Viessmann Vitodens 200 WB2 11-44 User manual

VITODENS 200
Installation Instructions
for use by heating contractor
Vitodens 200
WB2 Series
Wall-mounted, gas-fired condensing boiler
For natural gas and liquid propane
Heating input NG 55 to 230 MBH
16 to 67 kW
Heating input LP 55 to 214 MBH
16 to 63 kW
Read and save these instructions
for future reference.
IMPORTANT
Vitodens 200, WB2-44/60
(with preinstalled vent pipe adaptor)
Please file in Service Binder
5285 960 v1.2 10/2007

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/orloss
of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
HLicensed 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.
HProduct 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.
HAdvice to owner
Once the installation work 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.
HCarbon 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 200 Direct Vent System.
HEquipment venting
Never operate boiler without an
installed venting system. An improper
venting system can cause carbon
monoxide poisoning.
HWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
5285 960 v1.2
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Index
3
Page
Safety Important Regulatory and Installation Requirements 5...........................
General Information About these Installation Instructions 7..........................................................
Applicability 8............................................................................................................
Product Information 8...........................................................................................
Mechanical Room 9................................................................................................
Set-up Before Set-up 9.........................................................................................................
Minimum Clearances 9...........................................................................................
Boiler Connections Preparing the Connections 10..............................................................................
Connections overview 10........................................................................................
Wall Mounting 12......................................................................................................
Wall mounting bracket installation 12..............................................................
Mounting Vitodens 200 boiler 14........................................................................
Connections 14...........................................................................................................
Power supply connection 14..................................................................................
Flue gas connection 14...........................................................................................
Proper piping practice 15.........................................................................................
Gas connection and piping 15..............................................................................
Gas piping pressure test 17...................................................................................
Heating water connections 18.............................................................................
DHW Production Kit Installation 19....................................................................
Product information 19.............................................................................................
Making the DHW connections 19........................................................................
Electrical connection 21...........................................................................................
Condensate connection 21....................................................................................
Safety Connections and Pressure Testing 22.................................................
Installing safety devices on the boiler 22.......................................................
Performing pressure test on the boiler 23........................................................
Installation Examples 23.........................................................................................
Boiler in heating/cooling application 32.............................................................
Boiler with low water cut-off 34..........................................................................
Venting Connection 34............................................................................................
5285 960 v1.2

Index
4
Control Connections Electrical Connections 35.......................................................................................
Overview of electrical connections and plug-in connectors 35.............
Routing of connecting cables 37.........................................................................
Outdoor temperature sensor 39..........................................................................
DHW tank temperature sensor 40......................................................................
Low-loss header sensor 40.....................................................................................
External switching of heating program/External heat demand 41.........
External burner disable 41.......................................................................................
Power/Pump Module Installation 42...................................................................
Power supply connection 43..................................................................................
Technical data 43.......................................................................................................
Pump connections 43...............................................................................................
Product information (expansion board) 44.......................................................
Expansion board installation 44............................................................................
Technical data 45.......................................................................................................
Installing the Programming Unit of the Control Unit 46............................
Appendix Start-up Information 47..........................................................................................
Start-up and adjustments 47................................................................................
Technical Data 47......................................................................................................
Wiring Diagram 48......................................................................................................
Lighting and Operating Instructions 49............................................................
Ladder Diagram 50....................................................................................................
5285 960 v1.2

Safety
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.
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.
For installations in the Commonwealth of Massachusetts, the following local
requirements apply in addition to all other applicable NFPA requirements:
1) For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of
the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied.
1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:
a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch
services both the appliance and the carbon monoxide detector;
b. Have battery back-up power;
c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and
d. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527
CMR.
3. A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used.
Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation
instructions shall remain with the appliance or equipment at the completion of the installation.
4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the
location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away,
and read ”Gas Vent Directly Below”.
Continued on following page.
5285 960 v1.2

Safety
6
Important Regulatory and Installation Requirements (continued)
For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment where the bottom of the
vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied:
1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall:
a. Be located in the room that houses the appliance or equipment;
b. Be either hard-wired or battery powered or both; and
c. Shall comply with NFPA 720 (2005 Edition).
3. A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used.
Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation
instructions shall remain with the appliance or equipment at the completion of the installation.
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.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main gas supply valve. Take
precautions in all instances to avoid
accidental activation of power during
service work.
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
- System Design Guidelines
- 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.
5285 960 v1.2

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”, ”CAUTION”, and ”IMPORTANT”. 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.
5285 960 v1.2
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.
CAUTION
IMPORTANT

General Information
8
Applicability
Vitodens 200, WB2 44/60
Model No. Serial No.
WB2 11-44 7188578
and
WB2 15-60 7188577
Product Information
Gas-fired hot water heating boiler for space heating and domestic hot water
production with a stand-alone DHW tank (tank must be ordered separately).
For operation with modulating boiler water temperatures in closed loop, forced
circulation hot water heating circuits.
The Vitodens 200 comes factory set for operation with natural gas, with the
option of conversion to liquid propane using a field conversion kit.
(When planning on fuel converting the Vitodens 200 boiler, contact Viessmann to
order the required conversion kit.)
Boiler model must be selected based on an accurate heat loss calculation of the
building. Ensure boiler model is compatible with connected radiation.
5285 960 v1.2
Boiler serial number must be provided
when ordering replacement parts.
Some replacement parts are not
reverse compatible with previous
versions of the Vitodens 200 boiler.
CAUTION
Serial No. location
(16 digit barcode label)

General Information/Set-up
9
Mechanical Room
During the early stages of new home design, we recommend that proper
consideration be given to constructing a separate mechanical room dedicated to
gas- or oil-fired equipment including domestic hot water storage tanks.
The boiler must be located in a heated indoor space, near a floor drain, and as
close as possible to the wall.
Whenever possible, install boiler near an outside wall so that it is easy to duct the
venting system to the boiler.
Locate boiler on walls capable of supporting the weight of the boiler filled with
water (see section entitled “Technical Data” on page 47 for information required
for total boiler weight calculation). Ensure that boiler location does not interfere
with proper circulation of combustion and ventilation air of other fuel burning
equipment (if applicable) within the mechanical room.
The maximum room temperature of the mechanical room where the boiler is
located must not exceed 104°F/40°C.
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.
Recommended clearances to combustibles
The Vitodens 200 boiler is approved for closet and
alcove installation with the following clearances to
combustibles.
Top Front Rear Left Right Vent pipe*1
00AL,CL 0 0 0 0
AL = Alcove
CL = Closet
*1Refer to the Installation Instructions of the Vitodens 200
Venting System for details.
5285 960 v1.2
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.
CAUTION
Front
12”/305 mm
Top
12”/305 mm
0”/mm
28”/700 mm
Side
0”/mm
Back
Side
Diagram is not to scale.

Boiler Connections
10
Preparing the Connections
Use an approved pipe sealant or teflon tape when
connecting the following installation fittings.
Connections overview
This section constitutes an overview only! Refer to subsequent sections for
detailed information on individual piping connections.
Piping connections for Vitodens 200,
WB2 11-44 and 15-60
*These adapters are factory supplied.
Legend
BWR Boiler water return, 1¼” NPTF
BWS Boiler water supply, 1¼” NPTF
BD Boiler drain
DR Boiler heating return for
domestic hot water production,
1¼” NPTM
DS Boiler heating supply for
domestic hot water production,
1¼” NPTM
GC Gas connection, ¾” NPTM
PRV Pressure relif valve
NPT National Pipe Thread
5285 960 v1.2
BWS
BWR
NPT
GC
PRV
BD
DS DR
**
}}

Boiler Connections
11
Preparing the Connections
Connections Vitodens 200,
WB2 11-44/15-60
Legend
AV Air vent
BWR Boiler water return, 1¼” NPTF
BWS Boiler water supply, 1¼” NPTF
BD Boiler drain
DR Domestic hot water return,
1¼” NPTM
DS Domestic hot water supply,
1¼” NPTM
GC Gas connection, ¾” NPTM
PRV Pressure relief valve, ¾”
Vitodens 200, WB2
side view
Reference point for top of
boiler
Vitodens 200 boiler
Finished floor level
When preparing gas, water
and electrical connections in
the field, see section entitled
“Wall Mounting” on page 12
of this manual for information
regarding the installation of
the wall mounting bracket.
The maximum ambient temperature
must not exceed 95 ºF/35 ºC.
HHeating water connections and gas
connection to be made in the field.
See illustration to the left and
connection-specific section for
details.
HSee subsection entitled “Power
supply connection” for details
regarding power supply to the
Vitodens 200 boiler.
*1Recommendation
5285 960 v1.2
35.4”/900 mm
22”/550 mm24”/600 mm
2”/50 mm
min. 16”/400 mm
78”/1975 mm*1
AV
PRV
BWR
BWS
DS
GC
DR
BD
IMPORTANT

Boiler Connections
12
Wall Mounting
Wall mounting bracket installation
Legend
Reference point for top of boiler
Mounting template
Finished floor level
Dimensions
a 23.6”/600 mm
b 16”/407 mm
c3.7”/95mm
d0.7”/18mm
e 78”/1975 mm
*1Recommendation
The Vitodens 200 can be wall-mounted
on
Ha brick/concrete wall
Hwood studs
Hmetal studs
Following are the installation
instructions for the mounting bracket
on each material. Skip 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 bracket and
attach to wall with the screws and
bolts supplied.
5285 960 v1.2
1.
2.
a
b
c
d
e*1
2x
3/8”/10 mm
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.
CAUTION

Boiler Connections
Fig.
Installation of mounting bracket
a
a = 16”/407 mm
Fig.
Installation of mounting bracket on wood studs
16”/407 mm
3/16”
2x
Fig.
Installation of mounting bracket on metal studs
5/8”
2x
16”/407 mm
13
Wall Mounting (continued)
Mounting bracket installation (continued)
Installation of mounting bracket on
wood and metal studs
To mount the Vitodens 200 boiler on
wood or metal studs, install mounting
bracket on wall as shown in Fig. .
Refer to Figs. and below for more
detailed installation information.
Install mounting bracket on wood studs
as per illustration.
Drill 3/16” pilot holes to insert mounting
bolts.
Ensure that holes are located in the
center of each wood stud.
Install mounting bracket on metal studs
as per illustration.
Drill 5/8” pilot holes to insert mounting
bolts.
Ensure that holes are located in the
center of each metal stud.
Secure mounting bracket with bolts to
metal studs as shown.
5285 960 v1.2

Boiler Connections
Boiler Connections
14
Wall Mounting (continued)
Mounting Vitodens 200 boiler
1. Open hinged cover of the control unit
(by exerting slight pressure with
fingertip).
2. Unlock enclosure panel by loosening
screw as illustrated.
3. Remove front enclosure panel (lift up
and pull towards you).
4. Loosen the two screws holding base
panel in place and remove base
panel (if still installed) towards you.
5. Mount boiler onto the mounting
bracket.
For installation of the
mounting bracket, see
subsection entitled “Wall
mounting bracket
installation” on page 12 of
this manual.
6. Connect boiler to the installation
fittings.
Connections
Power supply connection
Installation Instructions
Power/Pump Module
The Vitodens 200 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 to power the
Vitodens 200 with 230 VAC. Refer to
the Installation Instructions shipped
with the module or those contained in
this manual for wiring details.
Flue gas connection
The Vitodens 200 boiler comes with a
preinstalled vent pipe adaptor (as
shown).
Run venting system, single-wall or
coaxial, through the side wall or the
roof, taking the shortest possible route
and at a rising angle (min. 3º).
See Installation Instructions
Vitodens 200 Venting System
for details.
5285 960 v1.2
2.
5.
1.
3.
4.
5285 960 v1.2

Boiler Connections
15
Connections (continued)
Proper piping practice
Support piping by proper suspension
method. Piping must not rest on or be
supported by boiler.
Gas connection and piping
GC Gas connection
1. Make gas connection 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. Close gas shutoff valve (field
supplied) on boiler.
3. Perform leak test.
4. Bleed air from gas supply pipe.
See following page for details on gas
connection and piping.
5285 960 v1.2
Use moderate amount of dope
Leave 2 end threads bare
T
hread pipe right length
2 imperfect threads
GC

Boiler Connections
16
Connections (continued)
Gas connection and piping (continued)
Gas connection
Accessible manual gas shutoff
valve (field supplied)
Ground joint union
Drip leg
Max. gas supply pressure: 14 “w.c.
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
–typeofgas
– 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. Make boiler gas
connection as shown on the left.
Gas connection (NPT) ∅¾“
...................
3. Perform gas piping pressure test as
described in the following
subsection.
4. Identify shutoff valves as such with
a tab and familiarize
operator/ultimate owner of boiler
with these valves.
5285 960 v1.25285 960 v1.2
IMPORTANT
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.
CAUTION
IMPORTANT

Boiler Connections
17
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 leak 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 leak detection fluid to
contact gas valve regulator or
regulator vent opening.
4. Correct any and all deficiencies.
5. Remove air from gas line.
5285 960 v1.2
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
IMPORTANT

Boiler Connections
18
Connections (continued)
Heating water connections
AV Air vent
BD Boiler Drain
BWR Boiler water return
BWS Boiler water supply
DR Boiler heating return for
domestic hot water production
DS Boiler heating supply for
domestic hot water production
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 3 bar/
.....
45 psig........................................................
Test pressure 4 bar/...........................
60 psig........................................................
Damage resulting from pressure
exceeding those values stated is not
covered by Viessmann warranty.
5285 960 v1.25285 960 v1.2
SVL
PRV
AV
BWR
BWS
DS
GC
DR
BD
IMPORTANT

Boiler Connections
19
DHW Production Kit Installation
Product information
The DHW Production Kit is required when using a stand-alone DHW storage tank
with the Vitodens 200 heating boiler. It comprises all components required for the
connection of a stand-alone tank.
See Vitodens 200
Start-up/Service Instructions
for applicable system coding
information.
See Installation Instructions
for DHW Production Kit for
standard equipment.
Making the DHW connections
1. Connect isolation valve and brass
adaptor to both the DHW supply and
return connections.
Apply sufficient amount of thread
sealant (supplied) when making the
connections.
Isolation valve
Gasket
5285 960 v1.2
2x
DS DR
1.
IMPORTANT

Boiler Connections
20
DHW Production Kit Installation (continued)
Making the DHW connections (continued)
2. 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.
Follow the Installation Instructions
supplied with the Viessmann DHW
storage tank when mounting and
securing DHW tank temperature
sensor .
5285 960 v1.2
2.
Vitocell-H 100 DHW storage tank shown
IMPORTANT
IF A DHW STORAGE TANK
OTHER THAN A
VIESSMANN VITOCELL
100 OR 300 TANK IS
USED, THE INSTALLER
MUST VERIFY PROPER
OPERATION OF THE
VIESSMANN DHW TANK
TEMPERATURE SENSOR
WITH ORIGINAL
MANUFACTURER OF THE
TANK. VIESSMANN
STRONGLY RECOMMENDS
THE INSTALLATION OF A
TEMPERATURE
TEMPERING VALVE IN THE
DHW SUPPLY LINE.
WARNING