Viessmann KW10 Dimensions and installation guide

VITOTRONIC 100
Installation, Start-up
and Service Instructions
Vitotronic 100
Model KW10
Boiler control unit
for modulating temperature heating systems
Part No. 7133 375
ertified as a component part
of Viessmann boilers only
Read and save these instructions
for future reference.
IMPORTANT
5167 483 v1.4 08/2010
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safet , Installation and Warrant Requirements
Please ensure that this manual is read and understood before commencing installation. Failure to compl with the issues listed
below and details printed in this manual can cause product/propert damage,severe personal injur , and/or loss of life. Ensure all
requirements below are understood and fulfilled (including detailed information found in manual subsections).
HLicensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
"
Please see sections
entitled “Safety” and
“Important Regulatory and
Installation Requirements”.
HProduct documentation
Read all applicable documentation
before commencing installation. Store
documentation near boiler in a readily
accessible location for reference in the
future by service personnel.
"
For a listing of applicable
literature, please see
section entitled “Important
Regulatory and Installation
Requirements”.
HAdvice to owner
Once the installation work is complete,
the heating contractor must familiarize
the system operator/ultimate owner
with all equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before the
heating season begins.
HWarrant
Information contained in this and
related product documentation must be
read and followed. Failure to do so
renders warranty null and void.
5167 483 v1.4

ontents
3
Page
Important Precautions Safet 4
................................................................................................
Important Regulator and Installation Requirements 5 ....
General Information About these Installation Instructions 5
...................................
Valid for ... 5 ......................................................................................
Heating S stem S stem Configuration
One direct-connected heating circuit
without mixing valve 6 ..................................................................
Electrical Connections Opening the Control 7
....................................................................
Overview 8 ..........................................................................................
Routing Cabling 9 .............................................................................
Power Suppl 9 .................................................................................
Burner Connection 10 .......................................................................
Room Thermostat Connection 10 ................................................
Pump Connection 11 .........................................................................
Installation of Outdoor Temperature Sensor 12 ....................
Altering Settings Fixed High Limit 13
............................................................................
Testing the FHL 13 ............................................................................
Adjustable High Limit 14 .................................................................
Dip Switch Settings 15 ....................................................................
Altering the Indoor/Outdoor Control Settings 16 ...................
Slope adjustment 16 ...........................................................................
Warm weather shut-down adjustment 17 ................................
Appendix After Installation ... 18
......................................................................
hecklist 18 ..........................................................................................
Service Binder 18 ................................................................................
Start-up Start-up Instructions 18
...................................................................
heck all connections 18 ................................................................
Set fixed high limit and adjustable high limit 18 ...................
Set correct operational settings on control 18 ........................
Troubleshooting Diagnostics 19
......................................................................................
(for qualified service personnel only)
Failure, ause, orrection 19 ........................................................
Electrical connections and sequence of operation 20 .........
Additional Information Replacement Components
(for qualified service personnel only) 22 ...................................
Boiler Protection 24 .............................................................................
Parts List 28 ...........................................................................................
Wiring Diagram 29 ...............................................................................
Technical Data 30 ................................................................................
Protocol 30 .............................................................................................
5167 483 v1.4

Important Precautions
4
Safet
Take note of all s mbols and notations intended to draw attention to potential hazards or important product information.
These include ”WARNING,” ”CAUTION,” and ”IMPORTANT.” See page 5 for details.
Approvals
Viessmann boilers, burners and
controls are approved for sale in North
America by SA International.
Codes
The installation of this unit shall be in
accordance with local codes. In the
absence of local codes, use:
HSA 22.1 Part 1 and/or local codes
in anada
HNational Electrical ode ANSI/NFPA
70 in the U.S.
Always use latest editions of codes.
Please carefully read this manual prior
to attempting installation. ny
warranty is null and void if these
instructions are not followed.
For information regarding other
Viessmann System Technology
componentry, please reference
documentation of the respective
product.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
Working on the equipment
The installation, adjustment, service,
and maintenance of this product must
be done by a licensed professional
heating contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water boilers.
There are no user serviceable parts on
the boiler, burner, or control.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main oil or gas suppl valve.
Take precautions in both instances to
avoid accidental activation of power
during service work.
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include low
water cut-offs, flow switches (if used),
staging controls, pumps, motorized
valves, air vents, thermostats, etc.
Technical literature
Literature applicable to all aspects of
the Vitotronic 100:
- Technical Data Manual
- Installation, Start-up
and Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of other Viessmann
products utilized and installed
- Installation codes mentioned
in this manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
5167 483 v1.4
Turn off electric power
suppl before
servicing. Contact with
live electric
components can cause
shock or loss of life.
WARNING

Important Precautions / General Information
5
Important Regulator and Installation Requirements
Power suppl
Install power supply in accordance with
the regulations of the authorities
having jurisdiction or, in the absence of
such requirements, in accordance with
National odes. Viessmann
recommends the installation of a
disconnect switch to the 120 VA
power supply outside of the boiler
room. The installer must provide
maximum 15 A overcurrent protection
for the 120 VA power supply (fuse or
circuit breaker).
Note on connecting external
“potential-free” contacts to the
Vitotronic 100 control’s 24 VAC
thermostat connections
Ensure that all contacts have sufficient
insulation clearance to live parts and
are certified for these applications.
A room thermostat or other
potential-free contact (i.e. end switch
of a zone valve) must be connected to
the Vitotronic 100 thermostat
connections.
Working with an open control
No static discharge to the internal
componentry must ever occur when
working with opened control
equipment.
About these Installation Instructions
Take note of all s mbols and notations intended to draw attention to potential hazards or important product information.
These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation,
operation or maintenance which
pertain to the product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
Valid for ...
Applies to Vitotronic 100, Model KW10:
Order No. 7133 375, starting with serial no. V00101
This control shall onl be installed with the Vitola 200, Vitorond 200,
Vitogas 050, RS Series, or with a Vitogas 100 hot water heating boiler.
5167 483 v1.45167 483 v1.4
Indicates an imminentl hazardous
situation which, if not avoided, could
result in death, serious injur or
substantial product/propert damage.
WARNING
Indicates an imminentl hazardous
situation which, if not avoided, ma
result in minor injur or
product/propert damage.
CAUTION
IMPORTANT

Heating System
6
S stem Configuration
One direct-connected heating circuit without mixing valve
Boiler with
Vitotronic 100, Model KW10
Heating circuit
System pump
Room thermostat
Outdoor temperature sensor
120 VAC connections
Power supply cord,
120 VA , 60 Hz
Burner connection
Pump connection
(used with:
Vitorond 200,
Vitogas 050, RS Series, and
Vitogas 100 boilers onl )
Required equipment
Description Quantity Order No.
Vitotronic 100, Model KW10 1 7133 375
Optional equipment
Description Quantity Order No.
DHW Pump Module for domestic hot water production using a
Viessmann Vitocell indirect-fired domestic hot water storage tank
1 9543 431
5167 483 v1.4
TH OTS

Electrical onnections
7
Opening the Control
1. Open front cover.
2. arefully unlock control top cover
using a screw driver and flip open
top cover.
5167 483 v1.4
1.
2.
2.

Electrical onnections
8
Overview
The control is pictured from the rear.
120 VAC connections
for power supply cord
120 VA , 60 Hz
for burner connection
Pump connection
FHL test connection
A B Test
24 VAC connections
Room thermostat connection
X2.1, X2.2
Dip switches
Outdoor temperature sensor
(field wired) and
boiler sensor connection
1 / 3
5167 483 v1.4

Electrical onnections
9
Routing Cabling
Strain relief clamps are located in the
fittings package supplied with the
control.
1. Remove breakouts as necessary.
2. Mount lower portion of strain relief
clamp.
3. ut rubber grommet (if applicable).
4. Insert rubber grommet in strain
relief and mount strain relief.
5. Fasten top portion of strain relief.
6. lose off openings in the control
which are not being used.
Rubber grommets ma alread be
mounted on cabling.
Power Suppl
Follow instructions under Important
Regulatory and Installation
Requirements.
1. Feed the power supply cord with
3-prong molded plug through rear
top panel wiring gate of the boiler.
2. Slide cable into the strain relief and
secure with strain relief set screw.
3. Plug power supply cord into
receptacle. Ensure receptacle is
designated for the heating system
only.
5167 483 v1.4
2.
1.
4.
5.
3.
6.
IMPORTANT

Electrical onnections
10
Burner Connection
to control
(RAST-5 plug)
to burner or wall vent system
(plug)
The Vitotronic 100 is prewired with the
Viessmann quick-connect plug-in
system.
1. onnect the RAST-5 plug to the
main circuit board of the control
(see page 8)
2. onnect 7-pole plug to the
counter plug of the burner
or
if installing a wall vent system
(accessory), connect 7-pole plug to
counter plug of wall vent system.
Refer to technical instructions
of the burner and/or wall vent
system
Room Thermostat Connection
The main circuit board is pictured from the top.
A room thermostat or end-switches
from zone valves (in multi-zone
systems) can be connected to the room
thermostat connection. onnection
must be potential-free (”dry contact”).
1. Feed the cabling from the room
thermostat through rear top panel
wiring gate of the boiler. Use 2
conductor AWG 18 copper wire
only.
2. Slide cable into the strain relief and
secure with strain relief set screw.
3. onnect wires to main circuit board
as shown.
4. Set thermostat anticipator to 0.1 A.
5167 483 v1.4
Do not connect the 41-plug from the
boiler control directl to the burner if
installing a wall vent s stem.
See technical instructions of the wall
v
e
n
t
s
s
t
e
m
.
WARNING