Installation Instructionsfor use by heating contractor

Low-Loss Header, Part Nos. 7134 791, 7134 792

for Vitodens 100, WB1A and Vitodens 200, WB2A (single-boiler installations only)

5285 318 v2.6 02/2009

Safety and Installation Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with theinstructions listed below can cause product/property damage, severe personal injury, and/or loss of life.

Working on the equipmentThe installation, adjustment, service,and maintenance of this product mustbe done by a licensed professionalheating contractor who is qualified andexperienced in the installation, service,and maintenance of hot water boilers.There are no user serviceable parts onthe boiler, burner, or control.

Ensure main power supply toequipment, the heating system, and allexternal controls has been deactivated.Close main gas supply valve. Takeprecautions in all instances to avoidaccidental activation of power duringservice work.

It is not permissible to perform servicework on any component part ensuringsafe operation of the heating system.When replacing parts, use originalViessmann or Viessmann approvedreplacement parts.

When used in conjunction with theVitodens 100 or Vitodens 200 boiler,the low-loss header acts as a hydraulicbreak, decoupling boiler and systemcircuits from each other.It is recommended to use the low-lossheader in applications in which the totalsystem flow rate exceeds the maximumboiler flow rate.Viessmann strongly recommends theuse of a low-loss header in cases wherethe system head and flow rates areunknown.

The temperature sensor connectionlocated at the top of the low-lossheader ensures low return temperaturesto the Vitodens 200 boiler only at alltimes, increasing operational efficiency.Please note that this temperaturesensor (Part No. 7134 240) forVitodens 200 must be purchasedseparately.No temperature sensor is used on theVitodens 100 boiler.In addition, the low-loss header helpseliminate air and debris from the heatingsystem.The low-loss header is available in thefollowing sizes. Select the size basedon the maximum system flow rate ofyour application.

Model No. Max. system flow rate

Type 80/50 4 m3/h / 17.6 GPM

Type 120/80 8 m3/h / 35.2 GPM

PleasefileinServiceBinder

Ensure that the installationliterature of other componentsof the Vitodens 100 orVitodens 200 boiler isreferenced.

Product Information

Fig. 1

Vitodens 200or Vitodens 100

Fig. 2

Fig. 3

2

Contents Low-Loss Header, Type120/80

Contents Low-Loss Header,Type 80/50

H Low-loss header (Type 80/50)H Sensor wellH½” BSPT/NPT adaptor (for drainvalve)

H Drain valveH Air bleed plugH Installation Instructions

The temperature sensor (Part No.7134 240) for Vitodens 200 mustbe purchased separately.

Contents Low-Loss Header, Type120/80

Contents Low-Loss Header,Type 120/80

H Low-loss header (Type 120/80)H Sensor wellH½” BSPT/NPT adaptor (for drainvalve)

H Drain valveH Air bleed plugH Installation Instructions

The temperature sensor (Part No.7134 240) for Vitodens 200 mustbe purchased separately.

Before commencing with the installationof the low-loss header, check low-lossheader orientation with respect to yourheating system.

If (when holding the low-loss headerwith the air bleed connection facingyou, as illustrated in Fig. 1)...

H the boiler is located to the left of thelow-loss header and the heatingsystem is located to the right, installthe low-loss header as illustrated inFig. 1 (with sensor well and airbleed opening located at top),following the installation steps on thefollowing page.

H the boiler is located to the right of thelow-loss header and the heatingsystem on the opposite side, performthe following steps:

1. Rotate low-loss header 180ºclockwise (from its originalorientation, see Fig. 2).

2. Remove sensor well and air bleedplug from its factory-installedlocation (now located at the bottom).

3. Install sensor well and air bleed plugon opposite end (top of low-lossheader) as illustrated in Fig. 3.

4. Proceed with the installation steps onthe following pages (depending onlow-loss header model).

Sensor wellAir bleed opening½” plugDrain

Standard Equipment

General Layout

5285318v2

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Fig. 4

22”/560mm

3”/80 mm

4”/100 mm

14”/360mm

10½

”/270mm

NPT

3

Low-loss header information

DimensionsOverall depth 3¼”/84 mmOverall width 11”/280 mmOverall height 22”/560 mm

Please note that the pipe connectionson the system side are at a closerdistance from each other than those onthe boiler side.

Sensor well, 200 mmAir bleed plug (c/w O-ring)Boiler supplySystem supplySystem returnBoiler return½” plugDrain

If the optional low loss headerinsulation is being installed, add extraclearance between the back of the lowloss header and the finished wall (2½” /64 mm for Type 80/50 and 4” /102 mm for Type 120/80).

Model Type 80/50

Low-loss header part number*(Vitodens 100/200)

7134791*

Connector size (NPT) inches 1¼Distance between boilersupply nipples

inchesmm

14360

Distance between systemsupply nipples

inchesmm

10½270

Matching insulation boxpart number

9560994

Additional clearance ifinstalling optional insulation

inchesmm

2½64

* Please note that the temperature sensor (Part No. 7134 240) for Vitodens 200must be purchased separately.

Overall Dimensions (Type 80/50)5285318v2

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IMPORTANT

IMPORTANT

Fig. 5

36”/914mm

4¾”/120 mm

4”/100 mm

25½”/650mm

21½”/550mm

NPT

4

Low-loss header information

Dimensions

Overall depth 5½”/140 mm

Overall width 12¾”/320 mm

Overall height 36”/914 mm

Please note that the pipe connections

on the system side are at a closer

distance from each other than those on

the boiler side.

Sensor well, 200 mm (for WB2

only)

Air bleed plug (c/w O-ring)

Boiler supply

System supply

System return

Boiler return

½” plug

Drain

If the optional low loss header

insulation is being installed, add extra

clearance between the back of the low

loss header and the finished wall (2½” /

64 mm for Type 80/50 and 4” /

102 mm for Type 120/80).

Model Type 120/80

Low-loss header part number*(Vitodens 100/200)

7134792*

Connector size (NPT) inches 2

Distance between boilersupply nipples

inchesmm

25½650

Distance between systemsupply nipples

inchesmm

21½550

Matching insulation boxpart number

9560993

Additional clearance ifinstalling optional insulation

inchesmm

4102

* Please note that the temperature sensor (Part No. 7134 240) for Vitodens 200

must be purchased separately.

Overall Dimensions (Type 120/80)

5285318v2.6

IMPORTANT

IMPORTANT

Fig. 6

BSPT

5

LegendLow-loss header½” Conversion adaptor(from BSPT to NPT)Drain valveAir bleed plug (c/w O-ring)Sensor well, 200 mm (Vitodens 200only, except model WB2 6-24C)Temperature sensor (Vitodens 200only, except model WB2 6-24C)½” plug0)

1. Remove low-loss header and suppliedaccessories from carton (see sectionentitled “Standard Equipment” on thefront page for a list of componentparts included with your low-lossheader).

2. Clean threads of drain valveconversion adaptor if required,and apply moderate amount of pipesealant to male BSPT ½” threads.

3. Connect ½” BSPT male end of theconversion adaptor to femaleBSPT ½” connection at the bottomof the low-loss header.

4. Connect ½” NPT female end of theconversion adaptor to ½” maleend of the drain valve .

5. Connect ½” air bleed plug (c/wO-ring) to corresponding openingon the low-loss header (located onthe top or bottom front depending onlow-loss header orientation).

6. Connect sensor well tocorresponding opening at the top ofthe low-loss header.Use hemp and pipe sealant whenmaking this connection.

7. Tighten all connections.

8. Install low-loss header only in verticalposition (see Fig. 6). Follow theinstructions attached to the low-lossheader (see Figs. 4 and 5), indicatingsystem and boiler connection sides.Make system and boiler connectionsaccordingly.

9. Insert temperature sensor probe end(Part No. 7134 240) deep into

sensor well . The other end of thelow-loss header temperature sensorcomes prewired to terminals 3 and 4on plug X7. Insert plug X7 intocorresponding terminal on boilercontrol console. See Fig. 7 on page6.

Installation Steps5285318v2

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6

Plug X7 wired for installation with low-loss header only

Low-loss header sensor 1. Insert plug X7 of the low-loss headersensor (Fig. 7) into terminal X7 onthe Vitodens 200 boiler controlconsole (not applicable for modelVitodens 200, WB2 6-24C).

Plug X7 wired for installation with low-loss header and DHW storage tank

DHW sensorLow-loss header sensor

The DHW sensor of the DHWstorage tank comes prewired toterminals 1 and 2 on plug X7.To connect a low-loss header sensor inaddition to the DHW sensor, performthe following steps:

1. Remove and discard plug X7 fromthe low-loss header sensor.

2. Rewire low-loss header sensor wiresto terminals 3 and 4 on plug X7 ofthe DHW sensor. See Fig. 8.

3. Insert plug X7 into terminal X7 onthe Vitodens 200 boiler controlconsole (not applicable for modelVitodens 200, WB2 6-24C).

Electrical Connection (for Vitodens 200 only)

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X7

3 421

Fig. 7

X7

3 421

Fig. 8

7

5285318v2

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8

Viessmann Manufacturing Company Inc.750 McMurray RoadWaterloo, Ontario • N2V 2G5 • Canada1-800-387-7373 • Fax (519) 885-0887www.viessmann.ca • info@viessmann.ca

Viessmann Manufacturing Company (U.S.) Inc.45 Access RoadWarwick, Rhode Island • 02886 • USA1-800-288-0667 • Fax (401) 732-0590www.viessmann-us.com • info@viessmann-us.com

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