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Cascade System Guide
for use by Viessmann representatives
5285 280 v1.0 08/2011
Read and save these instructions
for future reference.
Multiple V
itodens Systems
IMPORTANT
for Vitodens 200-W, WB2B 80/105 Series Boilers
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Purpose of this Document
The cascade system guide is intended for Viessmann
representatives to provide general information regarding
components, assembly and wiring for various system
configurations using multiple WB2B 80/105 Vitodens
boilers.
This document is to be used for general information
only and maybe subject to change without notice. Some
products may not be exactly as illustrated.
For additional information or other system configurations,
contact the Viessmann commercial projects department.
Table of Contents
Cascade System Guide
IMPORTANT
All distribution manifold inline installations can not be free
standing and must be securely fastened to the floor and
the wall.
Wall mount or wall and floor installations must be capable
of supporting the weight of the boilers, distribution
manifold(s) and insulation.
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Cascade System Guide
Purpose of this Document............................................2
Wall Mounted Multiple Boilers (without manifold)............3
Multiple Boilers using a Distribution Manifold, LLH..........4
Standard 2 Boiler Distribution Manifold with LLH.......4
Standard 3 Boiler Distribution Manifold with LLH.......5
Standard 2x-2 Boiler Distribution Manifold with LLH...6
Boilers for Cascade System..........................................7
Pumps per Boiler with the Manifold System...................7
Control for Heating System Loop..................................8
Additional Mixing Valves..............................................8
Venting Systems........................................................8
Set-up for Cascade System with External 0-10V
Temperature Signal to the Boiler..............................9
Set-up for Cascade System with Vitocontrol-S...........10
Heating Circuit/Boiler Pumps......................................11
Vitocontrol-S, 1 High/1 Low Temp. Heating Circuit &
1 DHW Tank............................................................12
Coding................................................................12
Wiring.................................................................13
2
Vitocontrol-S, 1 High/2 Low Temp. Heating Circuit &
1 DHW Tank............................................................14
Coding................................................................14
Wiring.................................................................15
Vitocontrol-S, 1 High/3 Low Temp. Heating Circuit &
1 DHW Tank............................................................16
Coding................................................................16
Wiring.................................................................17
Vitocontrol-S, 1 High/1 Low Temp. Heating Circuit,
1 DHW Tank & External Snow Melt............................18
Coding................................................................18
Wiring.................................................................19
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Cascade System Guide
Wall Mounted Multiple Boilers (without manifold)
Using standard Viessmann components, a maximum of 4 same size boilers can be connected in a cascade system using
a LL distribution manifold or field piped system (as shown below).
For systems requiring more than 4 boilers a custom Viessmann control is required.
A low loss header must be installed between the primary
boiler circuit and secondary system circuit. The LLH must
be sized to accommodate the highest flow rate.
All supply and return pipes are field supplied.
For systems that do not use the LLDM (field piped
systems) the contractor must size the pump according to
the pressure drop of the piping and the pressure drop of
the boiler heat exchanger.
For a list of recommended heating circuit/boiler pumps
refer to page 11.
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Control options for cascade system not using LLDM.
Vitocontrol-S WB2B cascade control.
For systems up to 4 boilers of the same size, using KMK
bus communication between the Vitotronic HC1 boiler
control and the Vitocontrol-S WB2B cascade control.
System type Wall mounted
WB2B 80 WB2B916
WB2B 105 WB2B917
BMS or third party cascading controller
For systems up to 4 boilers of the same size, using
0-10VDC temperature signal between the Vitotronic 200
HO1 and the third party controller.
System type Wall mounted
WB2B 80 WB2B912
WB2B 105 WB2B913
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Cascade System Guide
Multiple Boilers using a Standard Distribution Manifold and LLH
The following illustrations will show a 2, 3 and 4 multiple boiler configurations using standard 2 or 3 boiler distribution
manifolds. All low loss distribution manifold packages include a LLH.
Standard 2 Boiler Distribution Manifold with Low Loss Header (dimensions in. [mm])
(front view shown)
Part No. Z008 013 includes a 2 boiler distribution manifold, a low loss header and the necessary mounting hardware.
Part No. 7424 333 for manifold insulation (order separately if required, not shown).
Part No. 7424 336 for LLH insulation (order separately if required, not shown).
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Cascade System Guide
Multiple Boilers using a Standard Distribution Manifold and LLH (continued)
Standard 3 Boiler Distribution Manifold with Low Loss Header (dimensions in. [mm])
(front view shown)
Part No. Z008 014 includes a 3 boiler distribution manifold, a low loss header and the necessary mounting hardware.
Part No. 7424 334 for 3 boiler manifold insulation (order separately if required, not shown).
Part No. 7424 337 for LLH insulation (order separately if required, not shown).
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Cascade System Guide
Multiple Boilers using a Standard Distribution Manifold and LLH (continued)
Standard 2x - 2 Boiler Distribution Manifolds with Low Loss Header (dimensions in. [mm])
(front view shown)
Part No. Z008 015 includes 2x - 2 boiler distribution manifolds, a low loss header and the necessary mounting hardware.
Part No. 2x - 7424 333 for 2 boiler manifold insulation (order separately if required, not shown).
Part No. 7424 338 for LLH insulation (order separately if required, not shown).
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Cascade System Guide
Boilers for Cascade System
Control options for cascade system when using LLDM.
Vitocontrol-S WB2B cascade control.
For systems up to 4 boilers of the same size, using KMK
bus communication between the Vitotronic HC1 boiler
control and the Vitocontrol-S WB2B cascade control.
System type With manifold
WB2B 80 WB2B918
WB2B 105 WB2B919
BMS or third party cascading controller
For systems up to 4 boilers of the same size, using
0-10VDC temperature signal between the Vitotronic 200
HO1 and the third party controller.
System type With manifold
WB2B 80 WB2B914
WB2B 105 WB2B915
The packages listed above include the following
components;
- WB2B Boiler
- Vitotronic boiler control
- Power pump module
- 30 psig relief valve
- Pressure gauge
- Gas shut-off valve
- (2) fill/drain valves
- Mounting hardware
Optional components:
- 45 psig relief valve (PN 9549944)
- 60 psig relief valve (PN 9560183)
Pumps per Boiler with the Manifold System
One circulation pump per boiler is required:
- UPS 26-99 FC 7248585 for a max of 24 gpm
- UPS 26-150 F 7441596 for a max of 28 gpm
Boiler model 200-W, WB2B 80 105
r t for NG/LPG Output Btu/h
25º F rise (GPM) 20.8 28.0
30º F rise (GPM) 17.3 23.3
35º F rise (GPM) 14.9 20.0
40º F rise (GPM) 13.0 17.5
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260 000 350 000
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Control for Heating System Loop
Vitocontrol-S, is capable of controlling (1) high
temperature circuit and (2) low temperature circuits with
mixing valves.
Refer to the price book 1 and 2 for available 3 and 4 way
mixing valve sizes and corresponding part numbers.
BMS tie-ins to the Vitocontrol-S will require additional
integration equipment, the following integration equipment
is available from Viessmann;
0-10VDC Extension input module
Versatronik 505 BACIP Gateway
Versatronik 505 LONIP Gateway
Additional Mixing Valves
External mixing valve controllers are required when
controlling 3 or more mixing valve circuits, use one
Vitotronic 200 HK1M (PN 7134627) in conjunction with
the Vitocontrol-S for each additional mixing valve circuit
in the system.
Cascade System Guide
Additional equipment required when installing a Vitotronic
200 HK1M are as follows;
- (1) LON Connection cable 23 ft. (7 m) (7143495)
- (1) LON Terminal end resistors 92 pieces ( 7143497)
- (1) LON Communication modules for HK1M (7172173)
- (1) LON Communication modules for WB2B (7179113)
Venting Systems
Each boiler must be vented separately using one of the
following certified venting systems:
- Coaxial PP(s)
- Stainless steel
- CPVC Vent
- Flexible PP(s)
- PP(s) rigid venting
Refer to the Venting Installation Instructions
for more detail.
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Cascade System Guide
Set-up for Cascade System with External 0-10V Temperature Signal to the Boiler
Preparing the single boiler connections to the pump power module and coding addresses that needs to be changed.
Coding changes for the Vitotronic 200, HO1 boiler:
- No coding changes are required, boiler control is capable
of automatic recognition, if the BMS system fails to
recognize the Vitotronic 100 HO1, please refer to the
Vitodens 200 WB2B Start-up/Service Manual.
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Cascade System Guide
Set-up for Cascade System with Vitocontrol-S
Preparing the single boiler connections to the pump power module and the coding addresses that needs to be changed.
Require coding changes for the Vitotronic 100 HC1 boiler
control (changes to be made in Coding 2):
- coding address 01:1 changed to 01: 2
(multiple boiler systems)
- coding address 07: changed to 07:_(for each boiler #
in the cascade system)
- coding address 76:0 changed to 76:2
(with cascade communication module)
- coding address 77: changed to 77:_(for each boiler #
in the cascade system)
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Cascade System Guide
Set-up for Cascade System with Vitocontrol-S (continued)
The following 4 drawings are general and provide
additional information for the different cascade systems.
These include preparing the Vitocontrol-S with the
connections to the boilers and the necessary coding
changes for a cascade system as well as various
accessories.
Custom systems are available on request.
IMPORTANT
Configurations for 5, 6, 7 and 8 boilers are available with
a customized boiler control solutions from Viessmann.
Contact Viessmann (commercial projects) for boiler control
information and requests.
Heating Circuit / Boiler Pumps
We recommend the following (depending on r t):
Model WB2B 80
Flow rate Boiler pressure drop (ft.) Recommended pump Grundfos
20º F r t
25º F r t
30º F r t
35º F r t
40º F r t
Flow limitation L/h (GPM) 8000 (35.2)
Model WB2B 105
20º F r t
25º F r t
30º F r t
35º F r t
40º F r t
Flow limitation L/h (GPM) 8000 (35.2)
26.0 16.7 * UPS 32-160/2, 115V, Speed1
20.8 9.2 UPS 26-99FC, 115V, Speed3
17.3 6.5 UPS 26-99FC, 115V, Speed2
14.9 4.8 UPS 26-99FC, 115V, Speed2
13.0 3.4 UPS 26-99FC, 115V, Speed2
Flow rate Boiler pressure drop (ft.) Recommended pump Grundfos
35.0 30.0 * UPS 32-160/2, 115V, Speed3
28.0 20.0 * UPS 32-160/2, 115V, Speed2
23.3 12.5 * UPS 32-160/2, 115V, Speed1
20.0 9.0 UPS 26-99FC, 115V, Speed3
17.5 6.4 UPS 26-99FC, 115V, Speed2
* UPS 32 - 160/2 can not be installed with the manifold option.
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Vitocontrol-S - 1 High/1 Low Temp. Heating Circuit & 1 DHW Tank
Coding
VITOCONTROL-S
DESCRIPTION
00:6 System circuit A1 and mixing valve circuit M2, with DHW heating
35:4 4 boilers connected to Vitocontrol-S WB2B
3C:0 Gross calorific strategy (condensing) see install instructions
4C:0
73:7 Constantly ON
76:0 Without LON communication module
79:1 Control unit is fault manager
9d:1 With input module 0-10V; will be recognized automatically
DESCRIPTION
00:0 Boiler control connected to the cascade; this automatically occurs if 01:2 has been
01:2 Multi-boiler system with cascade control
07:1 Boiler number in multi-boiler system
2E:1 KM-bus connection of power/pump module automatically recognized
76:2 With cascade communication module; automatic recognition
82:0 Operation with natural gas
Connecting on plug
programmed
A1: heating and circuit pump
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CODING FOR BOILER No. 1
Cascade System Guide
CODING FOR BOILER No. 2
Boiler No. 2 same as Boiler No. 1 with exception to 07:2
07:2 Boiler No. 2 in multiple boiler system
CODING FOR BOILER No. 3
Boiler No. 3 same as Boiler No. 1 with exception to 07:3
07:3 Boiler No. 3 in multiple boiler system
CODING FOR BOILER No. 4
Boiler No. 4 same as Boiler No. 1 with exception to 07:4
07:4 Boiler No. 4 in multiple boiler system
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Cascade System Guide
Vitocontrol-S - 1 High/1 Low Temp. Heating Circuit & 1 DHW Tank (continued)
Wiring
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Vitocontrol-S - 1 High/2 Low Temp. Heating Circuit & 1 DHW Tank
Coding
VITOCONTROL-S
DESCRIPTION
00:10 System circuit A1 and mixing valve circuit M2 & M3, with DHW heating
35:4 4 boilers connected to Vitocontrol-S WB2B
3C:0 Gross calorific strategy (condensing) see install instructions
4C:0
73:7 Constantly ON
76:0 Without LON communication module
79:1 Control unit is fault manager
9d:1 With input module 0-10V; will be recognized automatically
DESCRIPTION
00:0 Boiler control connected to the cascade; this automatically occurs if 01:2 has been
01:2 Multi-boiler system with cascade control
07:1 Boiler number in multi-boiler system
2E:1 KM-bus connection of power/pump module automatically recognized
76:2 With cascade communication module; automatic recognition
82:0 Operation with natural gas
Connecting on plug
programmed
A1: heating and circuit pump
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CODING FOR BOILER No. 1
Cascade System Guide
CODING FOR BOILER No. 2
Boiler No. 2 same as Boiler No. 1 with exception to 07:2
07:2 Boiler No. 2 in multiple boiler system
CODING FOR BOILER No. 3
Boiler No. 3 same as Boiler No. 1 with exception to 07:3
07:3 Boiler No. 3 in multiple boiler system
CODING FOR BOILER No. 4
Boiler No. 4 same as Boiler No. 1 with exception to 07:4
07:4 Boiler No. 4 in multiple boiler system
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Cascade System Guide
Vitocontrol-S - 1 High/2 Low Temp. Heating Circuit & 1 DHW Tank (continued)
Wiring
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Vitocontrol-S - 1 High/3 Low Temp. Heating Circuit & 1 DHW Tank
Coding
VITOCONTROL-S
DESCRIPTION
00:10 System circuit A1 and mixing valve circuit M2 & M3, with DHW heating
35:4 4 boilers connected to Vitocontrol-S WB2B
3C:0 Gross calorific strategy (condensing) see install instructions
4C:0
73:7 Constantly ON
76:0 Without LON communication module
79:1 Control unit is fault manager
9d:1 With input module 0-10V; will be recognized automatically
DESCRIPTION
00:0 Boiler control connected to the cascade; this automatically occurs if 01:2 has been
01:2 Multi-boiler system with cascade control
07:1 Boiler number in multi-boiler system
2E:1 KM-bus connection of power/pump module automatically recognized
76:2 With cascade communication module; automatic recognition
82:0 Operation with natural gas
Connecting on plug
programmed
A1: heating and circuit pump
20
CODING FOR BOILER No. 1
Cascade System Guide
CODING FOR BOILER No. 2
Boiler No. 2 same as Boiler No. 1 with exception to 07:2
07:2 Boiler No. 2 in multiple boiler system
CODING FOR BOILER No. 3
Boiler No. 3 same as Boiler No. 1 with exception to 07:3
07:3 Boiler No. 3 in multiple boiler system
CODING FOR BOILER No. 4
Boiler No. 4 same as Boiler No. 1 with exception to 07:4
07:4 Boiler No. 4 in multiple boiler system
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Cascade System Guide
Vitocontrol-S - 1 High/3 Low Temp. Heating Circuit & 1 DHW Tank (continued)
Wiring
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Cascade System Guide
Vitocontrol-S - 1 High/1 Low Temp. Heating Circuit, 1 DHW Tank & External Snow Melt
VITOCONTROL-S
DESCRIPTION
00:6 System circuit A1 and mixing valve circuit M2, with DHW heating
35:4 4 boilers connected to Vitocontrol-S WB2B
3C:0 Gross calorific strategy (condensing) see install instructions
4C:0
Connecting on plug
20
A1: heating and circuit pump
73:7 Constantly ON
76:0 Without LON communication module
79:1 Control unit is fault manager
9b:7 Set point for external demand (adjustable between 1º and 80º C)
9d:1 With input module 0-10V; will be recognized automatically
CODING FOR BOILER No. 1
DESCRIPTION
00:0 Boiler control connected to the cascade; this automatically occurs if 01:2 has been
programmed
01:2 Multi-boiler system with cascade control
07:1 Boiler number in multi-boiler system
2E:1 KM-bus connection of power/pump module automatically recognized
76:2 With cascade communication module; automatic recognition
82:0 Operation with natural gas
CODING FOR BOILER No. 2
Boiler No. 2 same as Boiler No. 1 with exception to 07:2
07:2 Boiler No. 2 in multiple boiler system
CODING FOR BOILER No. 3
Boiler No. 3 same as Boiler No. 1 with exception to 07:3
07:3 Boiler No. 3 in multiple boiler system
CODING FOR BOILER No. 4
Boiler No. 4 same as Boiler No. 1 with exception to 07:4
07:4 Boiler No. 4 in multiple boiler system
Coding
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Cascade System Guide
Vitocontrol-S - 1 High/1 Low Temp. Heating Circuit, 1 DHW Tank & External Snow Melt
Wiring
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Cascade System Guide
Printed on environmentally friendly
(recycled and recyclable) paper.
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario · N2V 2G5 · Canada
1-800-387-7373 · Fax (519) 885-0887
www.viessmann.ca · info@viessmann.ca
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island · 02886 · USA
1-800-288-0667 · Fax (401) 732-0590
www.viessmann-us.com · info@viessmann-us.com
Technical information subject to change without notice.
5285 280 v1.0
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