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Viessmann B2TB004, Installation Instructions Manual, Page: 37 / 60

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Viessmann B2TB004 Installation Instructions Manual Download Page 37

37

5461 889 - 16

Vitodens 222-F, B2TB 19, 35, 68, 125 Installation

Installation Examples

 System Layout 6

Vitodens 222-F, B2TB with...

 

- Integrated DHW production

 

- one direct-connected heating circuit

 

- one heating circuit with system separation

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 222-F B2TB boiler (see page 30 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 low-

temperature level of the under floor heating circuit, is 

controlled by an accessory kit for a heating circuit with 

a mixing valve.

Legend

A

  Vitodens 222-F B2TB boiler with  

 

 

 

Vitotronic 200, HO1B outdoor reset control

B

  Outdoor temperature sensor 

!

C

  Vitotrol remote (optional)

D

  Under floor heating circuit

E

  Mixing valve temperature sensor 

?

F

  Accessory kit for heating circuit with mixing valve

G

  Heating circuit pumps

H

  DHW storage tank

I

  Integral expansion tank

J

  Pressure relief valve outlet

K

  Temperature and pressure relief valve outlet 

L

  Radiator heating circuit

M

 Boiler 

pump 

20

N

  DHW circulating pump 

sA

O

  Plate exchanger for system separation

P

 DCW 

inlet

 

Q

 DHW 

outlet

R

 Expansion 

tank

Summary of Contents for B2TB004

Page 1: ...Vitodens 222 F B2TB Models 19 35 68 125 Floor mounted gas fired condensing storage combi boiler For operation with natural gas and liquid propane gas Heating input 12 to 125 MBH 3 5 to 37 kW VITODENSr 222 F Read and save these instructions for future reference Product may not be exactly as shown IMPORTANT H ...

Page 2: ... 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 and...

Page 3: ... birth defects 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 remo...

Page 4: ...ure 6 Flow switch procedure 7 Applicability 8 Product Information 8 Mechanical Room 9 Before Set up 10 Minimum Clearances 10 Recommended minimum service clearances 10 Connections 11 Boiler venting 13 Connecting power 13 Connecting heating system 13 Proper piping practice 13 Gas shut off valve connection 14 Gas connection and piping 14 Gas piping pressure test 15 Flue gas connection 15 Removing the...

Page 5: ...ge plug X3 44 Accessing the X3 Plug 45 Connecting the Low loss Header Sensor 45 Connecting the Outdoor Temperature Sensor 46 LON Module 47 Installing the LON module to the boiler control board 47 Connecting the LON module cable 47 Routing the Connecting Cables 48 External 0 10 Volt Signal Connection 49 Connecting a 24 VAC Thermostat 50 Zone Circuit Thermostat Connections 51 Zone Circuit Pump Conne...

Page 6: ...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...

Page 7: ... 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 2...

Page 8: ...ion vessel D Graphical user interface E Integral 3 speed high efficiency circulation pump F Stainless steel DHW primary storage tank Natural gas and liquid propane gas fired 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 The Vitodens 222 F B2TB boiler comes factory set fo...

Page 9: ...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 s...

Page 10: ... during boiler operation and service Recommended minimum service clearances For typical Vitodens installations Viessmann recommends installing the boiler with the service 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 The 2 in...

Page 11: ...sure relief valve discharge pipe NPT in Connections Boiler water connection and piping 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 Note See installation fitting sets on page 58 Boiler Connections Min 6 Min 152 mm Min 6 ...

Page 12: ... 1 in mm 48 3 1227 l 1 in mm 68 0 1726 c 1 in mm 28 710 approx m in mm 16 1 410 d 1 in mm 52 6 1337 n in mm 8 8 224 f 1 in mm 57 0 1447 o in mm 15 3 389 g in mm 2 0 50 p in mm 14 2 361 h 1 in mm 59 1 1502 q in mm 12 6 320 i 1 in mm 64 2 1630 r in mm 13 0 330 j 1 in mm 65 6 1666 s in mm 8 7 220 Note All height dimensions of the boiler have a tolerance of 6 in 15 mm due to the factory installed adju...

Page 13: ...r C C if single wall boiler room air dependant venting system is used 2 imperfect threads Leave 2 threads bare 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...

Page 14: ... 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 by a nationally recognized testing agency Make boiler gas connection as shown choose one of three locations 3 Perform gas piping pressure test a...

Page 15: ...em during any pressure testing of that system at test pressures in excess of 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 IMPOR...

Page 16: ...e 4 Lift up and out to remove the lower front panel 5 Loosen the screws at the bottom of the boiler as shown do not remove completely 6 Move the boiler to the location where it is to be installed 7 Using the adjustable legs level the unit CAUTION The boiler must be level both vertically and horizontally to ensure proper draining of the condensate Connections continued Boiler Connections ...

Page 17: ...ections Accessing the control unit connections 1 Remove both screws from the external accessory connection box front plate and set aside 2 Remove both retaining screws as shown and set aside 3 Pull the external accessory connection box forward 4 Swing the external accessory connection box down ...

Page 18: ...orward 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 console 9 To open hinged cover lift cover and then fold down the control console Connections continued Boiler Connections ...

Page 19: ...rmissible 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 12 Route all connecting cables to the appropriate areas and secure the cables to the control base using existing strain reliefs as shown Connections continued Boiler Connections ...

Page 20: ...S ie VITOTROL REMOTE OR MIXING VALVE PUMP 120 1 60 12 Amps full load amperage POWER SUPPLY WITH DISCONNECT AND PROTECTION IMPORTANT Electrical installations must comply with the latest edition of In the U S A the National Electrical Code NEC ANSI NFPA 70 and any other state local codes and or regulations In Canada the Canadian Electrical Code CEC CSA C22 1 Part 1 and any other province territory l...

Page 21: ...dens 222 F B2TB 19 35 68 125 Installation Connections continued Boiler Connections Boiler control base Note See wiring diagram on page 20 for connection to the external accessory connection box OUTDOOR TEMPERATURE SENSOR ...

Page 22: ...e 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 far out of the boiler that no unnecessary bends are created inside the boiler Check tightness of siphon connection A IMPORTA...

Page 23: ...ing rings a turn to lock into place the ring opening should be facing to the side 3 Remove the tie wrap holding the factory installed gas line 4 Place the restraining bar with rings under the rear boiler frame 5 Align the mounting holes in the boiler frame and restraining bar and secure in place with screws provided 6 Remove the tie wrap and lock the top of the gas line into the centre restraining...

Page 24: ...e male connection boiler fittings Ensure that the O rings are properly seated in the groove 2 Slide the insulation sleeve over the DHW pipe as shown 3 Install the pipes through the top cutouts of the boiler 4 Align the pipes to the boiler fittings and push from the top until snug 5 Secure the ends of the pipes into the appropriate restraining rings ...

Page 25: ...ion continued Boiler Connections 1 Install the supplied locking clips over the bottom boiler connection and pipes 2 Remove the cap from the factory installed gas line 3 Install the supplied tees drain valves and gas valve as shown 4 Install security clips to the DHW pipe retaining clips ...

Page 26: ...raining rings to the restraining bar note their position 2 Rotate the restraining rings a turn to lock into place the ring opening should be facing down 3 Place the restraining bar with rings to the side boiler frame 4 Align the mounting holes in the boiler frame and restraining bar and secure in place with screws provided ...

Page 27: ...d Boiler Connections 1 Install the O rings over the male connection boiler fittings Ensure that the O rings are properly seated in the groove 2 Slide the insulation sleeve over the DHW pipe as shown 3 Install the pipes through the side cutouts of the boiler 4 Align the pipes to the boiler fittings and push from the top until snug 5 Secure the ends of the pipes into the appropriate restraining ring...

Page 28: ... safety devices 1 Remove the pressure relief valve drain valve and fittings from the box 2 Apply sufficient amount of pipe sealant to both ends of all pipe fittings and install onto tees 3 Install pressure relief valve and Isolation valve and tighten them 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 exte...

Page 29: ... be required by local codes Do not install an isolation valve between boiler and low water cut off Legend A Heating supply NPT in B DHW NPT in C Pressure relief valve discharge pipe NPT in D DCW NPT in E Heating return NPT in F Temperature and pressure relief valve discharge pipe NPT in WARNING Do not install an isolation valve between boiler and pressure relief valve The discharge pipe for the pr...

Page 30: ...ndary 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 Boiler Connections Waterside Flow Boiler maximum flow rate 6 2 GPM 1400 L h Boiler maximum flow r...

Page 31: ...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 DHW tank heat exchanger diverting valve and DHW circulating pump are installed in the unit with all the connections between components DHW connecting fittings inlet an...

Page 32: ...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 30 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 Legend A Vitodens 222 F B2TB boiler with Vitotronic 200 HO1B outdoor re...

Page 33: ...e of a low loss header is strongly recommended if the maximum water flow rate in the application concerned exceeds the values shown on page 30 or if the system flow rates are unknown The low loss header is available as accessory part Legend A Vitodens 222 F B2TB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol remote optional D Heating circuit E Boiler ...

Page 34: ...The low loss header is available as accessory part See following pages for installation examples with a low loss header 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 Legend A Vitodens 222 F B2TB boiler with Vitotronic 200 HO1...

Page 35: ...ader is strongly recommended if the maximum water flow rate in the application concerned exceeds the values shown on page 30 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 low temperature level of the under floor heating circuit is controlled by an accessory kit for a heating circuit with mixing valve Legend...

Page 36: ...se 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 low temperature level of the under floor heating circuit is controlled by an accessory kit for a heating circuit with mixing valve Legend A Vitodens 222 F B2TB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol ...

Page 37: ...rongly recommended The low loss header is available as accessory part 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 a mixing valve Legend A Vitodens 222 F B2TB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol remote optional D Under flo...

Page 38: ...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 Legend A Vitodens 222 F B2TB boiler with Vitotronic 200 HO1B outdoor reset control B Outdoor temperature sensor C Vitotrol remote optional D Under floor hea...

Page 39: ...ss header is available as accessory part A 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 Legend A Vitodens 222 F boilers B Low loss header C Thermostat zone circuits 1 2 3 D Zone circuit 1 output 157 E AM1 extension module accessory F Zone circuit 2 output A1 AM1 extensio...

Page 40: ...perature sensor C Vitotrol remote optional D DHW storage tank E Boiler pump 20 F DHW circulating pump sA G Expansion tank H Diverting valve I Boiler heat exchanger J DHW heat exchanger K Water softener L Boiler supply M Boiler return N Temperature and pressure relief valve outlet O Pressure relief valve outlet P DCW inlet Q DHW outlet R DHW users S DHW recirculation pump T Flow check valve U Integ...

Page 41: ...liance 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 WARNING DISCONNECT POWER BEFORE SERVICING BOILER Only one function connection may be assigned to each connection ...

Page 42: ... Pump Connection Internal 28 20 Heat Circuit A1 Pump Connection zone circuit pump output 30 Diverting Valve Stepper Motor 33 Flow Switch 35 Gas Valve 40 Power Supply 40A Accessory Power Output 47 Fixed High Limit 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 156...

Page 43: ...lve 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 system circulating pump IMPORTANT It is essential to route cables as illustrated to ensure freedom 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 ...

Page 44: ...0 H Extension kit for one heating circuit with mixing valve H Extension EA1 or AM1 H Install a disconnect switch in the power supply line that simultaneously isolates all live conductors from the mains We additionally recommend installing a GFCI receptacle switch H Max fuse rating 15 A Legend A Boiler control unit B Extension kit for heating circuit with mixing valve M2 C Extension kit for heating...

Page 45: ... page 19 2 Remove the X3 plug from the control board Attach sensors and reinsert the X3 plug Refer to the following sensor information 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 Control Connections ...

Page 46: ...er control board wires are not polarity sensitive 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 door...

Page 47: ...LON module to the boiler control board 1 Remove the control cover see page 19 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 Boiler Control See the Vitotronic 200 H HK1B Installation Instructions ...

Page 48: ...ible temperatures for these cables are not exceeded Remove the existing cable grommet when using larger cross sections 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 D Main PCB E Communication module accessories F Cable grommet for power cable G 120V from external ac...

Page 49: ...ternal 0 10 Volt DC Signal Connection 1 Connect the external 0 10VDC signal to plug 0 10VDC located in the external connection accessory box 2 Ensure correct polarity 3 See chart for maximum possible boiler water temperature and required signal Control Connections ...

Page 50: ...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 37...

Page 51: ...nstallation Control Connections Zone Circuit Thermostat Connections Legend A Room thermostat dry contact zone circuit 1 B Room thermostat dry contact zone circuit 2 C Room thermostat dry contact zone circuit 3 D EA1 module integrated into the boiler ...

Page 52: ...ircuit pumps can be connected to the boiler additional pumps will require the use of an AM1 extension module Connection at AM1 accessory Pump output assignment is done using the set up wizard Refer to the boiler Service Instructions for start up instructions Refer to the boiler Service Instructions for start up instructions Refer to the AM1 extension module Installation Instructions for additional...

Page 53: ... an alternative for a Vitotronic control Extension Module EA1 Boiler Control KM Bus Accessory Closing the Boiler Closing the control cover 1 Install the cover onto the control board 2 Flip the control console back into position 3 Secure the locking tabs as shown For details on coding and connection to the control refer to the Vitodens 222 F B2TB Service Instructions For details on installation ref...

Page 54: ...nection 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 Control Connections ...

Page 55: ...screw 9 Install the external accessory connection box cover screws 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 Fitting the front panels 1 Set in lower front panel 2 Insert and tighten the retaining screw 3 Install lower front...

Page 56: ...ating system side Precharge pressure Capacity psig USG L 12 3 2 12 12 3 2 12 Max operating pressure at 210ºF 99ºC psig bar 45 3 45 3 Boiler water temperature Adjustable high limit AHL range space heating steady state Fixed high limit FHL ºF ºC ºF ºC 68 to 180 20 to 82 210 99 68 to 180 20 to 82 210 99 Boiler connections Boiler heating supply and return Pressure relief valve Drain valve Boiler suppl...

Page 57: ...6 5 100 150 210ºF 99ºC 150 300 61 17 8 1 8 6 6 44 166 26 5 100 150 210ºF 99ºC 150 300 114 33 4 3 3 12 3 60 227 Standby losses 11 BTU 24h BTU h º F h 4435 184 0 8 4435 184 0 8 6 Measured flue gas temperature with a combustion air temperature of 68 F 20 C 7 Based on typical boiler cycles including partial load conditions 8 Requires 1 inch 25 mm tubing See the Installation Instructions of the Vitoden...

Page 58: ...ipe clips 0307 Pipe clip each 0310 Connector retaining clip Set of 2 1 0311 Pipe insulation 19x9x740 mm 0313 Gas ball valve in brass 0314 Sediment faucet in NPT 0316 Tee in brass 0318 Security clips set of 5 1 2 Other Parts not illustrated 0301 Flex pipe NG LP full length 3 0308 O Ring 18x3 mm for supply return 0309 Gasket 17x24x2 mm for gas connection pipe 3 0315 Outdoor temperature sensor NTC 03...

Page 59: ...nce 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 lowest setting 3 Turn off all electric power to the appliance 4 This app...

Page 60: ...5461 889 16 Vitodens 222 F B2TB 19 35 68 125 Installation Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper ...

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