Viessmann VITOTRONIC 200 Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitotronic 200
Type KO1B, KO2B
Weather-compensated, digital boiler control unit
For applicability, see the last page
VITOTRONIC 200
5458 905 GB 12/2014 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 author-
ised 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 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 the protection of the envi-
ronment
■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-TR Gas, 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.
Danger
Hot surfaces can cause burns.
■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 your
system.
Replace faulty components only with genuine
Viessmann spare parts.
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.
■Never 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).
Safety instructions
Safety instructions
5458 905 GB

3
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.
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 causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the structural conditions 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.
Apertures for supplying combustion air must be
non-closable.
Extractors
Operating appliances that route exhaust air outdoors
(cooker hoods, extractors, air conditioning units, etc.)
can create negative 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 route exhaust air outdoors can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5458 905 GB

4
1. Information Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 7
2. Vitotronic control unit
installation
Installing the control unit base ............................................................... 8
Fitting the top of the control unit for type KO1B ..................................... 8
Opening the control unit ......................................................................... 9
■Type KO1B ......................................................................................... 9
■Type KO2B ......................................................................................... 10
Plugging in the coding card ................................................................... 10
Adjusting the high limit safety cut-out (if required) ................................. 10
■Type KO1B ......................................................................................... 11
■Type KO2B ......................................................................................... 12
Adjusting the temperature controller (if required) .................................. 13
■Type KO1B ......................................................................................... 14
■Type KO2B ......................................................................................... 14
3. Electrical connections Overview of electrical connections ........................................................ 15
Inserting cables/leads and applying strain relief .................................... 16
Connecting the sensors ......................................................................... 16
■Fitting and connecting an outside temperature sensor ....................... 16
Connecting the pumps ........................................................................... 17
■Available pump connections ............................................................... 17
■Pumps 230 V~ .................................................................................... 17
■Pumps 400 V~ .................................................................................... 18
External burner start .............................................................................. 18
Provisional burner operation .................................................................. 18
External demand via switching contact .................................................. 19
■Connection ......................................................................................... 19
■Codes ................................................................................................. 19
External demand via 0 – 10 V input ....................................................... 19
External blocking via switching contact ................................................. 20
■Codes ................................................................................................. 21
Connecting a pressure-jet oil/gas burner ............................................... 21
Extending two-stage/modulating burners, part no. 7404 960 ................ 21
Connecting an atmospheric burner ........................................................ 22
■Extension, two-stage burner, part no. 7827 417 ................................. 23
Power supply ......................................................................................... 24
■Power supply for several accessories ................................................ 25
■Control unit power supply ................................................................... 26
4. Commissioning Testing the high limit safety cut-out ........................................................ 27
■Type KO1B ......................................................................................... 27
■Type KO2B ......................................................................................... 27
Changing the language .......................................................................... 27
Setting the date and time ....................................................................... 28
Adjusting coding addresses ................................................................... 28
Adjusting heating curves ........................................................................ 28
■Set room temperature, adjusting ........................................................ 29
■Changing the slope and level ............................................................. 30
Connecting the control unit to the LON .................................................. 31
■Example of a single boiler system with Vitotronic 200-H and
Vitocom 200 ........................................................................................ 31
■Carrying out a LON subscriber check ................................................. 32
Entering a service PIN for LON subscribers .......................................... 32
Entering a PIN for Vitocom 100, type GSM2 ......................................... 32
5. Coding levels Calling up coding levels ......................................................................... 33
Leaving the coding level ........................................................................ 33
Resetting codes to their delivered condition .......................................... 33
Index
Index
5458 905 GB

5
6. Coding level 1 "General" group ..................................................................................... 34
■Coding ................................................................................................ 34
"Boiler" group ......................................................................................... 35
■Coding ................................................................................................ 35
"DHW" group ......................................................................................... 36
■Coding ................................................................................................ 36
"Solar" group .......................................................................................... 36
"Heating circuit 1", "Heating circuit 2", "Heating circuit 3" group ........... 37
■Coding ................................................................................................ 37
7. Coding level 2 "General" group ..................................................................................... 41
■Coding ................................................................................................ 41
"Boiler" group ......................................................................................... 44
■Coding ................................................................................................ 44
"DHW" group ......................................................................................... 46
■Coding ................................................................................................ 46
"Solar" group .......................................................................................... 47
■Coding ................................................................................................ 47
"Heating circuit 1", "Heating circuit 2", "Heating circuit 3" group ........... 50
■Coding ................................................................................................ 50
8. Service scans Calling up the service menu .................................................................. 55
Closing the service menu ...................................................................... 55
Scanning operating data ........................................................................ 55
Resetting operating data ........................................................................ 56
Brief scan ............................................................................................... 56
Carrying out an actuator test ................................................................. 57
Checking the sensors ............................................................................ 58
Service indicator .................................................................................... 58
■Acknowledging the service display ..................................................... 58
■Calling up acknowledged service messages ...................................... 59
9. Troubleshooting Fault display ........................................................................................... 60
■Acknowledging a fault display ............................................................ 60
■Calling up acknowledged fault messages .......................................... 60
■Calling up fault codes from the fault memory (fault history) ............... 60
Fault messages ..................................................................................... 60
Faults that are not displayed at the programming unit .......................... 65
■Boiler cold, burner does not start ........................................................ 65
■Boiler water temperature is too high or too low .................................. 65
■Boiler hot enough, but the heating circuit pump connected to the
control unit is not running ................................................................... 65
10. Parts lists Ordering parts ........................................................................................ 67
Parts list type KO1B ............................................................................... 68
Parts list type KO2B ............................................................................... 72
11. Function description Boiler water temperature control ............................................................ 76
■Brief description .................................................................................. 76
■Functions ............................................................................................ 76
■Control sequence for burner switching hysteresis of 4 K ................... 77
Heating circuit control unit ..................................................................... 77
■Brief description .................................................................................. 77
■Functions ............................................................................................ 77
■Control sequence ............................................................................... 81
Cylinder temperature control ................................................................. 82
■Brief description .................................................................................. 82
■Functions ............................................................................................ 82
■Control sequence ............................................................................... 83
Index
Index
5458 905 GB

6
12. Components Coding card ........................................................................................... 84
Fuse ....................................................................................................... 84
Sensors .................................................................................................. 84
■Boiler water, cylinder, buffer, flow and room temperature sensors ..... 84
■Outside temperature sensor ............................................................... 85
■Flue gas temperature sensor, part no. 7452 531 ................................ 85
Radio clock receiver .............................................................................. 86
■Connection ......................................................................................... 86
■Checking the reception ....................................................................... 87
■Specification ....................................................................................... 87
Mixer extension kit ................................................................................. 87
■Rotary selector setting ........................................................................ 88
■Specification ....................................................................................... 89
■Mixer motor, part no. 7450 657 ........................................................... 89
■Checking the rotational direction of the mixer motor .......................... 89
■Changing the rotational direction of the mixer motor .......................... 90
Temperature limiter for restricting the maximum temperature ............... 90
EA1 extension, part no. 7452 091 ......................................................... 91
■Digital inputs DE1 to DE3 ................................................................... 91
■Analogue input 0 – 10 V ..................................................................... 92
■Output aBJ .......................................................................................... 92
External extension H5, part no. 7199 249 ............................................. 93
■External burner blocking ..................................................................... 93
■External safety equipment .................................................................. 93
■Temporary operation (burner stage 1) ................................................ 93
■Motorised flue gas damper ................................................................. 94
Vitoair draught stabiliser, part no. 7338 725, 7339 703 ......................... 95
■Function check ................................................................................... 95
■Motor faulty ......................................................................................... 95
13. System examples Designations in the system examples ................................................... 96
System example 1, ID: 4605372_1404_04 ........................................... 97
■One heating circuit without mixer and one heating circuit with mixer
plus DHW heating ............................................................................... 97
System example 2, ID: 4605373_1404_04 ........................................... 101
■One heating circuit without mixer and 2 heating circuits with mixer
plus DHW heating (optional solar DHW heating) ............................... 101
System example 3, ID: 4605377_1404_04 ........................................... 106
■Single boiler system: Vitogas with one heating circuit with mixer and
shunt pump for raising the return temperature ................................... 106
System example 4, ID: 4605378_1404_04 ........................................... 110
■Single boiler system: Vitogas with one heating circuit with mixer, dis-
tribution pump and low pressure distributor ........................................ 110
14. Connection and wiring dia-
gram
.................................................................................................................. 114
15. Specification .................................................................................................................. 115
16. Settings and equipment .................................................................................................................. 116
17. Keyword index .................................................................................................................. 119
Index
Index (cont.)
5458 905 GB

7
Symbol Meaning
Reference to other document containing
further information
Additional information, not safety relevant
1.
Step in a diagram:
The numbering corresponds to the se-
quence of work.
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.
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 Vitotronic 200, type KO1B and KO2B for
weather-compensated operation are designed for use
in single boiler systems.
One heating circuit without mixer and 2 heating circuits
with mixer can be controlled.
Standard delivery
■Control unit base and top
■Outside temperature sensor
■Boiler water temperature sensor
■Cylinder temperature sensor
■Power cable
Information
Symbols
5458 905 GB
Information

8
Boiler installation instructions
Fitting the top of the control unit for type KO1B
!Please note
'Live' voltage can lead to PCB damage.
Switch OFF the power supply at the control unit.
7.
4.
3.
2.
5. 1.
6.
Fig.1
Vitotronic control unit installation
Installing the control unit base
5458 905 GB
Installation

9
Type KO1B
1.
2.
3.
Fig.2
Vitotronic control unit installation
Opening the control unit
5458 905 GB
Installation

10
Type KO2B
Fig.3
Plugging in the coding card
Only insert the boiler coding card supplied with the
boiler pack (see table on page 84).
915 531145
Fig.4
Insert the boiler coding card through the opening in the
cover into slot "X7".
Adjusting the high limit safety cut-out (if required)
The high limit safety cut-out is set to 110 °C in the
delivered condition. It can be reset to 100 °C.
Note
The temperature value cannot be set back.
Vitotronic control unit installation
Opening the control unit (cont.)
5458 905 GB
Installation

11
When adjusting the safety cut-out to 100 °C, never set
the temperature controller higher than 75 °C.
Type KO1B
95
100
110
120
°C B
4.
3.
A
1.
2.
Fig.5
ASlotted screw for EGO products
BSlotted screw for JUMO products
Vitotronic control unit installation
Adjusting the high limit safety cut-out (if… (cont.)
5458 905 GB
Installation

12
B4.
3.
A1.
2.
°C
95
110
120
110
95
Fig.6
ASlotted screw for Rathgeber products
BSlotted screw for JUMO products
Type KO2B
1.
3.
2.
Fig.7
Vitotronic control unit installation
Adjusting the high limit safety cut-out (if… (cont.)
5458 905 GB
Installation

13
B
95
100
110
120
°C
1.
A
Fig.8
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
Never set the temperature controller 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 with a DHW cylinder,
the maximum permissible DHW temperature
must not be exceeded. If necessary, install suit-
able safety equipment for this purpose.
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 sits
between "75" and "90" or "95". Turn rotary selector
" " clockwise as far as it will go.
Vitotronic control unit installation
Adjusting the high limit safety cut-out (if… (cont.)
5458 905 GB
Installation

14
Type KO1B
1.
3.
2.
Fig.9
Type KO2B
X12
1.
2.
3.
Fig.10
Vitotronic control unit installation
Adjusting the temperature controller (if… (cont.)
5458 905 GB
Installation

15
Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
■Route LV leads < 42 V and cables
> 42 V/120 V~/230 V~ separately.
■Only strip the minimum of insulation from
cables, as close to the terminals as possible,
and bundle tightly to the corresponding termi-
nals.
■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 static
loads.
Prior to commencing work, touch an earthed
object such as a heating or water pipe to dis-
charge static load.
For opening the control unit, see page 9.
aVG% §aG
B
) ! Q
M
1~
L
N
fÖ lH
230 V~ 230 V~
sÖ
M
1~
sA
L
N1LN L NLN
N
L1 sK
LN
M
1~
A
41 191
Fig.11
AMCB/fuse
BCoding card slot
Connections on the low voltage PCB
Plug Component
!Outside temperature sensor/radio clock receiver (accessories)
§Boiler water temperature sensor
%Cylinder temperature sensor
) Buffer temperature sensor (accessories)
aG Flue gas temperature sensor (accessories)
aVG KM BUS subscriber (accessories), e.g. EA1 extension
a:A Two-stage/modulating burner extension (part of the standard boiler delivery)
PCB connections 230 V~
Plug Component
sÖ Heating circuit pump A1 for heating circuit 1
sA Circulation pump for cylinder heating (DHW cylinder accessory)
sK DHW circulation pump
fÖ Power supply
Electrical connections
Overview of electrical connections
5458 905 GB
Installation

16
Plug Component
fA Burner
lH Power supply for accessories
X12 External burner start, stage 1
Inserting cables/leads and applying strain relief
Blank off unnecessary apertures in the lower part of
the control unit with cable grommets (not cut out).
Cable with cast-on cable entry Cable without cast-on cable entry
2.
3.
1.
2.
1.
Connecting the sensors
Low voltage connections at the PCB (see page 15)
Plug Component
!Outside temperature sensor/radio clock receiver (accessories)
§Boiler water temperature sensor
%Cylinder temperature sensor
) Buffer temperature sensor (accessories)
aG Flue gas temperature sensor (accessories)
Fitting and connecting an outside temperature sensor
Fitting location for outside temperature sensor
■North or north-westerly 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 ventilation outlets.
■Not immediately below balconies or gutters.
■Never render over.
Outside temperature sensor connection
2-core lead, length up to 35 m with a cross-section of
1.5 mm2
Electrical connections
Overview of electrical connections (cont.)
5458 905 GB
Installation

17
Wireless outside temperature sensor
"Wireless base station" installation and service
instructions
Connecting the pumps
Available pump connections
Connections on the 230 V~ PCB
Plug Component
sÖ Heating circuit pump for heating circuit HC1/A1
sA Circulation pump for cylinder heating
sK DHW circulation pump
Pumps 230 V~
B
A
1~
M
Fig.12
APump
BTo the control unit
Rated current 4(2) A~
Recommended connecting
cable
H05VV-F3G 0.75 mm2
or
H05RN-F3G 0.75 mm2
Pumps with power consumption greater than 2 A
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
details)
Electrical connections
Connecting the sensors (cont.)
5458 905 GB
Installation

18
Pumps 400 V~
LN L1 L2 L3 N PE
A
C
3~
M
B
Fig.14
APump
BTo the control unit
CContactor
For switching the contactor
Rated current 4(2) A~
Recommended connecting
cable
H05VV-F3G 0.75 mm2
or
H05RN-F3G 0.75 mm2
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.15
AExternal starting (floating contact)
If the contact is closed, burner stage 1 is started and
the boiler water temperature is limited by the tempera-
ture controller.
Rated voltage 230 V~
Rated current 6 A~
Recommended connecting
cable
H05VV-F3G 0.75 mm2
Provisional burner operation
Insert jumper across terminals 1 and 2 of plug "X12".
X12
21
Fig.16
Burner stage 1 is started. The boiler water temperature
is limited by the temperature controller.
Electrical connections
Connecting the pumps (cont.)
5458 905 GB
Installation

19
Connection options:
■Plug lH
■EA1 extension (accessories, see page 91)
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
B
lH
N
?
1L
AFloating contact
BPlug lH
Rated voltage 230 V~
Rated current 10 mA~
Recommended connecting cable H05VV-F3G 0.75 mm2
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 the "General" group. The boiler water temperature is limited by this set value and the
electronic maximum limit (coding address "06" in the "Boiler" group).
Codes
Plug lH EA1 extension
"40:1" in the "General" group Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) in the "General" group to 2.
■Set the effect of the function on the relevant heating circuit pump in coding address "d7" in the "Heating cir-
cuit" group.
■Select the effect of the function on the circulation pump for cylinder heating in coding address "5F" in the
"DHW" group.
External demand via 0 – 10 V input
Connection at input 0 – 10 V to EA1 extension (see
page 91).
Ensure DC separation between the earth conductor
and the negative pole of the on-site voltage source.
Note coding address "1E" in the "General" group.
Electrical connections
External demand via switching contact
5458 905 GB
Installation

20
U
+
LNL
N
fÖ
SP
aBJ
Ö
[{{]
0-10V f-]
A
+ -
Fig.17
0–1 V ≙ No default set boiler water temperature
1 V ≙ Set value 10 °C
10 V ≙ Set value 100 °C
External blocking via switching contact
Connection options:
■Plug lH
■EA1 extension (accessories, see page 91)
■Plug aBÖ of external extension H5 (accessories, see
page 93).
!Please note
'Live' contacts lead to short circuits or phase fail-
ure.
The external connection must be potential-
free.
Plug aBÖ Plug lH EA1 extension
STB
A
B
EIN
TR
EIN
TR
NSTB
AFloating contact
BRemove jumper "TR" – "ON/TR"
A
B
lH
N
?
1L
AFloating contact
BPlug lH
B
[{S
DE [{D DE
[{A
DE
A
AFloating contact
BEA1 extension
When contact is open, the burner is
switched OFF.
Note
Connect only safety shutdown
equipment, e.g. a temperature limit-
er, to these terminals.
When the contact is closed, the burner is switched OFF. The heating cir-
cuit pump and circulation pump for cylinder heating are switched accord-
ing to the set code (see the following table "Codes").
Electrical connections
External demand via 0 – 10 V input (cont.)
5458 905 GB
Installation