig. 13 Gas pipe connections
5441 444 v1.3
The gas supply piping must be leak
tested before placing the boiler in
operation.
WARNING
Ensure that gas piping is large
enough for all appliances in the
residence. No noticeable gas
pressure drop in the gas line must
occur when any unit (or combination
of units) lights or runs.
CAUTI N
IMP RTANT
IMP RTANT

Boiler Connections
18
Connections (continued)
Gas piping pressure test
When performing the gas piping pressure test, ensure the following requirements are met.
½ psig = 14 ”w.c.
1. Isolate the boiler from the gas supply
piping system using the individual
manual shutoff valve during pressure
tests equal to or less than ½ psig/
14 ”w.c.
2. The boiler and its individual shutoff
valve must be disconnected from the
gas supply piping system during any
pressure testing of that system at
test pressures in excess of
½ psig/14 ”w.c.
3. Perform lea test.
Use approved liquid spray solution
for bubble test. Ensure that no liquid
is sprayed on any electrical
components, wires or connectors.
Do not allow lea detection fluid to
contact gas valve regulator or
regulator vent opening.
4. Correct any and all deficiencies.
5. Remove air from gas line.
5441 444 v1.3
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.
WARNING
IMP RTANT

Boiler Connections
19
Connections (continued)
Heating water connections
Legend
BD Boiler Drain
BF Boiler Fill
BWS Boiler Water Supply
BWR Boiler Water Return
PRV Pressure Relief Valve
1. Thoroughly flush heating system
(particularly before connecting the
boiler to an existing system).
2. Connect boiler to the heating
system.
Max. operating
pressure 4 bar / 60 psig
........................
Test pressure 6 bar / 90 psig ..............
Damage resulting from pressure
exceeding those values stated is not
covered by Viessmann warranty.
5441 444 v1.35441 444 v1.3
PRV
BD BF
Fig. 14
BWR
BWS
IMP RTANT

Boiler Connections
20
Connections (continued)
Making the DHW connections
1. With a Vitocell 100 DHW storage
tank:
Insert DHW tan 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 tan for details.
Follow the Installation Instructions
supplied with the Viessmann DHW
storage tank when mounting and
securing DHW tank temperature
sensor .
5441 444 v1.3
Fig. 16 Vitocell-H 100 DHW storage tank
5
1. IMP RTANT
IF A DHW ST RAGE TANK THER
THAN A VIESSMANN VIT CELL 100
R 300 TANK IS USED, THE
INSTALLER MUST VERIFY PR PER
PERATI N F THE VIESSMANN
DHW TANK TEMPERATURE SENS R
WITH RIGINAL MANUFACTURER
F THE TANK. VIESSMANN
STR NGLY REC MMENDS THE
INSTALLATI N F A TEMPERATURE
TEMPERING VALVE IN THE DHW
SUPPLY LINE.
WARNING