Low-Loss Headers

Technical Data Manual

Model nos. and pricing: see Price List

Model 160/80 floor-standing Low-Loss Header shown with optional PUR foam insulation

Low-Loss Headers
Steel chamber with supply and return tappings for both boiler and system loop.

5354 682

04/2008

Product Information

Low-Loss Headers
The benefits at a glance: H To decouple high flow rate systems from the boiler loop. H Enables constant flow through boiler. H Avoids flow problems in secondary heating circuits. H Promotes boiler condensation when used with condensing boilers. H Protect boiler heat exchanger. H Helps eliminate air, sediment, and debris from the heating system. H Stand-by losses minimized by highly effective foamed-in-place or mineral wool insulation. H Used as a seperation point between boiler and system loop for troubleshooting purposes.

When to use a low-loss header: H When the system flow rate exceeds the maximum boiler flow rate. H When the boiler flow rate exceeds the maximum system flow rate (usually in multiple boiler systems with a low system T). H For all Vitodens 200 multiple boiler installations. H For all installations where the system head and flow rates are unknown.

Standard equipment: Model 80/50 and 120/80: H Sensor well tapping, H Air bleed tapping, H Drain/flush tapping, 2 H NPT threaded connections Model 160/80 to 700/500: H Sensor well tapping, or Air bleed tapping, H Air bleed tapping, H Drain/flush tapping, 2 H Holes for anchor bolts H ANSI flanges welded on

Field supplied equipment: Model 160/80 to 700/500: H Sensor well H Drain/flush valve H Air vent H ANSI counter flanges H Anchor bolts

Optional equipment: H Insulation H Temperature sensor

Low-Loss Headers

Technical Information

Principle of Operation
The temperature sensor connection [TS] typically located at the top of the low-loss header ensures low return temperatures to the boiler at all times and increases operational efficiency. In addition, the low-loss header helps eliminate air and debris [D] from the heating system. See diagram on the right for an illustration of the principle of operation.
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Legend SC AB SW SS BS TS AB BR BS BY D DV SC SR SS TS SW Air Bleed Boiler Return Boiler Supply Bypass (with laminar flow) Debris and/or air Drain Valve Sensor Cable System Return System Supply Viessmann Temperature Sensor Sensor Well

Product may not look exactly as illustrated.

BY

IMPORTANT
SR For Vitodens 200 applications, use only a Viessmann supplied temperature sensor to guarantee a functional system.

BR

D DV

T1

T3

T1 Boiler supply temperature T2 Boiler return temperature T3 System supply temperature T4 System return temperature Vprimary Boiler circuit flow rate Vsecondary Heating circuit flow rate Vbypass Bypass flow rate Qprimary Heat supplied by boiler Qsecondary Heat consumed by system Vprimary < Vsecondary T1 > T3 T2 = T4 Qprimary = Qsecondary T1 167F / 75C Vsecondary=Vprimary+Vbypass

Vprimary

Vbypass

T4

Vsecondary

T2 T4

IMPORTANT
When installing a low-loss header, system mixed supply temperature (T3) must be calculated as follows: T3= T1 V primary+T4 V bypass V secondary

Low-Loss Headers

Technical Data

Residential and Semi-Commercial Low-Loss Headers

Pressure tested to 145 psig / 10 bar Model Connection Maximum Flow Rate Water Fill Volume Dimensions (without Insul.) Total height Total width Total depth L1 L2 L3 L4 Shipping Weight Low-Loss Header Insulation Diagram Model 80/50 and 120/80 C USGPM m3/hr USG Liter inches mm inches mm inches mm inches mm inches mm inches mm inches mm lbs kg lbs kg 80/50 1 NPT 17.5 4 0.5 2.0 22 570 11 280 3 84 14 360 10 270 3 80 4 100 10 4 1.7 0.8 see below 120/80 2 NPT 35 8 2.0 7.7 36 920 12 320 5 140 25 650 21 550 4 120 4 100 22 10 5.6 2.5 160/80 2 ANSI 44 10 4.4 16.7 58 1480 22 560 11 280 39 1000 15 390 3 97 12 310 100 45 40 18 see opposite page 200/120 3 ANSI 80 18 8.2 31.2 58 1490 23 600 12 320 39 1000 15 390 3 97 13 350 137 62 44 20

L4 L3 L4
A

Total Width Total Height Total Depth

L1

A D A B C D E Boiler supply (top) and boiler return (bottom) System supply (top) and system return (bottom) Sensor well tapping, Drain/flush tapping, Air bleed tapping

L2
B

Low-Loss Headers

5354 682

Technical Data

Commercial Low-Loss Headers

Pressure tested to 145 psig / 10 bar Model Connection Maximum Flow Rate Water Fill Volume Dimensions (without Insul.) Total height Total width Total depth L1 L2 L3 L4 Shipping Weight Low-Loss Header Insulation Diagram Model 160/80 to 700/500 USGPM m3/hr USG Liter inches mm inches mm inches mm inches mm inches mm inches mm inches mm lbs kg lbs kg 250/150 4 ANSI 119 27 12.9 48.7 59 1520 25 650 13 350 39 1000 15 400 4 107 15 400 185 84 46 21 300/200 5 ANSI 189 43 20.6 78.0 60 1525 27 700 15 400 39 1000 15 400 4 107 17 450 276 125 53 24 400/200 6 ANSI 251 57 27.5 104.0 60 1530 31 800 15 400 39 1000 15 400 4 107 23 600 340 154 60 26 450/250 8 ANSI 374 85 36.5 138.0 61 1555 33 845 17 450 39 1000 15 400 4 107 23 600 595 270 77 34 see below 500/300 8ANSI 484 110 64.0 242.0 73 1860 35 900 19 500 47 1200 19 500 4 107 25 650 860 390 95 42 600/400 10 ANSI 748 170 104.6 396.0 74 1885 39 1000 23 600 47 1200 19 500 4 107 30 760 1213 550 112 51 650/450 12 ANSI 1034 235 130.8 495.0 78 2000 40 1050 25 650 47 1200 22 570 4 107 32 830 1543 700 128 58 700/500 14 ANSI 1320 300 182.8 692.0 93 2360 43 1100 27 700 59 1500 23 600 4 107 33 860 1610 730 157 71

Total Width
A C B E

Total Height
B D

Total Depth

L1

L4 L3

A B C D E

Boiler supply (top) and boiler return (bottom) System supply (top) and system return (bottom) Sensor well, Drain/flush tapping, 2 Anchor bolt holes

Low-Loss Headers

L2

Residential Sizing

Low-Loss Header Single Boiler Applications

for Viessmann wall-mount boilers Boiler Model No. of Boilers B il Boiler max Flow Rate Typical System Flow Rates System t*2 20 11.0 7.2 1635 yes 80/50 9.0 2045 yes 80/50 8.1 1840 yes 80/50 8.1 1840 yes 80/50 11.2 2544 yes 80/50 15.4 3498 yes 80/50 20.6 4679 yes 120/80 25 13.9 5.8 1315 optional 80/50 7.2 1630 yes 80/50 6.5 1476 yes 80/50 6.5 1476 yes 80/50 9.0 2044 optional 80/50 12.3 2794 optional 80/50 16.5 3748 yes 80/50 30 16.8 4.8 1190 optional 80/50 6.0 1360 optional 80/50 5.4 1227 optional 80/50 5.4 1227 optional 80/50 7.5 1703 optional 80/50 10.3 2340 optional 80/50 13.7 3112 optional 80/50 35 16.1 4.1 930 optional 80/50 5.1 1150 optional 80/50 4.6 1045 optional 80/50 4.6 1045 optional 80/50 6.4 1454 optional 80/50 8.8 1999 optional 80/50 11.8 2680 optional 80/50 40 13.4 3.6 820 optional 80/50 4.5 1020 optional 80/50 4.1 931 optional 80/50 4.1 931 optional 80/50 5.6 1272 optional 80/50 7.7 1749 optional 80/50 10.3 2339 optional 80/50 F C GPM ltr/h ViTemp. T sensor required No

Vitodens 100 WB1A 8-24 1 6.2 1400 System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model

WB1A 8-30

6.2 1400

GPM ltr/h

No

Vitodens 200 WB2 6-24C 1 6.2 1400 GPM ltr/h No

WB2 6-24

6.2 1400

GPM ltr/h

Yes (immersion*1) Yes (immersion*1) Yes (immersion*1) Yes (immersion*1)

WB2 8-32

7.0 1600

GPM ltr/h

WB2 11-44

15.4 3500

GPM ltr/h

WB2 15-60

15.4 3500

GPM ltr/h

*1 Immersion Sensor 7134240 - sold seperately; for use in single-boiler *2 For system t < 20 F use low-loss header sizes for t 20 F
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applications in conjunction with Vitodens boiler control.

Low-loss header must be used in all applications where the system flow rate exceeds the maximum or minimum boiler flow rate. Optional indicates that a low-loss header may be used for purposes of air speration and/or debris removal, as opposed to for flow purposes.

Low-Loss Headers

Commercial Sizing

Low-Loss Header Multiple Boiler Applications

for Viessmann wall-mount boilers Boiler Model No. of Boilers B il Boiler max Flow Rate Total Flow Fl Rate Typical System Flow Rates System t*4 20 11.0 30.8 6995 yes 120/80 46.2 10493 yes 200/120 61.6 13991 yes 200/120 41.2 9358 yes 160/80 61.8 14036 yes 200/120 82.4 18715 yes 250/150 36.0 8177 yes 160/80 56.6 12855 yes 200/120 51.4 11674 yes 200/120 72.0 16353 yes 200/120 66.8 15172 yes 200/120 77.2 17534 yes 200/120 25 13.9 24.6 5587 yes 120/80 37.0 8404 yes 200/120 49.3 11197 yes 200/120 33.0 7495 yes 120/80 49.4 11220 yes 200/120 65.9 14967 yes 200/120 28.8 6542 yes 120/80 45.3 10289 yes 200/120 41.1 9335 yes 200/120 57.6 13082 yes 200/120 53.4 12129 yes 200/120 61.8 14036 yes 200/120 30 16.8 20.5 4656 yes 120/80 30.8 6995 yes 200/120 41.1 9335 yes 200/120 27.5 6246 yes 120/80 41.2 9358 yes 200/120 54.9 12469 yes 200/120 24.0 5451 yes 120/80 37.7 8563 yes 200/120 34.3 7790 yes 200/120 48.0 10902 yes 200/120 44.5 10107 yes 200/120 51.5 11697 yes 200/120 35 16.1 17.6 3997 yes 120/80 26.4 5996 yes 200/120 35.2 7995 yes 200/120 23.5 5337 yes 120/80 35.3 8018 yes 200/120 47.1 10698 yes 200/120 20.6 4679 yes 120/80 32.3 7336 yes 200/120 29.4 6678 yes 200/120 41.1 9335 yes 200/120 38.2 8676 yes 200/120 44.1 10016 yes 200/120 40 13.4 15.4 3498 yes 120/80 23.1 5247 yes 200/120 30.8 6995 yes 200/120 20.6 4679 yes 120/80 30.9 7018 yes 200/120 41.2 9358 yes 200/120 18.0 4088 yes 120/80 28.3 6428 yes 200/120 25.7 5837 yes 200/120 36.0 8177 yes 200/120 33.4 7586 yes 200/120 38.6 8767 yes 200/120 F C GPM ltr/h Vi Temp. T sensor required Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3) Yes (strapon*3)

Vitodens 200 WB2 11-44 2 15.4 3500 30.8 6995 System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model System Flow Rate LHH required LHH Model

WB2 11-44

15.4 46.2 3500 10493

GPM ltr/h

WB2 11-44

15.4 61.6 3500 13991

GPM ltr/h

WB2 15-60

15.4 3500

30.8 6995

GPM ltr/h

WB2 15-60

15.4 46.2 3500 10493

GPM ltr/h

WB2 15-60

15.4 61.6 3500 13991

GPM ltr/h

WB2 11-44 WB2 15-60

1 1

15.4 3500

30.8 6995

GPM ltr/h

WB2 11-44 WB2 15-60

1 2

15.4 46.2 3500 10493

GPM ltr/h

WB2 11-44 WB2 15-60

2 1

15.4 46.2 3500 10493

GPM ltr/h

WB2 11-44 WB2 15-60

2 2

15.4 61.6 3500 13991

GPM ltr/h

WB2 11-44 WB2 15-60

3 1

15.4 61.6 3500 13991

GPM ltr/h

WB2 11-44 WB2 15-60

1 3

15.4 61.6 3500 13991

GPM ltr/h

*3 Strap-on Sensor 7818115 - standard *4 For system t < 20 F use low-loss

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equipment of Vitocontrol-S WB2; for use in multiple-boiler applications 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.

Low-Loss Headers

Low-Loss Headers

5354 682

Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island 02886 USA Tel. (401) 732-0667 Fax (401) 732-0590 www.viessmann-us.com info@viessmann-us.com

Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario N2V 2G5 Canada Tel. (519) 885-6300 Fax (519) 885-0887 www.viessmann.ca info@viessmann.ca

Technical information subject to change without notice.

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