Viessmann VITOTRONIC 100 Dimensions and installation guide

Installation, Start-up
and Service Instructions
for use by engineers and heating contractors
5712 717 v1.0 06/2011
Read and save these instructions
for future reference.
Vitotronic 100
Model KW10B
For modulating temperature heating systems
Part No. 7834 238
VITOTRONIC 100
Please file in Service Binder
IMPORTANT
Certified as a component
part for Viessmann boilers

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual can cause product/property damage, severe personal
injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
Product 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.
uFor a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
uPlease see section entitled Safety and
“Important Regulatory and Installation
Requirements”.
Advice 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, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Safety
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service Table of Contents
Safety
Important Precautions
General Information
Heating System
Electrical Connections
Altering Settings
Safety, Installation and Warranty Requirements..............2
Product documentation...........................................2
Licensed professional heating contractor...................2
Advice to owner....................................................2
Warranty...............................................................2
Safety.......................................................................5
Approvals.............................................................5
Codes..................................................................5
Working on the equipment......................................5
Technical literature.................................................5
Important Regulatory and Installation Requirements........6
Power supply........................................................6
Working with an open control..................................6
About these Installation Instructions..............................7
Typical System Layout................................................8
One direct-connected heating circuit without
mixing valve..........................................................8
Opening the Control....................................................9
Overview................................................................10
Control PCB.......................................................10
Front panel.........................................................11
Summer mode switch...........................................11
Override switch..................................................11
Power switch......................................................11
Routing Cables.........................................................12
Power Supply...........................................................12
Burner Connection.....................................................13
Terminal Codes.........................................................13
Room Thermostat Connection.....................................14
Boiler/Space Heater Pump Connection.........................14
Boiler Sensor Connection...........................................14
Installation of the boiler sensor.............................14
Electrical connections...........................................14
DHW Pump Connection.............................................15
DHW Sensor Connection...........................................15
AlarmOutput............................................................15
Outdoor Temperature Sensor Installation......................16
Fixed High Limit........................................................17
Changing the Setting of the High Limit Safety Cut-out..17
Adjustment to 100oC for side scales.....................17
Adjustable High Limit.................................................18
Altering the Indoor/Outdoor Control Settings Internal....19
Factory settings...................................................19
Slope adjustment.................................................19
Warm weather shut-down adjustment..................20
Page

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
Table of Contents
Start-up
Troubleshooting
Additional Information
After Installation.......................................................21
Checklist.............................................................21
Service binder.....................................................21
Start-up Instructions..................................................21
Switches.................................................................22
Front panel switches............................................22
Dial switches.......................................................22
DIP switches.......................................................23
Boiler pump post purge.........................................23
Boiler pump continuous operation..........................23
Minimum boiler water temperature protection..........23
OpenTherm thermostat enable...............................23
Internal outdoor reset function...............................23
Auxiliary contact function(A1)...............................23
DHW priority.......................................................23
DHW pump post purge timer................................23
DHW pump post purge timer delay.........................23
DHW priority override timer (fixed at one hour)........23
DHW boiler temperature function...........................23
Minimum boiler water temperature protection..........23
Minimum boiler water temperature selection...........23
Pump Start-up Operation............................................25
Boiler pump sequence...........................................25
DHW pump sequence...........................................25
Alternate Control Function.........................................26
A1 Auxiliary input - heat demand...........................26
A1 Auxiliary input - 0-10VDC...............................26
Diagnostics..............................................................27
Failure, cause, correction......................................27
Test points..........................................................28
120V power flow................................................28
Dial switch..........................................................29
Front panel LEDs.................................................29
Temperature sensors..........................................29
Outdoor temperature sensor resistance chart...........29
Boiler and DHW temperature sensor resistance chart...29
Testing the FHL...................................................29
Flowchart...........................................................31
Replacement Components..........................................32
Fuse..................................................................32
Fixed high limit....................................................32
Adjustable high limit.............................................32
Parts List.................................................................33
Ordering replacement parts...................................33
Parts..................................................................33
Wiring Diagram.........................................................34
Technical Data.........................................................35
Protocol..................................................................35
Page

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service Important Precautions
Safety
Take note of all symbols and notations intended to draw attention to potential hazards or important
product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”.
Approvals
Viessmann boilers, burners and controls are approved for
sale in North America by CSA International.
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
gCSA C22.1 Part 1 and/or local codes in Canada
gNational Electrical Code ANSI/NFPA 70 in the U.S.
Always use latest editions of codes.
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 have been deactivated.
Close main oil or gas supply valve. Take precautions in
both instances to avoid accidental activation of power
during service work.
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
u Please carefully read this manual prior to attempting
installation. Any 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.
u 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.
u 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.
WARNING
Turn off electric power supply before
servicing. Contact with live electric
components can cause shock or loss
of life.
The control is static sensitive. To avoid damage caused
by static discharge, follow Electro-Static Discharge
safety proceedures.
CAUTION

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
Important Regulatory and Installation Requirements
Important Precautions
Power supply
Install power supply in accordance with the regulations
of the authorities having jurisdiction or, in the absence
of such requirements, in accordance with National Codes.
Viessmann recommends the installation of a disconnect
switch to the 120 VAC power supply outside of the boiler
room. The installer must provide maximum 15 A over
current protection for the 120 VAC 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.

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
About these Installation Instructions
General Information
Take note of all symbols and notations intended to draw attention to potential hazards or important
product information.
CAUTION
Cautions draw your attention to the presence of potential
hazards or important product information.
WARNING
Warnings draw your attention to the presence of potential
hazards or important product information.
u
IMPORTANT
u Indicates an imminently hazardous situation which,
if not avoided, could result in death, serious injury
or substantial product/property damage.
u Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product /
property damage.
u Helpful hints for installation, operation or maintenance
which pertain to the product.
u This symbol indicates to note additional information
u This symbol indicates that other instructions must be
referenced.
Valid for...
Applies to Vitotronic 100, Model KW10B:
Order No. 7834 238, starting with serial no. V00101
This control shall only be installed with the Vitola 200,
Vitorond 100, Vitogas 050, RS Series, or with a Vitogas
100 hot water heating boiler.

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
Heating System
Typical System Layout
One direct-connected heating circuit without mixing valve
ABoiler with Vitotronic 100, Model KW10B
BHeating circuit
CSystem pump
DDHW pump
R Room thermostat
1Outdoor temperature sensor
3Boiler temperature sensor
5DHW temperature sensor
20 Pump connection (used with: - Vitola 200,
- Vitorond 100,
- Vitogas 050,
(RS series,boilers only)
- Vitogas 100
21 DHW pump output
40 Power supply cord 120 VAC, 60Hz

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
Opening the Control
Electrical Connections
1. Open front cover.
2. Carefully unlock control top cover using a screw driver
and flip open top cover.

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5712 717 v1.0
Vitotronic 100, KW10B Installation, Start-up and Service
Overview
Electrical Connections
Rear view of the control
Control PCB