Viessmann KK10 Dimensions and installation guide

VITOTRONIC 100
Installation, Start-up
and Service Instructions
Vitotronic 100
Model KK10
Boiler control unit
for high temperature heating systems
Part No. 7133 374
ertified as a component part
of Viessmann boilers only
Read and save these instructions
for future reference.
IMPORTANT
5167 481 v1.2 08/2010
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safety Installation and Warranty Requirements
Please ensure that this manual is read and understood 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).
HLicensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
"
Please see sections
entitled “Safety” and
“Important Regulatory and
Installation Requirements”.
HProduct 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”.
HAdvice 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.
HWarranty
Information contained in this and
related product documentation must be
read and followed. Failure to do so
renders warranty null and void.
5167 481 v1.2

ontents
3
Page
Important Precautions Safety 4
................................................................................................
Important Regulatory and Installation Requirements 5 ....
General Information About these Installation Instructions 5
...................................
Valid for ... 5 ......................................................................................
Heating System System Configuration
One direct-connected heating circuit
without mixing valve 6 ..................................................................
Electrical Connections Opening the Control 7
....................................................................
Overview 8 ..........................................................................................
Routing Cabling 9 .............................................................................
Power Supply 9 .................................................................................
Burner Connection 10 .......................................................................
Room Thermostat Connection 11 ................................................
Pump Connection 11 .........................................................................
Altering Settings Fixed High Limit 12
............................................................................
Testing the FHL 12 ............................................................................
Adjustable High Limit 13 .................................................................
Dip Switch Settings 14 ....................................................................
Appendix After Installation ...
hecklist 15 ..........................................................................................
Service Binder 15 ................................................................................
Start-up Start-up Instructions
heck all connections 15 ................................................................
Set fixed high limit and adjustable high limit 15 ...................
Ensure correct operational settings on control are set 15 .
Troubleshooting Diagnostics
(for qualified service personnel only)
Failure, ause, orrection 17 ........................................................
Electrical connections and sequence of operation 18 .........
Additional Information Replacement Components
(for qualified service personnel only) 20 ...................................
Boiler Protection 22 .............................................................................
Parts List 24 ...........................................................................................
Wiring Diagram 25 ...............................................................................
Technical Data 26 ................................................................................
Protocol 26 .............................................................................................
5167 481 v1.2

Important Precautions
4
Safety
Take note of all symbols and notations intended to draw attention to potential hazards or important product information.
These include ”WARNING ” ”CAUTION ” and ”IMPORTANT”. See page 5 for details.
Approvals
Viessmann boilers, burners and
controls are approved for sale in North
America by SA International.
Codes
The installation of this unit shall be in
accordance with local codes. In the
absence of local codes, use:
HSA 22.1 Part 1 and/or local codes
in anada
HNational Electrical ode ANSI/NFPA
70 in the U.S.
Always use latest editions of codes.
Please carefully read this manual prior
to attempting installation. ny
warranty is null and void if these
instructions are not followed.
For information regarding other
Viessmann System Technology
componentry, please reference
documentation of the respective
product.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
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.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main oil or gas supply valve.
Take precautions in both instances to
avoid accidental activation of power
during service work.
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include low
water cut-offs, flow switches (if used),
staging controls, pumps, motorized
valves, air vents, thermostats, etc.
Technical literature
Literature applicable to all aspects of
the Vitotronic 100:
- Technical Data Manual
- Installation, Start-up
and Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of other Viessmann
products utilized and installed
- Installation codes mentioned
in this manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
5167 481 v1.2
Turn off electric power
supply before
servicing. Contact with
live electric
components can cause
shock or loss of life.
WARNING

Important Precautions / General Information
5
Important Regulatory and Installation Requirements
Power supply
Install power supply in accordance with
the regulations of the authorities
having jurisdiction or, in the absence of
such requirements, in accordance with
National odes. Viessmann
recommends the installation of a
disconnect switch to the 120 VA
power supply outside of the boiler
room. The installer must provide
maximum 15 A overcurrent protection
for the 120 VA power supply (fuse or
circuit breaker).
Note on connecting external
“potential-free” contacts to the
Vitotronic 100 control’s 24 VAC
thermostat connections
Ensure that all contacts have sufficient
insulation clearance to live parts and
are certified for these applications.
A room thermostat or other
potential-free contact (i.e. end switch
of a zone valve) must be connected to
the Vitotronic 100 thermostat
connections.
Working with an open control
No static discharge to the internal
componentry must ever occur when
working with opened control
equipment.
About these Installation 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”. See below.
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation,
operation or maintenance which
pertain to the product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
Valid for ...
Applies to Vitotronic 100, Model KK10:
Order No. 7133 374, starting with serial no. V00101
This control shall only be installed with the Vitola 200, Vitorond 200,
Vitogas 050, RS Series, or with a Vitogas 100 hot water heating boiler.
5167 481 v1.25167 481 v1.2
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

Heating System
6
System Configuration
One direct-connected heating circuit without mixing valve
Boiler with
Vitotronic 100, Model KK10
Heating circuit
System pump
Room thermostat
120 VAC connections
Power supply cord,
120 VA , 60 Hz
Burner connection
Pump connection
(used with:
Vitorond 200,
Vitogas 050, RS Series, and
Vitogas 100 boilers only)
Required equipment
Description Quantity Order No.
Vitotronic 100, Model KK10 1 7133 374
Optional equipment
Description Quantity Order No.
DHW Pump Module for domestic hot water production using a
Viessmann Vitocell indirect-fired domestic hot water storage tank
1 9543 431
5167 481 v1.2
TH

Electrical onnections
7
Opening the Control
1. Open front cover.
2. arefully unlock control top cover
using a screw driver and flip open
top cover.
5167 481 v1.2
1.
2.
2.

Electrical onnections
8
Overview
The control is pictured from the rear.
120 VAC connections
for power supply cord
120 VA , 60 Hz
for burner connection
Pump connection
FHL test connection
A B Test
24 VAC connections
Room thermostat connection or
DHW pump module connection
Dip switches
2nd stage adaptor connection,
191 plug
5167 481 v1.2

Electrical onnections
9
Routing Cabling
Strain relief clamps are located in the
fittings package supplied with the
control.
1. Remove breakouts as necessary.
2. Mount lower portion of strain relief
clamp.
3. ut rubber grommet (if applicable).
4. Insert rubber grommet in strain
relief and mount strain relief.
5. Fasten top portion of strain relief.
6. lose off openings in the control
which are not being used.
Rubber grommets may already be
mounted on cabling.
Power Supply
Follow instructions under Important
Regulatory and Installation
Requirements.
1. Feed the power supply cord with
3-prong molded plug through rear
top panel wiring gate of the boiler.
2. Slide cable into the strain relief and
secure with strain relief set screw.
3. Plug power supply cord into
receptacle. Ensure receptacle is
designated for the heating system
only.
5167 481 v1.2
2.
1.
4.
5.
3.
6.
IMPORTANT

Electrical onnections
10
Burner Connection
to control
(RAST-5 plug)
to burner or wall vent system
(plug)
The Vitotronic 100 is prewired with the
Viessmann quick-connect plug-in
system.
1. onnect the RAST-5 plug to the
main circuit board of the control
(see page 8).
2. onnect 7-pole plug to the
counter plug of the burner
or
if installing a wall vent system
(accessory), connect 7-pole plug to
counter plug of wall vent system.
Refer to technical instructions
of the burner and/or wall vent
system
5167 481 v1.2
Do not connect the 41-plug from the
boiler control directly to the burner if
installing a wall vent system.
See technical instructions of the wall
vent system.
WARNING

Stage 1 Stages 1 and 2
Electrical onnections
11
Room Thermostat Connection
The main circuit board is pictured from the top.
A room thermostat or end-switches
from zone valves (in multi-zone
systems) can be connected to the room
thermostat connection. onnection
must be potential-free (”dry contact”).
1. Feed the cabling from the room
thermostat through rear top panel
wiring gate of the boiler. Use AWG
18 copper wire only.
2. For single-stage boilers, connect a
single-stage thermostat or setpoint
control to terminals X2.1 and X2.2.
For two-stage boilers, a two-stage
thermostat or setpoint control has
to be connected to terminals X2.1,
X2.2 and X2.3.
3. Slide cable into the strain relief and
secure with strain relief set screw.
4. onnect cabling to main circuit
board as shown.
5. Set thermostat anticipator to 0.1 A.
Pump Connection
The main circuit board is pictured from the top.
Pump connection
The Vitotronic 100, Model KK10
incorporates a 120 VA pump output.
The output is activated when the boiler
water temperature exceeds the
minimum boiler temperature limit. The
Pump Junction Box (shipped with the
boiler) must be connected to the pump
connection.
The purpose of this output is to
minimize the possibility of flue gas
condensation with the following
boilers:
-Vitorond 200, VR2 Series
-Vitogas 050, RS Series
-Vitogas 100, GS1 Series
See Installation Instructions of
the Pump Junction Box
(shipped with the boiler)
The Vitola 200 boiler has no low limit.
Do not use the pump connection with
the Vitola 200.
5167 481 v1.2

Altering Settings
1.
12
Fixed High Limit
The default setting of the fixed high limit (FHL) is 230°F / 110°C.
Slot screw
The FHL deactivates the burner control
circuit if abnormally high temperatures
occur.
If tripped, it may be reset by pushing in
the pin, labelled with a “ ” (using a
ballpoint pen). If a “click” can be
heard, the limit was tripped.
Adjustment to 212°F / 100°C
1. Turn indicator screw at rear of FHL
to 212°F / 100° position using a
flat-head screwdriver (readjustment
to previous position is not
possible).
2. Please complete Protocol on page
26.
Testing the FHL
The main circuit board is pictured from the top
FHL test connection, A B Test
A test can be performed to ensure
proper operation of the FHL:
→Deactivate power to control.
→Install a jumper between
terminals A and B .
→The adjustable high limit “ ” is
disabled.
→Reactivate power to control.
→The burner is activated until the
boiler water temperature reaches the
FHL temperature and the FHL
deactivates the burner.
After deactivation of the FHL,
→Deactivate power to control.
→Remove jumper between
terminals A and B.
→wait until boiler water temperature
has cooled 27 to 36°F / 15 to 20°
below the FHL temperature and
reinitiate FHL by pushing in
the “ ” pin.
→Reactivate power to control.
5167 481 v1.2
If adjusting the fixed high limit to
212°F / 100°C do not set adjustable
high limit higher than 167°F / 75°C.
CAUTION
A B Test connection is a 120 VAC
circuit!
CAUTION
Boiler and burner must be supervised
during entire procedure. Allow boiler
water temperature to cool down to
140°F / 60°C before activating any
attached heat distribution system.
CAUTION
Connected low temperature (floor
heating) systems whether connected
with or without mixing valves must be
deactivated during this procedure.
Attached DHW tanks must be isolated
and proper water expansion to the
expansion tank must be guaranteed
before performing this test.
CAUTION

Altering Settings
13
Adjustable High Limit
The default setting of the adjustable high limit ( HL) is 167°F / 75°C.
The HL must not be set higher than 167°F / 75°C if the FHL is set to
212°F / 100°C.
The AHL sets the maximum boiler
water temperature. It deactivates the
burner control circuit when the desired
temperature is reached. The AHL
resets automatically on a decrease in
boiler temperature.
Adjustment to 189°F / 87°C
1. Remove dial using a flat-head
screwdriver.
2. Using needle-nose pliers, break off
tabs enabling dial to rotate right to
desired maximum temperature.
3. Install dial in such a way that its
mark is situated in the desired
temperature range.
4. Please complete Protocol on page
26.
Changing the setting of the high limit safety cut-out
Adjustment to 100°C for side scales
1. Remove reset button cover “E”.
2. Remove the nut.
3. Remove the high limit safety
cut-out.
4. Turn the screw until the indicator
points to 100° .
5167 481 v1.2
1.
2.
3.
The allowable temperature of domestic
hot water as specified by regional
standards must not be exceeded when
operating an indirect-fired DHW tank.
Install additional safety devices!
WARNING
3.
4.
2.
1.
If adjusted to 212°F/100°C do not
set the adjustable high limit above
167°F/75°C.
CAUTION

Altering Settings
14
Dip Switch Settings
The “sequence of operation” of the Vitotronic 100, Model KK10 can be
customized depending upon the boiler it is installed with, or the characteristics of
the heating system itself.
Dip switch settings are to be altered by a qualified heating contractor only. See
Overview on page 8 for dip switch location.
Default
Setting
Operation Possible
Change
Operation
S1.1 - ON Do not change
from ON
setting
S1.2 - ON Do not change
from ON
setting
S1.3 - OFF Staging and thermostat:
for single-stage boilers, the S1.3 setting
should be left in the default setting of OFF
for two-stage boilers where control of
both stages is needed; install a two-stage
room thermostat or electronic controller
ON Staging and thermostat:
for two-stage boilers where control of
both stages is not needed; install a
single-stage room thermostat or electronic
controller to terminals X2.2 and X2.3.
Both stages are activated simultaneously
for space heating, DHW production (where
DHW Pump Module is used), and for
minimum boiler temperature protection
S1.4 - ON For single- and two-stage boilers:
with minimum boiler temperature
protection
OFF For single- and two-stage boilers:
without minimum boiler temperature
protection
S1.5 - ON For two-stage boilers:
with minimum boiler temperature
protection using first and second stage
OFF For two-stage boilers:
with minimum boiler temperature
protection using first stage only
S1.6 - OFF For domestic hot water production and
space heating with a DHW Pump Module:
space heating pump and DHW pump are
disabled when boiler water temperature is
below the minimum value
ON For domestic hot water production and
space heating with a DHW Pump Module:
space heating pump and DHW pump are
enabled when boiler water temperature is
below the minimum value
S1.7 Not used
5167 481 v1.2
Ensure power switch on boiler control
is deactivated before attempting to
alter dip switch settings.
CAUTION

Appendix / Start-up
15
After Installation ...
Checklist
Please verify the following points
(check with a pen) and take corrective
actions as necessary:
jHave all limit capillaries and sensors
been completely inserted into the
boiler 5-point sensor wells?
jHave all electrical connections been
made as discussed in the previous
section?
jDid all plug-in connectors engage
with a “click” ?
jHave the settings of both the fixed
high limit and the adjustable high
limit been checked and altered as
necessary?
jHas the Pump Junction Box been
correctly wired (if applicable)?
Service Binder
1. File all technical documentation into
the Service Binder.
2. Install a protective service box
(optional equipment) near the boiler
and store the Service Binder in this
location.
Start-up Instructions
1. Check all connections
Based upon the Section entitled “Overview” on page 8, ensure all electrical
connections have been made according to the diagram.
2. Ensure settings on fixed high limit and adjustable high limit are correct
See pages 12 and 13.
3. Ensure correct operational settings on control are set
Read Operating Instructions and User’s Information Manual of Vitotronic.
The installer of the system is also responsible to ensure the system
operator/ultimate owner is made familiar with the system functioning, its
activation, and its shut-down.
5167 481 v1.2

Appendix / Start-up
16
Notes
5167 481 v1.2

Troubleshooting
17
Diagnostics (for qualified service personnel only)
Failure Cause Correction
jAre all controls operating properly
(i.e. thermostats, low water
cut-off, etc.)?
jAre all wire connections tight and
secure?
Failure Cause Correction
Heating system does not activate
(GREEN power LED is not
illuminated)
Power switch “ “ is in “ “
position
Ensure power switch “ “ is in “ “ position.
Main power to boiler control and
heating system has not been
activated
Activate main power; ensure 120 VA 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 plug-in connection
to burner and/or power venter is
made.
41
Fixed high limit (FHL) tripped Reset FHL by pushing in the pin, labelled with a
“ “ (using a ballpoint pen).
If a “click” can be heard, the limit was tripped.
No fuel *1 with oil: Ensure sufficient supply of oil
with gas: Open main gas supply valve
or
contact your local gas utility
ontrol 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.
Burner does not activate ontrol calls for heat but burner
does not respond
Power venter has to have separate
120 VA 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.
5167 481 v1.2

Troubleshooting
18
Diagnostics (for qualified service personnel only)
Electrical connections and sequence of operation
The plug of the Vitotronic 100, Model KK10 boiler control supplies power to
the RAST-5 connection on the main circuit board. This plug has L1, G and N
markings on its terminals.
If the power switch is closed, power is supplied to the F1 fuse (6.3 A). This fuse
is accessible from the front of the control. The output of the fuse is connected to
the fixed high limit (FHL), the pump aquastat (PA), the primary side of the
transformer (TR), and test point 1 . When the contacts of the FHL are closed,
terminal X1.5 and test point 2 will both have 120 VA present. Power flow will
continue to the L1 terminal of the connection on the RAST-5 terminal rail.
If the burner counter plug is connected, voltage will return back to the control
at terminal T1 on the RAST-5 plug. As the power flow continues in the control,
voltage will be present at test point 3 and X1.6. If the adjustable high limit (AHL)
is closed, and the boiler water temperature is below the AHL setting, 120 VA
will be present on X1.7 and test point 4.
On a call for heat or for domestic hot water production (with DHW Pump Module,
Accessory), contact 1K1 will be closed and 120 VA will be present on terminal
T2 of the RAST-5 plug. Test point 5 will also have 120 VA present at this
time. The power flow will continue to the burner. The burner will operate until the
thermostat ends the call for heat.
The space heating circuit switch is only operational if a DHW Pump Module
(Accessory) is installed.
5167 481 v1.2

Troubleshooting
19
Diagnostics (for qualified service personnel only)
Electrical connections and sequence of operation
Using a volt-ohm meter, place one probe onto neutral test point terminal (TPN).
Use the remaining probe to touch the individual test points to diagnose the
problem. Follow the steps below through the individual test points.
Test point 1
Is 120 VA present?
No heck main 6.3A fuse and replace as necessary. Retest.
Yes ontinue with Test point 2.
Test point 2
Is 120 VA present?
No FHL has tripped. Reset and ensure pump(s) is/are operating.
Yes ontinue with Test point 3.
Test point 3
Is 120 VA present?
No Power flow is not returning from burner. heck burner plug.
Yes ontinue with Test point 4.
Test point 4
Is 120 VA present?
No AHL has tripped. Allow boiler to cool and restart.
Yes ontinue with Test point 5.
Test point 5
Is 120 VA present?
No ontact 1K1 possible not closed.
Test burner operation using FHL test.
heck room thermostat circuit.
Yes Burner operation is required at this point.
Service burner.
Top view of main circuit board
5167 481 v1.2
Back of control
Front of control

Additional Information
20
Replacement Components (for qualified service personnel only)
Fuse Part No. 7815 580
F1: T 6.3 A / 250 V, slow blow
for control operation
Fixed high limit Part No. 7819 411
HElectro-mechanical temperature limit
with liquid filled capillary
HSafety feature: if capillary is not
liquid tight (leaks), switch deactivates
Due to the expansion characteristics of
the liquid contained in the capillary the
switch also deactivates (opens) at 14°F /
-10°C thereby shutting down the heating
system.
HSets a maximum limit for boiler water
temperature whereafter the switch
deactivates and locks
(factory setting 230°F / 110° )
H
HH
HAdjustable to 212°F / 100° via slot
screw on rear side (readjustment
to previous position is not possible)
5167 481 v1.2
IMPORTANT
If adjusting to 212°F / 100°C AHL
must not be set higher than 167°F /
75°C.
WARNING