Viessmann WB2B 45 User manual

VITODENS 200-W
Installation Instructions
for use by heating contractor
Vitodens 200-W, WB2B Series
Models 45, 60
Multiple boiler installations for gas-fired condensing boilers
For natural gas and liquid propane gas
Heating input 60 to 212 MBH
17 to 62 kW


Read and save these instructions
for future reference.
IMP RTANT
T is trademark is registered wit t e U.S. Patent and Trademark Office.
Please file in Service Binder
5441 443 v1.3 10/2011

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 wit t e
instructions listed below and details printed in t is 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
T e installation, service, and
maintenance of t is equipment must
be performed by a licensed
professional eating 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
t e 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 wit out an
installed venting system. An improper
venting system can cause carbon
monoxide poisoning.
Warranty
Information contained in
t is and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
Advice to owner
Once t e installation work is
complete, t e eating contractor
must familiarize t e system
operator/ultimate owner wit all
equipment, as well as safety
precautions/requirements, s ut-down
procedure, and t e need for
professional service annually before
t e eating season begins.
Warning
T is boiler requires fres air for safe operation and must be installed wit provisions for adequate combustion and
ventilation air (in accordance wit local codes and regulations of aut orities aving jurisdiction).
Do not operate t is boiler in areas wit contaminated combustion air. Hig levels of contaminants suc as dust, lint or
c emicals can be found at construction sites, ome renovations, in garages, works ops, in dry cleaning/laundry facilities,
near swimming pools and in manufacturing facilities.
Contaminated combustion air will damage t e 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 eating contractor at least once a year in
accordance wit t e Start-up/Service Instructions of t e boiler.
perating and Service Documentation
It is recommended t at all product documentation suc as parts lists, operating and service instructions be anded over to
t e system user for storage. Documentation is to be stored near boiler in a readily accessible location for reference by
service personnel.
5441 443 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 t e wall mounting bracket 13 ...........................................................
Mounting t e boiler 15 .............................................................................................
Connections 16 ...........................................................................................................
Connecting t e power supply 16 .........................................................................
Boiler venting 16 ........................................................................................................
Proper piping practice 16 .........................................................................................
Gas s ut-off valve connection 16 ......................................................................
Gas connection and piping 17 ..............................................................................
Gas piping pressure test 18 ...................................................................................
Heating water connections 19 .............................................................................
Making t e DHW connections 20 ........................................................................
Accessing t e control unit cables 21 ................................................................
Hig 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 wit low water cut-off (remote-mounted, field supplied) 29 ......
Venting Connection 29 ............................................................................................
5441 443 v1.3

Table of Contents
4
Control Connections Electrical Connections 30
.......................................................................................
Connecting t e Power/Pump module 30 .........................................................
Connecting t e Cascade Communication Module 33 .................................
Installing the Programming Unit of the Control Unit 34 ............................
Closing t e control unit and inserting t e programming unit 34 ...........
Reinstalling t e 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 443 v1.3

General Information
5
Important Regulatory and Installation Requirements
Codes
T e installation of t is unit s all be in
accordance wit local codes or, in t e
absence of local codes, use
CAN/CSA-B149.1 or .2 Installation
Codes for Gas Burning Appliances for
Canada. For U.S. installations use t e
National Fuel Gas Code ANSI Z223.1.
Always use latest editions of codes.
In Canada all electrical wiring is to be
done in accordance wit t e latest
edition of CSA C22.1 Part 1 and/or
local codes. In t e U.S. use t e
National Electrical Code ANSI/NFPA
70. T e eating contractor must also
comply wit bot t e Standard for
Controls and Safety Devices for
Automatically Fired Boilers,
ANSI/ASME CSD-1, and t e Installation
Code for Hydronic Heating Systems,
CSA B214-01, w ere required by t e
aut ority aving jurisdiction.
Instructing the system user
T e installer of t e system is
responsible to ensure t e system
operator/ultimate owner is made
familiar wit t e system functioning,
its activation, and its s ut-down.
Initial start-up
Initial start-up must be performed by a
qualified eating contractor. Proper
completion of t e Maintenance Record
by t e eating contractor is also
required.
Working on the equipment
T e installation, adjustment, service,
and maintenance of t is boiler must be
done by a licensed professional heating
contractor w o is qualified and
experienced in t e installation, service,
and maintenance of ot 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, t e eating system, and all
external controls as 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 t e Vitodens boiler:
- Tec nical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of ot er Viessmann
products utilized and installed
- Installation codes mentioned
in t is 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 443 v1.3

General Information
6
Important Regulatory and Installation Requirements (continued)
For installations on t e Commonwealt of Massac usetts, t e following modifications to NFPA-54 c apter 10 apply:
Excerpt from 248 CMR 5-08:
2(a) For all side-wall orizontally vented gas fueled equipment installed in every dwelling, building or structure used in
w ole or in part for residential purposes, including t ose owned or operated by t e Commonwealt and w ere t e
side-wall ex aust vent termination is less t an (7) feet above finis ed grade in t e area of t e venting, including but
not limited to decks and porc es, t e following requirements s all be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At t e time of installation of t e side-wall orizontal
vented gas fueled equipment, t e installing plumber or gasfitter s all observe t at a ard wired carbon monoxide
detector wit an alarm and battery back-up is installed on t e floor level w ere t e gas equipment is to be
installed. In addition, t e installing plumber or gasfitter s all observe t at a battery operated or ard wired carbon
monoxide detector wit an alarm is installed on eac additional level of t e dwelling, building or structure served
by t e side-wall orizontal vented gas fueled equipment. It s all be t e responsibility of t e property owner to
secure t e services of qualified licensed professional for t e installation of ard-wired carbon monoxide detectors.
a. In t e event t at t e side-wall orizontally vented gas fueled equipment is installed in a crawl space or an attic,
t e ard-wired carbon monoxide detector wit alarm and battery back-up may be installed on t e next adjacent
floor level.
b. In t e event t at t e requirements of t is subdivision can not be met at t e time of completion of installation, t e
owner s all ave a period of t irty (30) days to comply wit t e above requirements; provided, owever, t at
during said t irty (30) day period, a battery operated carbon monoxide detector wit an alarm s all be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Eac carbon monoxide detector as required in accordance wit
t e above provisions s all comply wit NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate s all be permanently mounted to t e exterior of t e building at a
minimum eig t of eig t (8) feet above grade directly in line wit t e ex aust vent terminal for t e orizontally
vented gas fueled eating appliance or equipment. T e sign s all read, in print size no less t an one- alf (1/2) inc
in size, ”GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. T e state or local gas inspector of t e side-wall orizontally vented gas fueled equipment s all not
approve t e installation unless, upon inspection, t e inspector observes carbon monoxide detectors and signage
installed in accordance wit t e provisions of 248 CMR 5.08(2)(a) 1 t roug 4.
(b) EXEMPTIONS: T e following equipment is exempt from 248 CMR 5.08(2)(a) 1 t roug 4:
1. T e equipment listed in C apter 10 entitled ”Equipment Not Required To Be Vented” in t e most current edition of
NFPA 54 as adopted by t e Board; and
2. Product Approved side-wall orizontally vented gas fueled equipment installed in a room or structure separate
from t e dwelling, building or structure used in w ole or in part for residential purposes.
5441 443 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 443 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.
Model No. WB2B 45
Serial No. 7374866 jjjjjjjjj
Model No. WB2B 60
Serial No. 7374867 jjjjjjjjj
Product Information
Natural/Liquid propane gas-fired wall-mounted condensing eating boiler for
weat er-responsive operation in closed loop, forced circulation ot water eating
systems for space eating and domestic ot water (DHW) production.
T e Vitodens 200-W, WB2B series boiler comes factory set for operation wit
natural gas. For a fuel conversion to liquid propane gas no conversion kit is
required
Boiler model must be selected based on an accurate eat loss calculation of t e
building. Ensure boiler model is compatible wit connected radiation.
Vitodens 200-W, WB2B series boilers are factory-tested and calibrated. Furt er
gas valve adjustments are not typically required during field start-up.
See the Vitodens 00-W, WB B
Start-up/Service Instructions.
.
5441 443 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 serial boiler 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 443 v1.3

General Information
9
Mechanical Room
During t e early stages of designing a new ome, we recommend t at proper consideration be given to constructing a
separate mec anical room dedicated to t e gas- or oil-fired eating equipment and domestic ot water storage tank(s).
T e boiler must be located in a eated indoor area, near a floor drain, and as close as possible to a wall. W enever possible,
install t e boiler near an outside wall so t at it is easy to duct t e venting system to t e boiler.
Locate t e boiler on a wall capable of supporting t e weig t of t e boiler filled wit water (see section entitled “Tec nical
Data” on page 55 for information required for total boiler weig t calculation). Ensure t at t e boiler location does not
interfere wit t e proper circulation of combustion and ventilation air of ot er fuel burning equipment wit in t e mec anical
room (if applicable).
T e maximum room temperature of t e mec anical room w ere t e boiler is located must not exceed 104ºF / 40ºC.
Installation area conditions
Ensure ambient temperatures are
ig er t an 32°F / 0°C and lower
t an 104°F / 40°C.
Prevent t e air from becoming
contaminated by alogenated
ydrocarbons (e.g. as contained in
paint solvents or cleaning fluids) and
excessive dust (e.g. t roug grinding
or polis ing work). Combustion air for
t e eating process, and ventilation
of t e boiler room must be free of
corrosive contaminants. To t at end,
any boiler must be installed in an area
t at as no c emical exposure. T e
list to t e rig t indicates t e main,
currently known sources.
Avoid continuously ig levels of
umidity (e.g. t roug 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, obby rooms
Garages wit works ops
Furniture refinis ing areas
Dry cleaning/laundry areas and
establis ments
Auto body s ops
Refrigeration repair s ops
Metal fabrication plants
Plastic manufacturing plants
P oto processing plants
Beauty salons
Products containing contaminants:
C lorine-type bleac es, detergents
and cleaning solvents found in
ouse old laundry rooms
Paint and varnis removers
Hydroc loric acid, muriatic acid
C lorine-based swimming pool
c emicals
Spray cans containing
c lorofluorocarbons
C lorinated waxes and cleaners
Cements and glues
Refrigerant leaks
Calcium c loride used for t awing
Sodium c loride used for water
softening salt
Permanent wave solutions
Ad esives used to fasten building
products and ot er similar items
Antistatic fabric softeners used in
clot es dryers
Boiler operation in marine environments
(damp, salty coastal areas)
T e service life of t e boiler’s exposed
metallic surfaces, suc as t e casing
and fan ousing, is directly influenced
by proximity to damp and salty marine
environments. In suc areas, ig er
concentration levels of c lorides from
sea spray, coupled wit relative
umidity, can lead to degradation of
t e exposed metallic surfaces
mentioned above. T erefore, it is
imperative t at boilers installed in suc
environments not be installed using
direct vent systems w ic draw
outdoor air for combustion. Suc
boilers must be installed using room air
dependent vent systems; i.e. using
room air for combustion. T e indoor air
will ave a muc lower relative
umidity and, ence, potential
corrosion will be minimized.
5441 443 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 t e boiler wit t e clearances
s own in t e illustration on t e left.
Note:
T e 12” (305 mm) side clearance specified is only
recommended to be able to view t e boiler certified
rating plate, decal and also accomodate t e PRV
installation kit.
If t e pressure relief valve is rotated 90º facing
forward by using an extension between t e tee and
t e boiler connection, t en t is clearance can be
reduced to b”. T is b” clearance is only required to
be able to remove t e boiler’s front cover and view
t e rating plate attac ed to it, if needed.
T is reduced clearance is also used in Vitodens
multiple boiler installation system as described in
t e multiple boiler installation instructions.
T e Vitodens 200-W, WB2B boiler is approved for
closet and alcove installation wit t e following
clearances to combustibles.
Table 1. Clearances
Top Front Rear Left Rig t Vent pipe
0 0 AL, CL 0 0 0 0
AL = Alcove
CL = Closet
See the Vitodens 00-W WB B Venting
System Installation Instructions for
details.
5441 443 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
12”/305 mm
0”/mm
28”/700 mm
Side
0”/mm
Back
Side
Fig. Recommended min. service clearances
Top
Note:
T e Vitodens 200-W, WB2B boiler as passed t e zero inc es
vent clearance to combustibles testing requirements dictated by
t e boiler Harmonized Standard ANSI Z21.13. CSA 4.9.2007
and t erefore is listed for zero clearance to combustibles w en
vented wit a single-wall special venting system (AL-29-4C ma-
terial) or UL/ULC-listed CPVC gas vent material. T e zero inc es
vent clearance to combustibles for t e Vitodens 200-W, WB2B
boiler supercedes t e clearance to combustibles listing t at ap-
pears on t e special venting system label.