Viessmann Vitotronic 100 HC1 Quick guide

VITOTRONIC 100, HC1
VITOTRONIC 300-K, MW2S
Installation and
Service Instructions
for use by heating contractor
Vitotronic 100, Model HC1
Digital boiler control unit
Vitotronic 300-K, MW2S
Outdoor-reset logic digital cascade control
Panel mount, controls up to 4 Vitodens WB2B boilers
Certified as a component part
of Viessmann boilers onl
Vitotronic 100, HC1
Vitotronic 300-K, MW2S
Please file in Service Binder
5727 946 v1.2 11/2011

2
Safety, Installation and Warranty equirements
Please ensure that this manual is 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).
Licensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed b a licensed
professional heating contractor.
Please see section
entitled “Important
Regulatory and
Installation
Requirements.”
Product documentation
Read all applicable documentation be-
fore commencing installation. Store
documentation near boiler in a readil
accessible location for reference in the
future b 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 s stem operator/ultimate owner
with all equipment, as well as safet
precautions/requirements, shut-down
procedure, and the need for
professional service annuall 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.
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Table of Contents
Index
Page
Safet , Installation and Warrant Requirements 2 ...................................................................................................................................................
General Information
Important Regulator and Safet Requirements 5
...................................................................................................................................................
About these Instructions 6 ................................................................................................................................................................................................
Heating System Designs
S stem design 7 .....................................................................................................................................................................................................................
Installation – Vitotronic 300-K
Installing the Cascade Communication Module 10 ...................................................................................................................................................
Summar of electrical connections (Power Pump Module) 11 .............................................................................................................................
Installing modules 13 ..............................................................................................................................................................................................................
Installing the programming unit 13 ..................................................................................................................................................................................
Summar of electrical connections 14 ...........................................................................................................................................................................
Sensor connection 17 ............................................................................................................................................................................................................
Connection of the pumps 19 ..............................................................................................................................................................................................
Connection to modulating valve actuators 20 .............................................................................................................................................................
Connection of external contacts 21 ................................................................................................................................................................................
Connection to compiled failure alarm 22 ........................................................................................................................................................................
Making the LON connection 23 .........................................................................................................................................................................................
Power suppl 24 ......................................................................................................................................................................................................................
Initial Start-up
Steps 25
......................................................................................................................................................................................................................................
Further step-b -step instructions 26 ...............................................................................................................................................................................
Service Scanning – Vitotronic 100, HC1
Service level summar 36 ....................................................................................................................................................................................................
Temperatures, boiler coding card and quick scans 37 ............................................................................................................................................
Scanning operating conditions 38 ....................................................................................................................................................................................
Scanning and resetting service displa s 39 .................................................................................................................................................................
Service Scanning – Vitotronic 300-K
Service level summar 40 ....................................................................................................................................................................................................
Temperatures and quick scans 41 ....................................................................................................................................................................................
Scanning operating conditions 43 ....................................................................................................................................................................................
Troubleshooting – Vitotronic 100, HC1
Retrieving fault codes from the fault memor (fault histor ) 44 .........................................................................................................................
Faults displa ed at the programming unit 44 ..............................................................................................................................................................
Troubleshooting – Vitotronic 300-K
Retrieving fault codes from the fault memor (fault histor ) 48 .........................................................................................................................
Faults with fault displa at the programming unit 48 ..............................................................................................................................................
Function Description – Vitotronic 100, HC1
Boiler temperature control 54 .............................................................................................................................................................................................
5727 946 v1.2

4
Table of Contents
Index (continued)
Function Description – Vitotronic 300-K
Cascade control unit 55 ........................................................................................................................................................................................................
Heating circuit control 60 .....................................................................................................................................................................................................
DHW tank temperature control 63 ...................................................................................................................................................................................
Components – Vitotronic 300-K
Components from the parts list 65 ..................................................................................................................................................................................
Mixing valve circuit extension kit 69 ..............................................................................................................................................................................
Installation examples 70 .......................................................................................................................................................................................................
Remote control 71 ...................................................................................................................................................................................................................
Room temperature sensor 77 .............................................................................................................................................................................................
Input Module 0 to 10 V 78 ..................................................................................................................................................................................................
Coding – Vitotronic 100, HC1
Resetting codes to the factor setting 79 ....................................................................................................................................................................
Coding Level 1 79 ..................................................................................................................................................................................................................
Coding Level 2 80 ....................................................................................................................................................................................................................
Coding – Vitotronic 300-K
Resetting codings to the factor setting 82 ................................................................................................................................................................
Coding Level 1 82 ....................................................................................................................................................................................................................
Coding Level 2 85 ....................................................................................................................................................................................................................
Slab curing function diagram 101 .......................................................................................................................................................................................
Connection and Wiring Diagrams - Vitotronic 100, HC1
Boiler control, Power Pump Module (models 45, 60) wiring diagram 102 ........................................................................................................
Boiler control, Power Pump Module (models 80, 105) wiring diagram 104 .....................................................................................................
Appendix
Specification – Vitotronic 100 106 ...................................................................................................................................................................................
Specification – Vitotronic 300-K 106 ...............................................................................................................................................................................
Parts list 107 ...............................................................................................................................................................................................................................
Product Information
Vitotronic 100, HC1, and Vitotronic 300-K
Onl for integration/installation on Viessmann boilers and for wall mounting.
These application examples are onl recommendations, and must therefore be checked on site for completeness and
function.
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General Information
5
Approvals
Viessmann boilers, burners and
controls are approved for sale in North
America b CSA International.
Codes
The installation of this unit shall be in
accordance with local codes. In the
absence of local codes, use:
CSA C22.1 Part 1 and/or local codes
in Canada
National Electrical Code ANSI/NFPA
70 in the U.S.
Alwa s use latest editions of codes.
Please carefully read t is manual prior
to attempting installation. Any
warranty is null and void if t ese
instructions are not followed.
For information regarding ot er
Viessmann System Tec nology
componentry, please reference
documentation of t e respective
product.
We offer frequent installation and
service seminars to familiarize our
partners wit our products. Please
inquire.
Working on the equipment
The installation, adjustment, service,
and maintenance of this product must
be done b 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 suppl to
equipment, the heating s stem, 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.
T e completeness and functionality of
field supplied electrical controls and
components must be verified by t e
eating contractor. T ese include low
water cut-offs, flow switc es (if used),
staging controls, pumps, motorized
valves, air vents, t ermostats, etc.
Technical literature
Literature applicable to all aspects of
the Vitotronic 300-K:
- Installation & Service Instructions
- Operating & User Instructions
- Instructions of other Viessmann
products utilized and installed
- Installation codes mentioned
in this manual
Leave all literature at t e installation
site and advise t e system operator/
ultimate owner w ere t e literature
can be found. Contact Viessmann for
additional copies.
Important egulatory and Safety equirements
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Turn off electric power
supply before servicing.
Contact with live
electric components
can cause shock or loss
of life.
WA NING

General Information
6
Important egulatory and Installation equirements
Power supply
Install power suppl in accordance with
the regulations of the authorities
having jurisdiction or, in the absence of
such requirements, in accordance with
National Codes. Viessmann
recommends the installation of a
disconnect switch to the 120 VAC
power suppl outside of the boiler
room. The installer must provide
maximum 15 A overcurrent protection
for the 120 VAC power suppl (fuse or
circuit breaker).
Working with an open control
No static discharge to the internal
componentr 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 ”WA NING”, ”CAUTION”, and ”IMPO TANT”. See below.
Warnings draw your attention to t e
presence of potential azards or
important product information.
Cautions draw your attention to t e
presence of potential azards or
important product information.
Helpful ints for installation,
operation or maintenance w ic
pertain to t e product.
T is symbol indicates t at additional,
pertinent information is to be found in
column t ree.
T is symbol indicates t at ot er
instructions must be referenced.
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Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WA NING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPO TANT

7
Heating S stem Designs
System design
AVitodens 200-W (models 45 to
105) with the Vitotronic 100, HC1,
with KMK cascade communication
module as part of the standard
deliver
BVitotronic 300-K with LON
communication module (accessor )
CDHW c linder
DVitotronic 200-H with LON
communication module
(accessories)
EMixing valve on Vitotronic 300-K
FMixing valve on Viotronic 200-H
GMaximum temperature controller
(underfloor heating)
HLow loss header
KTwo-wa valve
!Outdoor temperature sensor
?Suppl temperature sensor
common heating flow
(low loss header)
?M1 Suppl temperature sensor
mixing valve circuit 1 -
extended circuit
(Vitotronic 200-H)
?M2/M3Suppl temperature sensor
mixing valve circuit 2 or 3
(Vitotronic 300-K)
%DHW temperature sensor
sÖ Boiler pump (Vitotronic 100,
HC1)
sÖM1 Mixing valve circuit 1
(Vitotronic 200-H)
sÖM2/M3Mixing valve circuit 2 or 3
(Vitocontrol-S)
sA DHW pump
sK DHW recirculation pump
fÖ Power suppl , 120 V/60 Hz
gSM1 Motor mixing valve circuit 1
(Vitotronic 200-H)
gSM2/M3Motor mixing valve circuit 2
or 3 (Vitotronic 300-K)
aVD/aVH External hook-up
(Vitotronic 300-K),
see page 21.
aVG/KMK Connection to
Vitotronic 100, HC1 to
Vitotronic 300-K
KMK Interconnection between
boiler controls and Vitotronic
100, HC1
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Heating S stem Designs
System design (continued)
The codes must be set on every Vitotronic 100.
(see section on coding page 82)
Vitotronic 100, HC1
equired coding
01 : 2 Multi-boiler s stem with Vitocontrol-S, WB2B
07 : 2
07 : 3
07 : 4
Setting the boiler number at the Vitotronic 100 of the
second boiler
third boiler
fourth boiler
Vitotronic 300-K
equired coding
00 : 3,
00 : 4,
00 : 7,
or
00 : 8
Heating circuit M2 without DHW heating
Heating circuit M2 with DHW heating
Heating circuit M2 and M3 without DHW heating
Heating circuit M2 and M3 with DHW heating
35 : 1
35 : 2
35 : 3
35 : 4
Setting up Vitotronic 300-K with
one Vitotronic 100
two Vitotronic 100
three Vitotronic 100
four Vitotronic 100
Vitotronic 200-H (if installed)
equired coding
97 : 1 The outdoor temperature is accepted b the LON BUS
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Heating S stem Designs
System design (continued)
DHW and Space Heating
Multiple (up to four) Vitodens 200-W, models WB2B 45, 60, 80 and 105 with...
– multiple heating circuits with mixing valves
– low-loss header
Vitotronic 300-K
Boiler 1 Boiler 2 Boiler 3 Boiler 4
P V P V P V P V
TPV
DHW Tank Low-Loss
Header
Common
Supply
Temperature
Sensor
MM
Fig. 31
PPM PPM PPM PPM
When designing a multiple Vitodens s stem as shown above, please reference applicable multiple Vitodens technical
documentation, and contact our local Viessmann Sales Representative for further assistance.
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.
Proper installation and functionality in
the field is the responsibility of the
heating contractor.
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IMPORTANT
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.
WA NING

10
Installation – Vitotronic 300-K
Installing the Cascade Communication Module
AThe cascade communication module Installation Instructions shipped
with boiler.
CC
A
B
D
AVitotronic 300-K
BKMK-BUS
CBoiler control with Vitotronic 100
and KMK Module (max 4 boilers)
D2-core Cable
(cable cross-section 2 x 0.5 mm
2
20 AWG total length 164ft. / 50m)
EConnection to the Vitotronic 300-K
(to terminals X9.3 and X9.4 on
cascade electronic module A2)
FTerminal strip ”KMK1/KMK2” at
the cascade communication module
of the boiler control with
Vitotronic 100
1 2 3 41 2 3 4
KMK2KMK1 KMK2KMK1
34
X9
A2
Note:
T e total lengt of BUS cables B
s ould not exceed 164ft. / 50m.
T e wires from t e BUS cables are
commutable.
5727 946 v1.2
2.
1.
3.
X7
A

11
Installation – Vitotronic 300-K
Summary of electrical connections (Power Pump Module)
Installation
Instructions,
Power Pump
Module
5727 946 v1.2
N
40962035100
12
3
4
56
7
X4
X3
L
145
230 VAC
Boiler Control Board
X
X11
LON
KMK
9
X
8
X
7
20 40
NL
145144143
50
202120A
28
L G N
40
L2
NLNLNL
M
120VAC
120VAC
FAULT
ALARM
OUTPUT
BOILER
PUMP
1 2 3 1 2 3 1 2 3
L1 G N
SAFETY DEVICE
LOW WATER CUT-OFF
120VAC
RECEPTACLE
WALL
-TYPICAL
A
P2
P1
L2
L1
SWITCH
DISCONNECT
MAIN POWER SUPPLY
120V, 60HZ, 12A
N
MAIN
L
G
31 2
145
31 2
144
31 2
143
50
202120A40
NL
120/230
Transformer
Power/Pump module
4321
X1
KMK1KMK2
KMK
Module

12
Installation – Vitotronic 300-K
Summary of electrical connections (Power Pump Module) (continued)
5727 946 v1.2
139
305
129
1.
2.
318
X1
X2
X10
4.

A4 A3
A1 A2
13
Installation – Vitotronic 300-K
Installing modules
A1 Power suppl module
A2 Cascade electronic module
A3 Power module
A4 Extension module, mixing valves
1. Install the modules in accordance
with the la out indicated on DIN
rail inside the control panel.
2. Connect the modules in accordance
with the overview
on page 14 and 15, using the
connecting cables provided.
Installing the programming unit
1. Make a cutout with the dimensions
305 × 129 mm in the front door of
the control panel.
When installing two programming
units, maintain a distance between
both of 20 mm.
2. Snap the frame into place.
3. Insert the programming unit.
4. Plug the connecting cable into the
back of the programming unit and
into the cascade electronic module
(A2).
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Installation – Vitotronic 300-K
Summary of electrical connections
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F1 4A
(slow)

15
Installation – Vitotronic 300-K
Summary of electrical connections (continued)
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16
Installation – Vitotronic 300-K
Summary of electrical connections (continued)
A1 Power supply module
fÖ Power suppl connection
A2 Cascade electronic module
!Outdoor temperature sensor
(accessories)
?Common suppl temperature
sensor
%DHW tank temperature sensor
(accessories)
%B2nd tank temperature sensor
(accessories)
aJATemperature sensor T1
aJBTemperature sensor T2
or
temperature sensor - DHW tank
loading s stem
aVD External connections
aVG KM BUS users (accessories) link
to Vitotronic 100 and remote
controls Vitocontrol
aVH External connections
LON Connecting cable for data
transfer between the control
units
S1 Emissions test switch S
(optional)
A3 Power module
sÖA1 Heating circuit pump or
DHW tank loading s stem
sA DHW tank pump (accessories)
sK DHW re-circulation pump
sL Shunt or suppl pump
gÖ Compiled failure alarm
gSA1 Three-wa return elevation valve
A4 Expansion module
?M2/M3 Suppl temperature sensor
sÖM2/M3 Heating circuit pump
gSM2/M3 Mixing valve actuator
A5 Programming unit
incl. connecting cable
*1 Remove bot jumpers w en connecting t e emissions test circuit.
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Installation – Vitotronic 300-K
Sensor connection
Outdoor temperature sensor
T e outdoor temperature sensor s ould be mounted 6.5 to 8ft / 2 to 2.5m above
ground level on t e nort or nort -west facing wall of t e building. In t e case of
multi-storey buildings, it s ould be mounted in t e upper alf of t e second storey.
Make sure t at t e sensor is not located over windows, doors and air vents, nor
immediately beneat a balcony or guttering.
Do not paint over t e outdoor temperature sensor ousing.
1. Remove the cap.
2. Mount the bottom part of the sensor
housing.
3. Pull the sensor wire through the
opening in the terminal compartment
and through the strain relief
provided.
4. Connect the wires to the terminals.
5. Place the cap over the outdoor
temperature sensor.
5727 946 v1.2
2.
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4.
3.
Resistance in
400
420
440
460
480
500
520
540
560
580
600
-40 -30 -20 -10 0 10 20 30
Outdoor temperature in °C / °F
-40 -22 -4 14 32 50 68 86
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.
WA NING

18
Installation – Vitotronic 300-K
Sensor connection (continued)
DHW tank temperature sensor
T e sensor measures t e domestic hot
water tank temperature.
Heating systems with domestic hot
water heating (single-boiler systems
only)
1. Install the DHW tank temperature
sensor.
See installation instructions
for domestic ot water tank
Note:
W en installing t e sensor in DHW
tanks of ot er makes, make sure
t at t e sensor is pressed against
t e sensor well of t e DHW tank by
means of a suitable device.
2. Ensure that the maximum
permissible domestic hot water
temperature is not exceeded. If
necessar , install a suitable safet
device for this purpose.
Check the sensor
1. Disconnect wires from terminals
X2.7 and 2.1 of module A2.
2. Measure resistance of sensor at
terminals ”1” and ”2” of the plug.
DHW tank
temperature
in °F / °C /
esistance
in Ω
ΩΩ
Ω
104 / 40
122 / 50
140 / 60
578
597
616
3. Compare the value measured with
the current temperature. If the value
differs significantl , check
installation and, if necessar , replace
sensor.
Technical data
Degree of protection: IP 32
Ambient temperature
During operation:
32 to + 194°F
0 to + 90°C
During storage and transport:
-4 to + 158°F
-20 to + 170°C
Electrical connection
The sensors are read to connect.
Insert the DHW temperature sensor lead
wires to terminals X2.7 and 2.1 of the
A2 Module.
Heating systems without domestic hot
water heating
Do not connect the DHW tank
temperature sensor.
5727 946 v1.2
Resistance in
0 20 40 60 80 100
540
560
580
600
620
640
660
680
700
720
DHW tank temperature in °C / °F
32 68 104 140 176 212

19
Installation – Vitotronic 300-K
Connection of the pumps
Available pump connections
sÖ Heating circuit high temperature
(without mixing valve)
sÖM2 Heating circuit M2 pump
Terminals 2 - L, - G , - N
sÖM3 Heating circuit M3 pump
Terminals 1 - L, - G , - N
sA DHW pump for heating up the
domestic hot water tank -
Terminals 4 - L, - G , - N
sK DHW recirulation pump
Terminals 3 - L, - G, - N.
Install pumps: see
manufacturer’s
instructions.
120 VAC pumps
Note:
T e maximum power consumption of
all pumps is 4A .
Rated current: max. 2 FLA
Recommended connection
cable: AWG 14
Connect the 3-wire cable from the
pump to the corresponding terminals.
B
A
TE MINAL 4 or 3
240 VAC or 3 PH pumps
Note:
Use contactor to switc pump.
For activating t e contactor:
Rated current: max. 2 FLA
Recommended connection
cable: AWG 14
Please ensure t at all connections and
cable gauge comply wit local and
national codes.
1.Select the contactor and the
connecting cable in accordance with
the rating of the pump that is to be
connected.
2.Connect the pump and power suppl
to the contactor.
3.Connect contactor coil to the
corresponding terminals.
5727 946 v1.2

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Installation – Vitotronic 300-K
Connection of modulating valve actuators
1120V or 24V valve adaptor
2DIN rail in connection enclosure
3 aBH Terminals
120V Valve Adaptor
Rated voltage: 120 VAC
Rated current: max. 0.1 FLA
Recommended connection
wire size: AWG 14
24V Valve Adaptor
Rated voltage: 24 VAC
Rated current: max. 0.15 FLA
Recommended connection
wire size: AWG 14
Operating time:
5 to 199 sec. selected via coding
address “40”.
1120V valve adaptor
2120V valve actuator
124V valve adaptor
224V valve actuator
1. Disconnect power to control.
2. Install 120V or 24V valve adaptor
on DIN rail inside connection
enclosure.
3. Insert the plug gS into socket gS on
the control.
4. Fasten cable with tie.
5. Connect black wire of the adaptor to
connection aBH on the DIN rail
- Terminal 8, 9 or 10.
6. Connect valve actuator wires to the
adaptor terminals as shown on
figures.
5727 946 v1.2
Control unit