Viessmann VITOTRONIC 100 Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitotronic 100
Type KC2
Electronic boiler control unit
For applicability, see the last page
VITOTRONIC 100
5862 698 GB 02/2005 Please keep safe.

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
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
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
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5862 698 GB

Working on the system
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5862 698 GB

Installation instructions
Preparing for installation
Heating system design................................................................................ 6
Installation sequence
Summary of electrical connections.............................................................. 7
Inserting cables and applying strain relief.................................................... 8
Changing the high limit safety cut-out setting (if required) ............................ 9
Changing the control thermostat setting (if required).................................... 10
Inserting the boiler coding card ................................................................... 12
Low voltage connections............................................................................. 13
Pump connection........................................................................................ 13
External connection to plug X12.................................................................. 15
Burner connection ...................................................................................... 15
Power supply.............................................................................................. 17
Fitting the top part of the control unit ........................................................... 19
Opening the control unit .............................................................................. 20
Service instructions
Commissioning, inspection, maintenance............................................... 20
Commissioning
Display and operating controls .................................................................... 21
Testing the high limit safety cut-out ............................................................. 22
Matching up coding addresses.................................................................... 22
Checking outputs (actuators) and sensors................................................... 22
Service scans
Service level summary ............................................................................... 24
Brief scans ................................................................................................. 24
Operating conditions................................................................................... 25
Troubleshooting
Checking and acknowledging faults ............................................................ 27
Calling up fault codes from the fault memory (fault history) .......................... 29
Faults that are not displayed at the programming unit .................................. 30
Function description
Boiler water temperature control ................................................................. 32
Heating circuit control ................................................................................. 33
Cylinder temperature control....................................................................... 34
Index
4
Index
5862 698 GB

Coding
Calling up coding levels .............................................................................. 37
Resetting codes to the delivered condition .................................................. 37
Coding summary......................................................................................... 37
Burner switching hysteresis ........................................................................ 41
Designs
Connection and wiring diagram ................................................................... 43
Components
Room thermostat Vitotrol 100, type UTD ..................................................... 45
Boiler coding card....................................................................................... 45
Vitoair draught stabiliser ............................................................................. 46
Components from the parts list.................................................................... 47
Parts lists .................................................................................................. 52
Specification............................................................................................. 55
Settings and equipment............................................................................ 56
Keyword index .......................................................................................... 58
Index (cont.)
5
Index
5862 698 GB

System version
One directly connected heating circuit without mixer
ABoiler with Vitotronic 100
BDHW cylinder
CHeating circuit without mixer
Plug
§Boiler water temperature sensor
%Cylinder temperature sensor
sÖ Heating circuit pump (acces-
sories)
sA Cylinder primary pump (acces-
sories)
fÖ Power supply (230 V/50 Hz)
fA Burner stage 1
lÖ Burner stage 2
a-D Room thermostat Vitotrol 100
(type UTD) (accessories)
a:A Two-stage burner extension
Required coding
02:1 for two-stage burner operation
(requires the two-stage burner extension)
Automatic changeover
00:2 with DHW cylinder
Heating system design
6
Preparing for installation
5862 698 GB

Plug 230 V~
sÖ Heating circuit pump (acces-
sories)
sA Cylinder primary pump (acces-
sories)
fÖ Power supply
fA Burner stage 1
X12 External burner start (stage 1)
Low voltage plugs
§Boiler water temperature sensor
%Cylinder temperature sensor
a-D Room thermostat Vitotrol 100
(type UTD) (accessories)
a:A Two-stage burner extension
When connecting external switching
contacts or components to the low
voltage circuit of the control unit,
please observe the safety require-
ments of protection class II, i.e.
8.0 mm air gap/creep path or 2.0 mm
insulation thickness towards 'live'
components.
Ensure a safe electrical separation for
all on-site components (incl. PC/lap-
tops) to conform to EN 60 335 or
IEC 65.
Summary of electrical connections
7
Installation sequence
5862 698 GB
Installation

Note
Blank off unnecessary knockouts in
the lower part of the control unit with
cable grommets (not cut out).
Inserting cables and applying strain relief
8
Installation sequence
5862 698 GB

Adjustment to 100 °C (EGO and JUMO)
The high limit safety cut-out is set to 110 °C in the delivered condition.
Note
This EGO setting change is irreversible!
When adjusting the temperature to 100 °C, do not adjust the control thermostat
above 75 °C.
AEGO slotted screw BJUMO slotted screw
Conversion to 100 °C at T&G
The high limit safety cut-out is set to 110 °C in the delivered condition.
Changing the high limit safety cut-out setting (if required)
9
Installation sequence
5862 698 GB
Installation

Note
When adjusting the temperature to 100 °C, do not adjust the control thermostat
above 75 °C.
Changing the control thermostat setting (if required)
Adjustment to 87 °C/ 95 °C
The control thermostat is supplied with a factory setting of 75 °C.
Note
Never set the control thermostat higher than 75 °C if the high limit safety cut-out
has been changed to 100 °C.
Changing the high limit safety cut-out setting (if . . . (cont.)
10
Installation sequence
5862 698 GB

1. Lever out and remove rotary selec-
tor R.
2. Using a pair of pointed pliers, break
off the cams between 75 and 90 or
95 from the stop disc, as shown in
the drawing.
3. Fit rotary selector Rso that the
marking lies between 75 and 90 or
95. Turn rotary selector Rfully
clockwise.
!Please note
Excessive DHW temperatures
can damage the DHW cylinder.
If the system is operated in
conjunction with a DHW cylin-
der, ensure that the maximum
permissible DHW temperature
is not exceeded. If necessary,
install suitable safety equip-
ment for this purpose.
Changing the control thermostat setting (if . . . (cont.)
11
Installation sequence
5862 698 GB
Installation

Only use the boiler coding card included with the boiler product documentation
(see table).
Insert the boiler coding card through
the cut-out in the cover into slot "X7".
Boiler Coding card Part no.
Vitola 200 E1 7818 915
Inserting the boiler coding card
12
Installation sequence
5862 698 GB

ABoiler water temperature sensor BCylinder temperature sensor
CRoom thermostat Vitotrol 100,
type UTD
Remove the jumper between
terminals 1 and 3 at plug a-D
when making this connection.
2-core cable 0.75 mm
2
, max.
30 m.
Installation instructions
Vitotrol 100, type UTD
Pump connection
Available pump connections:
sÖ Heating circuit pump
sA Cylinder primary pump
Low voltage connections
13
Installation sequence
5862 698 GB
Installation

Pumps 230 V~ Pumps 400 V~
For controlling contactor A:
Rated voltage: 230 V~
Rated current: 4(2) A~ Rated current: 4(2) A~
Recommended
connecting cable: H05VV-F3G
0.75 mm
2
or
H05RN-F3G
0.75 mm
2
Recommended
connecting cable:
H05VV-F3G
0.75 mm
2
or
H05RN-F3G
0.75 mm
2
Note
When connecting both pumps, the
rated current for both pumps is limited
to 4 A .
Pump connection (cont.)
14
Installation sequence
5862 698 GB

!Please note
'Live' contacts lead to short cir-
cuits or phase failure.
The external connections must
be zero volt.
AExternal start (zero volt contact)
External starting of the burner
(stage 1):
Connect the zero volt contact.
If the contact is closed, the first burner
stage is started and the boiler water
temperature is regulated by the con-
trol thermostat.
Rated voltage: 230 V~
Rated current: 6 A~
Recommended
connecting cable:
H05VV–F3G
0.75 mm
2
Burner connection
Pressure-jet oil/gas burners
Connect the burner in accordance with DIN 4791 [or local regulations].
The burner cables are included in the standard boiler delivery.
Max. current consumption 4 (2) A.
External connection to plug X12
15
Installation sequence
5862 698 GB
Installation

ATo the control unit
BTo 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 Connection for burner fault
B4 Connection for hours run
meter
~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 control thermostat
H1 Burner fault signal
BZ Hours run counter
Burner without plug
Install the mating plug from
Viessmann or from the burner manu-
facturer; connect the burner cable.
Two-stage burner extension
The function extension is supplied with the boiler.
Max. power consumption: 1 (0.5) A
Note
Observe the coding addresses 02 and 10 to 12 (see overview).
Burner connection (cont.)
16
Installation sequence
5862 698 GB

ATo the control unit
BTo the burner
CConnecting chamber incl. relay
K1 and K2
Terminal markings
T6, T8 Control chain "Burner stage 2"
(via two-point controller)
T6 from the burner
T8 Stage 2 ON
~Signal pass direction:
Control unit →burner
|Signal pass direction:
Burner →control unit
Colour coding to DIN IEC 60757
BK black
BN brown
BU blue
Power supply
Regulations
Carry out the power supply connection and all earthing measures (i.e fault cur-
rent circuit) in accordance with IEC 364, the requirements of your local power
supply utility, VDE or national regulations. Protect the power supply cable to the
control unit with a fuse rated no higher than 16 A.
Burner connection (cont.)
17
Installation sequence
5862 698 GB
Installation

Main isolator requirements (if necessary)
For combustion equipment to DIN VDE 0116, the main isolator that is installed
on site must comply with the requirements of DIN VDE 0116 "section 6" [or local
regulations]. The main isolator must be fitted outside the installation room and
isolate all non-earthed conductors with simultaneous contact separation of at
least 3 mm.
Recommended power supply cable
Three-core cable selected from the
following options:
&H05VV-F3G 0.75 mm
2
&H05RN-F3G 0.75 mm
2
APower supply 230 V~
BFuse (max. 16 A~)
CMain isolator, two-pole (on-site)
DJunction box (on-site)
1. Check that the power supply cable
to the control unit is fitted with a
fuse with a max. rating of 16 A.
2. Terminate the enclosed power sup-
ply cable inside the connecting
chamber (on site).
Danger
Incorrect core terminations
can cause severe injuries
and damage to the equip-
ment.
Take care not to interchange
wires "L1" and "N":
L1 brown
N1 blue
PE green/yellow
3. Insert plug fÖ into the control unit.
Colour coding to DIN IEC 60757
BN brown
BU blue
GNYE green/yellow
Power supply (cont.)
18
Installation sequence
5862 698 GB

Fitting the top part of the control unit
19
Installation sequence
5862 698 GB
Installation

Opening the control unit
20
Installation sequence
5862 698 GB