Viessmann Vitotronic 100 GC1 Quick guide

VITOTRONIC 100, GC1
VITOTRONIC 300-K, MW1S
Installation and
Service Instructions
for use by heating contractor
Vitotronic 100, Model GC1
Digital boiler control unit
Vitotronic 300-K, Model MW1S
Outdoor-reset logic digital cascade control, for installation in Custom Control Panel
Certified as a component part
of Viessmann boilers only
\
Please file in Service Binder
558 750 v .3 /20

General information
2
Safety, Installation and Warranty equirements
Please ensure that this manual is read and uderstood before commencing installation. Failure to comply with the
issues 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).
Licensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
Please see section
entitled “Important
Regulatory and
Installation
Requirements.”
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.
For a listing of
applicable literature,
please see section
entitled “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, shut-down
procedure, and the need for
professional service annually before
the heating season begins.
Warranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
Safety Terminology
The following terms are used throughout this manual to bring attention to the presence of potential hazards or important product
information. Please heed the advice given!
Helpful hints for installation, operation
or maintenance which pertain to the
product.
558 750 v .3
Indicates an imminently hazardous
situation which, if not avoided, will
result in death, serious injury or
substantial product / property damage.
DANGER
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product / property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or product /
property damage.
CAUTION
IMPORTANT

3
Contents
Index
Page
General information
Product information 7 ..............................................................................................................
Heating system designs
Summary of system versions 9 ..........................................................................................
System versions to 7 9 ......................................................................................................
Installation – Vitotronic 100
Summary of electrical connections 27 ............................................................................
Inserting cables and applying strain relief 29 ...............................................................
Inserting the boiler coding card 30 ....................................................................................
Setting of the fixed high limit 3 .......................................................................................
Changing the adjustable high limit 32 ...............................................................................
Sensor connection 34 .............................................................................................................
Pump connection 36 .................................................................................................................
Connections to boiler return mixing valve or
isolation/modulating valve actuator 38 ............................................................................
External connections 38 ........................................................................................................
Connection to low water cut-off device 39 ..................................................................
Connection to combustion air devices 40 ......................................................................
Inserting the LON communication module 46 ................................................................
Making the LON connection 46 ..........................................................................................
Burner connection, burner control wiring 47 ................................................................
Power supply 53 .......................................................................................................................
Installing the control unit front 54 ....................................................................................
Opening the control unit 55 .................................................................................................
558 750 v .3

4
Contents
Index (cont.)
Installation – Vitotronic 300-K, MW1S
Installing modules 56 ...................................................................................................................
Installing programming unit 56 ................................................................................................
Summary of electrical connections 58 .................................................................................
Sensor connection 6 ..................................................................................................................
Pump connection 65 .....................................................................................................................
Connection to modulating actuators 65 ................................................................................
External connections 66 .............................................................................................................
Connection to compiled failure alarm 67 .............................................................................
Making the LON connection 68 ...............................................................................................
Power supply 70 ............................................................................................................................
Initial start-up
Steps 7 ............................................................................................................................................
Further step-by-step instructions 72 .....................................................................................
Service scanning – Vitotronic 100
Service level summary 85 ..........................................................................................................
Temperatures, boiler coding card and brief scans 86 ....................................................
Scanning operating conditions 88 ..........................................................................................
Scanning and resetting maintenance displays 89 ............................................................
Service scanning – Vitotronic 300-K, MW1S
Service level summary 90 ..........................................................................................................
Temperatures and brief scans 9 ...........................................................................................
Scanning operating conditions 93 ..........................................................................................
Scanning and resetting the maintenance display 94 ......................................................
Troubleshooting – Vitotronic 100
Fault displays at the programming unit 95 .........................................................................
Viewing fault codes from the fault memory (error history) 98 ..................................
Troubleshooting – Vitotronic 300-K, MW1S
Faults with fault display at the programming unit 99 ....................................................
Downloading fault codes from the fault memory (error history) 05 ........................
Function description – Vitotronic 100
Boiler temperature control 06 ...................................................................................................
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5
Contents
Index (cont.)
Function description – Vitotronic 300-K, MW1S
Cascade control unit 07 ......................................................................................................
Heating circuit control 3 ...................................................................................................
DHW tank temperature control 7 .................................................................................
Components – Vitotronic 100
Components from the parts list 23 ................................................................................
Flue gas temperature sensor 24 ......................................................................................
Components – Vitotronic 300-K, MW1S
Components from the parts list 25 ................................................................................
DHW tank sensor 25 .............................................................................................................
Strap-on temperature sensor and immersion temperature sensor 26 .............
Outdoor temperature sensor 27 ......................................................................................
Mixing valve circuit extension kit 28 ............................................................................
Installation examples 29 .....................................................................................................
Remote control 30 .................................................................................................................
Vitotrol 200 30 ...................................................................................................................
Vitotrol 300 32 ...................................................................................................................
Connecting several remote controls 34 ...................................................................
Room temperature sensor 36 ...........................................................................................
Input Module 0 to 0 V 37 ................................................................................................
Coding – Vitotronic 100
Resetting codes to the factory setting 37 ..................................................................
Coding 38 ..............................................................................................................................
Calling up coding 38 ....................................................................................................
Summary 38 ........................................................................................................................
Coding 2 40 ..............................................................................................................................
Calling up coding 2 40 ....................................................................................................
Overall summary 40 .........................................................................................................
Burner switching differential 47 ......................................................................................
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6
Contents
Index (cont.)
Coding – Vitotronic 300-K, MW1S
Resetting codings to the factory setting 47 ..............................................................
Coding 48 ..............................................................................................................................
Calling up coding 48 ....................................................................................................
Summary 48 ........................................................................................................................
Coding 2 5 ..............................................................................................................................
Calling up coding 2 5 ....................................................................................................
Overall summary 52 .........................................................................................................
Slab curing function diagram 68 .....................................................................................
Connection and wiring diagrams – Vitotronic 100, GC
Summary 69 .............................................................................................................................
Low voltage motherboard 70 .............................................................................................
Line voltage motherboard 20 VAC 75 .......................................................................
Connection and wiring diagrams – Vitotronic 300-K, MW1S
Parts list 73 ...............................................................................................................................
Appendix
Specification – Vitotronic 00, GC 74 ......................................................................
Specification – Vitotronic 300-K, MW S 75 .............................................................
Applicability 75 .......................................................................................................................
558 750 v .3

7
General information
Product information
Vitotronic 100, GC1, and Vitotronic 300-K, MW1S
Only for integration/installation on Viessmann boilers and for control panel mounting.
These application examples are only recommendations, and must therefore be checked on site for
completeness and function.
Vitotronic 00, GC , without LON communication module as part of the standard delivery.
LON module (PN: 7 72 73) is supplied with control panel.
Vitotronic 300-K, MW S, with integral LON communication module.
558 750 v .3

8
General information
Summary of system versions
Boiler Characteristics Page
Vitorond Shunt pump for controlling return temperature for each boiler 9
2 Vitorond Common supply pump and low-pressure manifold
3Three-way mixing valve for controlling return temperature 4
4 Low loss header and three-way mixing valve for controlling return temperature 6
5 Vitocrossal Several heating circuits and one low temperature heating circuit 8
6 Vitocrossal,
Vitorond
Several heating circuits, one low temperature heating circuit plus Vitorond with shunt pump 2
7 Vitocrossal Three-way mixing valve, several heating circuits and one low temperature heating circuit 24
Please note that the following examples are simplified conceptual drawings only!
Piping and necessary componentry must be field verified.
A low water cut off (LWCO) must be installed where required by local codes.
Proper installation and functionality in the field is the responsibilty of the heating contractor.
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9
Heating system designs
System version 1
eturn temperature control of each boiler with shunt pump
Vitorond 200
ABoiler with Vitotronic 00, GC
BVitotronic 300-K, MW S
CDHW tank
DMixing valve circuit
Plug
!Outdoor temperature sensor
?Supply temperature sensor
common heating supply
?M2/M3Supply temperature sensor
mixing valve circuit 2 or 3
§Boiler temperature sensor
%DHW tank temperature sensor
aJATemperature sensor T
aJBTemperature sensor T2
sÖM2/M3Heating circuit pump mixing
valve circuit 2 or 3
sA DHW pump
sK DHW recirculation pump
sL Shunt pump
fÖ Power supply, 20 VAC,
60 Hz
fA Burner (burner stage )
gSA Motorized isolation valve
gSM2/M3Mixing valve actuator
circuit 2 or 3
lÖ Burner
(burner stage 2/mod.)
aVD/aVH External connections
(see page 39)
558 750 v .3558 750 v .3
LON LON
7A
7B
3
D D
A
90
4
40
43
46
CA
52 A
T2
T
29
7A
7B
3
90
4
40
43
46
52 A
T2
T
29
LON LON
40
43
46
LON LON
28
5
2
2
2
20
52
2
20
52
M3
M2
B

10
Heating system designs
System version 1 (cont.)
Codings must be set on every Vitotronic 00, GC .
Vitotronic 00, GC
equired coding
0 : 2 Multi-boiler system with cascade control via LON BUS
02: 2 Modulating burner operation
*
03: Oil fired operation (non-reversible)
*
07: 2
07: 3
07: 4
Setting the boiler number on the Vitotronic of
boiler 2
boiler 3
boiler 4
77: 2
77: 3
77: 4
Setting the LON participant number on the Vitotronic of
boiler 2
boiler 3
boiler 4
Automatic changeover
4A: Connecting the T temperature sensor to plug aJA
4b: Connecting the T2 temperature sensor to plug aJB
Vitotronic 333, MW1S
equired coding
00: 3,
00: 4,
00: 7,
or
00: 8
Without system circuit A
*
35:
35: 2
35: 3
Vitotronic 300-K, MW S with
one Vitotronic 00, GC
two Vitotronic 00, GC
three Vitotronic 00, GC
Possible applications
Heating systems with distribution manifold installed close to the boiler. The boiler water volume flow will be reduced via the
motorized isolation valve.
Temperature sensor T2 activates the shunt pump if the required minimum return temperature is not reached. If this fails to
achieve the required minimum return temperature, the boiler water volume flow must be reduced by at least 50% via
temperature sensor T , via the isolation valve or the heating circuit control units. Where the T temperature sensor cannot
affect the motorized isolation valves it must, instead, regulate the mixing valves of the heating circuits downstream.
Size the shunt pump to approx. 30% of the total throughput capacity of the boiler.
The boiler receives optimum protection when controlling the heating circuits via Vitotronic 300-K, MW S or a
Vitotronic 200-H connected to the boiler control unit. No additional on-site protective measures are required.
The connection diagram is only a recommendation and needs to be verified for completeness and functionality at the
installation site. ingle-phase and three-phase pumps must be connected with field supplied motor contactors and/or motor
starters.
*
If required.
558 750 v .3
IMPORTANT

11
Heating system designs
System version 2
Common supply pump and low pressure distribution manifold
Vitorond 200
ABoiler with Vitotronic 00, GC
BVitotronic 300-K, MW S
CDHW tank
DMixing valve circuit
Plug
!Outdoor temperature sensor
?Supply temperature sensor
common heating supply
?M2/M3Supply temperature sensor
mixing valve circuit 2 or 3
§Boiler temperature sensor
%DHW tank temperature sensor
aJATemperature sensor T
sÖA Closing the mixing valves
with external heating circuit
control units
sÖM2/M3Heating circuit pump mixing
valve circuit 2 or 3
sA DHW pump
sK DHW recirculation pump
sL Common supply pump
fÖ Power supply, 20 VAC
60 Hz
fA Burner (burner stage )
gSA Motorized isolation valve
gSM2/M3Mixing valve actuator
circuit 2 or 3
lÖ Burner
(burner stage 2/mod.)
aVD/aVH External connections
(see page 39)
558 750 v .3
LON 20A 20A LON LON LON
D
7A
D
A
3
90
4
40
43
46
CA
52 A
7A
3
90
4
40
43 46
52 A
T T
28
5
2
2
20
52
2
20
52
M3
M2
B
40 29
LON LON
43 46
2

12
Heating system designs
System version 2 (cont.)
Coding must be set on every Vitotronic 00, GC .
Vitotronic 00, GC
equired coding
0 : 2 Multi-boiler system with cascade control via LON BUS
02: 2 Modulating burner operation
*
03: Oil fired operation (non-reversible)
*
07: 2
07: 3
07: 4
Setting the boiler number on the Vitotronic of
boiler 2
boiler 3
boiler 4
0d : Therm-Control controls the mixing valves of downstream heating circuits
77: 2
77: 3
77: 4
Setting the LON participant number on the Vitotronic of
boiler 2
boiler 3
boiler 4
Automatic changeover
4A: Connecting the T temperature sensor to plug aJA
Vitotronic 300-K, MW1S
equired coding
00: 3,
00: 4,
00: 7,
or
00: 8
Without system circuit A
*
35:
35: 2
35: 3
Vitotronic 300-K, MW S with
one Vitotronic 00, GC
two Vitotronic 00, GC
three Vitotronic 00, GC
4d: 0 Common supply pump on plug sL
*1
If required.
558 750 v .3

13
Heating system designs
System version 2 (cont.)
Possible applications
If the distribution manifold is located in
a remote location (> 20 m / 65 ft). The
heat transfer to the heating circuits
must be able to be reduced.
Temperature sensor T reduces or
closes the mixing valves if the required
minimum return temperature is not
achieved. Size the common supply
pump to 0% of the total flow rate of
the heating system.
The boiler receives optimum protection
when controlling the heating circuits
via Vitotronic 300-K, MW S or a
Vitotronic 200-H connected to the
boiler control unit. No additional on-site
protective measures are required.
The connection diagram is only a
recommendation and needs to be
verified for completeness and
functionality at the installation site.
ingle-phase and three-phase pumps
must be connected with field supplied
motor contactors and/or motor
starters.
Temperature sensor T1
Wiring diagram for reducing the volume
flow rate in heating systems with
heating circuit control units, which are
not connected to the boiler control unit
via the LON BUS.
Necessary coding: 4C : 2.
sÖA Closing mixing valves
(Vitotronic 00, GC )
AContactor relay
BDownstream heating circuit
control unit
Switching contact closed:
signal for close mixing valve(s)
CPower connection 20 VAC
60 Hz
DJunction box, field supplied
558 750 v .3
IMPORTANT

14
Heating system designs
System version 3
Controlling the return temperature with a 3-way mixing valve
Vitorond 200
ABoiler with Vitotronic 00, GC
BVitotronic 300-K, MW S
CDHW tank
DMixing valve circuit
Plug
!Outdoor temperature sensor
?Supply temperature sensor
common heating supply
?M2/M3Supply temperature sensor
mixing valve circuit 2 or 3
§Boiler temperature sensor
%DHW tank temperature sensor
aJATemperature sensor T
sÖM2/M3Heating circuit pump mixing
valve circuit 2 or 3
sA DHW pump
sK DHW recirculation pump
sL Boiler circuit pump
fÖ Power supply, 20 VAC
60 Hz
fA Burner (burner stage )
gSA Three-way mixing valve
gSM2/M3Mixing valve actuator
circuit 2 or 3
lÖ Burner
(burner stage 2/mod.)
aVD/aVH External connections
(see page 39)
558 750 v .3
29
LON LON LON
D
7A
D
A
3
CA
90
4
40
43 46
52 A
29
7A
3
90
4
40
43 46
52 A
29
T T
LON
2
20
52
2
20
52
M3
M2
B
40
LON LON
43 46
2
28
5
2

15
Heating system designs
System version 3 (cont.)
Coding must be set on every Vitotronic 00, GC .
Vitotronic 00, GC
equired coding
0 : 2 Multi-boiler system with cascade control via LON BUS
02: 2 Modulating burner operation
*
03: Oil fired operation (non-reversible)
*
07: 2
07: 3
07: 4
Setting the boiler number on the Vitotronic of
boiler 2
boiler 3
boiler 4
0C: Constant regulation of the return temperature
4d: 2 Boiler circuit pump on plug sL
77: 2
77: 3
77: 4
Setting the LON participant number on the Vitotronic of
boiler 2
boiler 3
boiler 4
Automatic changeover
4A: Connecting the T temperature sensor to plug aJA
Vitotronic 300-K, MW1S
equired coding
00: 3,
00: 4,
00: 7,
or
00: 8
Without system circuit A
*
35:
35: 2
35: 3
Vitotronic 300-K, MW S with
one Vitotronic 00, GC
two Vitotronic 00, GC
three Vitotronic 00, GC
Possible applications
For example, older heating systems or systems in nurseries and/or systems where downstream heating circuits cannot be
controlled.
Temperature sensor T closes the three-way mixing valve in proportion and therefore protects the boiler, if the required
minimum return temperature is not achieved.
Please note:
ize the boiler circuit pump for each boiler so that their volume flow rate is at least as large as the max. total heating circuit
volume flow rate.
Recommendation: 110%
The connection diagram is only a recommendation and needs to be verified for completeness and functionality at the
installation site. ingle-phase and three-phase pumps must be connected with field supplied motor contactors and/or motor
starters.
*
If required.
558 750 v .3
IMPORTANT

16
Heating system designs
System version 4
Controlling the return temperature with a low loss header and a three-way mixing valve
Vitorond 200
ABoiler with Vitotronic 00, GC
BVitotronic 300-K, MW S
CDHW tank
ELow loss header
DMixing valve circuit
Plug
!Outdoor temperature sensor
?Supply temperature sensor
common heating supply
?M2/M3Supply temperature sensor
mixing valve circuit 2 or 3
§Boiler temperature sensor
%DHW tank temperature sensor
aJATemperature sensor T
sÖM2/M3Heating circuit pump mixing
valve circuit 2 or 3
sA DHW pump
sK DHW recirculation pump
sL Boiler circuit pump
fÖ Power supply, 20 VAC
60 Hz
fA Burner (burner stage )
gSA Three-way mixing valve
gSM2/M3Mixing valve actuator
circuit 2 or 3
lÖ Burner
(burner stage 2/mod.)
aVD/aVH External connections
(see page 39)
558 750 v .3
LON LON LON LON
D
7A
D
A
3
CA
90
4
40
43 46
52 A
29
7A
3
90
4
40
43 46
52 A
29
T T
E
2
20
52
2
20
52
M3
M2
B
40 29
LON LON
43 46
2
28
5
2

17
Heating system designs
System version 4 (cont.)
Coding must be set on every Vitotronic 00, GC .
Vitotronic 00, GC
equired coding
0 : 2 Multi-boiler system with cascade control via LON BUS
02: 2 Modulating burner operation
*
03: Oil fired operation (non-reversible)
*
07: 2
07: 3
07: 4
Setting the boiler number on the Vitotronic of
boiler 2
boiler 3
boiler 4
0C: Constant regulation of the return temperature
4d: 2 Boiler circuit pump on plug sL
77: 2
77: 3
77: 4
Setting the LON participant number on the Vitotronic of
boiler 2
boiler 3
boiler 4
Automatic changeover
4A: Connecting the T temperature sensor to plug aJA
Vitotronic 300-K, MW1S
equired coding
00: 3,
00: 4,
00: 7,
or
00: 8
Without system circuit A
*
35:
35: 2
35: 3
Vitotronic 300-K, MW S with
one Vitotronic 00, GC
two Vitotronic 00, GC
three Vitotronic 00, GC
Possible applications
For example, older systems or systems in nurseries and/or systems, where the hydraulic conditions cannot be clearly
defined and/or systems where downstream heating circuits cannot be controlled.
Temperature sensor T closes the three-way mixing valve in proportion and therefore protects the boiler, if the required
minimum return temperature is not achieved. The temperature sensor in the low loss header controls the supply
temperature.
Please note:
ize the boiler circuit pumps for each boiler so that their volume supply is at least as large as the max. total heating circuit
volume supply.
Recommendation: 110%
The connection diagram is only a recommendation and needs to be verified for completeness and functionality at the
installation site. ingle-phase and three-phase pumps must be connected with field supplied motor contactors and/or
motor starters.
*
If required.
558 750 v .3
IMPORTANT

18
Heating system designs
System version 5
Heating circuit and one low temperature heating circuit
Vitocrossal 300
ABoiler with Vitotronic 00, GC
BVitotronic 300-K, MW S
CDHW tank
DMixing valve circuit
ENeutralising system
Plug
!Outdoor temperature sensor
?Supply temperature sensor
common heating supply
?M2/M3Supply temperature sensor
mixing valve circuit 2 or 3
§Boiler temperature sensor
%DHW tank temperature sensor
sÖM2/M3Heating circuit pump mixing
valve circuit 2 or 3
sA DHW pump
sK DHW recirculation pump
fÖ Power supply, 20 VAC
60 Hz
fA Burner (burner stage )
gSA Motorized isolation valve
gSM2/M3Mixing valve actuator
circuit 2 or 3
aVD/aVH External connections
(see page 39)
lÖ Burner
(burner stage 2/mod.)
558 750 v .3
29
LON LON LON LON
3
90
4
40
43 46 43 46
D D
C
52 A
56
3
90
4
40
43 46 43 46
52 A
56
AE AE
2
20
52
2
20
52
M3
M2
B
40
LON LON
43 46
2
28
5
2

19
Heating system designs
System version 5 (cont.)
Codings must be set on every Vitotronic 00, GC .
Vitotronic 00, GC
equired coding
0 : 2 Multi-boiler system with cascade control via LON BUS
02: 2 Modulating burner operation
*
07: 2
07: 3
07: 4
Setting the boiler number on the Vitotronic of
boiler 2
boiler 3
boiler 4
0d: 0 Without Therm-Control
77: 2
77: 3
77: 4
Setting the LON participant number on the Vitotronic of
boiler 2
boiler 3
boiler 4
Vitotronic 300-K, MW1S
equired coding
00: 3,
00: 4,
00: 7,
or
00: 8
Without system circuit A
*
35:
35: 2
35: 3
Vitotronic 300-K, MW S with
one Vitotronic 00, GC
two Vitotronic 00, GC
three Vitotronic 00, GC
3C: 0 Condensing strategy
*1
If required.
558 750 v .3

20
Heating system designs
System version 5 (cont.)
Possible applications
Vitocrossal 300 is operated via a
Viessmann boiler control unit with
outdoor reset function, modulating
boiler water temperature, and
load-dependent sequential
control – two-stage or modulating
burners are controlled.
Vitocrossal 300 is equipped with two
return connections. The heating circuits
with the higher return temperature are
connected to the upper return
connection, and those with lower
return temperatures to the lower return
plug. Please note: Connect at least
5% of the rated output to the lower
return connection.
Due to the LON-BUS communication
between controls, a boiler supply
temperature is automatically set.
This temperature is based on the
highest required mixing valve circuit
temperature plus adjustable differential.
The connection diagram is only a
recommendation and needs to be
verified for completeness and
functionality at the installation site.
ingle-phase and three-phase pumps
must be connected with field supplied
motor contactors and/or motor
starters.
558 750 v .3
IMPORTANT