Page 1
Installation Instructions
for use by heating contractor
Vitodens 200-W, Series B2HB
Models 45, 57
Wall-mounted, gas-fired condensing boiler
For operation with natural gas and liquid propane gas
Heating input: 32 to 199 MBH
9 to 58 kW
VITODENSr 200-W
H
5680 493 - 05 12/2015
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder
Page 2
Safety
Vitodens 200-W B2HB 45, 57 Installation
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).
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 Safety Requirements”.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Contaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to
Viessmann equipment.
For a listing of chemicals which
cannot be stored in or near the
boiler room, please see subsection
entitled “Mechanical room” in the
“Installation Instructions”.
Advice 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, shutdown procedure, and
the need for professional service annually before the
heating season begins.
WARNING
Installers must follow local regulations with respect to
installation of carbon monoxide detectors. Follow the
Viessmann maintenance schedule of the boiler contained
in this manual.
Operating 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.
22
Carbon monoxide
Improper installation, adjustment, 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, adjustment, service
and maintenance of this equipment to
avoid formation of carbon monoxide,
please see subsection entitled
“Mechanical room” and “Venting
requirements” in the “Installation Instructions”.
Fresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
For information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Mechanical room” in the “Installation
Instructions”.
Equipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Connection”. All products of
combustion must be safely vented
to the outdoors.
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, workshops, 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 Service
Instructions of the boiler.
5680 493 - 05
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Vitodens 200-W B2HB 45, 57 Installation
Safety, Installation and Warranty Requirements
Safety
Fiberglass wool and ceramic fiber materials
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
The state of California has listed the airborne fibers of
these materials as a possible cancer hazard through
inhalation. When handling these materials, special care
must be applied.
Suppliers of ceramic fiber products recommend the
following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the person
to a dust free location.
- Eye irritation: If eyes become irritated, flush immediately
with large amounts of lukewarm water for at least 15
minutes. Eyelids should be held away from the eyeball
to ensure thorough rinsing. Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin. Wash area
of contact thoroughly with soap and water. Using
a skin cream or lotion after washing may be helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/mist respirator.
- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
- Wash work clothes separately from other clothing.
Rinse washer thoroughly.
- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.
First aid measures
- If eye contact occurs, flush eyes with water to remove
dust. If symptoms persist, seek medical attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
WARNING
Appliance materials of construction, products of
combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes
and/or other toxic or harmful substances which can
cause serious injury or loss of life and which are
known to the State of California to cause cancer,
birth defects and other reproductive harm. Always
use proper safety clothing, respirators and equipment
when servicing or working nearby the appliance.
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
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious injury
or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.
IMPORTANT
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.
This symbol indicates that other instructions must
be referenced.
5680 493 - 05
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Page 4
Table of Contents
Vitodens 200-W B2HB 45, 57 Installation
Page
Safety
General Information
Set-up
Safety, Installation and Warranty Instructions................2
Product documentation.............................................2
Warranty................................................................2
Licensed professional heating contractor....................2
Contaminated air....................................................2
Advice to owner......................................................2
Carbon monoxide.....................................................2
Fresh air................................................................2
Equipment venting...................................................2
About these Installation Instructions..........................3
Important Regulatory and Installation Requirements........5
Codes.......................................................................5
Instructing the system user......................................5
Initial start-up..........................................................5
Working on the equipment.......................................5
Technical literature..................................................5
For installations on the Commonwealth of
Massachusetts........................................................6
CSD-1 field testing of high limit switches..................6
Applicability..............................................................8
Product Information....................................................8
Multi boiler system..................................................8
Mechanical Room.....................................................9
Before Set-up........................................................10
Minimum Clearances.................................................10
Recommended minimum service clearances..............10
Boiler Connections
Preparing the Connections.........................................11
Wall Mounting.........................................................13
Fitting the wall mounting bracket............................13
Installing the wall mounting bracket.........................13
Installation of mounting bracket on
brick/concrete wall................................................13
Boiler mounting bracket and frame...........................14
Installation on wood studs......................................14
Installation on metal studs....................................14
Frame Mounting....................................................16
Models B2HB 45, 57 Frame Mounting....................17
Connections............................................................18
Connecting power..................................................18
Boiler venting........................................................18
Proper piping practice.............................................18
Gas shut-off valve connection.................................18
Gas connection and piping......................................19
Gas piping pressure test.........................................20
Heating water connections......................................20
DHW storage tank information.................................21
Making the DHW connections...............................21
Accessing the control unit connections.....................22
Routing the connecting cables.................................24
Connecting DHW sensor.........................................25
Setting altitude parameters.....................................25
Control base.........................................................26
External accessory connection box..........................27
Condensate connection........................................28
4
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Vitodens 200-W B2HB 45, 57 Installation
Table of Contents
Page
Boiler Connections (continued)
Control Connections
Safety Connections and Pressure Testing.....................29
Installing boiler safety devices.................................29
Low water cut-off..................................................30
Performing a boiler pressure test.............................30
Waterside Flow........................................................30
Waterside flow (primary circuit)...............................30
Installation Examples.................................................32
General.................................................................32
Clearances............................................................32
System Layout 1-9...................................................33
Alternative DHW Connection....................................42
Boiler in Heating/Cooling............................................43
Boiler in heating/cooling application..........................43
Boiler with Low Water Cut-off..................................44
Boiler with low water cut-off (remote-mounted
field supplied)........................................................44
Venting Connection.................................................42
Electrical Connections..............................................43
Power supply connection of accessories...................43
Connection of accessories.......................................43
Overview of Electrical Connections,
Models B2HB 45 and 57...........................................44
Additional Information
Accessing the X3 Plug..............................................48
Connecting the Low-loss Header Sensor......................48
Connecting the Outdoor Temperature Sensor..............49
External 0-10 Volt Signal Connection.........................50
24 VAC Thermostat Connection...............................51
LON Module..........................................................52
Installing the LON module to the boiler
control board.........................................................52
Connecting the LON module cable...........................52
Accessory Kit..........................................................53
Accessory kit connections for heating circuit
with mixing valve..................................................53
Closing the Control Unit............................................53
Closing the control cover .......................................52
Closing the External Accessory Connection Box............53
Reinstalling the Front Enclosure Panel..........................55
Instructing the system user.....................................55
Technical Data.........................................................57
Installation Fittings....................................................59
Lighting and Operating Instructions.............................60
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Page 6
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. 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.
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 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 Service
Instructions
Please carefully read this manual prior to attempting startup, 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.
Technical literature
Literature for the Vitodens boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instructions and User’s Information Manual
- Instructions of other Viessmann products utilized and
installed
- Installation codes mentioned in this manual
The completeness and functionality of field supplied
electrical controls and components must be verified by
the heating contractor. These include low water cutoffs, flow switches (if used), staging controls, pumps,
motorized valves, air vents, thermostats, etc.
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.
Vitodens 200-W B2HB 45, 57 Installation
6
5680 493 - 05
Page 7
Vitodens 200-W B2HB 45, 57 Installation
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 sidewall exhaust vent
termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satisfied:
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 back-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 back-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.
CSD-1 Field Testing of High Limit Switches for Vitodens boilers – where required by law.
As per ASME Boiler and Pressure Vessel Code, section IV, subsection HG-613 TEMPERATURE CONTROL requirements, Vitodens
200-W hot water boilers are protected from over-temperature by two temperature-operated controls. These temperature control
devices conform to Standards for Limit Controls, and are accepted by CSA, a nationally recognized testing agency. Each boiler
is equipped with a manual reset high temperature limit control and a temperature control that will cut off fuel supply when the
system water temperature reaches a preset operating temperature. VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES
THAT THE FOLLOWING TEST PROCEDURE MAY RESULT IN BY OVERHEATING THE SYSTEM.
The Vitodens 200 boilers are equipped with flow switches or sensors that when activated enable the burner to operate.
The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control.
Fixed High Limit fault simulation #1:
- Ensure that the boiler and boiler pump are in normal operating condition (pump output sÖ is the boiler pump).
- Remove the cover from the back of the boiler control allowing access to the boiler control plugs.
- Under the extended menu (in the Operating manual), select ‘Test mode’ then ‘flue gas test ON’ and press ‘OK’.
- The boiler/burner will start a firing cycle and will gradually go into high fire mode.
- Once the burner ignites, disconnect the boiler pump plug sÖ from the boiler control board (gently with pliers).
Note: For boiler models equipped with flow switches (only boiler sizes 19 to 100), it may be required that flow switches be
jumpered during testing.
- Observe the boiler temperature on the control display.
- The temperature will gradually rise as more heat is put into the boiler heat exchanger. The burner will then shut off.
- The boiler temperature should continue to rise and once it reaches 210ºF (99ºC) the manual reset high limit safety switch
will trip electronically generating an F2 fault.
- Should the limit temperature not be reached during the test, repeat the test with the following additional step;
- two minutes after the burner shuts off, energize the boiler pump for a maximum of 1 second (by plugging in boiler pump plug sÖ).
Fixed High Limit fault simulation #2:
- Close the boiler valve and jumper across the flow switch.
- Run the boiler at high fire and it will shut down by the coding card (in B2TB models, set coding address 06 to maximum) but
should continue to steady increase the boiler temperature until the fixed high limit is tripped.
- Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
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Page 8
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 B2HB 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. Refer to page 15
for instructions on how to remove front enclosure panel.
NG and LPG
Model No. B2HB 45
Serial No. 7454703 jjjjjjjjj
Model No. B2HB 57
Serial No. 7454704 jjjjjjjjj
Vitodens 200-W B2HB 45, 57 Installation
Product Information
Natural 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.
Models B2HB 45 and 57 are for operation with natural
gas. For a fuel conversion to liquid propane gas
refer to the service instructions for details.
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, B2HB series boilers are factory-tested
and calibrated. Further gas valve adjustments are not
typically required during field start-up.
Product may not be exactly as shown
A Inox-Radial heat exchanger made from stainless steel
– for high operational reliability and a long service life.
Large heating output in the smallest of spaces
B Modulating MatriX cylinder burner for extremely
clean combustion and quiet operation
C Variable speed combustion fan for quiet and
economical operation
D Gas and water connections
E Digital boiler control unit
Multi boiler system
In connection with the installation of a multi boiler system
observe the installation instructions of the multi boiler
system accessories.
8
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Page 9
Vitodens 200-W B2HB 45, 57 Installation
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.
Locate the boiler on a wall capable of supporting 210 lb. (95 kg) [the weight of the boiler filled with water]. 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
WARNING
Incorrect ambient conditions can lead to damage to the
heating system and put safe operation at risk.
H Ensure ambient temperatures are higher than 32°F
(0°C) and lower than 104°F (40°C).
H 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 work). 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 known sources.
H Avoid continuously high levels of humidity (e.g. through
frequent drying of laundry).
H Never close existing ventilation openings.
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.
IMPORTANT
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.
Sources of combustion and ventilation air contaminants
Areas likely to contain contaminants:
H New building construction
H Swimming pools
H Remodelling areas, hobby rooms
H Garages with workshops
H Furniture refinishing areas
H Dry cleaning/laundry areas and establishments
H Auto body shops
H Refrigeration repair shops
H Metal fabrication plants
H Plastic manufacturing plants
H Photo processing plants
H Beauty salons
Products containing contaminants:
H Chlorine-type bleaches, detergents and cleaning
solvents found in household laundry rooms
H Paint and varnish removers
H Hydrochloric acid, muriatic acid
H Chlorine-based swimming pool chemicals
H Spray cans containing chlorofluorocarbons
H Chlorinated waxes and cleaners
H Cements and glues
H Refrigerant leaks
H Calcium chloride used for thawing
H Sodium chloride used for water softening salt
H Permanent wave solutions
H Adhesives used to fasten building products and other
similar items
H
Antistatic fabric softeners used in clothes dryers
Boiler operation in marine environments (damp, salty
coastal areas)
WARNING
Fire causes a risk of burns and explosion!
H Shut down the boiler
H Close fuel shut-off valves
H Use a tested fire extinguisher, class ABC.
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Page 10
Set-up
Before Set-up
Before placing boiler in its installation location, ensure all
necessary accessories are installed.
Minimum Clearances
Vitodens 200-W B2HB 45, 57 Installation
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.
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 in. (305 mm) side clearance specified is
only recommended to be able to view the boiler
certified rating plate, decal and also accommodate
the PRV installation kit.
Note: The Vitodens 200-W, B2HB boiler has passed the
zero inches vent clearance to combustibles testing
requirements dictated by the boiler Harmonized
Standard ANSI Z21.13. CSA 4.9 (latest edition)
and therefore is listed for zero clearance to
combustibles when vented with a single-wall
special venting system (AL-29-4C material) or
UL/ULC-listed CPVC/PPs gas vent material. The
zero inches vent clearance to combustibles for
the Vitodens 200-W, B2HB boiler supercedes the
clearance to combustibles listing that appears on
the special venting system label.
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 in.
This b in. 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, B2HB boiler is approved for closet
and alcove installation with the following clearances to
combustibles.
Table 1 Clearances
Top Front Rear Left Right Vent pipe
00 AL CL0000
AL = Alcove
CL = Closet
See the Vitodens 200-W B2HB Venting
System Installation Instructions for details.
10
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Page 11
Vitodens 200-W B2HB 45, 57 Installation
Preparing the Connections
*1 DHW
Connections
(Field Supplied)
Boiler Connections
Use an approved pipe sealant or teflon tape when
connecting the following installation fittings.
This section constitutes an overview only! Refer to
subsequent sections for detailed information on individual
piping connections.
Legend
DR Boiler heating return for domestic hot water production
DS Boiler heating supply for domestic hot water production
BD Boiler Drain
BF Boiler Fill
BR Boiler Return
BS Boiler Supply
GC Gas Connection
PRV Pressure Relief Valve
*1 See page 40 for alternate DHW connection.
*2 Discard when using the multi-boiler distribution
manifold
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Page 12
Boiler Connections
Preparing the Connections (continued)
Vitodens 200-W B2HB 45, 57 Installation
This section constitutes an overview only! Refer to
subsequent sections for detailed information on individual
piping connections.
Use an approved pipe sealant or teflon tape when
connecting the following installation fittings.
IMPORTANT
The maximum ambient temperature must not exceed
104ºF (40ºC).
Note: When preparing gas, water and electrical
connections in the field, see section entitled
“Wall Mounting” on page 13, 14 and 15 of this
manual for information regarding the installation
of the wall mounting bracket.
1. Heating water connections and gas connection to
be made in the field. See illustration and connectionspecific section for details.
2. See subsection entitled “Electrical Connections”
for details regarding power supply to the Vitodens
200-W B2HB boiler.
Legend
A Boiler Supply
B Gas Connection, 1” NPTF
C Boiler Return
D Recommended height (single boiler system)
E Condensate drain
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Page 13
Vitodens 200-W B2HB 45, 57 Installation
Wall Mounting
Boiler Connections
Fitting the wall mounting bracket
Following are the installation instructions for the mounting
bracket on each material. See the instructions applicable
to your installation requirements.
Installing the wall mounting bracket
The Vitodens 200-W B2HB can be wall-mounted on a
concrete wall.
Note: The enclosed screws and rawl plugs are only
suitable for concrete. For other construction
materials, use bolts and anchors that are suitable
for 210 lb (95 kg) loads.
Installation of mounting bracket on brick/concrete wall
1. Drill holes 7 31/64 in. (12 mm).
2. Install rawl plugs and screw mounting bracket
to wall.
3. Ensure the mounting bracket is level.
CAUTION
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.
5680 493 - 05
13
Page 14
Boiler Connections
Wall Mounting (continued)
Vitodens 200-W B2HB 45, 57 Installation
Boiler mounting bracket
Install the boiler mounting bracket to the wall studs.
Ensure the mounting bracket is level.
To mount on wood or metal studs a cross bar or frame
may be required as reinforcement. The wall and studs
must be capable of supporting a minimum of 210 lb.
(95 kg).
For construction materials, use fixings that are suitable
for 210 lb (95 kg) loads.
Installation on wood studs
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. Secure
with bolts to wooden studs as shown.
Installation on metal studs
install mounting bracket on metal studs as per illustration.
Drill f” pilot holes to insert anchors. Ensure that holes are
located in the center of each metal stud. Use appropriate
fasteners to mount to metal studs (not supplied). Secure
with bolts to metal studs as shown. Ensure the mounting
bracket is level.
14
5680 493 - 05
Page 15
Vitodens 200-W B2HB 45, 57 Installation
Wall Mounting (continued)
Boiler Connections
1. Remove the external accessories connection box
cover.
2. Loosen the screws at the bottom of the boiler
(do not remove completely).
3. Remove the front encloser panel (lift up and pull
away from the boiler).
4. Mount boiler onto the mounting bracket.
5. Adjust the levelling screws to ensure the boiler
is level. Place the round bubble level on top of the
boiler to verify.
Note: For draining of the condensate (see page 26).
6. Install supplied installation fittings as per layout on
page 11.
CAUTION
The boiler must be level both vertically and horizontally
to ensure proper draining of the condensate.
5680 493 - 05
15
Page 16
Boiler Connections
Frame Mounting
Vitodens 200-W B2HB 45, 57 Installation
The boiler stand is used for free-standing installation of a
single boiler within the mechanical room.
When using the boiler stand, ensure that the stand is
securely fastened to the floor (recommended concrete
expansion anchors are Hilti model KB-TZ e x 4 or
equivalent.
The Vitodens 200-W, model B2HB does not come with
a mounting template. The wall location for the frame,
mounting bracket and all vents must be field calculated.
Boiler mounting bracket and frame
1. Attach the wall mounting bracket (supplied with the
boiler) to the boiler mounting frame using the supplied
hardware. Ensure that the wall mounting bracket is
level.
2. Move the rack into position and secure to the floor
(and to the wall if needed).
16
5680 493 - 05
Page 17
Vitodens 200-W B2HB 45, 57 Installation
Models B2HB 45, 57 Frame Mounting
Boiler Connections
1. Remove the external accessories connection box
cover.
2. Loosen the screws at the bottom of the boiler
(do not remove completely).
3. Remove the front encloser panel (lift up and pull
away from the boiler).
4. Mount boiler onto the mounting bracket and ensure
the boiler is securely mounted. Then install the
holding bracket to the frame on top of the boiler.
5. Adjust the levelling screws to ensure the boiler
is level.
6. Connect the boiler to the installation fittings.
CAUTION
The boiler must be level both vertically and horizontally
to ensure proper draining of the condensate.
5680 493 - 05
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Page 18
Boiler Connections
Connections
Vitodens 200-W B2HB 45, 57 Installation
Connecting power
The Vitodens 200-W boiler has a external accessories
connection box installed, which requires a 120VAC/12A
power supply. Refer to the wiring diagram (see page 44).
Boiler venting
The Vitodens 200-W B2HB boiler comes with a pre-installed
vent pipe adaptor.
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).
WARNING
Remove outer gasket if single wall (boiler room air
dependant) venting system is used.
2 imperfect threads
Leave 2 threads bare
Manual gas shutoff
Closed
Open
Proper piping practice
Support piping by proper suspension method. Piping
must not rest on or be supported by boiler. Use moderate
amount of dope.
Gas shut-off valve connection
1. Make 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.
18
5680 493 - 05
Page 19
Vitodens 200-W B2HB 45, 57 Installation
Connections (continued)
Boiler Connections
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.
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.
3. Perform gas piping pressure test as described in the
following subsection.
Legend
A Gas connection 7 1 in. (NPT)
B Accessible manual gas shutoff valve
C Ground joint union
D Drip leg
IMPORTANT
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 200-W B2HB Service Instructions
for applicable system coding information.
WARNING
The gas supply piping must be leak tested before placing
the boiler in operation.
CAUTION
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.
IMPORTANT
Regarding operation with LPG, we recommend the
installation of an external safety solenoid valve when
installing the boiler in rooms below ground level.
5680 493 - 05
19
Page 20
Boiler Connections
Connections (continued)
Vitodens 200-W B2HB 45, 57 Installation
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. 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.
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: 4 bar (60 psig)
Test pressure: 6 bar (90 psig)
IMPORTANT
Damage resulting from pressure exceeding those values
stated is not covered by Viessmann warranty.
3. Connect field supplied nipples and tees as shown
for DHW supply and return.
*1 DHW
Connections
(Field Supplied)
20
Legend
DR Boiler heating return for domestic hot water production
DS Boiler heating supply for domestic hot water production
BD Boiler Drain
BF Boiler Fill
BR Boiler Return
BS Boiler Supply
GC Gas Connection
PRV Pressure Relief Valve
*1 See page 40 for alternate DHW connection.
*2 Discard when using the multi-boiler distribution
manifold
IMPORTANT
Apply sufficient amount of thread sealant (supplied) when
making the connections.
5680 493 - 05
Page 21
Vitodens 200-W B2HB 45, 57 Installation
Connections (continued)
Boiler Connections
DHW storage tank information
The DHW water tank sensor is required when using a
stand-alone DHW storage tank with the Vitodens 200-W
B2HB 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 B2HB Service Instructions
for applicable system coding information.
IMPORTANT
Apply sufficient amount of thread sealant (supplied) when
making the connections.
Making the DHW connections
1. With a Vitocell 100 and 300 series tanks locate the
DHW temperature sensor well and install the
DHW temperature sensor % using the installation
instructions provided with the DHW storage tanks.
IMPORTANT
Follow the Installation Instructions supplied with the
Viessmann DHW storage tank when mounting and
securing DHW tank temperature sensor %.
WARNING
If a DHW storage tank other 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.
5680 493 - 05
21
Page 22
Boiler Connections
Connections (continued)
Vitodens 200-W B2HB 45, 57 Installation
Accessing the control unit connections
1. Remove both screws from the junction box cover
and set screws aside.
2. Loosen both retaining screws as shown (do not
remove).
22
3. Pull the external accessory connection box forward
until the retaining screws are clear of the guides (built
into the rails).
4. Swing the external accessory connection box down.
5680 493 - 05
Page 23
Vitodens 200-W B2HB 45, 57 Installation
Connections (continued)
Boiler Connections
5. Tilt the bottom of the external accessory connection
box cover forward.
6. Pull the cover up to clear the locating pins and out
to remove, then set aside.
7. Slide both sides of the programming unit cover closed.
8. Release the hinged hooks located on both sides of
the control unit.
9. To open hinged cover, lift cover and then fold down
the control unit.
10. Release locking tabs as shown.
11. Remove cover.
5680 493 - 05
23
Page 24
Boiler Connections
Connections (continued)
Vitodens 200-W B2HB 45, 57 Installation
12. Route all connecting cables to the appropriate areas
and secure the cables to the control base using
existing strain reliefs as shown.
CAUTION
When running and securing connecting cables on site,
ensure that the maximum permissible temperatures of
the cables are not exceeded.
Electronic modules can be damaged by
electrostatic discharges. Before commencing
work, touch grounded objects (such as heating
or water pipes) to discharge static loads.
Legend
A Low voltage connections
B 120V connections
C Internal extension
D Main PCB
E Communication module (accessory)
F Cable grommet for power cable
% Plugs for connecting the DHW temperature
sensor to the cable harness
Routing the connecting cables
Note: If connecting cables touch hot components they will
be damaged. When routing and securing connecting
cables on site, ensure that the maximum permissible
temperatures for these cables are not exceeded.
Remove the existing cable grommet when using larger
wire (cable) size [up to
cable with the cable grommet plugged into the lower
casing section (orange).
9/16 in. (7 14 mm)]. Secure the
24
5680 493 - 05
Page 25
Vitodens 200-W B2HB 45, 57 Installation
Connections (continued)
Field Connection
Connection
X9 Connector
(boiler control board)
Boiler Connections
Connecting DHW sensor
1. Attach the DHW sensor to the quick connect plugs
provided from the boiler control board (see page 24).
Install DHW tank temperature sensor
as described in the Vitocell Installation
Instructions supplied with the DHW
storage tank.
Setting altitude parameters
In the factory default setting, the boiler is equipped to
operate in altitudes of up to 5,000 ft. (1,500 m).
Altitude can be set using coding address 93 (in coding
level 2 General).
See Vitodens 200-W B2HB Service Instructions
for applicable system coding information.
5680 493 - 05
25
Page 26
Boiler Connections
Connections (continued)
Vitodens 200-W B2HB 45, 57 Installation
Control base
Note: See wiring diagram on page 44 for connection to
the external accessory connection box.
DHW
TEMPERATURE
SENSOR
OUTDOOR
TEMPERATURE
SENSOR
26
5680 493 - 05
Page 27
Vitodens 200-W B2HB 45, 57 Installation
Connections (continued)
ACCESSORIES
(ie VITOTROL
REMOTE OR
MIXING VALVE)
0-10V INPUT
Boiler Connections
External accessory connection box
Note: See wiring diagram on page 44 for connection
to the control base.
120/1/60 12 AMP
POWER SUPPLY WITH
DISCONNECT AND
PROTECTION
PUMP
5680 493 - 05
27
Page 28
Boiler Connections
Connections (continued)
Condensate Connection for Vitodens
200-W, models B2HB 45, 57
Legend
A Retaining clip
B Siphon trap
C Flexible discharge tubing
D Flexible discharge tubing
Vitodens 200-W B2HB 45, 57 Installation
Condensate connection
The Vitodens 200-W B2HB boiler comes with a builtin 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 in.
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. In Canada use CSA or ULC listed schedule 40
CPVC or PVC drain pipe, fittings and cement.
If the condensate outlet of the Vitodens 200-W B2HB
boiler is lower than the drain, a condensate pump must be
installed. Select a pump which is approved for condensing
boiler applications. To avoid condensate spillage, select
a pump with an overflow switch. The drain connection
must terminate into an open or vented drain as close to
the boiler as possible to prevent siphoning of the boiler
drain.
1. Install the condensate drain pipe with a suitable
gradient. Pull the condensate hose so far out of the
boiler that no unnecessary bends are created inside
the boiler. Check tightness of siphon connection.
Condensate installation example:
Air gap
IMPORTANT
As shipped, the flexible discharge tubing E will be found
to be pushed up inside the boiler housing. Ensure the
condensate drain pipe is pulled down and positioned to
allow the condensate to properly drain.
2. Discharge condensate from the boiler into the vented
drainage system, either directly or (if required) via a
neutralization unit (accessory).
Installation Instructions of Neutralization Unit
(if applicable)
IMPORTANT
Pipe ventilation must take place between the siphon trap
and the neutralization unit (if applicable).
IMPORTANT
Do not connect the drain pipe from any other appliance,
such as water softener backwash pipe, to Vitodens
condensate drain pipe.
3. Ensure the condensate discharge tubing is vented
to the atmosphere prior to being plumbed into the
neutralization unit.
28
5680 493 - 05
Page 29
Vitodens 200-W B2HB 45, 57 Installation
Safety Connections and Pressure Testing
Legend
A Reducing tee, 1½ in. x 1½ in. x ¾ in.
B Nipple, length 1½ in. x 2½ in. (field supplied)
C Isolation valve, 1½ in. (field supplied)
D Nipple, length 3½ in. x ¾ in.
E Tee ¾ in.
F Nipple, length 1½ in. x ¾ in.
G Pressure relief valve, ¾ in. NPT
H Drain valve connection, ¾ in.
Minimum connection diameters:
Pressure relief valve.........................¾ in.
Discharge pipe................................¾ in.
Piping to precharged expansion tank..(field supplied)
Boiler Connections
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 B,D,F and H and install onto
tees A, and E.
3. Install pressure relief valve G and isolation valve
C and tighten.
4. Install discharge pipe on pressure relief valve in such
a way that...
- the end of the pipe is not threaded.
- the pressure relief discharge pipe extends to a floor
drain and ends approximately 6 in. (150 mm) above
the drain.
Ensure that...
- there is no shutoff valve installed in the discharge pipe.
- discharge pipe diameter is not reduced.
- discharge is not piped to outdoors.
IMPORTANT
Install the (approved) factory supplied pressure relief
valve.
Removal of air from the system must occur via use of air
vent(s) in the system supply. To ensure the boiler can be
purged of all air, ensure supply/return water lines do not
contain restrictive piping where air could be trapped.
WARNING
Do not install an isolation valve between boiler and
pressure relief valve.
The discharge pipe for the pressure relief valve must
be oriented to prevent scalding of attendants.
Pipe pressure relief valve discharge pipe close to floor
drain. Never pipe discharge pipe to the outdoors.
5680 493 - 05
29
Page 30
Boiler Connections
Safety Connections and Pressure Testing (continued)
Vitodens 200-W B2HB 45, 57 Installation
Low water cut-off
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. Do not install an isolation valve between
boiler and low water cut-off.
WARNING
Exposing the boiler to pressures and temperatures in
excess of those listed will result in damages, and will
render warranty null and void.
Max. operating pressure...............4 bar (60 psig)
Testing pressure..........................6 bar (90 psig)
Max. boiler water temperature......210ºF (99ºC)
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 in. x 2 in. nipple.
2. Cap supply and return connections.
3. Connect ½ in. garden hose to boiler fill valve at
the bottom of the boiler and fill boiler slowly until
pressure gage indicates max. 8 bar (120 psig).
4. Maintain pressure for 15 minutes. During time of
pressure testing, do not leave boiler unattended.
5. Inspect all pipe joint connections and safety devices
with a flashlight for leaks. A lower manometer
reading than 8 bar (120 psig) usually indicates loss
of water due to leakage. All leaks must be repaired.
6. After 15 minutes, release water pressure from boiler
by opening boiler drain valve slowly, remove caps
from supply and return connections as well as ¾ in.
cap from 2 in. nipple, and install pressure relief valve
immediately instead of ¾ in. cap.
7. After boiler has passed pressure test, proceed with
the installation.
Waterside Flow
Waterside flow (primary circuit)
The Vitodens 200-W, B2HB is designed for closed loop,
forced circulation hot water heating systems only.
Use standard friction loss method for pipe sizing. Observe
boiler maximum and minimum flow rate limitations.
If system flow rate exceeds boiler maximum flow rate
(as stated above), falls below the minimum flow rate
or if system flow rate is unknown, Viessmann strongly
recommends the installation of a low-loss header.
Once the low-loss header is connected, the built-in lowloss header logic of the Vitodens 200-W boiler ensures
the required t across the system through the sensory
communication between the low-loss header and the
boiler.
An alternative method may be used, such as primary
secondary piping using closely spaced tees. A low-loss
header offers additional benefits not provided by a pair
of closely spaced tees. Viessmann therefore strongly
recommends and prefers the use of a low-loss header
over closely spaced tees. Refer to the Technical Data
manual for low-loss header information.
30
5680 493 - 05
Page 31
Vitodens 200-W B2HB 45, 57 Installation
Boiler Connections
Waterside Flow (continued)
Pressure drop (primary circuit) for
Vitodens 200-W, B2HB 45 - 57
For sizing an on-site circulation system.
Max. flow rate: 14.3 GPM (3,250 L/H)
Boiler max. flow rate 14.3 GPM (3250 L/h)
Model B2HB 45 1 boiler 2 boilers 3 boilers 4 boilers 5 boilers 6 boilers 7 boilers 8 boilers
Output (NG/LPG)
MBH 149 298 447 596 745 894 1043 1192
t for NG/LPG
20º F (11º C) rise GPM
(L/h)
25º F (14º C) rise GPM
(L/h)
30º F (17º C) rise GPM
(L/h)
35º F (19.5º C) rise GPM
(L/h)
40º F (22º C) rise GPM
(L/h)
14.9
(3384)
11.9
(2707)
9.9
(2256)
8.5
(1934)
7.5
(1692)
29.8
(6768)
23.8
(5415)
19.9
(4512)
17.0
(3868)
14.9
(3384)
44.7
(10152)
35.8
(8122)
29.8
(6768)
25.5
(5801)
22.4
(5076)
59.6
(13536)
47.7
(10829)
39.7
(9024)
34.1
(7735)
29.8
(6768)
74.5
(16920)
59.6
(13536)
49.7
(11280)
42.6
(9669)
37.3
(8460)
89.4
(20305)
71.5
(16244)
59.6
(13536)
51.1
(11603)
44.7
(10152)
104.3
(23689)
83.4
(18951)
69.5
(15792)
59.6
(13536)
52.2
(11844)
119.2
(27073)
95.4
(21658)
79.5
(18048)
68.1
(15470)
59.6
(13536)
Boiler max. flow rate 14.3 GPM (3250 L/h)
Model B2HB 57 1 boiler 2 boilers 3 boilers 4 boilers 5 boilers 6 boilers 7 boilers 8 boilers
Output (NG/LPG)
MBH 185 370 555 740 925 1110 1295 1480
t for NG/LPG
20º F (11º C) rise GPM
(L/h)
25º F (14º C) rise GPM
(L/h)
30º F (17º C) rise GPM
(L/h)
35º F (19.5º C) rise GPM
(L/h)
40º F (22º C) rise GPM
(L/h)
5680 493 - 05
18.5
(4202)
14.8
(3361)
12.3
(2801)
10.6
(2401)
9.3
(2101)
37.0
(8403)
29.6
(6723)
24.7
(5602)
21.1
(4802)
18.5
(4202)
55.5
(12605)
44.4
(10084)
37.0
(8403)
31.7
(7203)
27.8
(6303)
74.0
(16807)
59.2
(13446)
49.3
(11205)
42.3
(9604)
37.0
(8403)
92.5
(21009)
74.0
(16807)
61.7
(14006)
52.9
(12005)
46.3
(10504)
111.0
(25210)
88.8
(20168)
74.0
(16807)
63.4
(14406)
55.5
(12605)
129.5
(29412)
103.6
(23530)
86.3
(19608)
74.0
(16807)
64.8
(14706)
148.0
(33614)
118.4
(26891)
98.7
(22409)
84.6
(19208)
74.0
(16807)
31
Page 32
Boiler Connections
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 in. (51 mm) circumferential clearance
from non-insulated hot water pipes to combustible
construction must be maintained. In cases where the
pipes are insulated with pipe insulation of appropriate
and sufficient thickness and insulation values, the above
clearance may be reduced to 0 in. (refer to local gas
codes).
CAUTION
For underfloor heating applications, an additional
immersion or strap-on aquastat must be installed in the
low temperature underfloor loop (downstream of the
mixing valve) to de-energize the pump and/or boiler
to prevent overheating. High water temperatures can
damage concrete slabs.
IMPORTANT
The examples on the following pages depict possible
piping layouts of the Vitodens 200-W B2HB boiler
equipped with Viessmann System Technology.
For boiler and tank combinations, please install only
feasible combinations listed in the Viessmann Price List.
Please note that the following examples are simplified
conceptual drawings only!
Piping and necessary componentry must be field verified.
A low water cut-off (LWCO) must be installed where
required by local codes.
Proper installation and functionality in the field is the
responsibility of the heating contractor.
Vitodens 200-W B2HB 45, 57 Installation
WARNING
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 the original manufacturer of the tank.
Viessmann strongly recommends the installation of a
temperature tempering valve in the DHW supply line.
IMPORTANT
DHW supply and return piping between boiler DHW
connections and the Viessmann DHW tank connections,
shall be a minimum of 1¼ in. pipe size. This will ensure
the residual head of the field supplied pump is fully utilized
to overcome the resistance of the DHW heat exchanger
coil and to provide sufficient water flow to the boiler heat
exchanger.
In non-Viessmann DHW tank applications, perform, in
addition to the above, accurate calculations for DHW
tank coil pressure drop versus boiler pump (field supplied)
residual head to ensure sufficient water flow to the boiler
heat exchanger. Failure to heed the above instructions
may cause boiler short-cycling and inadequate DHW
supply.
Note: In the following piping layout examples all pumps
are field supplied.
32
5680 493 - 05
Page 33
Vitodens 200-W B2HB 45, 57 Installation
System Layout 1
Vitodens 200-W, B2HB with a direct-connected heating circuit
Boiler Connections
Legend
A Vitodens 200-W B2HB boiler with
Vitotronic 200, HO1B outdoor reset control
B Outdoor temperature sensor !
C Vitotrol remote (optional)
D Heating circuit
E Heating circuit pump
F DHW circulating pump sA
G DHW storage tank
H DHW tank temperature sensor %
I Expansion tank
J Flow check valve
K DHW recirculation pump
L Temperature and pressure relief valve
M Pressure relief valve
* Function based on coding of address 33
5680 493 - 05
20
28/20 *
Installation of ...
■ radiator heating circuit (high-temp. circuit)
■ DHW production
... with the following flow conditions:
The flow rate of the heating circuit is less than the
maximum possible water flow rate of the Vitodens 200-W
B2HB boiler (see page 31 for maximum water flow rate of
boiler).
The use of a low-loss header is strongly recommended if
the maximum water flow rate in the application concerned
exceeds the values shown in the applicable table on page
31, or if the system flow rates are unknown.
The low-loss header is available as accessory part.
See following pages for installation examples with a lowloss header.
IMPORTANT
DHW circulating pump F must pump into the Vitodens
200-W boiler (as illustrated).
33
Page 34
Boiler Connections
System Layout 2
Vitodens 200-W, B2HB with one heating circuit and low-loss header
Vitodens 200-W B2HB 45, 57 Installation
Legend
A Vitodens 200-W B2HB boiler with
Vitotronic 200, HO1B outdoor reset
control
B Outdoor temperature sensor !
C Vitotrol remote (optional)
D Heating circuit
E Boiler pump 20
F DHW circulating pump sA
G DHW storage tank
H DHW tank temperature sensor %
I Expansion tank
J Temperature and pressure relief valve
K DHW recirculation pump 28/20 *
L Low-loss header
M Pressure relief valve
N Viessmann temperature sensor for
low-loss header ?
O Heating circuit pump 28/20 *
* Function based on coding of address 33
34
Installation of ...
■ radiator heating circuit (high-temp. circuit)
■ DHW production
... with the following flow conditions:
The flow rate of the heating circuit is greater than the
maximum possible water flow rate of the Vitodens
200-W B2HB boiler (see page 31 for maximum water
flow rate of boiler).
The use of a low-loss header is strongly recommended
if the maximum water flow rate in the application
concerned exceeds the values shown on page 31,
or if the system flow rates are unknown.
The low-loss header is available as accessory part.
IMPORTANT
Please note location of expansion tank.
DHW circulating pump F must pump into the Vitodens
200-W B2HB boiler (as illustrated).
5680 493 - 05
Page 35
Vitodens 200-W B2HB 45, 57 Installation
System Layout 3
Vitodens 200-W, B2HB with...
- DHW storage tank
- one heating circuit with mixing valve and system separation
Boiler Connections
Legend
A Vitodens 200-W B2HB boiler with
Vitotronic 200, HO1B outdoor reset
control
B Outdoor temperature !
C Vitotrol remote (optional)
D Underfloor heating circuit
E Mixing valve temperature sensor ?
F Pressure relief valve
G Plate heat exchanger for system
separation
H Accessory kit for heating circuit with
mixing valve
I DHW circulating pump sA
J DHW storage tank
K DHW tank temperature sensor %
L Expansion tank
M DHW recirculation pump 28/20 *
N Temperature and pressure relief valve
O Flow check valve
P Heating circuit pump 20
Q Heating circuit pump
* Function based on coding of address 33
IMPORTANT
DHW circulating pump must pump I into the Vitodens
200-W B2HB boiler (as illustrated).
5680 493 - 05
Installation of ...
■ underfloor heating circuit with 3-way mixing valve
and system separation (low-temp. circuit)
■ DHW production
... with the following flow conditions:
The flow rate of the heating circuit is less than the
maximum possible water flow rate of the Vitodens
200-W B2HB boiler.
See page 31 for maximum water flow rate of the Vitodens
200-W B2HB boilers. The use of a low-loss header is
recommended if the system water flow rate is unknown.
The low-loss header is available as accessory part.
See following pages for installation examples with a
low-loss header.
IMPORTANT
System separation is required of underfloor heating
systems employing non-oxygen diffusion barrier tubing.
All components on the secondary side of the heat
exchanger must be made of corrosion-resistant materials.
IMPORTANT
Sizing of field-supplied pump P is critical for proper
boiler operation in this system layout. See page 31 for the
supply head pressure drop of the boiler. An undersized
pump may cause short-cycling and/or improper operation
of the boiler. Viessmann STRONGLY recommends using a
low-loss header and a boiler pump in this system layout.
35
Page 36
Boiler Connections
System Layout 4
Vitodens 200-W, B2HB with...
- DHW storage tank
- one direct-connected heating circuit
- one heating circuit with a mixing valve
Vitodens 200-W B2HB 45, 57 Installation
Legend
A Vitodens 200-W B2HB boiler with
Vitotronic 200, HO1B outdoor reset
control
B Outdoor temperature sensor !
C Vitotrol remote (optional)
D Under floor heating circuit
E Radiator heating circuit
F Heating circuit pump
G Mixing valve temperature sensor ?
H Accessory kit for heating circuit with mixing valve
I Domestic hot water storage tank
J DHW tank temperature sensor %
K Expansion tank
L Temperature and pressure relief valve
M Pressure relief valve
N DHW recirculation pump 28/20 *
O Boiler pump 20
P DHW circulating pump sA
* Function based on coding of address 33
IMPORTANT
DHW circulating pump P must pump into the Vitodens
200-W B2HB boiler (as illustrated).
36
Installation of different heating circuits...
■ radiator heating circuit (high-temp. circuit)
■ under floor heating circuit with 3-way mixing valve
(low-temp. circuit)
■ DHW production
... with the following flow conditions:
1. The water flow rate (output) of the radiator heating
circuit is at least 30% greater than that of the under
floor heating circuit.
2. The total flow rate of the two heating circuits is
less than the maximum possible water flow rate of
the Vitodens 200-W B2HB boiler (see page 31 for
max. water flow rate).
The use of a low-loss header is strongly
recommended if the maximum water flow rate in the
application concerned exceeds the values shown on
page 31, or if the system flow rates are unknown.
The low-loss header is available as accessory part.
See following pages for additional installation examples
with a low-loss header.
The 3-way mixing valve, built-in to achieve the lowtemperature level of the under floor heating circuit, is
controlled by an accessory kit for a heating circuit with
mixing valve.
5680 493 - 05
Page 37
Vitodens 200-W B2HB 45, 57 Installation
System Layout 5
Vitodens 200-W, B2HB with...
- DHW storage tank
- one heating circuit with mixing valve
- one heating circuit without mixing valve
- low-loss header
Boiler Connections
Legend
A Vitodens 200-W B2HB boiler with
Vitotronic 200, HO1B outdoor reset control
B Outdoor temperature sensor !
C Vitotrol remote (optional)
D Under floor heating circuit
E Radiator heating circuit
F Boiler circuit pump 20
G Mixing valve temperature sensor ?
H Kit for heating circuit with mixing valve
I Domestic hot water storage tank
J DHW tank temperature sensor %
K Expansion tank
L Temperature and pressure relief valve
M Pressure relief valve
N DHW recirculation pump 28/20 *
O DHW circulating pump sA
P Heating circuit pump
Q Low-loss header
R Viessmann temperature sensor for low-loss header ?
S Heating circuit pump 28/20 *
* Function based on coding of address 33
5680 493 - 05
Installation of different heating circuits...
■ radiator heating circuit (high-temp. circuit)
■ under floor heating circuit with 3-way mixing valve
(low-temp. circuit)
■ DHW production
... with the following flow conditions:
The total flow rate of the two heating circuits is greater
than the maximum possible water flow rate of the
Vitodens 200-W B2HB boiler (see page 31 for maximum
water flow rate of boiler).
The use of a low-loss header is strongly recommended.
The low-loss header is available as accessory part.
The 3-way mixing valve, built-in to achieve the lowtemperature level of the under floor heating circuit, is
controlled by an accessory kit for a heating circuit with
mixing valve.
IMPORTANT
DHW circulating pump O must pump into the Vitodens
200-W B2HB boiler (as illustrated).
37
Page 38
Boiler Connections
System Layout 6
Vitodens 200-W, B2HB with...
- DHW storage tank
- one heating circuit without a mixing valve
- two heating circuits with a mixing valve
- low-loss header
Vitodens 200-W B2HB 45, 57 Installation
Legend
A Vitodens 200-W B2HB boiler with
Vitotronic 200, HO1B outdoor reset control
B Outdoor temperature sensor !
C Vitotrol remote (optional)
D Under floor heating circuit
E Heating circuit pump 28/20 *
F Mixing valve temperature sensor ?
G Accessory kit for heating circuit with mixing valve
H Heating circuit pumps
I DHW storage tank
J DHW tank temperature sensor %
K Expansion tank
L Temperature and pressure relief valve
M Low-loss header
N Viessmann temperature sensor for low-loss header ?
O Pressure relief valve
P DHW recirculation pump 28/20 *
Q Radiator heating circuit
R Boiler pump 20
S DHW circulating pump sA
* Function based on coding of address 33
Installation of different heating circuits...
■ two heating circuits with 3-way mixing valve
(low-temp. circuit)
■ DHW production
... with the following flow conditions:
The total flow rate of the two heating circuits is greater
than the maximum possible water flow rate of the
Vitodens 200-W B2HB boiler (see page 31 for maximum
water flow rate of boiler).
The use of a low-loss header is strongly recommended.
The low-loss header is available as accessory part.
The 3-way mixing valve, built-in to achieve the lowtemperature level of the under floor heating circuit, is
controlled by an accessory kit for a heating circuit with
a mixing valve.
IMPORTANT
DHW circulating pump S must pump into the Vitodens
200-W B2HB boiler (as illustrated).
38
5680 493 - 05
Page 39
Vitodens 200-W B2HB 45, 57 Installation
System Layout 7
Vitodens 200-W, B2HB with...
- direct-connected heating circuit
- one heating circuit with system separation
Boiler Connections
Legend
A Vitodens 200-W B2HB boiler with Vitotronic 200,
HO1B outdoor reset control
B Outdoor temperature sensor !
C Vitotrol remote (optional)
D Under floor heating circuit
E Radiator heating circuit
F Plate heat exchanger for system separation
G Heating circuit pump
H Mixing valve temperature sensor ?
I Accessory kit for heating circuit with mixing valve
J DHW storage tank
K DHW tank temperature sensor %
L Expansion tanks
M Temperature and pressure relief valve
N Pressure relief valve
O DHW recirculation pump 28/20 *
P Boiler pump 20
Q DHW circulating pump sA
* Function based on coding of address 33
IMPORTANT
DHW circulating pump Q must pump into the Vitodens
200-W B2HB boiler (as illustrated).
5680 493 - 05
Installation of different heating circuits...
■ radiator heating circuit (high-temp. circuit)
■ under floor heating circuit with 3-way mixing valve
(low-temp. circuit)
■ DHW production
... with the following flow conditions:
The total flow rate of the two heating circuits is less than
the maximum possible water flow rate of the Vitodens
200-W B2HB boiler (see page 31 for maximum water flow
rate of boiler).
The use of a low-loss header is strongly recommended if
the maximum water flow rate in the application concerned
exceeds the max. boiler flow rate, or if the system flow
rates are unknown. The low-loss header is available as
accessory part.
The 3-way mixing valve, built-in to achieve the lowtemperature level of the under floor heating circuit, is
controlled by an accessory kit for a heating circuit with
mixing valve I. The boiler pump
radiator heating circuit and the plate heat exchanger
for system separation.
20 supplies the
IMPORTANT
The pressure drop (secondary circuit) of the plate heat
exchanger F must be less/equal to the pressure drop of
the 3-way mixing valve. This must be taken into account
when sizing the plate heat exchanger.
39
Page 40
Boiler Connections
System Layout 8
Vitodens 200-W, B2HB with...
- DHW storage tank
- low-loss header
- multiple heating circuits with mixing valves
- one heating circuit without mixing valve
Vitodens 200-W B2HB 45, 57 Installation
When designing a system as illustrated above, please contact your local Viessmann Sales Representative for assistance.
Legend
A Vitodens 200-W B2HB boiler with Vitotronic
200, HO1B outdoor reset control
B Outdoor temperature !
C Boiler pump 20
D Vitotronic 200-H, HK1B *1
E Mixing valve temperature sensor ?
F Heating circuit pumps
G Accessory kit for heating circuit with mixing valve
H Heating circuits with mixing valves
I Viessmann temperature sensor for low-loss header ?
J Low-loss header
K DHW circulating pump sA
L DHW tank temperature sensor %
M DHW storage tank
N Expansion tank
O DHW recirculation pump sK
P Heating circuit pump 28/20 *
Q Vitotrol remote (optional)
R Radiator heating circuit
S Temperature and pressure relief valve
T Pressure relief valve
* Function based on coding of address 33
*1 Contact your local Sales Representative for details.
Vitotronic 200-H, HK1B mixing valve control with
LON communication module can be used instead
of the accessory kit and Vitocontrol.
IMPORTANT
Please note location of expansion tank N.
IMPORTANT
Pumps C and K must pump into the Vitodens 200-W
B2HB boiler (as illustrated).
40
5680 493 - 05
Page 41
Vitodens 200-W B2HB 45, 57 Installation
System Layout 9
Multiple (up to eight) Vitodens 200-W, models B2HB 45 to 57 with...
- multiple heating circuits with mixing valves
- low-loss header
Boiler Connections
Legend
A Vitodens boiler
B Vitotronic 300K
C Low-loss header/common supply temperature sensor
D Low-loss header
E DHW storage tank
F High temperature heating circuit
G Low temperature heating circuit
When designing a multiple Vitodens system as shown
above, please reference applicable multiple Vitodens
technical documentation, and contact your local Viessmann
Sales Representative for further assistance.
This installation example depicts a possible piping layout
for multiple Vitodens 200-W, B2HB boilers equipped with
Viessmann System Technology. Please note that this
example is based on a simplified conceptual drawing only!
Piping and necessary componentry must be field verified.
A low water cut-off (LWCO) must be installed where
required by local codes.
Proper installation and functionality in the field is the
responsibility of the heating contractor.
WARNING
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 the original manufacturer
of the tank. Viessmann strongly recommends the
installation of a temperature tempering valve in the
DHW supply line.
5680 493 - 05
41
Page 42
Boiler Connections
Vitodens 200-W B2HB 45, 57 Installation
Alternative 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 Service Instructions.
42
*Note: When using a low loss header in the system, the
DHW connections can be made downstream of
the low loss header. See Vitodens 200-W B2HB
Service Instructions for applicable system coding
information (see coding level 2):
00: ...
A2: ...
5b: ...
5680 493 - 05
Page 43
Vitodens 200-W B2HB 45, 57 Installation
Boiler in Heating/Cooling
Boiler Connections
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.
The boiler piping system of a hot water heating boiler
connected to heating coils located in air handling units
where they may be exposed to refrigerated air circulation
must be equipped with flow control valves or other
automatic means to prevent gravity circulation of the
boiler water during the cooling cycle.
Check installation instructions of the chiller manufacturer
carefully for additional requirements.
Cooling season starts:
Close valve “v1” and open valve “v2”.
Heating season starts:
Close valve “v2” and open valve “v1”.
Legend
A Heating/Cooling unit
B Spring-loaded flow check valve
C Circulation pump
D Safety header with automatic air vent and
pressure relief valve
E Expansion tank
F Water chiller
G Boiler circuit pump (field supplied)
IMPORTANT
Viessmann strongly suggests that the
valves illustrated be labelled “v1” and “v2”.
IMPORTANT
In the illustration, the circulating pump
must be operated from a separate on/off
switch, not from the pump aquastat on
the boiler control.
5680 493 - 05
43
Page 44
Boiler Connections
Boiler with Low Water Cut-off
Automatic
air vent
Automatic
air vent
Vitodens 200-W B2HB 45, 57 Installation
Boiler with low water cut-off (remote-mounted,
field supplied)
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.
Follow the installation instructions of the
low water cut-off from the manufacturer.
For low water cut-off wiring information specific to your
application, refer to applicable wiring diagram (see page 44).
Venting Connection
CAUTION
Under certain climatic conditions some building materials
may be affected by flue products expelled in close
proximity to unprotected surfaces. Sealing or shielding of
the exposed surfaces with a corrosion resistant material
(e.g. aluminum sheeting) may be required to prevent
staining or deterioration. The protective material should
be attached and sealed (if necessary) to the building
before attaching the vent termination. It is strongly
recommended to install the vent termination on the
leeward side of the building.
Vitodens 200-W, B2HB
Installation Instructions
Venting System
44
5680 493 - 05
Page 45
Vitodens 200-W B2HB 45, 57 Installation
Electrical Connections
Control Connections
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, HK1B mixing valve control, the
mixing valve accessory kit and the Solartrol control
require a separate 120VAC power supply from the wall
receptacle.
Closing the control unit casing and inserting (continued)
Insert programming unit (packed separately) into the
control unit support.
Note: The programming unit can also be used in a wall
mounting base (accessory) near the boiler
Cabling required for:
H outdoor temperature sensor
H Vitotronic 200-H, HK1B mixing valve control
H accessory kit for heating circuit with mixing valve
H remote switching of operating mode
H remote disable
H alarm output
H wall-mount base
H circulating pump
IMPORTANT
It is essential to route cables as illustrated to ensure
freedom of movement of control unit.
IMPORTANT
When running and securing connecting cables on site,
ensure that the maximum permissible temperatures of the
cables are not exceeded.
IMPORTANT
Cables in the vicinity of the control unit must not be
secured to the control unit bracket.
Connection of accessories
For details regarding other installation steps
required, please reference the Installation
Instructions supplied with the respective
accessory part.
Note: Only one accessory part or one
switch contact can be connected
to the contacts of a plug at a time.
5680 493 - 05
45
Page 46
Control Connections
Vitodens 200-W B2HB 45, 57 Installation
Overview of Electrical Connections, Models B2HB 45 and 57
WARNING
DISCONNECT POWER BEFORE
SERVICING BOILER.
If any of the original wires as
supplied with the appliance must
be replaced, it must be replaced
with the exact equivalent.
46
CAUTION
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation. Verify proper operation
after servicing.
Only one function/accessory may
*
be assigned to each connection.
5680 493 - 05
Page 47
Vitodens 200-W B2HB 45, 57 Installation
Electrical Connections (continued)
Legend
1 Outdoor Temperature Sensor
2 Supply Temperature Sensor/Low Loss Header
3 Boiler Temperature Sensor/High Limit Sensor
3A Boiler Temperature Sensor/High Limit Sensor
5 DHW Temperature Sensor
11 Ionization Electrode
15 Flue Gas temperature Sensor
20 Boiler Pump
21 DHW Pump
[21] Pump Output Connection
28/20 Programmable Pump Output*
33 Flow Switch (X2 FOR MODELS 80/88/100)
35 Gas Valve (X2 FOR MODELS 80/88/100)
40 Power Supply
40A Accessory Power Output
[53] Powered Accessory Connection
54 Ignition Transformer
96 Powered Accessory Connection
100 Fan Motor
100A Fan Motor Control
111 Not Used
145 KM-BUS
Multi Powered Accessory Connection
156A Switched Output F2
156B Switched Output F1
DE1 Digital Input 1 (Dry Contact)
DE2 Digital Input 2 (Dry Contact)
DE3 Digital Input 3 (Dry Contact)
0-10V 0-10VDC Input
157 Fault Alarm/DHW Recirc. Pump*
190 Gas Modulation Coil
190A Gas Modulation Coil (for 80/88/00)
Control Connections
* See wiring diagram
A Boiler Control
B External Accessory Connection Board
C Pump Connection Interface
D Extension Module EA1
E KM-BUS for External Devices
F Electrical Junction Box
G Field Wiring Connections
A1 Main Board
A2 Internal Power Supply Unit
A3 Optolink
A4 Burner Control Unit
A5 Programming Unit
A6 Coding Card
A7 Connection Adaptor
A8 LON Communication Module
S1 ON/OFF Switch
S2 Reset Button
X.. Electrical Interface
5680 493 - 05
47
Page 48
Control Connections
Accessing the X3 Plug
Vitodens 200-W B2HB 45, 57 Installation
1. Remove the control unit cover (see page 15).
2. Remove the X3 plug from the control board. Install
the required sensors as per installation instructions.
3. Reinstall the control cover.
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.
48
5680 493 - 05
Page 49
Vitodens 200-W B2HB 45, 57 Installation
Connecting the Outdoor Temperature Sensor
1. Remove cover of outdoor temperature sensor.
2. Mount wall-mount base (cable entry must point
downward).
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.
Ensure that sensor is not located above windows, doors
and air vents, or immediately underneath a balcony or
gutter.
The outdoor temperature sensor must not be covered
by plaster. If mounting on an unplastered wall, make
allowances for thickness of plaster or remove sensor
before plastering wall.
3. Route cable from the boiler control board to the
outdoor sensor. Connect cable to sensor terminals
(wires are interchangeable).
Cable specifications:
2-wire cable, max. cable length 95 ft. (35 m) with a
wire size of min. AWG 16 copper.
4. Connect the outdoor temperature sensor to terminals
X 3.1/X3.2 on the boiler control board (wires are
interchangeable).
5. Place cover on base and snap into place.
Control Connections
5680 493 - 05
IMPORTANT
Cable to the outdoor sensor must not be laid near line
voltage wiring (120/240V).
49
Page 50
Control Connections
External 0-10 Volt Signal Connection
Extension Module EA1
Vitodens 200-W B2HB 45, 57 Installation
1. Connect the external 0-10V signal to plug 0-10V
located in the extension module EA1.
2. Ensure correct polarity.
3. See chart for maximum possible boiler water
temperature and required signal.
Example: Voltage to temperature setpoint
8VDC = 176ºF (80ºC)
50
5680 493 - 05
Page 51
Vitodens 200-W B2HB 45, 57 Installation
Connecting a 24 VAC Thermostat
Control Connections
1. Connect normally open dry contact of the switching
relay (‘T-T’ contact) to terminal DE1, DE2 or DE3
of the EA1 module located in the boiler electrical
junction box.
2. Connect switching relay to thermostat and power
supply as per manufacturers instructions.
When the thermostat contact is closed, burner
operation is load-dependent. The supply water is
heated to the value set in the coding address “9b” in
the “General” group of the boiler.
The supply water temperature is limited by this set
value and the electronic supply temperature maximum
limit.
Codes
Extension EA1 Set “3A”, “3B” or “3C” in the “General”
group to 2.
Note: ‘Live’ contacts lead to short circuits or phase
failure. The external connection must be potential free.
Note: When only using a thermostat (field supplied) for
room temperature control, the boiler standard and
reduced room temperature set points may be set to
37º F (3º C) to reduce boiler cycling.
5680 493 - 05
Legend
A Boiler electrical junction box
B Switch relay (ie Taco SR501, Honeywell
RA889A-1001, field supplied)
C 24VAC room thermostat (field supplied)
D Internal EA1 module
E 120VAC power supply for switching relay (refer to
manufacturers instructions)
F Dry contact connection from switching relay (to boiler
‘T-T’)
51
Page 52
Control Connections
LON Module
Vitodens 200-W B2HB 45, 57 Installation
Installing the LON module to the boiler control board
1. Remove the control cover (see page 15).
2. Insert the LON module into the boiler control board.
3. Connect the LON connector cable to the LON module.
Boiler Control
Connecting the LON module cable
See the Vitotronic 200-H
HK1B Installation Instructions.
52
5680 493 - 05
Page 53
Vitodens 200-W B2HB 45, 57 Installation
Accessory Kit
Control Connections
Boiler
Control
Extension Module EA1
KM Bus
Accessory
Closing the Control Unit
Accessory kit connections for heating circuit with
mixing valve
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 control.
For details on coding and connection to the
control, refer to the Vitodens 200-W B2HB
Service Instructions.
For details on installation, refer to the accessory
kit Installation Instructions.
Closing the control cover
1. Install the cover onto the control board.
2. Flip the control board back into position.
3. Secure the locking tabs as shown.
5680 493 - 05
53
Page 54
Control Connections
Closing the External Accessory Connection Box
4. Tilt the top of the external accessory connection
box cover forward.
5. Drop down over the locating pins and set the cover
in place.
Vitodens 200-W B2HB 45, 57 Installation
6. Swing the external accessory connection box up.
7. Push the external accessory connection box in until
the holding screw is in place.
54
5680 493 - 05
Page 55
Vitodens 200-W B2HB 45, 57 Installation
Closing the External Accessory Connection Box (continued)
8. Tighten the external accessory connection box
retaining screw.
9. Install the external accessory connection box cover
screws.
Control Connections
5680 493 - 05
55
Page 56
Control Connections
Reinstalling the Front Enclosure Panel
Vitodens 200-W B2HB 45, 57 Installation
10. Set front enclosure panel on the guide rails and
push in place.
11. Tighten screws at the bottom.
12. Insert the external accessories connection box
cover in place.
Note: Ensure the locking screws are fitted before
operating.
Instructing the system user
The system installer should hand the operating
instructions to the system user and instruct the user in
operating the system.
IMPORTANT
Read and follow, where applicable, the safety instructions
of all labels and stickers attached to boiler surfaces. Do
not remove any of these instructions. Contact Viessmann
if any replacement labels are required.
56
5680 493 - 05
Page 57
Vitodens 200-W B2HB 45, 57 Installation
Additional Information
Technical Data
Boiler Model No. 200-W B2HB 45 57
CSA input Natural Gas (NG)
CSA input Liquid Propane Gas (LPG)
CSA output/DOE *1
heating capacity NG
CSA output/DOE *1
heating capacity LPG
Net AHRI rating *2
Heat exchanger surface area ft.
Minimum gas supply pressure
Natural gas
Liquid propane gas
Maximum gas supply pressure *3
Natural gas
Liquid propane gas
A.F.U.E. % 95.0 95.0
Weight lbs
Boiler water content USG
Boiler maximum flow rate *4 GPM
Maximum operating pressure
at 210°F (99°C)
Boiler water temperature
- Adjustable high limit (AHL) range
space heating (steady state)
DHW production
- Fixed high limit (FHL)
Boiler connections
Boiler heating supply and return
Pressure relief valve
Drain valve
(male thread)
MBH
(kW)
MBH
(kW)
MBH
(kW)
MBH
(kW)
MBH
(kW)
2)
(m
“w.c.
“w.c.
“w.c.
“w.c.
(kg)
(L)
(L/h)
psig
(bar)
°F
(°C)
°F (°C)
°F (°C)
NPTM in.
NPTF in.
2
32-160
(9-47)
60-160
(17.5-47)
30-149
(9-44)
56-149
(17-49)
127
(37)
31.99
(2.9)
4
10
14
14
210
(95)
3.85
(14.6)
14.3
(3250)
60
(4)
68 to 165
(20 to 74)
165 (74)
210 (99)
1
b
¾
¾
32-199
(9-58)
60-199
(17.5-58)
30-185
(9-54)
56-185
(17-54)
160
(47)
31.99
(2.9)
4
10
14
14
210
(95)
3.85
(14.6)
14.3
(3250)
60
(4)
68 to 165
20 to 74
165 (74)
210 (99)
1
b
¾
¾
Boiler supply/return for
indirect-fired DHW storage tank
(field supplied)
Gas valve connection
*1 Output based on 140ºF (60ºC), 120ºF (49ºC) system supply/return temperature.
*2 Net AHRI rating based on piping and pick-up allowance of 1.15.
*3 If the gas supply pressure exceeds the maximum gas supply pressure value, a separate gas pressure regulator
must be installed upstream of the heating system.
*4 See “Waterside Flow” on page 31 of this manual.
5680 493 - 05
NPT in.
NPTF in.
1b
1
1b
1
57
Page 58
Additional Information
Vitodens 200-W B2HB 45, 57 Installation
Technical Data (continued)
Boiler Model No. 200-W B2HB 45 57
Dimensions
Overall depth
Overall width
Overall height
Flue gas *5
Temperature (at boiler return
temperature of 86°F (30°C)
- at rated full load
- at rated partial load
Temperature (at boiler return
temperature of 140°F (60°C)
Max. condensate flow rate *6
with natural gas and
T
=122/86°F (50/30°C) USG/h
S/TR
Condensate connection*7 hose nozzle
Boiler flue gas connection *8 Ø
Combustion air supply
connection (coaxial)
Sound Rating
- at maximum input
- at minimum input
inches
(mm)
inches
(mm)
inches
(mm)
ºF (ºC)
ºF (ºC)
ºF (ºC)
(L/h)
Ø in
in (mm)
outer
Ø in (mm) 5 (125) 5 (125)
dB
dB
21
(530)
19
(480)
43b
(1105)
95 (35)
91 (33)
149 (65)
1.55
(6.0)
(530)
(480)
43b
(1105)
104 (40)
95 (35)
158 (70)
(8.0)
¾-1 ¾-1
3
¼ (80) 3¼ (80)
56
39
21
19
2.0
67
39
*5 Measured flue gas temperature with a combustion air temperature of 68°F (20°C).
*6 Based on maximum input rate.
*7 Requires 1 inch (25 mm) tubing. See the Installation Instructions of the Vitodens 200-W, B2HB for details.
*8 For side wall vent installations (coaxial system):
Do not exceed max. equivalent length specified in the Installation Instructions of the Vitodens 200-W, B2HB
Venting System.
Do not attempt to common-vent Vitodens 200-W B2HB 19, 26, 35 with any other appliance.
The Vitodens 200-W B2HB 45, 57 can only be common vented with other Vitodens 200-W boilers of the same
size and series. Side wall co-axial vent installation must include Viessmann protective screen!
For details refer to the Installation Instructions for the Vitodens 200-W, B2HB Venting System.
For information regarding other Viessmann System Technology componentry, please reference documentation
of respective product.
Note: For high altitude installation at 10,000 ft. the input for model B2HB 19 to 80 will have an altitude de-ration of 21%.
58
5680 493 - 05
Page 59
Vitodens 200-W B2HB 45, 57 Installation
Installation Fittings
Additional Information
Parts
0301 Nipple ¾” x 1b”
0302 Sediment faucet ¾”
0303 Tee, ¾”
0304 Nipple ¾” x 3b”
0305 Reducing tee 1b” x 1b” x ¾”
0306 Gas ball valve 1”
0312 Pressure relief valve, 30 psig
Other Parts (not illustrated)
0309 Accessory pack (metal stud mount kit)
0311 Outdoor temperature sensor
0325 Parts List, Installation Fittings
0320 Technical literature set
0350 Temperature gauge 2” 30-250ºF *1
0351 Temperature sensor (immersion)
for DHW production NTC
0352 Temperature sensor (immersion)
for low-loss header NTC (if low-loss header installed)
*1 Install anywhere in supply piping near boiler
*2 Discard when using multi-boiler distribution manifold
5680 493 - 05
59
Page 60
Vitodens 200-W B2HB 45, 57 Installation
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. Be sure to smell next to the floor
because some gas is heavier than air and will
settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on
this label.
2. Set thermostat or other operating control to
lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the burner.
Do not try to light the burner by hand.
Manual gas shutoff
Closed
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not push in or turn by hand, don’t try to
repair it, call a qualified service technician.
Force or attempted repair may result in a fire
or explosion.
(recycled and recyclable) paper.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance
and to replace any part of the control system
and any gas control which has been under
water.
5. Close main gas shut-off valve.
6. Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas, STOP! Follow “B” in the
safety information above on this label. If you
don’t smell gas, go to the next step.
7. Open main gas shut-off valve.
8. Turn on all electric power to the appliance.
9. Set thermostat or other operating control to
desired setting.
10. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance”
and call your service technician or gas
supplier.
Open
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat or other operating control to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Close main gas shut-off valve.
Technical information subject to change without notice. Printed on environmentally friendly
5680 493 - 05
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