Viessmann B2HB 45 Installation Instructions Manual Download Page 53

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Vitodens 200-W B2HB 45, 57 Installation

5680 493 - 05

Control Connections

Accessory Kit

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.

Accessory kit connections for heating circuit with

mixing valve

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 Unit

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.

Boiler

Control

Extension Module EA1

KM Bus

Accessory

Summary of Contents for B2HB 45

Page 1: ...uctions VITODENSr 200 W 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 Read and save these instructions for future reference Product may not be exactly as shown IMPORTANT H ...

Page 2: ...e the heating season begins 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 an...

Page 3: ...efects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance 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 First aid measures If eye contact occurs flush eyes with water to remove dust ...

Page 4: ...es 10 Recommended minimum service clearances 10 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 Con...

Page 5: ...ting 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 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 t...

Page 6: ...er 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 fo...

Page 7: ...ions 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 bui...

Page 8: ...ting 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 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 p...

Page 9: ...efinishing 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...

Page 10: ...fied rating plate decal and also accommodate the PRV installation kit 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...

Page 11: ...s 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 PRVPressure Relief Valve 1 See page 40 for alternate DHW connection 2 Discard when using the multi boiler distribution manifold Boil...

Page 12: ...rding the installation of the wall mounting bracket 1 Heating water connections and gas connection to be made in the field See illustration and connection specific section for details 2 See subsection entitled Electrical Connections for details regarding power supply to the Vitodens 200 W B2HB boiler IMPORTANT The maximum ambient temperature must not exceed 104ºF 40ºC This section constitutes an o...

Page 13: ...lation 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 Fitting the wall mountin...

Page 14: ... 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 Boiler mounting bracket Install the boiler mounting bracket to the wall studs Ensure the mounting bracket is level To mount on wood or metal st...

Page 15: ...ont 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...

Page 16: ... 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 b...

Page 17: ...emove 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 en...

Page 18: ...t 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 Connecting power The Vitodens 200 W boiler has a external accessories connection box installed which requires a 120VAC 12A power su...

Page 19: ...s lights or runs IMPORTANT Design piping layout in such a way that piping does not interfere with serviceable components IMPORTANT Max gas supply pressure 14 w c WARNING The gas supply piping must be leak tested before placing the boiler in operation 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...

Page 20: ...PORTANT psig 14 w c 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 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 ...

Page 21: ...r applicable system coding information 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 s...

Page 22: ... 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 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 ...

Page 23: ...tion 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 ...

Page 24: ...y 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 9 16 in 7 14 mm Secure the cable with the cable grommet plugged into the lower casing section orange Legend A Low voltage connections B 120V connections C Internal extension...

Page 25: ...ed 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 Field Connection Connection X9 Connector boiler control board See Vitodens 200 W B2HB Service Instructions for applica...

Page 26: ...57 Installation 5680 493 05 26 Connections continued Boiler Connections OUTDOOR TEMPERATURE SENSOR DHW TEMPERATURE SENSOR Control base Note See wiring diagram on page 44 for connection to the external accessory connection box ...

Page 27: ... Connections Connections continued 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 0 10V INPUT ACCESSORIES ie VITOTROL REMOTE OR MIXING VALVE PUMP ...

Page 28: ...oning 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 IMPORTANT Pipe ventilation must take place between the siphon trap and the neutralization unit if applicable IMPORTANT As shipped the flexible discharge tubing E will be ...

Page 29: ...ameters Pressure relief valve in Discharge pipe in Piping to precharged expansion tank field supplied 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 WAR...

Page 30: ...r water temperature 210ºF 99ºC WARNING Exposing the boiler to pressures and temperatures in excess of those listed will result in damages and will render warranty null and void 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 ...

Page 31: ...8403 46 3 10504 55 5 12605 64 8 14706 74 0 16807 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 14 9 3384 29 8 6768 44 7 10152 59 6 13536 74 5 16920 89 4 20305 104 3 23689 119 2 27073 25º F 14º C rise GPM L h 11 9 2707 23 8 5415 35 8 8122 47 7 10829 59 6 13536 71 ...

Page 32: ...iessmann 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 IMPORTANT DHW supply and return piping between boiler DHW connections an...

Page 33: ...ned 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 low loss header DHW circulating pump F must pump into the Vitodens 200 W boiler as illustrated IMPORTANT Legend A Vitodens 200 W B2HB boiler with Vitotronic 200 HO1B outdoor reset control B Ou...

Page 34: ...eeds the values shown on page 31 or if the system flow rates are unknown The low loss header is available as accessory part Please note location of expansion tank DHW circulating pump F must pump into the Vitodens 200 W B2HB boiler as illustrated IMPORTANT Legend A Vitodens 200 W B2HB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol remote optional D He...

Page 35: ...he heat exchanger must be made of corrosion resistant materials 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 IMPOR...

Page 36: ...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 low temperature level of the under floor heating circuit is controlled by an accessory kit for a heating circuit with mixing valve IMPORTANT Legend A Vito...

Page 37: ... way mixing valve built in to achieve the low temperature level of the under floor heating circuit is controlled by an accessory kit for a heating circuit with mixing valve DHW circulating pump O must pump into the Vitodens 200 W B2HB boiler as illustrated IMPORTANT Legend A Vitodens 200 W B2HB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol remote opt...

Page 38: ...built in to achieve the low temperature level of the under floor heating circuit is controlled by an accessory kit for a heating circuit with a mixing valve DHW circulating pump S must pump into the Vitodens 200 W B2HB boiler as illustrated IMPORTANT Legend A Vitodens 200 W B2HB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol remote optional D Under fl...

Page 39: ...el of the under floor heating circuit is controlled by an accessory kit for a heating circuit with mixing valve I The boiler pump 20 supplies the radiator heating circuit and the plate heat exchanger for system separation 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 th...

Page 40: ...nk N Pumps C and K must pump into the Vitodens 200 W B2HB boiler as illustrated IMPORTANT IMPORTANT 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 ...

Page 41: ...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 operati...

Page 42: ...e 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 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 ...

Page 43: ...e 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 ...

Page 44: ...y 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 th...

Page 45: ... of movement of control unit IMPORTANT Cables in the vicinity of the control unit must not be secured to the control unit bracket When running and securing connecting cables on site ensure that the maximum permissible temperatures of the cables are not exceeded IMPORTANT Connection of accessories Power supply connection of accessories The power supply connection of accessories can be made directly...

Page 46: ...plied with the appliance must be replaced it must be replaced with the exact equivalent 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 WARNING DISCONNECT POWER BEFORE SERVICING BOILER ...

Page 47: ...e 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...

Page 48: ... 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 1 Connect the low loss header sensor if used to terminals X3 4 X3 5 on the boiler control board Connecting the Low loss Header Sensor ...

Page 49: ...er control board wires are interchangeable 5 Place cover on base and snap into place 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 a...

Page 50: ...Volt Signal Connection 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 Extension Module EA1 ...

Page 51: ...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 m...

Page 52: ... 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 LON Module Connecting the LON module cable See the Vitotronic 200 H HK1B Installation Instructions Boiler Control ...

Page 53: ...rol Accessory kit connections for heating circuit with mixing valve 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 Unit Closing the control cover 1 Install the cover onto the control board 2 Flip the control board back into position 3 Secur...

Page 54: ...nal 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 6 Swing the external accessory connection box up 7 Push the external accessory connection box in until the holding screw is in place ...

Page 55: ...Installation 55 5680 493 05 Control Connections 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 ...

Page 56: ... labels are required Reinstalling the Front Enclosure Panel 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 10 Set front enclosure panel on the guide rails and push in place 11 Tighten screws at the bottom 12 Insert the external accesso...

Page 57: ...2 199 9 58 60 199 17 5 58 30 185 9 54 56 185 17 54 160 47 Heat exchanger surface area ft 2 m2 31 99 2 9 31 99 2 9 Minimum gas supply pressure Natural gas Liquid propane gas w c w c 4 10 4 10 Maximum gas supply pressure 3 Natural gas Liquid propane gas w c w c 14 14 14 14 A F U E 95 0 95 0 Weight lbs kg 210 95 210 95 Boiler water content USG L 3 85 14 6 3 85 14 6 Boiler maximum flow rate 4 GPM L h ...

Page 58: ... 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 Boiler Model No 200 W B2HB 45 57 Dimensions Overall depth Overall width Overall height inches mm ...

Page 59: ...g 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...

Page 60: ...d repair may result in a fire or explosion 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 OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set thermostat or other operating control to lowes...

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