Viessmann VITOTRONIC 200, KW2 Technical Data Manual

Technical Data Manual

VITOTRONIC 200

Weather-responsive indoor/outdoor, digital boiler control

for heating systems with one or more heating circuits

Vitotronic 200

Model KW2, Part No. Z001 230

For operation with modulating boiler water temperatures,
and single-stage, two-stage or modulating burners

With DHW tank temperature sensor and integrated
diagnostic system

Operating module with clear text LCD display

Remote control interface with room temperature sensor
(optional)

Viessmann quick-connect plug-in system

5167 888 v1.1 11/2002

Certified as a component part

of Viessmann boilers only

Product Information/Standard Equipment/
Application

Product Information

The benefits at a glance:

H Easy and uniform operation:

– Different programming levels for

system user and heating contractor.

– Large, clear text LCD display format

facilitates legibility of all data.

– Illuminated operating mode and

heating circuit keys.

– Easy-to-program switching times.
– Digital tracking of day and week.

Programmed times for domestic hot
water production and recirculation
pump are adjusted automatically
when heating program is altered.

– Plug & Work quick-connect system for

automatic sensor and system
recognition and adaptation.

– Automatic resetting to daylight

savings time.

– Service interval display for

demand-related maintenance.

– Fuel consumption display.

H Program selection for controlled drying

of concrete floor in radiant floor heating

application.

H Short installation time,start-upand

maintenance due to Rast-5 connector
system, plug-in function modules and
integrated diagnostic system

.

Vitotronic 200, Model KW2

OTS

STS

H Weather-responsive indoor/outdoor,

digital boiler and heating system
control:

– for heating systems with one boiler
– for heating circuits without and

heating circuits with a mixing valve

– for single-stage, 2-stage and

modulating burners

– with DHW tank temperature sensor
– with digital tracking of day and week
– with separate switching times for

room heating, domestic hot water
heating and recirculation pump

– with integrated diagnostic system

Standard Equipment

Vitotronic 200, Model KW2
(Part No. Z001 230)
with

H operating module with clear text LCD

display

H outdoor temperature sensor
H boiler water temperature sensor
H DHW tank temperature sensor
H Power/Pump Module

For the heating circuit with a mixing
valve, a mixing valve actuator accessory
kit is required. Due to the low return
water temperature of condensing boilers
only 3-way mixing valves should be
installed. Th e circulation pump with a
flow check valve for DHW tank
temperature control must be ordered
separately.

Heating system with underfloor heating

The underfloor heating circuit requires an
accessory kit for operation with a mixing
valve.
A temperature control with high limit
must be installed in the heating supply of
the radiant floor heating application.
The underfloor heating circuit must not
be controlled by a remote control with
room temperature sensor.

Application

In conjunction with the following Viessmann boilers
Boiler Model and Series

Oil-fired hot water
heating boiler with
power burner

Oil-/gas-fired hot water
heating boiler with
power burner

Atmospheric
gas-/propane-fired hot
water heating boiler

Atmospheric gas-fired
hot water heating boiler

2

Vitorond 200

Vitola 200

Vitogas 050, RS Series

Vitogas 100, GS1 up to 240 MBH / 70 kW
Vitogas 100, GS10 up to 380 MBH / 111 kW

Fuel

Oil

Oil/Gas

Gas

Gas
Gas

Minimum boiler water
temperature

without low
limit

x

with low limit
(average temp.)

104 ºF/40 ºC

120 ºF/49 ºC

104 ºF/40 ºC
120 ºF/49 ºC

5167 888 v1.1

Structure and Operation

Structure a nd Operation

Modular structure

The complete control consists of a
control base, control unit
(electronic/operating modules) and a
Power/Pump Module.
The control unit comprises:
Power on/off switch, an electronic high
limit, a temperature gage and a low
temperature control

– adjustable high limit
– fixed high limit

TUV test switch, override switch,
buttons for:

– holiday program
– party and economy modes
– reduced operating mode temperature
– domestic hot water temperature
– programming of heating curves for

boiler water temperature and/or mixing
valve circuit temperature

– heating circuit selection,

a selector knob for normal operating
temperatures and a digital timer.
Heat-demand-controlled circuit pump and
burner activation, adjusting of a variable
temperature limit, pump cycling,
integrated diagnostic system and flue gas
monitoring in connection w ith flue gas
temperature sensor (optional) and
maintenance display.

Boiler-specific functions

The Vitotronic control modulates the
boiler water temperature.
It gradually regulates the boiler water
temperature (= the supply temperature
of the direct-connected heating circuit) as
well as the s upply water temperature of a
mixing valve circuit. The control contains
an adaptive tank temperature control
logic with priority switching (heat pump
off, mixing valve closed).
An additional function for domestic hot
water heating (short-term heating to an
increased temperature) can be selected.

5167 888 v1.1

The Vitotronic 200 is an ideal control
option for your heating system with
mixing valve circuit. It is the perfect
solution for your underfloor heating
circuit with supply and return water
temperature sensor or for controlled
drying of a concrete floor.

Control characteristics

– Boiler circuit control unit (high

temperature)

– Heating circuit control with mixing

valve
Dead zone: ±1.80 ºF/1ºC

– Adjustable high limit factory default

setting: 167 ºF/75 ºC

– Adjustment of the fixed high limit:

230 ºF/110 ºC
adjustable to
212 ºF/100 ºC

– Adjustment range of heating curve:

Slope: 0.2 to 3.5
Shift: –23 ºF to +72 ºF/

–13 ºC to +40 ºC

High limit: 68 to 266 ºF/

20 to 130 ºC

Low limit: 34 to 261 ºF/

1 to 127 ºC
Differential temperature for heating
circuit with mixing valve: 0 to 72 ºF/

0to40ºC

– Adjustment range for domestic hot

water setpoint temperature:

50 to 140 ºF/
10 to 60 ºC
adjustable to
50 to 203 ºF/
10 to 95 ºC

Technical data

Rated voltage: 120 VAC
Rated frequency: 60 Hz
Rated current: 6 A
Power consumption: 5 W
Maximum ambient
temperature

– at operation: 32 to 104 ºF/

0 to 40 ºC
(in rooms and
installation sites
with normal
ambient
conditions)

– when storing or transporting:

–4 to +149 ºF/

–20 to +65 ºC

Relay output rating in conjunction with a
Power/Pump Module:

– Heating circuit

pumps: 3 FLA/120 VAC

– DHW tank heating

circulation pump: 3 FLA/120 VAC

– Domestic hot water

recirculation pump:3 FLA/120 VAC

– Mixing valve

actuator: 0.1 FLA/120 VAC

*1

*1

*1

*1

Operating time approx. 2 minutes

– Burner plug : 2 FLA/120 VAC
– 2-stage burner

– Total: max. 12 A/120 VAC

*1

*2

*2

plug

: 0.5 FLA/120 VAC

Total 12 A/120 VAC

Available only with extension module
for 2-stage burner (included in boiler
package).

Boiler coding card

Adapts the control to the specific boiler
model being used (included in boiler
package).

Connections

– Sensors, burner and Power/Pump

Module are connected to the back of
the control unit via system plugs.

– Pumps, power supply and mixing valve

are connected to the Power/Pump
Module via screw terminals or system
plugs.

Operating unit

– With digital timer
– Clear text LCD display
– Temperature and fault display
– Coding via display of operating unit
– All adjustments and basic coding

information in clear text format.

3

Structure a nd Operation

Structure and Operation (continued)

Digital timer of operating unit

A digital timer with day and week
feature, calendar, automatic resetting to
daylight savings time and automatic
functions for domestic hot water heating
and recirculation pump.
Time, day and standard switching times
for room heating, domestic hot water
heating and domestic hot water
recirculation pump are factory preset
(individually programmable), max. four
time switch intervals programmmable per
day.
Shortest interval: 10 minutes
Power reserve: 5 years

Adjusting the operating system

All operating programs feature freeze-up
protection

*1

for the heating system.
With the program selector buttons the
following can be selected:

– heating and domestic hot water
– domestic hot water only
– standby operation

*1

See Freeze-up Protection Function
below.

Freeze-up protection function

The freeze-up protection function is

– activated when the outside temperature

drops to +34 ºF/1ºC.
The freeze-up protection function
activates the circulation pumps and
keeps the boiler water temperature at
the reduced operation setpoint level, at
a minimum temperature of approx.
68 ºF/20 ºC (for heating boilers with
low limit the respective temperature
will be maintained).

– deactivated when the outside

temperature exceeds +37 ºF/3ºC.
When the freeze-up protection function
is deactivated, heating boiler and
circulation pumps are turned off.

Summer economy mode

(Domestic hot water heating only,
program selector switch ”

”)

The burner only activates if domestic hot
water needs to be produced (as required
by DHW setpoint).

Heating curve adjustment

The weather-responsive Vitotronic 200
regulates the boiler water temperature
(= supply water temperature of the
heating circuit without mixing valve) and
the supply temperature of the heating
circuit with a mixing valve.
The required supply temperature for a
certain room temperature depends on the
heating system and the insulation of the
building in question.
The adjustment of both heating curves
individually allows for the boiler water
temperature and the supply temperature
of the mixing valve circuit to be adjusted
to the respective conditions.

Heating curves:

Low temperature heating system,
e.g. radiant floor heating
Medium temperature heating system,
e.g. cast iron radiation, staple-up
radiant floor heating
High temperature heating system,
e.g. fintube radiation, fan coils

The maximum boiler water temperature is
restricted by both the adjustable high
limit and the electronic maximum
temperature limit.
The supply water temperature cannot
exceed the boiler water temperature.

Boiler water temperature sensor

Cable length 5.2 ft./1.6 m, ready to plug
in.
Maximum ambient temperature
– at operation: 32 to 266 ºF/

0 to 130 ºC

– when storing or transporting:

–4 to +158 ºF/

–20 to +70 ºC

Outdoor temperature sensor

Installation site:

– North or northwest side of building
– 6.6 to 8.2 ft./2 to 2.5 m above ground,

for multi-storey buildings mount sensor
on upper half of second storey.

Connection:

– 2-wire cable, cable length 115 ft./

35 m with a wire size of min. AWG 16
copper.

– the cable to the outdoor sensor must

not be laid near line voltage wiring
(120/240 V).
Maximum ambient temperature at
operation,
when storing or
transporting: – 40 to +158 ºF/

–40 to +70ºC

Domestic hot water tank temperature
sensor

Cable length 19 ft./5.8 m, ready to plug
in.
Maximum ambient temperature
– at operation: 32 to 194 ºF/

0to 90ºC

– when storing or transporting:

–4 to +158 ºF/

–20 to +70 ºC

5167 888 v1.1

4

Accessories

Accessories

Note on the room temperature sensing
function (RS function)

*1

when using a

remote control

Due to the slow response of the
underfloor heating, the RS function must
not influence the underfloor heating
circuit.
For heating boilers with a low limit, the
RS function must not influence the
heating circuit without a mixing valve.

*1

RS function = remote control with

room sensor function

*2

WS function = remote control only, no

room sensor function

5167 888 v1.1

Vitotrol 200,

Part No. 7133 378

The Vitotrol 200 remote control takes
care of the room temperature setpoint
adjustment at normal operation and
determines the heating program from any
given room.
The Vitotrol 200 features illuminated
heating program selector buttons as well
as a party and an economy button.
Fault messages are displayed on the
boiler control.
A remote control can be connected for
each heating circuit.

WS function
any given place in the building.
RS function

*2

: Allows for installation at

*1

: The remote control is to
be installed on an inside wall of the main
living area, across from radiators, but not
on shelves, in niches, in the close vicinity
of doors or heat sources of any kind (e.g.
direct sunlight, fireplace, TV, etc.).
The installed sensor measures room
temperature and, if necessary, takes
corrective action and initiates fast
heat-up at the outset of the heating
operation (if coded).
Connection:

– 2-wire cable, cable length

max. 164 ft./50 m (also for the
connection of several remote controls).

– The cable must not be placed together

with line voltage wiring.

– Low voltage plug is included.

Rated voltage: 33 VAC
Rated current: 10 mA
Power consumption: 3.3 W
Maximum ambient
temperature
– at operation: 32 to 104 ºF/

0to 40ºC

–when storing

or transporting: –4 to+149 ºF/

–20 to +65 ºC
Adjustment range of
room temperature
setpoint: 50 to 86 ºF/

10 to 30 ºC

adjustable to

37 to 73 ºF/

3to23ºC
or
63 to 99 ºF/
17 to 37 ºC

Adjustment of the room temperature
setpoint at reduced operation takes place
at the Vitotronic 200.

Vitotrol 300,

Part No. 7133 382

The Vitotrol 300 remote control takes
care of the room temperature setpoint
adjustment at normal and reduced
operation for the heating program,
switching times for room heating,
domestic hot water heating and the
domestic hot water recirculation pump.
The Vitotrol 300 features illuminated
heating program selector buttons, a party
and an economy button, an automatic
reset function to daylight savings time,
buttons for the holiday program, day of
the week and time.

WS function
any given place in the building.
RS function

*2

: Allows for installation at

*1

: The remote control is to
be installed on an inside wall of the main
living area, across from radiators, but not
on shelves, in niches, in the close vicinity
of doors or heat sources of any kind (e.g.
direct sunlight, fireplace, TV, etc.).
The installed sensor measures room
temperature and, if necessary, takes
corrective action and initiates fast
heat-up at the outset of the heating
operation (if coded).
Connection:

– 2-wire cable, cable length

max. 164 ft./50 m (also for the
connection of several remote controls).

– The cable must not be placed together

with line voltage wiring.

– Low voltage plug is included.

Rated voltage: 33 VAC
Rated current: 10 mA
Power consumption: 3.3 W
Maximum ambient
temperature
– at operation: 32 to 104 ºF/

0to 40ºC

–when storing

or transporting: –4 to +149 ºF/

–20 to +65 ºC
Adjustment range of
room temp. setpoint:
– at normal operation: 50 to 86 ºF/

10 to 30 ºC

adjustable to

37 to 73 ºF/

3to23ºC
or
63 to 99 ºF/
17 to 37 ºC

– at reduced operation: 37 to 99 ºF/

3to37ºC

5

Accessories

Accessories (continued)

Room temperature sensor,

Part No. 7133 379

A separate room temperature sensor as
an addition to the Vitotrol 200 or 300; to
be used when the Vitotrol 200 or 300
remote controls cannot be placed in the
main living area or in a position suitable
for monitoring the room temperature.
The room temperature sensor must be
installed on an inside wall of the main
living area, across from radiators, but not
on shelves, in niches or in the close
vicinity of doors or heat sources of any
kind (e.g. direct sunlight, fireplace, TV,
etc.).
The room temperature sensor is to be
connected with the Vitotrol 200 or 300.
Connection:

– 2-wire cable with a wire diameter of

AWG 16 copper.

– Cable length between control unit,

remote control and room temperature
sensor must not exceed 115 ft./35 m.

– Cable must not be placed together with

line voltage wiring.
Maximum ambient
temperature
–at operation: 32 to 104 ºF/

0to 40ºC

–when storing

or transporting:

–4 to +149 ºF/

–20 to +65 ºC

KM-BUS Expansion Module,

Part No. 7133 393

With cable (10 ft./3 m long) and low
voltage plug.
To connect up to 6 devices to the single
KM-BUS connection of the boiler control
(Vitotrol, Switching Module-V etc.).

Switching Module-V,

Part No. 7133 387

With cable (10 ft./3 m long) and low
voltage plug.
With the Switching Module-V the
following additional functions are
feasible:

– external burner activation upon heat

demand (influences burner, possible
pumps and mixing valves), e.g. pool
heating, ventilation equipment etc.

– external disabling of burner
– remote switching of heating/operating

program, separate for each heating
circuit

– external error message input
– output of error message (SPDT contact)
– connection for short-term operation of

domestic hot water recirculation pump
(e.g. by external button)

6

5167 888 v1.1

Accessories (continued)

Accessories

Mixing valve actuator accessory kit,

Part No. 7133 390
consisting of a mixing valve actuator and
supply temperature sensor (strap-on
sensor)

Mixing valve actuator

The mixing valve actuator is to be
installed directly onto the Viessmann ¾
to 2½“ mixing valve.
The mixing valve actuator is a
bi-directional, single-phase, synchronous
motor with gear system and two limit
switches.
Rated voltage: 120 VAC
Rated frequency: 60 Hz
Power consumption: 4 W
Maximum ambient
temperature
– at operation: 32 to 104 ºF/

0to 40ºC

– when storing

or transporting: –4 to +149 ºF/

0to 65ºC
Torque: 3 Nm
Operating time
for 90º∢: 2 minutes

Strap-on sensor (included with mixing
valve actuator accessory kit),
Part No. 7133 895

To determine the supply temperature of
the mixing valve circuit.
Installed with a strapping band.
Cablelength19ft./5m,readytoplugin.
Maximum ambient
temperature
– at operation: 32 to 212 ºF/

0 to 100 ºC

–when storing

or transporting: –4 to +158 ºF/

–20 to +70 ºC

5167 888 v1.1

7

Printed on environmentally friendly

(recycled and recyclable) paper.

Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island • 02886 • USA
Tel. [phone] • Fax [phone]
www.viessmann-us.com • [e-mail]

8

Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario • N2V 2G5 • Canada
Tel. [phone] • Fax [phone]
www.viessmann.ca • [e-mail]

Technical information subject to change without notice.

5167 888 v1.1