Viessmann KW10A Guide

Operating Instructions
and User’s Information Manual
for use by engineers and heating contractors
5728 556 v1.0 01/2011
Read and save these instructions
for future reference.
Vitotronic 100
Model KW10A
Boiler control unit
for modulating temperature heating systems
Part No. 7453 016
VITOTRONIC 100
Please file in Service Binder
IMPORTANT
Certified as a component
part for Viessmann boilers

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Vitotronic 100, KW10A Operating and User’s Information
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual can cause product/property damage, severe personal
injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.
uFor a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
uPlease see section entitled Safety and
“Important Regulatory and Installation
Requirements”.
Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Safety
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Safety requirements
For safety information on carbon monoxide
and frozen water pipe hazards, please refer
to page 12 in these instructions.

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About these Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important
product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”.
u Indicates an imminently hazardous situation which,
if not avoided, could result in death, serious injury or
substantial product/property damage.
u Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product /
property damage.
u Helpful hints for installation, operation or maintenance
which pertain to the product.
u This symbol indicates to note additional information
u This symbol indicates that other instructions must be
referenced.
WARNING
Warnings draw your attention to the presence of potential
hazards or important product information.
CAUTION
Cautions draw your attention to the presence of potential
hazards or important product information.
IMPORTANT
u
Safety

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Vitotronic 100, KW10A Operating and User’s Information
Table of Contents
Safety
Operation
Safety, Installation and Warranty Requirements..............2
Product documentation...........................................2
Licensed professional heating contractor...................2
Advice to owner....................................................2
Warranty...............................................................2
About these Instructions..........................................3
Overview..................................................................5
Front panel............................................................5
Summer mode switch.............................................5
Override switch.....................................................5
Power switch........................................................5
Location of Controls....................................................5
Starting Up the Heating System....................................6
Shutting Down the Heating System............................6
Altering the maximum Boiler Water Temperature............7
Diagnostics...............................................................8
Failure, Cause, Correction.....................................8
Service Notice for your Heating System.......................12
Boiler..................................................................12
System.............................................................12
Additional Safety Requirements..................................12
Carbon monoxide.................................................12
Frozen water pipe hazard.....................................12
Saving Energy..........................................................13
with a modern heating system..............................10
with proper heating............................................10
with regular servicing..........................................10
with good insulation...........................................10

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5728 556 v1.0
Vitotronic 100, KW10A Operating and User’s Information Operation
Overview
Location of Controls
The control is located behind the flip-down cover.
Open the flip-down cover by carefully pulling it forward
from the top.
Close the flip-down cover when finished all operations.
Front view of the control
Summer mode switch
The front mounted summer mode switch Fwhen in the
up (summer/winter) position awill allow the thermostat
terminal to call for heat, DHW functionality and outdoor
reset when programmed. Outdoor reset operation is based
on the Warm weather shut down setting.
When the summer mode switch F is in the down
(summer/DHW) position w, the thermostat terminal to
call for heat will be disabled. Units equipped with an
outdoor temperature sensor and programmed for either
internal outdoor reset or OpenTherm enabled thermostat
will start calculating a boiler water temperature at an
outdoor temperature of 37o F (3o C) and below. The boiler
pump will be turned on and run continuously.
Override switch
The front mounted override switch H when in the up
position h, turns the boiler pump on and enables stage 1
and 2 call for heat. The boiler operates on the adjustable
high limit temperature.
When the override switch H is in the down position a,
the system is in normal operation.
Power switch
The front mounted power switch Gwhen in the up
position I, the control system is on.
When the power switch G in the down position 0, the
control system is off.
Front panel

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Vitotronic 100, KW10A Operating and User’s Information
Starting-Up the Heating System
Operation
The initial start-up and set-up of the control must be done by a licensed professional heating contractor. We strongly
recommend a service visit if reactivating the heating system after an extended shut-down.
1. Check the pressure of the heating system on the
pressure gage . An operating pressure of 15 psi
is typical - consult your heating contractor.
Take corrective actions if necessary.
2. Ensure proper/adequate fuel supply exists; open oil
or gas shut-off valve.
3. Activate power to heating system (from, for example,
a switch located external to the mechanical room).
4. Activate power on boiler control “8“
The green power indicator illuminates.
5. Set room thermostat (or other heat demand control)
to desired temperature. A call for heat causes the red
burner status indicator to illuminate.
Your heating system is now ready for operation.
Shutting-Down the Heating System
If it is likely that the heating system will not be used for an extended period of time, we recommend a full shut-down.
We strongly recommend a service visit if deactivating the heating system after an extended operating period.
This ensures preventative service measures such as heat exchanger cleaning and burner calibration are undertaken.
1. Deactivate power on boiler control “8“
The green power indicator deactivates.
2. Close oil or gas shut-off valve on the tank
(if applicable) and near the burner.
3. Deactivate power to heating system
(from, for example, a switch located external
to the mechanical room).
CAUTION
In this circumstance, the control is completely deactivated
and the system will not respond in the event of cold
weather conditions.

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Vitotronic 100, KW10A Operating and User’s Information
Altering the Maximum Boiler Water Temperature
Operation
The adjustable high limit (AHL) limits the maximum boiler water temperature when a call for heat is made.
The call for heat is typically made by a room thermostat.
Select an appropriate boiler water temperature (based upon advice from your heating contractor).
The factory default setting is between 104° F and 167° F (40° C and 75° C).
An elevated setting between 104° F and 212° F (40° C and 100° C) is possible if an adjustment has been made
by the heating contractor.
Turn selector to the right uBoiler water temperature limit
(clockwise) increases.
or
Turn selector to the left uBoiler water temperature limit
(counter-clockwise) decreases.

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Vitotronic 100, KW10A Operating and User’s Information
Diagnostics
Operation
Failure, cause, correction
oAre all controls operating properly (i.e. thermostats,
low water cut-off, etc.)?
oAre all wire connections tight and secure?
Symptom/Condition Cause Correction
Boiler control is not active
(GREEN power LED is not illuminated)
Power switch “8“ is in “0“ position Ensure power switch “8“ is in “I“
position.
Main power to boiler control and
heating system has not been
activated
Activate main power; ensure
120 VAC is supplied to control
(receptacle).
Fuse on Vitotronic boiler control has
deactivated heating system
Replace fuse in control with same
type and rating
(F1: T 6.3 A / 250 V, slow blow).
Burner does not activate, or activates
intermittently
(RED fault LED flashes)
Burner is not electrically connected Ensure 7-pole fA plug-in connection
to burner and/or power venter is/are
made.
Fixed high limit (FHL) tripped Reset FHL by pushing in the pin,
labelled with a “E“ (using a
ballpoint pen).
If a “click” can be heard, the limit
was tripped.
No fuel *1with oil: Ensure sufficient supply of oil
with gas: Open main gas supply valve
or
contact your local gas utility
F1 fuse blown Pumps on Replace fuse
Burner does not activate Control calls for heat but burner does
not respond *1
Attempt to reset burner using reset
button on the burner
(underneath burner hood).
Service burner if necessary.
Refer to troubleshooting section in
burner manual.
Control calls for heat but burner does
not respond
Power venter has to have separate
120 VAC power supply to motor (see
power venter instructions).
Refer to troubleshooting section in
power venter manual. Air proving
switch, blower wheel or timer/relay
inside power vent may be defective.
Other accessory defect Ensure proper operation of all
accessories; replace if necessary.
Refer to technical literature supplied
with accessories.
*1Red LED does not flash when Honeywell S8600 ignition control module is used with boiler.

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Vitotronic 100, KW10A Operating and User’s Information Operation
Service Notice for your Heating System
Additional Safety Requirements
WARNING
The are no user-serviceable components on the boiler,
burner, control or on the heating system. Contact a
qualified heating contractor for service!
CAUTION
Ensure the mechanical room and the hot water heating
boiler itself, is kept clean.
WARNING
Failure to protect against frozen pipes could result in burst
water pipes, serious property damage and/or personal
injury. Boiler may shut down. Do not leave your home
unattended for long periods of time during freezing
weather conditions without turning off the water supply
and draining water pipes or otherwise protecting against
the risk of frozen pipes.
We strongly recommend that you have your heating system checked and serviced by a qualified heating contractor on
an annual basis to ensure a safe and energy efficient operation.
A service contract is advisable.
Boiler
Every boiler must be cleaned within certain time frames.
A lack of cleaning causes soot build-up in the combustion
chamber which raises the flue gas temperature and
reduces the efficiency of your heating system.
System
Ensure that a qualified heating contractor checks all
system components such as the expansion tank, the
pressure relief valve, the pump(s), the zone valves, the
low water cut-off and all other system componentry
regularly.
Carbon monoxide
The U.S. Consumer Product Safety Commission strongly
recommends the installation of carbon monoxide detectors
in buildings in which gas-burning equipment is installed.
Carbon monoxide (CO) is a colorless, odorless gas, which
may be produced during incomplete combustion of fuel
and/or when the flame does not receive an adequate
supply of combustion air.
Carbon monoxide can cause severe personal injury or loss
of life.
Therefore, carbon monoxide detectors that are in
compliance with a nationally recognized standard (e.g.
ANSI/UL 2034-2002, CSA 6.19-01) should be installed
and maintained in buildings that contain gas-burning
equipment.
Note: Viessmann does not test any detectors and makes
no representation regarding any brand or type of
detector.
Frozen water pipe hazard
Your heating boiler is designed to provide a warm and
comfortable living environment. It is NOT designed to
ensure against freezing of water pipes.
The boiler is equipped with several safety devices that
are designed to shut down the boiler and to prevent it
from restarting in the event of various unsafe conditions.
If your boiler remains off for an extended period of time
during cold weather, water pipes may freeze and burst,
resulting in extensive water damage and conditions in
which mold could grow. Certain molds are known to
cause respiratory problems, as well as to pose other
serious health risks. In case of water damage, immediate
measures should be taken to dry out affected areas as
quickly as possible to prevent mold from developing.
If your home will be unattended for an extended period of
time during cold weather, you should...
Shut off the water supply to the building, drain the water
pipes and add an antifreeze for potable water to drain
traps and toilet tanks. Open faucets where appropriate.
or
Have someone check the building frequently during cold
weather and call a qualified service agency if required.
or
Install a reliable remote temperature sensor that will notify
somebody of freezing conditions within the home.

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Vitotronic 100, KW10A Operating and User’s Information
Saving Energy
... with a modern heating system
By purchasing a “modern” heating
system, you have taken a decisive
step towards saving energy.
Viessmann boilers operate optimally
to ensure minimum fuel consumption
for maximum heating value -
efficient, environmentally friendly
and comfortable.
Your new heating system provides
the following alternatives to save
energy:
- a well insulated hot water heating
boiler and domestic hot water tank
- clean combustion and high energy
extraction
...with proper heating Additional energy can be saved by
considering the following measures
in addition to the above technical
improvements:
- proper ventilation: briefly open
the windows 1while turning off
thermostats or radiator valves 2
- avoid excess space heating; strive
for a room temperature of 68º F
(20º C) since every 2º F (1º C) of
lower room temperature can save
up to 5% in heating costs.
- proper control settings 5.
- properly set the temperature for
the DHW tank 4
- set thermostatic zone valves
properly 2
- do not block heat transfer
surfaces or thermostatic zone
valves 3
- control use of warm water:
a shower generally requires less
water than a bath
- close window shutters
(if applicable) during night time
hours.
...with regular servicing Regular servicing of your heating
system 6by a qualified heating
contractor ensures energy-efficient
and environmentally friendly
operation.
...with good insulation If still searching for additional
possibilities to save energy,
review the insulation installed
- on the heating system pipes and
DHW supply pipes,
- on the outside walls and on the
roof 7
- between heated (shaded grey)
and unheated (white fill) rooms 8
- around windows 9.
WARNING
Ensure properly sized fresh combustion
air supply to all fuel burning appliances,
including the hot water heating boiler.
Tightly insulated homes require a duct
or opening in the boiler room to allow
outside air in for combustion. Refer to
codes and instructions.
Operation

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Vitotronic 100, KW10A Operating and User’s Information

5728 556 v1.0 Printed in Canada Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island · 02886 · USA
1-800-288-0667 · Fax [phone]
www.viessmann-us.com · [email protected]
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario · N2V 2G5 · Canada
1-800-387-7373 · Fax [phone]
www.viessmann.ca · [email protected]
Vitotronic 100, KW10A Operating and User’s Information