Viessmann KW10 Installation, Start-up And Service Instructions Manual

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Installation, Start-up and Service Instructions

Vitotronic 100 Model KW10

Boiler control unit for modulating temperature heating systems Part No. 7133 375

Please file in Service Binder

VITOTRONIC 100

Certified as a component part

of Viessmann boilers only

5167 483 v1.4 08/2010

IMPORTANT

Read and save these instructions for future reference.

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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/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

H Licensed 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”.

H 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.

For a listing of applicable literature, please see section entitled “Important Regulatory and Installation Requirements”.

H 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, shut-down procedure, and the need for professional service annually before the heating season begins.

H Warranty

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

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Page

Contents

Important Precautions

General Information

Heating System

Electrical Connections

Altering Settings

Safety 4 Important Regulatory and Installation Requirements 5

About these Installation Instructions 5 Valid for ... 5

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System Configuration

One direct-connected heating circuit without mixing valve 6

Opening the Control 7 Overview 8

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Routing Cabling 9 Power Supply 9

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Burner Connection 10 Room Thermostat Connection 10 Pump Connection 11 Installation of Outdoor Temperature Sensor 12

Fixed High Limit 13

Testing the FHL 13

Adjustable High Limit 14

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Appendix

Start-up

Troubleshooting

Additional Information

Dip Switch Settings 15

Altering the Indoor/Outdoor Control Settings 16

Slope adjustment 16 Warm weather shut-down adjustment 17

After Installation ... 18 Checklist 18

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Service Binder 18

Start-up Instructions 18 Check all connections 18 Set fixed high limit and adjustable high limit 18 Set correct operational settings on control 18

Diagnostics 19

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(for qualified service personnel only) Failure, Cause, Correction 19 Electrical connections and sequence of operation 20

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Replacement Components

(for qualified service personnel only) 22

Boiler Protection 24 Parts List 28 Wiring Diagram 29 Technical Data 30 Protocol 30

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5167 483 v1.4

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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.” See page 5 for details.

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: H CSA C22.1 Part 1 and/or local codes

in Canada

H National 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.

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.

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.

Ensure main power supply to equipment, the heating system, and all external controls has 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

WARNING

Turn off electric power supply before servicing. Contact with live electric components can cause shock or loss of life.

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

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Important Precautions / General Information

Important Regulatory and Installation Requirements

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 overcurrent 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.

About these Installation 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

WARNING

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.

presence of potential hazards or important product information.

Valid for ...

Cautions draw your attention to the

CAUTION

Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.

IMPORTANT

Applies to Vitotronic 100, Model KW10: Order No. 7133 375, starting with serial no. V00101 This control shall only be installed with the Vitola 200, Vitorond 200, Vitogas 050, RS Series, or with a Vitogas 100 hot water heating boiler.

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 483 v1.45167 483 v1.4

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Heating System

System Configuration

One direct-connected heating circuit without mixing valve

TH OTS

Boiler with Vitotronic 100, Model KW10 Heating circuit System pump Room thermostat Outdoor temperature sensor

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

120 VAC connections

Power supply cord, 120 VAC, 60 Hz Burner connection Pump connection (used with: Vitorond 200, Vitogas 050, RS Series, and Vitogas 100 boilers only)

1 9543 431

5167 483 v1.4

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Opening the Control

Electrical Connections

1. Open front cover.

2. Carefully unlock control top cover

using a screw driver and flip open top cover.

5167 483 v1.4

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Electrical Connections

Overview

The control is pictured from the rear.

120 VAC connections

for power supply cord 120 VAC, 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

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Routing Cabling

Electrical Connections

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. Cut rubber grommet (if applicable).

4. Insert rubber grommet in strain

relief and mount strain relief.

5. Fasten top portion of strain relief.

6. Close off openings in the control

which are not being used.

IMPORTANT

Rubber grommets may already be mounted on cabling.

Power Supply

5167 483 v1.4

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.

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Electrical Connections

ventsystem.

Burner Connection

The Vitotronic 100 is prewired with the Viessmann quick-connect plug-in system.

to control (RAST-5 plug) to burner or wall vent system

plug)

(

1. Connect the main circuit board of the control (see page 8)

2. Connect 7-pole counter plug of the burner

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

RAST-5 plug to the

plug to the

WARNING

Do not connect the 41-plug from the boiler control directly to the burner if installing a wall vent system.

See technical instructions of the wall

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. Connection

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. Connect wires to main circuit board as shown.

4. Set thermostat anticipator to 0.1 A.

5167 483 v1.4

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Pump Connection

Electrical Connections

The main circuit board is pictured from the top.

The Vitotronic 100, KW10 incorporates a 120 VAC pump output. The output is activated when the boiler water temperature exceeds the minimum boiler temperature limit. The Pump Junction Box (shipped with the boiler) must be connected to the pump connection.

The purpose of this output is to minimize the possibility of flue gas condensation with the following boilers:

- Vitorond 200, VR2 Series

- Vitogas 050, RS Series

- Vitogas 100, GS1 Series

Pump connection

Boiler Sensor

See Installation Instructions of the Pump Junction Box (shipped with the boiler)

The Vitola 200 boiler has no low limit. Do not use the pump connection with the Vitola 200.

The main circuit board is pictured from the top.

Installation of boiler sensor

1. Insert the boiler sensor into the

boiler sensor well.

Do not kink any of the surrounding capillaries.

2. Route cabling to boiler control between enclosure panels and insulation jacket.

Electrical connections

3. A plug is prewired to the boiler

sensor. Plug the “1/3” connector

into the socket of the main

circuit board.

5167 483 v1.4

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Electrical Connections

Installation of Outdoor Temperature Sensor

To mount outdoor temperature sensor, experience has shown that the north or north-west outside wall of the building is the best location. If, however, the boiler is intended to supply heat to the south side of the building only (split piping system), the sensor must be mounted on the south side.

The sensor must be mounted so that water cannot infiltrate the sensor housing.

Care must be taken to install the sensor where it will not be affected by heat sources such as windows or ventilation openings. The sensor should be installed far enough above the ground to prevent accidental damage or tampering. Operating temperature range is -60 to 160 °F / -50 to 70 °C. Total cable length from boiler to sensor should not exceed 1000 ft. / 300 m if 18 gage wire is used. This sensor cable should not be placed in direct contact with line voltage.

Installation

1.Remove cover1.

2.Mount housing base2(cable inlet

opening3to bottom).

The outdoor temperature sensor must be surface-mounted on exterior cladding - not encased in any way by outside façade.

3.Affix wires to connectors Wires are interchangeable.

4.Slip cover1in place and affix with a snap.

Do not paint cover.

Electrical connections

5.Connect the other end of the

two-conductor cable to terminals “1” and “2” of the “1 / 3” plug (boiler sensor plug). Wires are interchangeable.

In addition, the outdoor sensor must not be covered with mortar, stucco, paint or any form of coating or siding. If the outside wall is finished after the sensor is installed, the sensor should be removed and placed on the finished wall.

Temperature Resistance

ºF ºC Ω ºF ºC Ω ºF ºC Ω ºF ºC Ω

-50 -46 490813 20 -7 46218 90 32 7334 160 71 1689

-45 -43 405710 25 -4 39913 95 35 6532 165 74 1538

-40 -40 336606 30 -1 34558 100 38 5828 170 77 1403

-35 -37 280279 35 2 29996 105 41 5210 175 79 1281

-30 -34 234196 40 4 26099 110 43 4665 180 82 1172

-25 -32 196358 45 7 22763 115 46 4184 185 85 1073

-20 -29 165180 50 10 19900 120 49 3760 190 88 983

-15 -26 139402 55 13 17436 125 52 3383 195 91 903

-10 -23 118018 60 16 15311 130 54 3050 200 93 829

-5 -21 100221 65 18 13474 135 57 2754 205 96 763

0 -18 85362 70 21 11883 140 60 2490 210 99 703

5 -15 72918 75 24 10501 145 63 2255 215 102 648

10 -12 62465 80 27 9299 150 66 2045 220 104 598

15 -9 53658 85 29 8250 155 68 1857 225 107 553

Temperature Resistance Temperature Resistance Temperature Resistance

6.The outdoor sensor can be checked by measuring resistance in respect to current outdoor temperature. Disconnect outdoor sensor from control. Using an Ohmmeter, measure resistance between the sensor cable terminals. The expected values are as follows:

5167 483 v1.4

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Fixed High Limit

highlimithigherthan167°F/75°C

Altering Settings

The default setting of the fixed high limit (FHL) is 230°F / 110°C.

The FHL deactivates the burner control circuit if abnormally high temperatures occur.

If tripped, it may be reset by pushing in the pin, labelled with a “ ballpoint pen). If a “click” can be heard, the limit was tripped.

Adjustment to 212°F / 100°C

1. Turn indicator screw at rear of FHL

to 212°F / 100°C position using a flat-head screwdriver (readjustment to previous position is not possible).

2. Please complete Protocol on page

27.

” (using a

Testing the FHL

CAUTION

A B Test connection is a 120 VAC circuit!

CAUTION

Boiler and burner must be supervised during entire procedure. Allow boiler water temperature to cool down to 140°F / 60°C before activating any attached heat distribution system.

5167 483 v1.4

If adjusting the fixed high limit to 212°F / 100°C, do not set adjustable

Slot screw

The main circuit board is pictured from the top.

A test can be performed to ensure proper operation of the FHL:

→ Deactivate power to control. → Install a jumper between

→ The adjustable high limit “ ” is

→ Reactivate power to control.

FHL test connection, A B Test

CAUTION

Connected low temperature (floor heating) systems, whether connected with or without mixing valves, must be deactivated during this procedure. Attached DHW tanks must be isolated and proper water expansion to the expansion tank must be guaranteed before performing this test.

→ The burner is activated until the

After deactivation of the FHL,

→ Deactivate power to control. → Remove jumper between

→ wait until boiler water temperature

→ Reactivate power to control.

CAUTION

terminal A and B .

disabled.

boiler water temperature reaches the FHL temperature and the FHL deactivates the burner.

terminals A and B.

has cooled 27 to 36°F / 15 to 20°C below the FHL temperature and reinitiate FHL by pushing in

“ ” pin.

the

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Altering Settings

Adjustable High Limit

The default setting of the adjustable high limit (AHL) is 167°F / 75°C. The AHL must not be set higher than 167°F / 75°C if the FHL is set to 212°F / 100°C.

The AHL sets the maximum boiler water temperature. It deactivates the burner control circuit when the desired temperature is reached. The AHL

resets automatically on a decrease in boiler temperature.

Adjustment to 189°F / 87°C

1. Remove

screwdriver.

2. Using needle-nose pliers, break off tabs enabling dial to rotate right to desired maximum temperature.

3. Install dial in such a way that its mark is situated in the desired temperature range.

dial using a flat-head

Changing the setting of the high limit safety cut-out

4. Please complete Protocol on page

27.

WARNING

The allowable temperature of domestic hot water, as specified by regional standards, must not be exceeded when operating an indirect-fired DHW tank. Install additional safety devices!

Adjustment to 100°C for side scales

1. Remove reset button cover “E”.

2. Remove the nut.

3. Remove the high limit safety

cut-out.

4. Turn the screw until the indicator points to 100°C.

CAUTION

If adjusted to 212° F/100° C do not set the adjustable high limit above 167°F/75°C.

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Dip Switch Settings

alterdipswitchsettings.

CAUTION

Ensure power switch on boiler control is deactivated before attempting to

Altering Settings

The “sequence of operation” of the Vitotronic 100, Model KW10 can be customized depending upon the boiler it is installed with, or the characteristics of the heating system itself.

Dip switch settings are to be altered by a qualified heating contractor only. See Overview on page 8 for dip switch location.

Default Setting

S1.1 - OFF Do not change

S1.2 - OFF Staging and thermostat:

S1.3 - ON Do not change

S1.4 - ON For single- and two-stage boilers:

S1.5 - ON For two-stage boilers:

Operation Possible

for two-stage boilers where control of both stages is needed

with minimum boiler temperature protection

with minimum boiler temperature protection and DHW production (where DHW pump module is used), using first and second stage

Change

from OFF setting

ON Staging and thermostat:

from ON setting

OFF For single- and two-stage boilers:

OFF For two-stage boilers:

Operation

for two-stage boilers where control of both stages is not needed

Both stages are activated simultaneously for space heating and for minimum boiler temperature protection

without minimum boiler temperature protection

with minimum boiler temperature protection and DHW production (where DHW pump module is used), using first stage only

S1.6 - OFF For domestic hot water production and

S1.7 Not used

See DHW pump module Installation Instructions for jumper J1position.

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space heating with a DHW Pump Module:

space heating pump and DHW pump are disabled when boiler water temperature is below the minimum value

ON For domestic hot water production and

space heating with a DHW Pump Module:

space heating pump and DHW pump are enabled when boiler water temperature is below the minimum value

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Altering Settings

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

Slope adjustment

IMPORTANT

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.

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 ˚F 90 ˚F

= = 1.4

70 ˚F - 5 ˚F 65 ˚F

For further assistance, please see section entitled “Helpful hints.”

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Altering the Indoor/Outdoor Control Settings (Continued)

Warm weather shut-down adjustment

Altering Settings

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” in the Operating

Instructions and User’s Information Manual.

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Appendix / Start-up

After Installation ...

Checklist

Please verify the following points (check with a pen) and take corrective actions as necessary:

Service Binder

j Have all limit capillaries and sensors

been completely inserted into the boiler 5-point sensor wells?

j Have all electrical connections been

made as discussed in the previous section?

j Did all plug-in connectors engage

with a “click” ?

j Have the settings of both the fixed

high limit and the adjustable high limit been checked and altered as necessary?

j Has the Pump Junction Box been

wired correctly (if applicable)?

1. File all technical documentation into the Service Binder.

2. Install a protective service box (optional equipment) near the boiler and store the Service Binder in this location.

Start-up Instructions

1. Check all connections

Based upon the Section entitled “Overview” on page 8, ensure all electrical connections have been made according to the diagram.

2. Ensure settings on fixed high limit and adjustable high limit are correct

See pages 13 and 14.

3. Ensure correct operational settings on control are set

Read Operating Instructions and User’s Information Manual of Vitotronic. The installer on the system is also responsible to ensure the system operator/ultimate owner is made familiar with the system functioning, its activation, and its shut-down.

5167 483 v1.4

Page 19

Diagnostics (for qualified service personnel only)

Failure, Cause, Correction

j Are all controls operating properly

(i.e. thermostats, low water cut-off, etc.)?

j Are all wire connections tight and

secure?

Failure Cause Correction

Heating system does not activate

(GREEN power LED is not illuminated)

Burner does not activate, or activates intermittently

(RED fault LED flashes)

Power switch “ “ is in “ “ position

Main power to boiler control and heating system has not been activated

Fuse on Vitotronic boiler control has deactivated heating system

Burner is not electrically connected

Fixed high limit (FHL) tripped

No fuel

Control calls for heat but burner does not respond

Ensure power switch “ “ is in “ “ position.

Activate main power; ensure 120 VAC is supplied to control (receptacle).

Replace fuse in control with same type and rating (F1: T 6.3 A / 250 V, slow blow).

Ensure 7-pole plug-in connection to burner and/or power venter is/are made.

Reset FHL by pushing in the pin, labelled with a “ “ (using a ballpoint pen). If a “click” can be heard, the limit was tripped.

with oil: Ensure sufficient supply of oil with gas: Open main gas supply valve or contact your local gas utility

Attempt to reset burner using reset button on the burner (underneath burner hood).

Troubleshooting

Burner does not activate

Red LED does not flash when Honeywell S8600 ignition control module is used with boiler.

5167 483 v1.4

Control calls for heat but burner does not respond

Other accessory defect

Service burner if necessary. Refer to troubleshooting section in burner manual.

Power venter has to have separate 120 VAC power supply to motor (see power venter instructions). Refer to troubleshooting section in power venter manual. Air proving switch, blower wheel or timer/relay inside power vent may be defective.

Ensure proper operation of all accessories; replace if necessary. Refer to technical literature supplied with accessories.

Page 20

Troubleshooting

Diagnostics (for qualified service personnel only)

Electrical connections and sequence of operation

The plug of the Vitotronic 100, Model KW10 boiler control supplies power to the RAST-5 connection on the main circuit board. This plug connector has L1, G and N markings on its terminals.

If the power switch is closed, power is supplied to the F1 fuse (6.3 A). This fuse is accessible from the front of the control. The output of the fuse is connected to the fixed high limit (FHL), the pump aquastat (PA), the primary side of the transformer (TR), and test point 1 . When the contacts of the FHL are closed, terminal X1.5 and test point 2 will both have 120 VAC present. Power flow will continue to the L1 terminal of the

If the burner counter plug is connected, voltage will return back to the control at terminal T1 on the RAST-5 plug. As the power flow continues in the control, voltage will be present at test point 3 and X1.6. If the adjustable high limit (AHL) is closed, and the boiler water temperature is below the AHL setting, 120 VAC will be present on X1.7 and test point 4.

On a call for heat or for domestic hot water production (with DHW Pump Module, Accessory), contact 1K1 will be closed and 120 VAC will be present on terminal T2 of the RAST-5 burner plug. Test point 5 will also have 120 VAC present at this time. The power flow will continue to the burner. The burner will operate until the thermostat ends the call for heat.

connection on the RAST-5 terminal rail.

The space heating circuit switch is only operational if a DHW Pump Module (Accessory) is installed.

5167 483 v1.4

Page 21

Diagnostics (for qualified service personnel only)

Backofcontrol

Electrical connections and sequence of operation

Using a volt-ohm meter, place one probe onto neutral test point terminal (TPN). Use the remaining probe to touch the individual test points to diagnose the problem. Follow the steps below through the individual test points.

Test point 1

Is 120 VAC present? No Check main 6.3A fuse and replace as necessary. Retest. Yes Continue with Test point 2.

Test point 2

Is 120 VAC present? No FHL has tripped. Reset and ensure pump(s) are operating. Yes Continue with Test point 3.

Test point 3

Is 120 VAC present? No Power flow is not returning from burner. Check burner plug. Yes Continue with Test point 4.

Troubleshooting

Test point 4

Is 120 VAC present? No AHL has tripped. Allow boiler to cool and restart. Yes Continue with Test point 5.

Test point 5

Is 120 VAC present? No Contact 1K1 possible not closed.

Test burner operation using FHL test. Check room thermostat circuit.

Yes Burner operation is required at this point.

Service burner.

Top view of main circuit board

5167 483 v1.4

Front of control

Page 22

Additional Information

Replacement Components (for qualified service personnel only)

Fuse, Part No. 7815 580

F1: T 6.3 A / 250 V, slow blow for control operation

Fixed high limit, Part No. 7819 411

H Electro-mechanical temperature limit

with liquid filled capillary

H Safety feature: if capillary is not

liquid tight (leaks), switch deactivates

IMPORTANT

Due to the expansion characteristics of the liquid contained in the capillary, the switch also deactivates (opens) at 14°F /

-10°C thereby shutting down the heating

system.

H Sets a maximum limit for boiler water

temperature whereafter the switch deactivates and locks (factory setting 230°F / 110°C)

HHHH Adjustable to 212°F / 100°C via slot

screw on rear side (readjustment to previous position is not possible)

WARNING

If adjusting to 212°F / 100°C, AHL must not be set higher than 167°F / 75°C.

5167 483 v1.4

Page 23

Replacement Components (for qualified service personnel only)

Adjustable high limit, Part No. 7819 316

Additional Information

H Electro-mechanical temperature limit

with liquid filled capillary

H Controls maximum boiler water

temperature (Factory setting 167°F / 75°C)

H Adjustable to 189, 203 and 212°F /

87, 95 and 100°C by breaking off tabs desired maximum temperature.

enabling dial to rotate right to

WARNING

AHL setting must be at least 36°F / 20°C higher than DHW tank temperature.

IMPORTANT

The AHL must not be set higher than 167°F / 75°C if the FHL is set to 212°F / 100°C.

Other replacement components (not shown)

Description Quantity Part No.

Temperature gage, °F 1 7334 598 Temperature gage, °C 1 7334 599 Temperature gage, °C / °F 1 9543 566 Vitotronic 100 main circuit board, KW10 1 9544 170 LED circuit board 1 Indoor/outdoor control 1 Pump aquastat 1 9525 828

5167 483 v1.4

Page 24

Additional Information

Boiler Protection

Minimum boiler temperature protection has been selected for all Vitotronic controls. It is the responsibility of the installer to determine the requirements of the boiler for each specific installation. The minimum boiler temperature function may be disabled; to do so, refer to table in subsection “Minimum Boiler Temperature Setting”. The boiler construction determines the necessity of a minimum boiler temperature protection function.

Minimum boiler protection is the result of two separate functions of the Vitotronic, KW10 control: – activation of the burner – deactivation of the space heating pump.

The Vitotronic 100, KW10 control uses a pump aquastat (PA) in conjunction with an Outdoor Reset Control (ORC) to maintain a minimum boiler temperature. The aquastat uses a probe-type mechanical limit which monitors the boiler water temperature. When the boiler water temperature drops below the setpoint of the pump aquastat, the burner activates and the space heating pump is deactivated. The ORC also controls the burner by sensing the boiler temperature through the electronic boiler sensor. When the boiler water temperature drops below the selected setpoint temperature, the ORC will activate the burner and deactivate the space heating pump. This only occurs when the room thermostat initiates a call for heat. The room thermostat may be jumpered to provide a constant call for heat. The ORC will also deactivate the space heating pump when connected to the

DHW pump module.

The space heating pump may be connected to the Vitotronic 100, KW10 control in one of two ways: – using a boiler-mounted pump junction box – using a DHW pump module (accessory). The presence of the boiler-mounted pump junction box is determined by the boiler-specific construction.

When the space heating pump is connected to the boiler-mounted pump junction box, the pump is deactivated when the boiler water temperature drops below the pump aquastat setpoint. If continuous operation of the space heating pump is required, a separate power supply connection is needed. When connecting the pump to a direct power supply, the use of a pump on/off switch is recommended.

When the space heating pump is connected to the boiler via the DHW pump module, pump operation is similar to that with pump connection via the pump junction box. When the boiler temperature drops below the aquastat setpoint, the space heating pump is switched off. If a DHW pump is connected, it also is switched off. To modify pump operation, refer to table in subsection “Minimum Boiler Temperature Setting”.

Burner activation is similar to that of the pump control. When the boiler temperature drops below the pump aquastat setpoint, the burner is activated. The pump aquastat controls the burner operation when the boiler temperature is below the aquastat setpoint. If the ORC detects that the boiler water temperature has dropped below the setpoint, the burner will be activated by the ORC control.

5167 483 v1.4

Page 25

Boiler Protection (continued)

Additional Information

There is a 7-pole DIP switch located on the motherboard of the control and a 5-pole DIP switch on the outdoor reset control. Operation of the PA or the burner can be modified by changing the DIP switch settings. Refer to the table in subsection “Minimum Boiler Temperature Settings” for the Vitotronic 100, KW10 control.

The ORC can maintain two alternate minimum boiler water temperatures.

H DIP switch S2.2 maintains the boiler temperature at 100 H deactivate DIP switch S2.2 and activate DIP switch S2.3 for a new minimum

boiler temperature of 120°F / 49°C

H deactivate DIP switches S2.2 and S2.3 and activate DIP switch S2.4 for a new

minimum boiler temperature of 140°F / 60°C The S2.2, S2.3 and S2.4 DIP switches are found on the position switch assembly on the outdoor reset board.

When all three DIP switches are kept deactivated or in the downwards position, the ORC will not maintain a minimum boiler water temperature and the space heating pump will not deactivate on low boiler temperatures. These settings must be used in conjunction with the S1 DIP switch settings to fully disable minimum boiler temperature protection.

°F / 38°C

Minimum boiler temperature setting

Boiler control without DHW pump module

Minimum temperature setpoint

PA 86-95 °F / 30-35 °C

ORC 100 °F / 38 °C

PA 86-95 °F / 30-35 °C

No ORC minimum temperature

No PA minimum temperature

ORC 100 °F / 38 °C

No PA minimum temperature

No ORC minimum temperature

Vitotronic DIP switch S1.4 position

ON ON Burner enabled when

ON OFF Burner enabled when

OFF ON Burner enabled when

OFF OFF Burner NOT enabled

Minimum temperature protection can be deactivated by changing the position of the DIP switch S1.4 (downwards movement of the DIP switch). Please refer to table in subsection “Minimum Boiler Temperature Setting”.

ORC minimum temperature DIP switch S2.2

Burner operation Boiler pump connected to

boiler below ORC set-

ting

boiler temperature below PA setting

boiler temperature below ORC setting

No minimum boiler temperature maintained

boiler junction box

Pump off when below PA setting

5167 483 v1.4

Page 26

Additional Information

Boiler Protection (continued)

Minimum boiler temperature setting (continued)

Boiler control with DHW pump module

Minimum temperature setpoint

PA 86-95 °F / 30-35 °C

ORC 100 °F / 38 °C

PA 86-95 °F / 30-35 °C

No ORC minimum temperature

No PA minimum temperature

ORC 100 °F / 38 °C

Vitotronic DIP switch S1.4 position

ON On Burner enabled when

ON OFF Burner enabled when

OFF ON Burner enabled when

ORC minimum temperature DIP switch S2.2

Burner operation Boiler pump connected to

DHW pump module

Pump off when boiler boiler temperature below ORC setting

temperature below PA

setting

Pump off when boiler boiler temperature below PA setting

temperature below PA

setting

Pump off when boiler boiler temperature below ORC setting

temperature below PA

setting

No PA minimum temperature

OFF OFF Burner NOT enabled

No minimum boiler temperature maintained

Pump off when boiler

temperature below PA

setting

No ORC minimum temperature

PA Pump Aquastat ORC Outdoor Reset Control

The minimum boiler water temperature, with the outdoor reset control, will only be activated when the room thermostat connection is closed or a jumper is used.

When the Vitotronic 100, KW10 control is used with DHW Pump Module, the factory default setting will allow the space heating pump and the DHW pump to turn off below minimum boiler water temperature. This function can be disabled by changing the S1.6 DIP switch setting from the OFF position to the ON position (upwards movement of DIP switch). The Outdoor Reset Control in this table is referred to as ORC and the Pump Aquastat is referred to as PA. The Vitola 200 does not have a boiler-mounted pump junction box.

Page 27

Boiler Protection (continued)

Minimum temperature adjustment for Vitotronic KW10

The minimum boiler water temperature setpoint can be adjusted to a higher boiler water temperature. This may be useful in applications using high temperature heating circuits. To determine whether an increase in minimum boiler water temperature setpoint is recommended for your application, read the following information.

Minimum boiler water temperature

Boiler model Fuel type (by boiler) Minimum boiler temperature

Vitola 200 Oil/Gas No minimum

Vitorond 200 Oil 104 ºF/40 ºC

Vitogas 050, RS Gas 120 ºF/49 ºC

Vitogas 100, GS1 Gas 104 ºF/40 ºC

Vitogas 100, GS10 Gas 120 ºF/49 ºC

Additional Information

To adjust the minimum temperature for the Vitotronic 100, KW10 control, select an alternate DIP switch setting. The table below outlines the three DIP switch settings for the three various temperatures. Select the temperature which best suits your application.

Note: Select only one of the three DIP switch positions that effect minimum temperature.

DIP switch setting on outdoor reset board

Minimum boiler temperature setpoint

100 °F / 38 °C 120 °F / 49 °C 140 °F / 60 °C

Do not change the pump aquastat setting for minimum boiler water temperature. Only change the minimum boiler water temperature by adjusting the DIP switch settings.

Page 28

Additional Information

Parts List

Ordering Replacement Parts:

Please provide control Model No., Serial Number from rating plate, as well as the position number of the part (see Parts List) when ordering replacement parts. Order replacement components from your Viessmann distributor.

040

042

Part

001 Cable clip 004 Adjustable high limit dial 005 Fixed high limit cover 007 Flip-down cover 010 Control housing cover, top 011 Control housing, front 016 Control housing, bottom 017 Control housing, rear 018 Temperature gage 019 Switch knockout 023 Fuse holder 024 Fuse holder cover 030 Fixed high limit 031 Adjustable high limit 032 Pump aquastat 033 AHL knob

030 010

031

035 Space heating circuit switch 036 Power switch 037 Main circuit board 038 LED circuit board 039 Indoor/outdoor control 040 Outdoor temperature sensor 042 Boiler sensor 065 Burner cable with

plug connector (shipped with burner or boiler)

091 Fuse

T 6.3 A / 250 V, slow blow

098 Strain relief fittings package

Parts not illustrated

080 Installation, Start-up

and Service Instructions

085 Operating Instructions

and User’s Information Manual

099 Other fittings package

018

004

033

005

024

011

091

023

019

035

036

038

039

065

032

037

017

098

007

016

001

5167 483 v1.4

Page 29

Wiring Diagram

0.4

3.6

2.0 70

PCB3 VBR1002

1 2 3 4 5 6 7 8 9 10 11

Additional Information

PCB1 Mother circuit board

984 65 7 10 11

321

LED CONTROL

345

24VAC CIRCUIT

24VDC

AHL

654

4 5

1 2 3

TP6

TP4

BNGYVTOGBURDBK

2/C*

PORT

COMMUNICATION

1 32 54

1K2

ALT

TP5

1K1

TPN

TP1

6.3A

TP3

TP2

543

2 4

1 2 3 4 5 6 7 8 9

2 3

ABTEST

T1 T2 S3

PCB2 Diode circuit board

1/3

PCB3 Outdoor reset control F Fuse K1, K2, K4 Relays S1 DIP switch S2 Power switch S3 Space heating switch AHL Adjustable high limit FHL Fixed high limit PA Pump aquastat

120 VAC Connections

191

Power supply (120 V, 60 Hz) Heating circuit pump

Burner connection ALT Alternative input/output TEST FHL test terminal

ALT

24 VAC Connections

X2 Room thermostat connection or

DHW pump module connection

X4 Outdoor reset control connection

191

2nd stage cable connection

1/3 Sensors connection

This wiring diagram applies only to installations where Viessmann products

are used.

Technical information subject to

change without notice.

Wire color code

BK black BN brown

PCB1

RD red OG orange YE yellow GN green BU blue VT violet (purple) GY gray WH white

12/2*

FHL

PCB2

11/1*

*The terminal designation shown will

depend on the switch model used.

Page 30

Additional Information

Technical Data

Power: 120 VAC

1 Phase 60 Hz 15 A pre-fuse

Burner switching capacity:

120 VAC

2.5 FLA

Room thermostat:

24 VAC

Anticipator setting:

0.1 A

Fixed high limit:

230°F / 110°C max. (fixed)

Adjustable high limit:

167 to 239°F max.

75 to 115°C max.

(adjustable)

Pump output:

120 VAC 1 Phase 60 Hz 3 FLA

Outdoor temperature sensor:

10 kilo Ohms at 77°F / 25°C max. wire length

up to 1000 ft. / 300 m Allowable ambient temperature: H operation: 32 to 104°F

0 to 40°C

H storage and transport:

-4 to 149°F

-20 to 65°C

Protocol

Please indicate settings which have been altered ...

Factory default settings Altered settings

H Fixed high limit “ ” set to 230°F / 110°C j Altered to 212°F / 100°C

H Adjustable high limit “ ” set to 167°F / 75°C j Altered to 189°F / 87°C

5167 483 v1.4

Page 31

5167 483 v1.4

Page 32

Quick Reference

°C °F

-40 -40

-35 -31

-25 -13

-20 -4

-18 0

-16 +3

-14 +7

-12 +10

-10 +14

-9 +16

-8 +18

-7 +19

-6 +21

-5 +23

-4 +25

-3 +27

-2 +28

-1 +30 0 +32

+1 +34 +2 +36 +3 +37 +4 +39 +5 +41 +6 +43 +7 +45 +8 +46

+9 +48 +10 +50 +12 +54 +14 +57 +16 +61 +18 +64 +20 +68 +25 +77 +30 +86 +35 +95 +40 +104 +50 +122 +60 +140 +70 +158 +80 +176 +90 +194

+100 +212 +110 +230

Printed on environmentally friendly

(recycled and recyclable) paper.

Technical information subject to change without notice.

Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island • 02886 • USA Tel. (401) 732-0667 • Fax (401) 732-0590 www.viessmann-us.com • [email protected]

Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario • N2V 2G5 • Canada Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann.ca • [email protected]