Viessmann VITOTRONIC 200 Operating instructions

VIESMANN
Installation and service
instructions
for contractors
Vitotronic 200
Type KW1
Weather-compensated, digital boiler control unit
For applicability, see the last page
VITOTRONIC 200
5862 699 GB 8/2008 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 699 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 699 GB

Installation instructions
Preparing for installation
System version........................................................................................... 6
Installation sequence
Overview of electrical connections .............................................................. 7
Inserting cables and applying strain relief.................................................... 8
Inserting the boiler coding card ................................................................... 9
Changing the high limit safety cut-out setting (if required) ............................ 10
Changing the thermostat setting (if required) ............................................... 11
Connecting sensors.................................................................................... 13
Connecting pumps...................................................................................... 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 .............................................................................. 21
Service instructions
Commissioning
Controls and display elements .................................................................... 22
Changing the language............................................................................... 22
Testing the high limit safety cut-out ............................................................. 23
Matching coding addresses ........................................................................ 23
Checking outputs (actuators) and sensors................................................... 23
Adjusting the heating curves ....................................................................... 24
Service scans
Service level overview ................................................................................ 28
Diagnosis (temperatures, boiler coding card and brief scans) ...................... 29
Scanning operating conditions .................................................................... 31
Display "Service" ........................................................................................ 32
Troubleshooting
Faults with fault display on the programming unit......................................... 34
Faults that are not displayed at the programming unit .................................. 41
Function description
Boiler water temperature control ................................................................. 44
Heating circuit control ................................................................................. 47
Cylinder temperature control....................................................................... 52
Index
4
Index
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Codes
Resetting codes to their delivered condition ................................................ 56
Calling up code 1 ........................................................................................ 56
Overview .................................................................................................... 56
Code 2........................................................................................................ 57
Designs
Connection and wiring diagram ................................................................... 72
Components
Components from the parts list.................................................................... 74
Radio clock receiver, part no. 7450 563....................................................... 79
Flue gas temperature sensor, part no. 7450 630 .......................................... 80
Remote control ........................................................................................... 82
Control module V, part no. 7143 513............................................................ 85
KM BUS distributor, part no. 7415 028......................................................... 86
Boiler coding card....................................................................................... 87
Function extension 0-10 V, part no. 7174 718 .............................................. 87
External extension H5, part no. 7199 249 .................................................... 89
Secondary air device Vitoair, part no. 7338 725, 7339 703........................... 92
Parts lists .................................................................................................. 94
Specification............................................................................................. 97
Settings and equipment............................................................................ 98
Keyword index .......................................................................................... 100
Index (cont.)
5
Index
5862 699 GB

One directly connected heating circuit without mixer
ABoiler with Vitotronic 200
BDHW cylinder
CKM BUS subscriber or KM BUS
distributor (only with several KM
BUS subscribers)
DHeating circuit without mixer
(Heating circuit A1)
Plug
!Outside temperature sensor
§Boiler water temperature sen-
sor
%Cylinder temperature sensor
sÖ A1 Heating circuit pump
sA Circulation pump for cylinder
heating
sK DHW circulation pump
fÖ Power supply, 230 V/50 Hz
fA Burner, stage 1
lÖ Burner, stage 2/mod.
aVG KM BUS subscriber/distributor
a:A Two-stage/mod. burner exten-
sion
System version
6
Preparing for installation
5862 699 GB

The illustration shows the lower part of the control unit from the back.
230 V~ plugs
sÖ Heating circuit pump (heating cir-
cuit A1) (accessory)
sA Circulation pump for cylinder
heating (accessories)
sK DHW circulation pump (on site)
fÖ Power supply
fA Burner
X12 External burner start (stage 1)
Low voltage plug
!Outside temperature sensor
§Boiler water temperature sensor
%Cylinder temperature sensor
aG Flue gas temperature sensor
(accessories)
aVG KM BUS subscriber or KM BUS
distributor (accessories)
a:A Two-stage/modulating burner
extension (part of the standard
boiler delivery)
Overview of electrical connections
7
Installation sequence
5862 699 GB
Installation

&When connecting external switching
contacts or components to the low
voltage circuit of the control unit, the
safety requirements of protection
class II, i.e. 8.0 mm air gap/creeping
distance or 2.0 mm insulation thick-
ness from 'live' components must be
observed.
&For all on-site components (incl.
PC/laptops), ensure safe electrical
separation to EN 60 335 or IEC 65.
Inserting cables and applying strain relief
Blank off unnecessary knockouts in the lower part of the control unit with cable
grommets (not cut out).
Overview of electrical connections (cont.)
8
Installation sequence
5862 699 GB

Inserting the boiler coding card
Only use the boiler coding card included with the boiler product documentation
(see also table below).
Boiler Coding card Part no.
Vitola 200, type VB2A, VX2A E1 7818 915
Vitola 222 E1 7818 915
Vitoladens 300-T E1 7818 915
Vitocrossal 300, type CU3 Cb 7818 913
Inserting cables and applying strain relief (cont.)
9
Installation sequence
5862 699 GB
Installation

Insert the boiler coding card through
the cut-out in the cover into slot "X7".
Changing the high limit safety cut-out setting (if required)
In the delivered condition, the high limit safety cut-out is set to 110 °C and can
be adjusted to 100 °C.
Never set the thermostat above 75 °C when adjusting the temperature to
100 °C.
Inserting the boiler coding card (cont.)
10
Installation sequence
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AEGO slotted screw BJUMO slotted screw
Changing the thermostat setting (if required)
In the delivered condition, the thermostat is set to 75 °C and can be adjusted to
87 °C/95 °C.
Changing the high limit safety cut-out setting (if . . . (cont.)
11
Installation sequence
5862 699 GB
Installation

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 is operated in conjunction with a DHW cylinder, ensure that
the maximum permissible DHW temperature is not exceeded. If neces-
sary, install suitable safety equipment for this purpose.
1. Remove rotary selector "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 diagram.
3. Install rotary selector "R" so the
mark is between "75" and "90" or
"95". Turn rotary selector "R" fully
clockwise.
Changing the thermostat setting (if required) (cont.)
12
Installation sequence
5862 699 GB

AFlue gas temperature sensor
BBoiler water temperature sensor
CCylinder temperature sensor
DOutside temperature sensor
Installation point for outside temperature sensor
&North or north-western wall, 2 to
2.5 m above ground level; in multi-
storey buildings, in the upper half of
the second floor
&Not above windows, doors or venti-
lation outlets
&Not immediately below balconies or
gutters
&Never render over
Outside temperature sensor connection
2-core lead, up to 35 m long with a
cross-section of 1.5 mm
2
Connecting pumps
Available pump connections
sÖ Heating circuit pump A1
sA Circulation pump for cylinder
heating
sK DHW circulation pump
Connecting sensors
13
Installation sequence
5862 699 GB
Installation

Pumps 230 V~
APump
BTo the control unit
Rated current 4(2) A~
Recommended
connecting cable H05VV-F3G
0.75 mm
2
or
H05RN-F3G
0.75 mm
2
Pumps 400 V~
AContactor
BPump
For controlling the contactor
Rated current 4(2) A~
Recommended
connecting cable H05VV-F3G
0.75 mm
2
or
H05RN-F3G
0.75 mm
2
Connecting pumps (cont.)
14
Installation sequence
5862 699 GB

Variable speed pumps
Connect via plug aVG in the control
unit or in the KM BUS distributor.
External connection to plug "X12"
!Please note
'Live' contacts lead to short circuits or phase failure.
The external connection must be zero volt.
AExternal start (zero volt contact)
External burner start (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 ther-
mostat.
Rated voltage 230 V~
Rated current 6 A~
Recommended
connecting cable
H05VV-F3G
0.75 mm
2
Burner connection
Pressure-jet oil/gas burners
The burner cable is included in the standard delivery of the boiler.
Connect the burner in accordance
with DIN 4791 [or local regulations].
Max. power consumption 4 (2) A.
Connecting pumps (cont.)
15
Installation sequence
5862 699 GB
Installation

ATo the control unit
BTo the burner
Terminal codes
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 thermostat
H1 Burner fault signal
BZ Hours run meter
Burner without plug
Install the mating plug from
Viessmann or from the burner manu-
facturer; connect the burner cable.
Extension with a two-stage/modulating burner, part no. 7404
960
The function extension is supplied with the boiler.
Max. power consumption
&Two-stage: 1 (0.5) A
&Modulating: 0.1 (0.05) A
Observe coding addresses "02", "10" to "13", "15" to "18", "1A", "26" and "29"
(see overview).
Burner connection (cont.)
16
Installation sequence
5862 699 GB

ATo the control unit
BTo the burner
CJunction box with relay K1 and K2
Terminal codes
T6, T7, T8 Control chain "Burner
stage 2 or modulation con-
troller" (for two-stage
operation via two-point
controller; for modulating
operation via three-point
controller)
T6 From the burner
T7 Mod. burner closed
T8 Mod. burner open/stage 2
on
~Signal pass direction:
Control unit →burner
|Signal pass direction:
Burner →control unit
Colour coding to DIN IEC 60 757
BK black
BN brown
BU blue
Power supply
Directives
Regulations
Carry out the power supply connec-
tion and all earthing measures (i.e.
RCD 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 16 A max. rated
fuse.
Burner connection (cont.)
17
Installation sequence
5862 699 GB
Installation

Main isolator requirements (if required)
For combustion equipment to DIN
VDE 0116, the main isolator installed
on site must comply with the require-
ments of DIN VDE 0116 "section 6" [or
local regulations].
Fit the main isolator outside the instal-
lation room; it must be able to sepa-
rate all non-earthed conductors
simultaneously with a gap of 3 mm at
least.
Replacing the power supply cable
Three-core cable selected from the
following options:
&H05VV-F3G 0.75 mm
2
&H05RN-F3G 0.75 mm
2
Connection
APower supply 230 V~
BFuse (max. 16 A~)
CMain isolator, two-pole (on-site)
DJunction box (on-site)
1. Check whether the power supply
cable to the control unit has appro-
priate fuse protection.
2. Connect the power supply cable
inside the wiring chamber.
Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Take care not to interchange
wires "L1" and "N":
L1 brown
Nblue
PE green/yellow
3. Insert plug fÖ into the control unit.
Power supply (cont.)
18
Installation sequence
5862 699 GB

Colour coding to DIN IEC 60757 BN brown
BU blue
GNYE green/yellow
Fitting the top part of the control unit
!Please note
To prevent damage to the PCB,
switch off the control unit
power supply.
Power supply (cont.)
19
Installation sequence
5862 699 GB
Installation

Fitting the top part of the control unit (cont.)
20
Installation sequence
5862 699 GB