Viessmann VITOTRONIC 100 Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitotronic 100
Type KC2B, KC4B
Electronic boiler control unit
VITOTRONIC 100
5600124 GB 10/2018 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5600124

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5600124

4
1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
System examples .................................................................................. 8
2. Installation sequence Opening the control unit ......................................................................... 9
■Type KC2B ......................................................................................... 9
■Type KC4B ......................................................................................... 10
Inserting the coding card ....................................................................... 10
Adjusting the high limit safety cut-out (if required) ................................. 11
■Type KC2B ......................................................................................... 12
■Type KC4B ......................................................................................... 12
Adjusting the temperature controller (if required) .................................. 13
■Type KC2B ......................................................................................... 14
■Type KC4B ......................................................................................... 14
3. Electrical connections Overview of electrical connections ........................................................ 15
Inserting cables/leads and applying strain relief .................................... 16
■Cable with cast-on cable entry ........................................................... 16
■Cable without cast-on cable entry ...................................................... 17
Connecting the sensors ......................................................................... 17
Connecting the pumps ........................................................................... 17
■Available pump connections ............................................................... 17
■230 V~ pumps .................................................................................... 18
■230 V~ pumps with power consumption greater than 2 A or high effi-
ciency circulation pumps .................................................................... 18
■400 V~ pumps .................................................................................... 19
External burner start .............................................................................. 19
Provisional burner operation .................................................................. 19
External demand via switching contact .................................................. 20
■Connection ......................................................................................... 20
■Codes ................................................................................................. 20
External demand via 0-10 V input .......................................................... 20
External blocking via switching contact ................................................. 21
■Codes ................................................................................................. 22
Connecting a pressure-jet oil/gas burner ............................................... 22
■2-stage/modulating burner extension ................................................. 22
Connecting an atmospheric burner ........................................................ 23
■2-stage burner extension .................................................................... 24
Power supply ......................................................................................... 25
■Power supply for several accessories ................................................ 26
■Power supply for the control unit ........................................................ 27
4. Commissioning Testing the high limit safety cut-out ........................................................ 28
■Type KC2B ......................................................................................... 28
■Type KC4B ......................................................................................... 28
Matching coding addresses ................................................................... 28
Checking the outputs (actuator test) ...................................................... 28
5. Coding levels Calling up coding levels ......................................................................... 30
Resetting codes to their delivered condition .......................................... 30
6. Coding level 1 Group 1 "General" ................................................................................. 31
Group 2 "Boiler" ..................................................................................... 31
Group 3 "DHW" ...................................................................................... 32
Group 4 "Solar" ...................................................................................... 32
Group 5 "Heating circuit 1" .................................................................... 33
7. Coding level 2 Group 1 "General" ................................................................................. 35
Index
Index
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5
Group 2 "Boiler" ..................................................................................... 37
Group 3 "DHW" ...................................................................................... 38
Group 4 "Solar" ...................................................................................... 39
Group 5 "Heating circuit 1" .................................................................... 43
8. Service checks Calling up the service level .................................................................... 44
Exiting the service level ......................................................................... 44
Operating data ....................................................................................... 44
■Checking operating data ..................................................................... 44
■Calling up operating data .................................................................... 44
■Resetting operating data .................................................................... 44
Brief scan ............................................................................................... 44
Service display ....................................................................................... 45
■Acknowledging the service display ..................................................... 46
■Calling up acknowledged service displays ......................................... 46
9. Troubleshooting Fault display ........................................................................................... 47
■Acknowledging a fault display ............................................................ 47
■Calling up acknowledged fault displays .............................................. 47
■Calling up fault codes from the fault memory (fault history) ............... 47
■Deleting the fault history ..................................................................... 47
■Fault codes ......................................................................................... 47
Faults that are not displayed at the programming unit .......................... 50
■Boiler cold, burner does not start ........................................................ 50
■Heating circuit pump is not running although boiler water tempera-
ture is sufficiently high ........................................................................ 51
Checking the sensors ............................................................................ 51
■Boiler water, cylinder and buffer temperature sensors ....................... 51
■Flue gas temperature sensor .............................................................. 51
Checking the fuses ................................................................................ 52
10. Parts lists Ordering parts ........................................................................................ 53
11. Parts list type KC2B Casing assembly ................................................................................... 54
PCB assembly ....................................................................................... 56
12. Parts list type KC4B Casing assembly ................................................................................... 58
PCB assembly ....................................................................................... 60
13. Function description Boiler water temperature control ............................................................ 62
■Brief description .................................................................................. 62
■Functions ............................................................................................ 62
■Control sequence ............................................................................... 63
Cylinder temperature control ................................................................. 63
■Brief description .................................................................................. 63
■Functions ............................................................................................ 63
■Control sequence ............................................................................... 64
EA1 extension ........................................................................................ 65
■Digital data inputs DE1 to DE3 ........................................................... 65
■Analogue input 0 - 10 V ...................................................................... 65
■Output aBJ .......................................................................................... 66
External H5 extension ............................................................................ 66
■External burner blocking ..................................................................... 67
■External safety equipment .................................................................. 67
■Temporary operation (burner stage 1) ................................................ 67
■Motorised flue gas damper ................................................................. 68
Vitoair draught stabiliser ........................................................................ 69
■Function check ................................................................................... 69
■Motor faulty ......................................................................................... 69
Index
Index
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6
14. Connection and wiring dia-
gram
................................................................................................................ 70
15. Specification ................................................................................................................ 71
16. Settings and equipment ................................................................................................................ 72
17. Keyword index ................................................................................................................ 73
Index
Index (cont.)
5600124

7
Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Information
Disposal of packaging
5600124
Information

8
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Product information
The control units Vitotronic 100, type KC2B and
KC4B for constant temperature operation, are
designed for use in single boiler systems.
For room temperature-dependent operation
System examples
Available system examples: See www.viessmann-
schemes.com.
Information
Intended use (cont.)
5600124
Information

9
!Please note
When the power supply is connected, touching
electrical contacts can result in appliance dam-
age.
Before opening the control unit, switch off its
mains power supply.
Type KC2B
1.
2.
3.
Fig. 1
Installation sequence
Opening the control unit
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Service

10
Type KC4B
Fig. 2
Inserting the coding card
Only use the coding card included with the boiler prod-
uct documentation (see following table).
915 531145
Fig. 3
Insert the boiler coding card through the opening in the
cover into slot "X7".
Installation sequence
Opening the control unit (cont.)
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Service

11
Boiler Coding card
Display in brief scan Identification Part no. of individual
part
Vitola 200, type VB2A, VX2A 00e1:02 7435 808 7834 995
Vitola 222, type VE2A
Vitoladens 300-T, type VW3B
Vitorond 100, type VR2B, 18 to 63 kW
Vitorond 111, type RO2D
Vitorondens 200-T, type BR2 and BR2A 01e1:02 7435 809 7834 996
Vitorondens 222-F, type BS2A
Vitorondens 200-T, type J2RA, 67.6 to
107.3 kW
Vitorond 100, type VR2B, 80 to 100 kW 00c6:02 7435 811 7834 998
Vitogas 200-F, type GS2, 72 to 144 kW
Vitogas 200-F, type GS2, 11 to 60 kW 00f0:02 7435 806 7834 993
Adjusting the high limit safety cut-out (if required)
The high limit safety cut-out is factory-set to 110 °C. It
can be changed to 100 °C.
Note
The temperature cannot be returned to its original set-
ting.
If the high limit safety cut-out is adjusted to 100 °C, do
not set the temperature controller to above 75 °C.
Installation sequence
Inserting the coding card (cont.)
5600124
Service

12
Type KC2B
95
100
110
120
°C B
4.
3.
A
1.
2.
Fig. 4
ASlotted screw for EGO products
BSlotted screw for JUMO products
Type KC4B
1.
3.
2.
Fig. 5
Installation sequence
Adjusting the high limit safety cut-out (if… (cont.)
5600124
Service

13
B
95
100
110
120
°C
1.
A
Fig. 6
ASlotted screw for EGO products
BSlotted screw for JUMO products
Adjusting the temperature controller (if required)
The temperature controller is set to 75 °C in the deliv-
ered condition. It can be adjusted to 87/95 °C.
Note
If the high limit safety cut-out is adjusted to 100 °C, do
not set the temperature controller to above 75 °C.
!Please note
Excessive DHW temperatures can damage the
DHW cylinder.
If the system is operated with a DHW cylinder,
the maximum permissible DHW temperature
must not be exceeded. If necessary, install suit-
able safety equipment.
1. Remove rotary selector " ".
2. Using a pair of pointed pliers, break off the tabs
between "75" and "90" or "95" from the stop dial,
as shown in the diagram.
3. Fit rotary selector " " so that the mark sits
between "75" and "90" or "95". Turn rotary selector
" " clockwise as far as it will go.
Installation sequence
Adjusting the high limit safety cut-out (if… (cont.)
5600124
Service

14
Type KC2B
1.
3.
2.
Fig. 7
Type KC4B
X12
1.
2.
3.
Fig. 8
Installation sequence
Adjusting the temperature controller (if… (cont.)
5600124
Service

15
Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
■Route LV leads < 42 V separately from cables
> 42 V/120 V~/208 V~.
■Only strip the minimum of insulation from
cables, as close to the terminals as possible,
and bundle them close to the corresponding
terminals.
■Secure cables with cable ties.
■When connecting external switching contacts and
on-site components, observe the insulation require-
ments of IEC/EN 60335-1.
!Please note
Electronic assemblies can be damaged by elec-
trostatic loads.
Before beginning work, touch an earthed object
such as a heating or water pipe to discharge any
static.
Opening the control unit
See page 9
M
1~
L
N
fÖ lH
230 V~ 230 V~
sÖ
M
1~
sA aVG% §
L
N1LNLNLN
A B
N
L1
41
3 2 4 6
1 L N
1L
1
L
N
NO
NC
COM
COM
NO NC
L
N
C
D
E
1
aG)
191
Fig. 9
AFuse
BCoding card slot
CVitotrol 100, type UTA
or
DVitotrol 100, type UTDB
or
EVitotrol 100, type UTDB-RF
Electrical connections
Overview of electrical connections
5600124
Installation

16
Connections on the low voltage PCB
Plug Component
!No function
§Boiler water temperature sensor
%Cylinder temperature sensor
)Buffer temperature sensor if the heating circuit is connected to a heating water
buffer cylinder
aG Flue gas temperature sensor
aVG KM-BUS subscriber (accessories), e.g. EA1 extension
a:A 2-stage/modulating burner extension (part of the standard boiler delivery)
Connections on the 230 V~ PCB
Plug Component
sÖ Heating circuit pump, heating circuit A1
or
Boiler circuit pump if the heating circuit is connected to a heating water buffer
cylinder
sA Circulation pump for cylinder heating (accessories)
fÖ Power supply
fA Burner
lH ■Mains connection for accessories
■Vitotrol 100
or
■External demand/external blocking
X12 External burner start, stage 1
Inserting cables/leads and applying strain relief
Seal unnecessary apertures in the control unit base
with cable grommets (not cut out).
Cable with cast-on cable entry
2.
3.
1.
Fig. 10
Electrical connections
Overview of electrical connections (cont.)
5600124
Installation

17
Cable without cast-on cable entry
2.
1.
Fig. 11
Connecting the sensors
Connections on the low voltage PCB: See Fig. 9, page 15
Plug Component
§Boiler water temperature sensor
%Cylinder temperature sensor
)Buffer temperature sensor (accessories)
aG Flue gas temperature sensor (accessories)
Connecting the pumps
Available pump connections
Connections on the 230 V~ PCB
Plug Component
sÖ Heating circuit pump for heating circuit HC1/A1
or
Boiler circuit pump if the heating circuit is connected to a heating water buffer
cylinder
sA Circulation pump for cylinder heating
sK DHW circulation pump
Electrical connections
Inserting cables/leads and applying strain… (cont.)
5600124
Installation

18
230 V~ pumps
Rated current: 4(2) A~
B
A
1~
M
Fig. 12
APump
BTo the control unit
230 V~ pumps with power consumption greater than 2 A or high efficiency circulation pumps
Pumps with switching input
LN
External
ON/OFF
LN
N PE
NL
L
D
C
A
B
Fig. 13
APump
BTo the control unit
CContactor
DSeparate power supply (observe manufacturer's
instructions)
Pumps without switching input
LN
LN
N PE
NL
L
D
C
A
B
Fig. 14
APump
BTo the control unit
CContactor
DSeparate power supply (observe manufacturer's
instructions)
Electrical connections
Connecting the pumps (cont.)
5600124
Installation

19
400 V~ pumps
Rated current for switching the contactor: 4(2) A~
LN L1 L2 L3 N PE
A
C
3~
M
B
Fig. 15
APump
BTo the control unit
CContactor
External burner start
!Please note
Live contacts lead to short circuits or phase fail-
ure.
The external connection must be potential-
free.
A
X12
21
Fig. 16
AExternal starting (floating contact)
If the contact is closed, burner stage 1 is switched on
and the boiler water temperature is limited by the tem-
perature controller.
Rated voltage 230 V~
Rated current 6 A~
Provisional burner operation
Insert jumper across terminals 1 and 2 of plug "X12".
X12
21
Fig. 17
Burner stage 1 is switched on. The boiler water tem-
perature is limited by the temperature controller.
Electrical connections
Connecting the pumps (cont.)
5600124
Installation

20
Connection options:
■EA1 extension (accessories, see page 65).
■Plug lH if no Vitotrol 100 is connected.
Connection
!Please note
Live contacts lead to short circuits or phase fail-
ure.
The external connection must be potential-
free.
Plug lH EA1 extension
A
lH
N
?
1L
AFloating contact (when connecting, remove
jumper between L and 1)
Rated voltage 230 V~
Rated current 10 mA~
B
[{S
DE [{D DE
[{A
DE
A
AFloating contact
BEA1 extension
When the contact is closed, burner operation is load-dependent. The boiler water is heated to the value set in
coding address "9b" in group 1 "General". The boiler water temperature is limited by this set value and the elec-
tronic maximum limit (coding address "06" in the "Boiler" group).
Codes
Plug lH EA1 extension
"40:1" in group 1 "General" Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) in group 1 "General" to 2.
■Select the effect of the function on the heating circuit pump in coding address "d7" in group 5 "Heating circuit".
■Select the effect of the function on the circulation pump for cylinder heating in coding address "5F" in group 3
"DHW".
External demand via 0-10 V input
Connection at input 0–10 V to EA1 extension (see
page 65).
Ensure galvanic separation between the earth conduc-
tor and the negative pole of the on-site power source.
Observe coding address "1E" in group 1 "General".
Electrical connections
External demand via switching contact
5600124
Installation