Viessmann KW10 Guide

VITOTRONIC 100
Operating Instructions
and User’s Information Manual
Vitotronic 100
Model KW10
Boiler control unit
for modulating temperature heating systems
Part No. 7133 375
Certified as a component part
of Viessmann boilers only
Read and save these instructions
for future reference.
IMPORTANT
5167 484 v1.1 09/2007
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty Requirements
Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed
below and details printed in this manual can cause product/property damage,severe personal injury,and/orloss 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”
in the Installation,
Start-up and Service Instructions.
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” in the
Installation, Start-up and Service
Instructions.
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.
HWarranty
Information contained in this and
related product documentation must be
read and followed. Failure to do so
renders warranty null and void.
HSafety requirements
For safety information on carbon
monoxide and frozen water pipe
hazards, please refer to page 11 in
these instructions.
About these Instructions
Take note of all symbols 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.
5167 484 v1.1
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT

Operation
3
Overview of Display Elements
Slope adjustment (page 6)
Warm weather shut-down adjustment
(page 7)
Boiler temperature gage
Adjustable high limit (Page 5)
Power switch (Page 4)
Space heating switch (Page 5)
Fuse F1 T 6.3 A / 250 V
Fixed high limit
LED: Burner status indicator*
LED: Power indicator
LED: Burner fault indicator*
*Not available on the following boiler models:
Vitogas 100, GS1; Vitogas 100, GS10 and Vitogas 050, RS (natural gas only)
Location of Controls
The control is located behind the flip-down cover.
Open the flip-down cover by carefully pulling it forward from the top.
Close the flip-down cover when finished all operations.
5167 484 v1.1

Operation
4
Starting-Up the Heating System
The initial start-up and set-up of the control must be done by a licensed
professional heating contractor.
We strongly recommend a service visit if reactivating the heating system after an
extended shut-down.
1. Check the pressure of the heating
system on the pressure gage .An
operating pressure of 15 psi is
typical - consult your heating
contractor. Take corrective actions if
necessary.
2. Ensure proper/adequate fuel supply
exists; open oil or gas shut-off valve.
3. Activate power to heating system
(from, for example, a switch located
external to the mechanical room).
4. Activate power on boiler
control “ .“
The green power indicator
illuminates.
5. Set room thermostat (or other heat
demand control) to desired
temperature.
A call for heat causes the red burner
status indicator to illuminate.
Your heating system is now ready for operation.
Shutting-Down the Heating System
If it is likely that the heating system will not be used for an extended period of
time, we recommend a full shut-down.
We strongly recommend a service visit if deactivating the heating system after an
extended operating period. This ensures preventative service measures such as
heat exchanger cleaning and burner calibration are undertaken.
1. Deactivate power on boiler
control “ .“
The green power indicator
deactivates.
2. Close oil or gas shut-off valve on the
tank (if applicable) and near the
burner.
3. Deactivate power to heating system
(from, for example, a switch located
external to the mechanical room).
5167 484 v1.1
In this circumstance, the control is
completely deactivated and the system
will not respond in the event of cold
weather conditions.
CAUTION

Operation
5
Altering the Maximum Boiler Water Temperature
The adjustable high limit (AHL) limits the maximum boiler water temperature when
a call for heat is made. The call for heat is typically made by a room thermostat.
Select an appropriate boiler water temperature (based upon advice from your
heating contractor).
The factory default setting is between 104 and 167°F / 40 and 75°C.
An elevated setting between 104 and 212°F / 40 and 100°C is possible if an
adjustment has been made by the heating contractor.
Turn selector to the right
(clockwise)
or
Turn selector to the left
(counter-clockwise)
Boiler water temperature limit
increases.
Boiler water temperature limit
decreases.
Space Heating Circuit Switch
The space heating circuit switch is only operational if a Viessmann
DHW Pump Module (Accessory) is installed and connected to the control.
For heating systems with domestic hot
water production:
HWinter operation:
for space heating and DHW
production, set space heating circuit
switch “ ”to“ .”
HSummer operation:
for DHW production only, set space
heating circuit switch “ ”to“ .”
5167 484 v1.1
Space heating pump is fully disabled; it
will not reactivate during cold weather
conditions.
CAUTION

Operation
6
Altering the Indoor/Outdoor Control Settings
The adjustable high limit determines the maximum available boiler (supply)
temperature. Therefore, it functions as a high limit.
The room thermostat (if used) enables and disables the outdoor reset processor in
order to add indoor control (fine tuning) to the outdoor reset function.
The curve for the outdoor reset function can be adjusted by opening the front
flip-down cover.
Factory settings
Heating curve slope
““
selection = 1.2
Warm weather shut-down (WWSD)
““
selection = 70 °F / 21 °C
If there is no call for heat from the room
thermostat, the burner will not be
activated, even if the heating curve
setting calls for a higher temperature.
Slope adjustment
As outdoor temperatures drop, heat
losses from a space become greater and
the heating system supply water
temperature must be raised to maintain a
constant room temperature. The heating
curve value describes how many degrees
the supply water temperature is raised for
a one degree drop in outdoor
temperature. The supply temperature
starts to increase when the outdoor
temperature falls below the warm
weather shut-down (WWSD) setting.
To calculate the correct setting for the
heating curve, use the following formula:
heating curve slope =
design supply temp. - WWSD temp.
WWSD temp. - design outdoor temp.
Example:
design outdoor temp.: 5 ˚F/-15˚C
WWSD temperature: 70 ˚F/21˚C
design supply temp.: 160 ˚F/71˚C
heating curve slope =
160 ˚F-70˚F90˚F
==1.4
70 ˚F-5˚F65 ˚F
For further assistance, please see section
entitled “Helpful hints.”
5167 484 v1.1
IMPORTANT

Additional Safety Requirements
7
Altering the Indoor/Outdoor Control Settings (Continued)
Warm weather shut-down adjustment
The reset function starts at the warm
weather shut-down (WWSD) point and
supplies increasingly more heat to a
building to make up for the greater heat
loss as outdoor temperatures get colder.
When the outdoor temperature rises
above the setting of the WWSD dial, no
more heat is required by the control, and
the boiler will be shut down. The WWSD
dial setting shifts the heating curve up or
down in parallel, increasing or decreasing
the system supply water temperature
(and consequently, the indoor air
temperature) at all outdoor temperatures.
If the indoor air temperature is too hot or
too cold at all outdoor temperatures, the
WWSD setting is probably incorrect and
should be checked and adjusted to suit
your requirements.
For further assistance, please see section
entitled “Helpful hints.”
5167 484 v1.1

Operation
8
Altering the Indoor/Outdoor Control Settings (Continued)
Helpful hints
Alter your heating curve, if ... Type of alteration
...heat output is insufficient when
outdoor temperatures are cold, but
adequate during spring and fall
...heat output is toohighwhen
outdoor temperatures are cold, but
adequate during spring and fall
Increase the value of the “slope” to
the next level.
Decrease the value of the “slope” one
level.
...heat output during spring and fall
is inadequate, but sufficient when
outdoor temperatures are cold
...heat output during spring and fall
is too high, but sufficient when
outdoor temperatures are cold
In Figure the “WWSD” of the
heating curve is raised one level, in
Figure the “slope” is lowered one
level.
In Figure the “WWSD” of the
heating curve is lowered one level, in
Figure the “slope” is raised one
level.
1
2
1
2
5167 484 v1.1

Operation
9
Diagnostics
Failure, Cause, Correction
Failure Cause Correction
Heating system does not activate
(only GREEN power LED is
illuminated)
Thermostat is not set to a
sufficiently high temperature
Adjust thermostat.
Heating system does not activate
(GREEN power LED is not
illuminated)
Power switch “ “ is in “ “
position
Ensure power switch “ “ is in “ “ position.
Main power to boiler control and
heating system has not been
activated
Activate main power; ensure 120 VAC is
supplied to control (receptacle).
Fuse on Vitotronic boiler control
has deactivated heating system
Replace fuse with same type and rating
(F1: T 6.3 A / 250 V, slow blow).
Burner does not activate, or
activates intermittently
(RED fault LED flashes)
Fixed high limit (FHL) tripped Reset FHL by pushing in the pin, labelled with a
“ “ (using a ballpoint pen).
If a “click” can be heard, the limit was tripped.
If the limit requires multiple resets, please
contact your heating contractor immediately.
No fuel *1 with oil: Ensure sufficient supply of oil
with gas: Open main gas supply valve
or
contact your local gas utility
Control calls for heat but burner
does not respond *1
Attempt to reset burner using reset button on
the burner (underneath burner hood).
If still unsuccessful, please contact your heating
contractor.
Burner does not start Power venter (if installed) will not
activate or is defective
Contact your heating contractor.
*1Red LED does not flash when Honeywell S8600 ignition control module is used with boiler.
5167 484 v1.1

Operation
10
Service Notice for your Heating System
We strongly recommend that you have your heating system checked and serviced
by a qualified heating contractor on an annual basis to ensure a safe and energy
efficient operation.
A service contract is advisable.
Boiler
Every boiler must be cleaned within
certain time frames. A lack of cleaning
causes soot build-up in the combustion
chamber which raises the flue gas
temperature and reduces the efficiency
of your heating system.
System
Ensure that a qualified heating
contractor checks all system
components such as the expansion
tank, the pressure relief valve, the
pump(s), the zone valves, the low
water cut-off and all other system
componentry regularly.
5167 484 v1.1
Ensure the mechanical room and the
hot water heating boiler itself, is kept
clean.
CAUTION
The are no user-serviceable
components on the boiler, burner,
control or on the heating system.
Contact a qualified heating
contractor for service!
WARNING

Additional Safety Requirements
11
Safety Requirements
Carbon monoxide
The U.S. Consumer Product Safety
Commission strongly recommends the
installation of carbon monoxide detectors
in buildings in which gas-burning
equipment is installed. Carbon monoxide
(CO) is a colorless, odorless gas, which
may be produced during incomplete
combustion of fuel and/or when the
flame does not receive an adequate
supply of combustion air.
Carbon monoxide can cause severe
personal injury or loss of life.
Therefore, carbon monoxide detectors
that are in compliance with a nationally
recognized standard (e.g. ANSI/UL
2034-2002, CSA 6.19-01) should be
installed and maintained in buildings that
contain gas-burning equipment.
Note:
Viessmann does not test any detectors
and makes no representation regarding
any brand or type of detector.
Frozen water pipe hazard
Your heating boiler is designed to provide
a warm and comfortable living
environment. It is NOT designed to
ensure against freezing of water pipes.
The boiler is equipped with several safety
devices that are designed to shut down
the boiler and to prevent it from
restarting in the event of various unsafe
conditions.
If your boiler remains off for an extended
period of time during cold weather, water
pipes may freeze and burst, resulting in
extensive water damage and conditions
in which mold could grow. Certain molds
are known to cause respiratory problems,
as well as to pose other serious health
risks. In case of water damage,
immediate measures should be taken to
dry out affected areas as quickly as
possible to prevent mold from developing.
If your home will be unattended for an
extended period of time during cold
weather, you should...
Shut off the water supply to the building,
drain the water pipes and add an
antifreeze for potable water to drain traps
and toilet tanks. Open faucets where
appropriate.
Or..
Have someone check the building
frequently during cold weather and call a
qualified service agency if required.
Or...
Install a reliable remote temperature
sensor that will notify somebody of
freezing conditions within the home.
5167 484 v1.1
Failure to protect against frozen pipes
could result in burst water pipes,
serious property damage and/or
personal injury. Boiler may shut down.
Do not leave your home unattended for
long periods of time during freezing
weather conditions without turning off
the water supply and draining water
pipes or otherwise protecting against
theriskoffrozenpipes.
WARNING

Saving Energy
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario •N2V 2G5 •Canada
Tel. [phone] •Fax [phone]
www.viessmann.ca •[email protected]
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island •02886 •USA
Tel. [phone] •Fax [phone]
www.viessmann-us.com •[email protected]
12
Saving Energy
... with a modern heating system
By purchasing a “modern” heating
system, you have taken a decisive step
towards saving energy.
Viessmann boilers operate optimally to
ensure minimum fuel consumption for
maximum heating value - efficient,
environmentally friendly and
comfortable.
Your new heating system provides the
following alternatives to save energy:
- a well insulated hot water heating
boiler and domestic hot water tank
- clean combustion and high energy
extraction
...with proper heating
Additional energy can be saved by
considering the following measures in
addition to the above technical
improvements:
- proper ventilation: briefly open the
windows 1while turning off
thermostats or radiator valves 2
- avoid excess space heating; strive for
a room temperature of 68 ºF/20ºC
since every 2 ºF/1ºC of lower room
temperature can save up to 5% in
heating costs.
- proper control settings 5.
- properly set the temperature for the
DHW tank 4
- set thermostatic zone valves properly
2
- do not block heat transfer surfaces or
thermostatic zone valves 3
- control use of warm water: a shower
generally requires less water than a
bath
- close window shutters (if applicable)
during night time hours.
...with regular servicing
Regular servicing of your heating
system 6by a qualified heating
contractor ensures energy-efficient and
environmentally friendly operation.
...with good insulation
If still searching for additional
possibilities to save energy, review the
insulation installed
- on the heating system pipes and
DHW supply pipes,
- on the outside walls and on the roof
7,
- between heated (shaded grey) and
unheated (white fill) rooms 8,
- around windows 9.
5167 484 v1.1 Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.
Ensure properly sized fresh
combustion air supply to all fuel
burning appliances, including the hot
water heating boiler.
Tightly insulated homes require a
duct or opening in the boiler room to
allow outside air in for combustion.
Refer to codes and instructions.
WARNING