Installation Instructions
Low-Loss Header
Please file in Service Binder
Safety and Installation Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions listed below can cause product/property damage, severe personal injury, and/or loss of life.
Working on the equipment
The installation, adjustment, service,
and maintenance of this product must
be done by a licensed professional
heating contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water boilers.
There are no user serviceable parts on
the boiler, burner, or control.
Product Information
5458 697 v1.0 06/2010
Ensure main power supply to Ensure that the installation
equipment, the heating system, and all literature of other applicable
external controls has been deactivated. components of the Vitodens
Close main gas supply valve. Take 200 boiler is referenced.
precautions in all instances to avoid
accidental activation of power during
service work.
When used in conjunction with Viessmann boilers, the low-loss header acts as
hydraulic break, decoupling boiler and system circuits from each other. The
low-loss header increases operational efficiency. In addition, the low-loss header
helps eliminate debris from the heating system.
The common supply temperature sensor located of the low-loss header connects
to the Vitocontrol-S controller ensuring optimum staging of the boilers and
accurate control of system supply water temperatures.
The low-loss header must be used in multiple Vitodens 200 installations
(maximum of 4 boilers).
The low-loss header is available in the following sizes.
Select the size based on the maximum system flow rate of your application.
Model No. Maximum system flow rate (m3/h / GPM)
160/80 10 / 44
200/120 18 / 80
250/150 27 / 119
300/200 43 / 189
400/200 57 / 251
450/250 85 / 374
500/300 110 / 484
600/400 170 / 748
650/450 235 / 1034
700/500 300 / 1320
Please refer to the respective section for installation steps of your low-loss header.
Standard Equipment

Standard Equipment for Low-Loss Optional:

Header, Types: 160/80 IMPORTANT
Low-loss header Insulation jacket
200/120
250/150 7834 470 7834 480 A minimum of 2” circumferential
300/200 7834 471 7834 481 clearance from a non-insulated LLH to
400/200 combustible construction must be
450/250 7834 472 7834 482 maintained. If optional LLH insulated
500/300 7834 473 7834 483 jacket (mentioned above) is used, the
600/400 above clearance to combustibles is
7834 474 7834 484
650/450 reduced to 0”.
700/500 7834 475 7834 485
H Low-loss header 7834 476 7834 486
H Installation Instructions
7834 477 7834 487
Viessmann strongly recommends the 7834 478 7834 488
installation of an insulation jacket.
7834 479 7834 489

System Layout (Vitodens 200, WB2A boilers)

Outdoor temperature
sensor Power supply
120 V, 60 Hz, 1 PH

120 V, 60 Hz, 1 PH

120 V, 60 Hz, 1 PH

120 V, 60 Hz, 1 PH
120 V, 60 Hz,
1 PH
Boiler 1* Boiler 2 Boiler 3 Boiler 4 Vitocontrol-S
WB2A
Viessmann 2-wire
4
3
2
1
Boiler
BUS
Boiler
Boiler
Boiler
KM-BUS
KM-BUS
KM-BUS
KM-BUS
20-A

20-A
20-A

20-A
21

HK1

System
Common supply pump
M
temperature sensor

21
DHW tank Low-loss
header

Vitodens 200 boiler (maximum of Expansion tank

4 boilers) Fill line system IMPORTANT
Boiler pump (field supplied) Power / pump module
(120 V, 8 A max.) (120 V / 60 Hz) * A DHW recirculation pump (#20) can
DHW circulating pump (field be connected to Boiler 1 only.
supplied)
DHW storage tank In a Vitocontrol-S application, ALL
boiler pumps must be connected to
connector #20-A in the power pump
5458 697 v1.0

module.

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 System Layout (Vitodens 200, WB2B boilers)

Vitocontrol-S
WB2B

Boiler 1 Boiler 2 Boiler 3 Boiler 4

PRV PRV PRV PRV PRV

Common
Supply
Temperature
Sensor M M

DHW Tank
Low-Loss
Header

Legend
Vitodens 200, WB2B boiler Expansion tank
(maximum of 4 boilers) Fill line system
Power / pump module
(120 V / 60 Hz)
Boiler pump (field supplied)
(120 V, 8 A max.)
DHW circulating pump (field
supplied)

IMPORTANT
This installation example depicts a
possible piping layout for multiple
Vitodens 200-W, WB2B boilers
equipped with Viessmann System
Technology. Please note that this
example is 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.
5458 697 v1.0
WARNING
If a DHW storage tank other than a
Viessmann Vitocell 100 or 300 tank
is used, the installer must verify
proper operation of the Viessmann
DHW tank temperature sensor with
the original manufacturer of the tank.
Viessmann strongly recommends the
installation of a temperature
tempering valve in the DHW supply
line.

Proper installation and functionality in

the field is the responsibility of the
heating contractor.

3
4

Example: Typical System Layout

Outdoor
sensor

Vitocontrol-S
MW1
High mass
radiant floor

Sensor

Main supply

PRV PRV

P
Main return

S
Floor-mounted
Low Loss Header

Vitocrossal or Vitorond boiler(s) Low water cut off

contractor.
field is the responsibility of the heating
Proper installation and functionality in the
installed where required by local codes.
A low water cut-off (LWCO) must be
be field verified.
Piping and necessary componentry must
conceptual drawings only!
the following examples are simplified
a possible piping layout. Please note that
The following installation example depicts
Vitotronic 100 GC1 Outdoor temperature sensor

IMPORTANT
Boiler pump (field supplied) Common supply temperature
DHW circulating pump (field supplied) sensor (strap-on) supplied with
System heating pump (field supplied) boiler control
Low-loss header (floor-mounted) Optional immersion sensor
with optional insulation jacket location (order separately
DHW storage tank PN 7450641)
Expansion tank Drain connection
Fill line system P Air vent

5458 697 v1.0

 Technical Specifications

A C
X1 X2

X1 X2

B D

Front View
Side View

Legend
Boiler supply
Boiler return
System supply
System return
Drain / clean-out opening
Anchor bolt holes
Top View

For dimensions please see table on

following page.
5458 697 v1.0

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Technical Specifications (continued)

Low-Loss Header Dimensions

Low-Loss Header Model

Dimension 160/80 200/120 250/150 300/200 400/200 450/250 500/300 600/400 650/450 700/500
a inches 56.7 57 57.8 58.3 58.9 59.8 71.6 72.6 76.6 90.2
mm 1440 1450 1468 1481 1495 1520 1819 1845 1945 2291
b inches 15.3 15.3 15.7 15.7 15.7 15.7 19.7 19.7 22.4 22.4
mm 390 390 400 400 400 400 500 500 570 570
c inches 39.4 39.4 39.4 39.4 39.4 39.4 47.2 47.2 47.2 59
mm 1000 1000 1000 1000 1000 1000 1200 1200 1200 1500
d inches 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9
mm 200 200 200 200 200 200 200 200 200 200
e inches 6.3 7.9 9.8 11.8 15.7 17.7 19.7 23.6 25.6 27.6
mm 160 200 250 300 400 450 500 600 650 700
f inches 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9 7.9
mm 200 200 200 200 200 200 200 200 200 200
g inches 3.1 4.7 5.9 7.9 7.9 9.8 11.8 15.7 17.7 19.7
mm 80 120 150 200 200 250 300 400 450 500
i inches 3.8 3.8 4.2 4.2 4.2 4.2 4.2 4.2 4.2 4.2
mm 97 97 107 107 107 107 107 107 107 107
j inches 11 12.6 13.8 15.7 15.7 17.7 19.7 23.6 25.6 27.6
mm 280 320 350 400 400 450 500 600 650 700
k inches 12.2 13.8 15.7 17.7 21.7 23.6 25.6 30 32.7 33.9
mm 310 350 400 450 550 600 650 760 830 860
Flange ANSI ANSI ANSI ANSI ANSI ANSI ANSI ANSI ANSI ANSI 14”
X1 2b” 3” 4” 5” 6” 8” 8” 10” 12”
Flange ANSI ANSI ANSI ANSI ANSI ANSI ANSI ANSI ANSI ANSI 14”
X2 2b” 3” 4” 5” 6” 8” 8” 10” 12”

5458 697 v1.0

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 Installation Steps

1. Before commencing with the

installation, plan the location and
orientation of the low-loss header.
Take the following into
consideration...
H The sensor well is installed on the
system side of the low-loss header.
G The low-loss header can be rotated
as required.
H Ensure that the drain connection
is not pointing towards the wall.
H Low-loss header must be installed
in vertical position.

2. The ANSI counter flanges, gaskets

and bolts are field supplied

3. Fasten low-loss header to floor with

anchor bolts (field supplied), using
anchor holes provided.
Solid flooring such as concrete is
required when floor-mounting the
low-loss header.

4. Complete piping as required.

5. Tighten all connections.

6. Install and connect common supply

temperature sensor according to the
instructions on page 8.

Legend
Air vent
Common supply temperature
sensor well (immersion sensor) *
Common supply temperature sensor
(strap-on sensor) *
Low-loss header
Flange of low-loss header, ANSI
standard
Drain connection, 2” NPT male
Low-loss header label

*Immersion or strap-on sensor

depending on application and
boiler/control models.

Note:
All counter flanges shall be ANSI
standard (field supplied).
5458 697 v1.0

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Electrical Connection - Vitocontrol-S (WB2A)

The common supply temperature sensor

(strap-on sensor) comes in two parts:
– Sensor
– Spring band.

1. Place sensor on side of pipe. Install

on system supply pipe as close to
low-loss header as possible (see Figs.
4 & 5).

1 2 3 4 2. Hook tension spring to one side of

the sensor tab.
OTS STS

3. While holding sensor on pipe, bring

Fig. 1
tension spring around pipe and hook
spring to second sensor tab. Ensure
OTS Outdoor temperature sensor that sensor has compressed into
STS Supply temperature sensor sensor housing.

Supply temperature sensor 4. The sensor is supplied with

(strap-on sensor, STS) approximately 6 ft. / 2 m of cable.
Vitocontrol-S, WB2 terminal strip If required connect extension wire
(18 AWG) from sensor to the panel
of the Vitocontrol.

WARNING
When extending wire, there is the
possibility of exposure to
electromagnetic interference. Avoid
running wires beside or near high
voltage 120/240 VAC conductors.
If proximity to high voltage
conductors cannot be avoided, use
stranded, twisted pair or shield
design wire. Ensure that only one
end of the shielding is grounded.

5. Terminate wires into Vitocontrol

control panel on terminals X3.3 and
X3.4 to complete installation of
sensor.

See Vitocontrol-S
Installation, Start-up/Service
Instructions
5458 697 v1.0

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 Electrical Connection (WB2B boilers only)
For multiboiler applications refer
IMPORTANT to Vitocontrol-S, WB2B
Installation and Service
The following applies only to Vitodens Instructions.
200, WB2B Series boilers in
single-boiler applications with Vitotronic
200, HO1 controls.

Accessing the X3 plug

1. Remove the control unit cover.

3. 2. Remove the X3 plug from the control

board. Attach sensors and/or KM-BUS
and/or accessories and reinsert the X3
plug. Refer to the following sensor
information.

3. Reinstall the control cover.

1.

X3

2.

Fig. 2

Connecting the low-loss header sensor

1. Connect the low-loss header sensor

(if used) to terminals X3.4/X3.5 on
the boiler control board.

1.
7 6 5 4 3 2 1

X3
5458 697 v1.0

Fig. 3

9
Electrical Connection (Vitocontrol-S WB2B)

AThe cascade communication module

2.

3.

1.

X7

B 145

3 2 1

C C

A Vitocontrol-S, MW1 or MW2 1 2 3 4 1 2 3 4

B KMK-BUS KMK1 KMK2 KMK1 KMK2
C Boiler control with Vitotronic 100
and KMK Module (max 4 boilers)
D 2-core Cable
(cable cross-section 2 x 0.5 mm2
total length 164 ft. / 50 m)
E Plug aVG into the Vitocontrol-S Note
WB2B The total length of BUS cables B
F Terminal strip ”KMK1/KMK2” at the should not exceed 50 m.
cascade communication module of The wires from the BUS cables are
the boiler control with commutable.
5458 697 v1.0

Vitotronic 100

10
 Electrical Connection

*
*Immersion or strap-on sensor depending
on application and boiler/control models.
5458 697 v1.0

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Technical Data

Low-loss header multiple boiler applications

for Viessmann wall-mount boilers
Boiler Model No. of Boiler Total Typical System Flow Rates Viessmann
Boilers max flow temperature
flow rate sensor
rate System ∆t *2 20 25 30 35 40 °F required
11.0 14.0 17.0 19.5 22.0 °C
Vitodens 200
WB2A 11-44 2 15.4 30.8 System Flow Rate 30.8 24.6 20.5 17.6 15.4 GPM Yes *1
3500 6995 6995 5587 4656 3997 3498 L/h
LLH required yes yes yes yes yes
LLH Model 120/80 120/80 120/80 120/80 120/80
WB2A 11-44 3 15.4 46.2 System Flow Rate 46.2 37.0 30.8 26.4 23.1 GPM Yes *1
3500 10493 10493 8404 6995 5996 5247 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 11-44 4 15.4 61.6 System Flow Rate 61.6 49.3 41.1 35.2 30.8 GPM Yes *1
3500 13991 13991 11197 9335 7995 6995 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 15-60 2 15.4 30.8 System Flow Rate 41.2 33.0 27.5 23.5 20.6 GPM Yes *1
3500 6995 9358 7495 6246 5337 4679 L/h
LLH required yes yes yes yes yes
LLH Model 160/80 120/80 120/80 120/80 120/80
WB2A 15-60 3 15.4 46.2 System Flow Rate 61.8 49.4 41.2 35.3 30.9 GPM Yes *1
3500 10493 14036 11220 9358 8018 7018 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 15-60 4 15.4 61.6 System Flow Rate 82.4 65.9 54.9 47.1 41.2 GPM Yes *1
3500 10493 18715 14967 12469 10698 9358 L/h
LLH required yes yes yes yes yes
LLH Model 250/150 200/120 200/120 200/120 200/120
WB2A 11-44 1 15.4 30.8 System Flow Rate 36.0 28.8 24.0 20.6 18.0 GPM Yes *1
WB2A 15-60 1 3500 6995 8177 6542 5451 4679 4088 L/h
LLH required yes yes yes yes yes
LLH Model 160/80 120/80 120/80 120/80 120/80
WB2A 11-44 1 15.4 46.2 System Flow Rate 56.6 45.3 37.7 32.3 28.3 GPM Yes *1
WB2A 15-60 2 3500 10493 12855 10289 8563 7336 6428 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 11-44 2 15.4 46.2 System Flow Rate 51.4 41.1 34.3 29.4 25.7 GPM Yes *1
WB2A 15-60 1 3500 10493 11674 9335 7790 6678 5837 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 11-44 2 15.4 61.6 System Flow Rate 72.0 57.6 48.0 41.1 36.0 GPM Yes *1
WB2A 15-60 2 3500 10493 16353 13082 10902 9335 8177 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 11-44 3 15.4 61.6 System Flow Rate 66.8 53.4 44.5 38.2 33.4 GPM Yes *1
WB2A 15-60 1 3500 10493 15172 12129 10107 8676 7586 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120
WB2A 11-44 1 15.4 61.6 System Flow Rate 77.2 61.8 51.5 44.1 38.6 GPM Yes *1
WB2A 15-60 3 3500 10493 17534 14036 11697 10016 8767 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 200/120

*1 Low-loss header temperature sensor - standard equipment of Vitocontrol-S; for use in multiple-boiler applications
*2 For system ∆t < 20 °F use low-loss header sizes for ∆t 20 °F

" Low-loss header must be used in all applications where the system flow rate exceeds the maximum or minimum boiler flow rate.
5458 697 v1.0

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 Technical Data (continued)

Low-loss header multiple boiler applications

for Viessmann wall-mount boilers
Boiler Model No. of Boiler Total Typical System Flow Rates Viessmann
Boilers max flow tempera-
flow rate ture sensor
rate System ∆t *2 20 25 30 35 40 °F required
11.0 14.0 17.0 19.5 22.0 °C
Vitodens 200
WB2B 45 2 15.4 30.8 System Flow Rate 29.2 23.4 19.5 16.7 14.6 GPM Yes *1
3498 6995 6632 5306 4421 3790 3316 L/h
LLH required yes yes yes yes yes
LLH Model 120/80 120/80 120/80 120/80 120/80
WB2B 45 3 15.4 46.2 System Flow Rate 43.8 35.0 29.2 25.0 21.9 GPM Yes *1
3498 10493 9948 7958 6632 5685 4974 L/h
LLH required yes yes yes yes yes
LLH Model 160/80 120/80 120/80 120/80 120/80
WB2B 45 4 15.4 61.6 System Flow Rate 58.4 46.7 38.9 33.4 29.2 GPM Yes *1
3498 13991 13264 10611 8843 7579 6632 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 160/80 120/80 120/80

WB2B 60 2 15.4 30.8 System Flow Rate 38.8 31.0 25.9 22.2 19.4 GPM Yes *1
3498 6995 8812 7050 5875 5036 4406 L/h
LLH required yes yes yes yes yes
LLH Model 160/80 120/80 120/80 120/80 120/80
WB2B 60 3 15.4 46.2 System Flow Rate 58.2 46.6 38.8 33.3 29.1 GPM Yes *1
3498 10493 13219 10575 8812 7554 6609 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 160/80 120/80 120/80
WB2B 60 4 15.4 61.6 System Flow Rate 77.6 62.1 51.7 44.3 38.8 GPM Yes *1
3498 13991 17625 14100 11750 10071 8812 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 160/80 160/80

WB2B 80 2 35 70 System Flow Rate 52.0 41.6 34.7 29.7 26.0 GPM Yes *1
7949 15899 11810 9448 7874 6749 5905 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 160/80 160/80 160/80 160/80
WB2B 80 3 35 105 System Flow Rate 78.0 62.4 52.0 44.6 39.0 GPM Yes *1
7949 23848 17716 14173 11810 10123 8858 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 200/120 160/80
WB2B 80 4 35 140 System Flow Rate 104.0 83.2 69.3 59.4 52.0 GPM Yes *1
7949 31797 23621 18897 15747 13498 11810 L/h
LLH required yes yes yes yes yes
LLH Model 250/150 250/150 200/120 200/120 200/120

WB2B 105 2 35 70 System Flow Rate 70.0 56.0 47.0 40.0 35.0 GPM Yes *1
7949 15899 15899 12719 10599 9085 7949 L/h
LLH required yes yes yes yes yes
LLH Model 200/120 200/120 200/120 160/80 160/80
WB2B 105 3 35 105 System Flow Rate 105.0 84.0 70.0 60.0 53.0 GPM Yes *1
7949 23848 23848 19078 15899 13627 11924 L/h
LLH required yes yes yes yes yes
LLH Model 250/150 250/150 200/120 200/120 200/120
WB2B 105 4 35 140 System Flow Rate 140.0 112.0 93.0 80.0 70.0 GPM Yes *1
7949 31797 31797 25438 21198 18170 15899 L/h
LLH required yes yes yes yes yes
LLH Model 300/200 250/150 250/150 200/120 200/120

*1 Low-loss header temperature sensor - standard equipment of Vitocontrol-S, WB2B; for use in multiple-boiler applications
5458 697 v1.0

*2 For system ∆t < 20 °F use low-loss header sizes for ∆t 20 °F

" Low-loss header must be used in all applications where the system flow rate exceeds the maximum or minimum boiler flow rate.

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5458 697 v1.0

 5458 697 v1.0
15
 Printed on environmentally friendly
(recycled and recyclable) paper.
Technical information subject to change without notice.
5458 697 v1.0

Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc.

45 Access Road 750 McMurray Road
Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada
Tel. (401) 732-0667 • Fax (401) 732-0590 Tel. (519) 885-6300 • Fax (519) 885-0887
www.viessmann-us.com • info@viessmann-us.com www.viessmann.ca • info@viessmann.ca

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