Viessmann VITOTRONIC 100 Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitotronic 100
Type KC3
Boiler control unit for constant temperature operation
For applicability, see the last page
VITOTRONIC 100
5862 701 GB 1/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland), Build-
ing Regulations (Northern Ireland),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
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.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5862 701 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any 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 function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5862 701 GB

4
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5862 701 GB

5
Installation instructions
Preparing for installation
System example................................................................................................... 6
Installation sequence
Opening the control unit casing............................................................................ 7
Terminal overview................................................................................................ 8
Inserting cables/leads and applying strain relief................................................... 9
Adjusting the high limit safety cut-out (if required)............................................... 10
Adjusting the thermostat (if required)................................................................... 11
Connecting the Vitotrol 100.................................................................................. 12
Connecting pumps............................................................................................... 17
Connecting external safety equipment................................................................. 18
Connecting a burner............................................................................................. 19
Power supply........................................................................................................ 21
Service instructions
Commissioning
Testing the high limit safety cut-out...................................................................... 23
Troubleshooting................................................................................................. 24
Designs
Connection and wiring diagram............................................................................ 25
Components
Vitotrol 100........................................................................................................... 27
Vitoair secondary air device, part no. 7338 725 and 7339 703............................ 28
MCB inside the control unit.................................................................................. 29
Parts lists
Ordering parts...................................................................................................... 30
Specification....................................................................................................... 32
Settings and equipment..................................................................................... 33
Keyword index.................................................................................................... 34
Index
Index
5862 701 GB

6
One directly connected heating circuit without mixer
A
41
ABoiler with Vitotronic 100
BPower supply (230 V/50 Hz)
CVitotrol 100 (accessory)
DHeating circuit pump
EHeating circuit without mixer
Plug
fA Burner
Preparing for installation
System example
5862 701 GB

7
Installation sequence
Opening the control unit casing
5862 701 GB
Installation

8
A
B
C
Terminals 230 V~
ATerminals 1 to 12
■ Power supply (see page 21)
■ Vitotrol 100 (see from page 12)
■ Heating circuit pump (see
page 17)
■ External burner blocking (see
page 25)
CTerminals 13 to 18
■ External safety equipment
(page 18)
■ Testing the high limit safety cut-
out (page 23)
Plug 230 V~
BBurner plug fA (page 19)
Installation sequence
Terminal overview
5862 701 GB

9
1.
4.
3.
2.
Installation sequence
Inserting cables/leads and applying strain relief
5862 701 GB
Installation

10
2.
1.
4.
3.
In the delivered condition, the high limit
safety cut-out is set to 110 °C and can be
adjusted to 100 °C.
Note
The temperature cannot be returned to
its original setting.
When adjusting the temperature to
100 °C, never set the thermostat higher
than 75 °C.
Installation sequence
Adjusting the high limit safety cut-out (if required)
5862 701 GB

11
A
1.
F1
0
1
110
95
°C
95
110
120
B
AJUMO slotted screw BRathgeber slotted screw
Adjusting the thermostat (if required)
In the delivered condition, the thermostat
is set to 75 °C and can be adjusted to
87/95 °C.
Note
Never set the thermostat higher than
75 °C if the high limit safety cut-out has
been adjusted to 100 °C.
!Please note
Excessive DHW temperatures
can damage the DHW cylinder.
If the system operates with a
DHW cylinder, ensure that the
maximum permissible DHW tem-
perature is not exceeded. If nec-
essary, install suitable safety
equipment for this purpose.
Installation sequence
Adjusting the high limit safety cut-out (if… (cont.)
5862 701 GB
Installation

12
1.
2.
3.
1. Remove rotary selector " ".
2. Using a pair of pointed pliers, break
off the cams between "75" and "90"
or "95" from the stop dial, as shown
in the diagram.
3. Install rotary selector " " so that the
mark is between "75" and "90" or
"95". Turn rotary selector " " fully
clockwise.
Connecting the Vitotrol 100
■ The Vitotrol 100 switches the heating
circuit pump or the burner.
■ The thermostat regulates the boiler
water temperature to the selected tem-
perature.
Installation sequence
Adjusting the thermostat (if required) (cont.)
5862 701 GB

13
Connecting the Vitotrol 100, type UTA
Switching the heating circuit pump
Remove jumper across terminals 4 and
5.
Recommended connecting cable:
3-core cable with a cross-section of
1.5 mm²
1 2 3 4 5 6 7 8 9 10 11 12
A
26 34
D
1
ATerminal strip inside the control
unit
DVitotrol 100, type UTA
Connecting the Vitotrol 100, type UTDB
Switching the heating circuit pump
Remove jumper across terminals 4 and
5.
Recommended connecting cable:
2-core cable with a cross-section of
1.5 mm²
Installation sequence
Connecting the Vitotrol 100 (cont.)
5862 701 GB
Installation

14
A
1 2 3 4 5 6 7 8 9 10 11 12
NO
NC
COM
E
ATerminal strip inside the control
unit
EVitotrol 100, type UTDB
Switching the burner
Remove jumper across terminals 9 and
10.
Recommended connecting cable:
2-core cable with a cross-section of
1.5 mm²
A
1 2 3 4 5 6 7 8 9 10 11 12
NO
NC
COM
E
ATerminal strip inside the control
unit
EVitotrol 100, type UTDB
Installation sequence
Connecting the Vitotrol 100 (cont.)
5862 701 GB

15
No minimum temperature is main-
tained.
Note
There is no frost protection when the
burner is switched off.
Connecting the Vitotrol 100, type UTDB-RF
Switching the heating circuit pump
Remove jumper across terminals 4 and
5.
Recommended connecting cable:
4-core cable without earth conductor and
with a cross-section of 1.5 mm²
1 2 3 4 5 6 7 8 9 10 11 12
A
NO
NC
COM
N
L
F
ATerminal strip inside the control
unit
FWireless receiver of the Vitotrol 100,
type UTDB-RF
Switching the burner
Remove jumper across terminals 9 and
10.
Recommended connecting cable:
4-core cable without earth conductor and
with a cross-section of 0.75 mm²
Installation sequence
Connecting the Vitotrol 100 (cont.)
5862 701 GB
Installation

16
1 2 3 4 5 6 7 8 9 10 11 12
A
NO
NC
COM
N
L
F
ATerminal strip inside the control
unit
FWireless receiver of the Vitotrol 100,
type UTDB-RF
No minimum temperature is main-
tained.
Note
There is no frost protection when the
burner is switched off.
Installation sequence
Connecting the Vitotrol 100 (cont.)
5862 701 GB

17
Pumps 230 V~ Pumps 400 V~
A
M
1~
LN
678
N
LL1 L2 L3 N PE
G
M
3~
A
LN
6 7 8
ATerminal strip inside the control unit ATerminal strip inside the control unit
GContactor
For switching the contactor:
Rated voltage: 230 V~
Rated current: 4(2) A~ Rated current: 4(2) A~
Recommended con-
necting cable:
H05VV-F3G
0.75 mm2
or
H05RN-F3G
0.75 mm2
Recommended
connecting cable:
H05VV-F3G
0.75 mm2
or
H05RN-F3G
0.75 mm2
Installation sequence
Connecting pumps
5862 701 GB
Installation

18
!Please note
'Live' contacts lead to short cir-
cuits or phase failure.
The external connections must
be potential-free.
H
K
L
P
P
P
N
C
13 14 15 16 17 18
CTerminal strip inside the control
unit
HLow water indicator
KMaximum pressure limiter
LFurther safety equipment
1. Remove jumper across terminals 17
and 18.
2. Connect the external safety equip-
ment in series.
Installation sequence
Connecting external safety equipment
5862 701 GB

19
Pressure jet oil/gas burner
The burner cables are included in the
standard boiler delivery.
Connect the burner according to DIN
4791 [or local regulations].
Max. current drawn 4 (2) A.
B
M
41
L B4S3T2T1N
Störung H1
BZ
N PE L1
STB
TR
L1 N T1 T2 S3 B4
fA
ATo the control unit
MTo the burner
Terminal markings
L1 Phase via high limit safety cut-
out to the burner
PE Earth conductor to burner
N Neutral conductor to burner
T1, T2 Control chain
S3 Burner fault terminal
B4 Hours run meter terminal
Signal pass direction:
Control unit → burner
Signal pass direction:
Burner → control unit
Equipment codes
STB Control unit high limit safety cut-
out
TR Control unit thermostat
H1 Burner fault signal
BZ Hours run meter
Burner without plug
Install the mating plug from Viessmann
or from the burner manufacturer; con-
nect the burner cable.
Atmospheric burner
The burner cables are included in the
standard boiler delivery.
Max. current drawn 4 (2) A.
Installation sequence
Connecting a burner
5862 701 GB
Installation

20
5-core burner cable 6-core burner cable
B
M
BK GY BU BN
41
fA
fY]
BTo the control unit
MTo the burner
BK → B4
BN → T2
BU → N
GY → S3
BK1 BK2
BK3
B
M
BK4 BK5
41
fA
fY]
BTo the control unit
MTo the burner
BK1 → T1
BK2 → N
BK3 → T2
BK4 → S3
BK5 → B4
Terminal designation
L1 Phase via high limit safety cut-
out to the burner
PE Earth conductor to burner
N Neutral conductor to burner
T1, T2 Control chain
S3 Burner fault terminal
B4 Hours run meter terminal
Colour coding to DIN IEC 60757
BK Black
BN Brown
BU Blue
GY Grey
Installation sequence
Connecting a burner (cont.)
5862 701 GB