wb2b cascade system guide

Cascade System Guidefor use by Viessmann representatives

5285 280 v1.0 08/2011

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Multiple Vitodens Systems

IMPORTANT

for Vitodens 200-W, WB2B 80/105 Series Boilers

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Cascade System Guide

Purpose of this Document

Table of Contents

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.

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





Vitocontrol-S, 1 High/1 Low Temp. Heating Circuit,

1 DHW Tank & External Snow Melt............................18 Coding................................................................18 Wiring.................................................................19

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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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.

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 pumpsrefer to page 11.

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.

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.

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 WB2B916

WB2B 105 WB2B917

System type Wall mounted

WB2B 80 WB2B912

WB2B 105 WB2B913

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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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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).


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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).


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Boilers for Cascade System

Pumps per Boiler with the Manifold 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.

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.

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)

System type With manifold

WB2B 80 WB2B918

WB2B 105 WB2B919

System type With manifold

WB2B 80 WB2B914

WB2B 105 WB2B915

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 260 000 350 000

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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Control for Heating System Loop

Additional Mixing Valves

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 moduleVersatronik 505 BACIP GatewayVersatronik 505 LONIP Gateway

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.

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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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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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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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.

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.

IMPORTANT

Heating Circuit / Boiler Pumps

Model WB2B 80

Flow rate Boiler pressure drop (ft.) Recommended pump Grundfos

20º F r t 26.0 16.7 * UPS 32-160/2, 115V, Speed1

25º F r t 20.8 9.2 UPS 26-99FC, 115V, Speed3




Flow limitation L/h (GPM) 8000 (35.2)

Model WB2B 105

Flow rate Boiler pressure drop (ft.) Recommended pump Grundfos

20º F r t 35.0 30.0 * UPS 32-160/2, 115V, Speed3

25º F r t 28.0 20.0 * UPS 32-160/2, 115V, Speed2

30º F r t 23.3 12.5 * UPS 32-160/2, 115V, Speed1



Flow limitation L/h (GPM) 8000 (35.2)

We recommend the following (depending on r t):

* 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

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

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


Boiler No. 2 same as Boiler No. 1 with exception to 07:2

07:2 Boiler No. 2 in multiple boiler system







Coding

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Vitocontrol-S - 1 High/1 Low Temp. Heating Circuit & 1 DHW Tank (continued)

Wiring

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VITOCONTROL-S

DESCRIPTION

00:10 System circuit A1 and mixing valve circuit M2 & M3, with DHW heating




73:7 Constantly ON





DESCRIPTION
















Coding

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Wiring

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VITOCONTROL-S

DESCRIPTION

00:10 System circuit A1 and mixing valve circuit M2 & M3, with DHW heating




73:7 Constantly ON





DESCRIPTION
















Coding

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Wiring

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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




73:7 Constantly ON



9b:7 Set point for external demand (adjustable between 1º and 80º C)



DESCRIPTION

00:0 Boiler control connected to the cascade; this automatically occurs if 01:2 has been

programmed















Coding

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Vitocontrol-S - 1 High/1 Low Temp. Heating Circuit, 1 DHW Tank & External Snow Melt

Wiring

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Viessmann Manufacturing Company (U.S.) Inc.45 Access RoadWarwick, Rhode Island · 02886 · USA1-800-288-0667 · Fax (401) 732-0590www.viessmann-us.com · [email protected]

Viessmann Manufacturing Company Inc.750 McMurray RoadWaterloo, Ontario · N2V 2G5 · Canada1-800-387-7373 · Fax (519) 885-0887www.viessmann.ca · [email protected]


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