installation and service instructions - viessmann...viessmann maintenance schedule of the boiler...

Installation and Service Instructionsfor use by heating contractors

5693 970 - 05 02/2015

Read and save these instructionsfor future reference.

Vitotronic 100Type GC1BDigital boiler control unitFor use with Boiler models VD2A, VD2 and CT3

VITOTRONICr 100

Please file in Service Binder

IMPORTANT

Certified as a component part for Viessmann boilers

Product may not be exactly as shown

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Vitotronic 100, GC1B Installation and Service General

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).

WARNINGInstallers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the boiler containedin this manual.

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 “For your 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.

Licensed professional heating contractor The installation, adjustment, service and maintenance of this equipment must be performed by a licensed professional heating contractor.

Please see section entitled “For your safety”.

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.

Operating and Service Documentation

It is recommended that all product documentation such as parts lists, operating and service instructions be handed over to the system user for storage. Documentation is to be stored near boiler in a readily accessible location for reference by service personnel.

Product Information

This document describes Vitotronic 100 when used: in a single boiler system in a multi boiler system with higher third party control unit

These instructions are not required for multi boiler systems with the Vitotronic 300-K.

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Vitotronic 100, GC1B Installation and Service

General

Safety

Installation Examples

Safety, Installation and Warranty Requirements..............2Product Information....................................................2

For your Safety......................................................6 Overview of System Examples.....................................7Designations in the System Schemes...........................8

System Example 1......................................................9 Single Boiler System: Boiler with Therm-Control.......................................................9 Equipment Required.............................................10 Electrical Installation Scheme................................11 Wiring Diagram....................................................12 Required Code....................................................12

System Example 2....................................................13 Single Boiler System: Boiler with Shunt Pump and 3-Way Mixing Valve for Return Temperature Raising...........................................13 Equipment Required..............................................14 Electrical Installation Scheme................................15 Required Code....................................................16

System Example 3....................................................17 Single Boiler System with Vitocrossal....................17 Equipment Required..............................................18 Electrical Installation Scheme................................19 Required Code....................................................20

System Example 4....................................................21 Multi Boiler System: Boiler with Therm-Control.....................................................21 Equipment Required..............................................22 Electrical Installation Scheme................................23 Required Code....................................................24

System Example 5....................................................25 Multi Boiler System: Any Boiler with Shunt Pump for Return Temperature Raising...........25 Equipment Required..............................................26 Electrical Installation Scheme................................27 Required Code....................................................28

System Example 6....................................................29 Multi Boiler System: Any Boiler with Circuit Pump and 3-way Mixing Valve for Return Temperature Raising..................................29 Equipment Required..............................................30 Electrical Installation Scheme................................31 Required Code....................................................32

System Example 7....................................................33 Multi Boiler System: Vitocrossal or Vitorond With Therm-Control (with a low temperature heating circuit)..................................33 Equipment Required.............................................34 Electrical Installation Scheme................................35 Required Code....................................................36

Page

Table of Contents

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Installation Example (continued)

Control Unit Installation

Installation Sequence

Commissioning

System Example 8....................................................37 Multi Boiler System: Vitocrossal and Low Temperature Boiler with Shunt Pump for Raising the Return Temperature........................37 Equipment Required..............................................38 Electrical Installation Scheme................................39 Required Code....................................................40

System Example 9....................................................41 Multi Boiler System: Vitocrossal and Low Temperature Boiler with 3-way Mixing Valve and Boiler Circuit Pump.....................41 Equipment Required..............................................42 Electrical Installation Scheme................................43 Required Code....................................................44

Mounting the Control Unit..........................................45Fitting the Control Unit Front......................................46Opening the Control Unit...........................................47

Overview of Electrical Connections.............................48Pump Connection Overview.......................................50Inserting Cables and Applying Strain Relief...................51Inserting the Boiler Coding Card.................................52Inserting the LON Communication Module (if required)...52Adjusting the Fixed High Limit (if required)...................53Changing the Adjustable High Limit (if required)...........53Connecting Sensors..................................................54Power Supply...........................................................54120V External Connection.........................................55Connecting Actuators................................................56Connecting the Central Fault Message Facility..............57Connection of Low Water Cut-off Device.....................57Connections to Safety Equipment aBÖ.........................58Connections to Terminal aBA.....................................58External Blocking - Single Boiler System.......................59Vitotronic 100, GC1B with 30% LTP Package (VD2 only)............................................60External Changeover of Staged/Modulating Burners.......61Connection of Combustion Air Device.........................61Provisional Burner Operation aBÖ................................62Single Boiler System - Connecting an External Control Unit.................................................62Multi Boiler System - Connecting anExternal Control Unit.................................................66Burner Connection, Burner Control Wiring....................71Burner Connection, Motor Power Supply......................73

Testing the Fixed High Limit.......................................76Matching the Coding Addresses to the System Version....76Checking Actuator and Sensors..................................78Connecting the Control Unit to the LON.......................79Integrating a Control Unit into the LON........................80Making the LON Connections.....................................81Entering a Service PIN for LON Participants..................82Entering a PIN Code for Vitocom 100..........................82

Page

Table of Contents

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Vitotronic 100, GC1B Installation and Service Table of Contents

Page

Calling up Service Level.............................................83Leaving the Service Level...........................................83Scanning Operating Data...........................................83Brief Scan................................................................83Scanning and Resetting Service Display.......................85

Fault Display............................................................85

Boiler Water Temperature Control ..............................91DHW Tank Control ..................................................96

Calling Up Coding Level 1..........................................98Category 1 “General”................................................98Category 2 “Boiler”...................................................99Category 3 “DHW”.................................................100Category 4 “Solar”..................................................101

Calling Up Coding Level 2........................................102Category 1 “General”..............................................103Category 2 “Boiler”.................................................106Category 3 “DHW”.................................................109Category 4 “Solar”.................................................110 Connection and Wiring Diagram................................113 Overview..........................................................113 Main PCB Low Voltage.......................................114 Main PCB 120V~.............................................115

Boiler Coding Card..................................................116Sensors.................................................................116 Checking Sensors...............................................116 Flue Gas Temperature Sensor...............................116

Extension EA1 Accessory (optional)..........................117 Parts List...............................................................118

Specification..........................................................119

Service Scans

Troubleshooting

Function Description

Code 1

Code 2

Designs

Components

Parts Lists Specification

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If you smell gasH Don’t smoke! Don’t use naked flames or cause sparks (e.g. by switching lights or electrical appliances on and off)H Open windows and doorsH Close the gas shut-off valveH Inform your heating engineer/service contractor from outside the buildingH Observe the safety regulations of your gas supply company (see gas meter) and those of your heating engineers (see start-up or installation report).

In emergenciesH Immediately switch off the power supply, e.g. at the separate fuse or power supply disconnect switch (unless there is a smell of gas).H Close the shut-off valves in the oil pipes or close the gas shut-off valve, whichever applicable.H Use suitable extinguishers in the event of fire.

Installation of additional componentsThe installation of additional components which have not been tested together with the boiler can adversely affect the function and performance of the boiler.Our warranty does not cover and we accept no liability for damage attributable to the installation of such components.

Boiler room conditionsH Do not use a room in which the air is polluted by halogenated hydro-carbons (e.g. as contained in aerosols, paints, solvents and cleaning agents)H Do not use a room subject to high levels of dustH Do not use a room subject to permanently high humidityH The room should be frost-protectedH Max. ambient temperature 95°F (35°C).H Provide good ventilation and do not close or obstruct vents (if installed).

This symbol indicates a reference to other instructions which must be observed.

Safety

CAUTIONFollow these safety instructions closely to avoid the risk of injury and damage to property.

For your Safety

H Operation Before operating the boiler, make sure you fully understand its method of operation. Your heating contractor should always perform the initial start-up and explain the system. Any warranty is null and void if these instructions are not followed.

H Flue gas smell - Deactivate heating equipment. - Open windows and doors. - Inform your heating contractor.

H Working on the equipment All personnel working on the equipment or the heating system must have the proper qualifications and hold all necessary licenses. Ensure main power to equipment, heating system, and all external controls has been deactivated. Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.

H Dangerous conditions - Deactivate main power immediately. - Close gas supply valve.

H Maintenance and cleaning Regular inspection and service by a qualified heating contractor is important to the performance of the boiler. Neglected maintenance impacts on warranty; regular inspection ensures clean, environmentally friendly and efficient operation. We recommend a maintenance contract with a qualified heating contractor.

H Technical Data Manual - Installation Instruction and Service Instructions - Operating Instructions and User’s Information ManualAdditional applicable literature: - Accessory manuals

This symbol indicates a reference to other

instructions which must be observed.

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Vitotronic 100, GC1B Installation and Service Installation Examples

Overview of System Examples

Boiler Characteristics Page

Single Boiler Systems

1 Vitorond (VD2A) Therm-Control 10

2 Vitorond (VD2) Shunt pump and 3-way mixing valve for raising the return temperature 14

3 Vitocrossal (CT3) Several heating circuits and one low temperature heating circuit 18

Multi Boiler Systems

4 Vitorond (VD2A) Therm-Control 22

5 Vitorond (VD2) Shunt pump for every boiler for return temperature raising 26

6 Vitorond (VD2) 3-way mixing valve for raising the return temperature 30

7 Vitorond (VD2A) Several heating circuits and one low temperature heating circuit, Therm-Control

34

8 Vitocrossal (CT3), Vitorond (VD2/VD2A)

Several heating circuits and one low temperature heating circuit and low temperature boiler with shunt pump

38

9 Vitocrossal (CT3), Vitorond (VD2/VD2A)

Several heating circuits and one low temperature heating circuit and low temperature boiler with 3-way mixing valve and boiler circuit pump

42

These system examples are merely recommendations and must therefore be checked on site for completeness and function.

The heating circuits must be regulated by an external control unit.

Connect three-phase consumers via additional contactors.

For multi boiler systems, the cascade and DHW tank temperature must be controlled by a higher third party control unit.

For multi boiler systems, all the relevant coding addresses must be set on each Vitotronic 100.

For connecting a single boiler system to a higher third party control unit, see page 62.

For connecting a multi boiler system to a higher third party control unit, see page 66.

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Designations in the System Schemes

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System Example 1

Single Boiler System: Boiler with Therm-Control


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System Example 1 (continued)

Equipment Required

Pos. Designation

1 Boiler

2 Vitotronic 100, type GC1B

3 Boiler water temperature sensor KTS

5 Therm-Control temperature sensor

tP ON/OFF switch

qP DHW tank

qQ DHW tank temperature sensor STS

qW DHW pump

qE Heating Circuits

Boiler Accessories

eP Connection to safety equipment aBÖ (see page 58)

eQ Minimum pressure limiter SDB

eW Maximum pressure limiter SDB

eE Water level limiter (low water cut-off) WB

eT Flue gas temperature sensor AGS

External connections (for connection to a higher third party control unit), (see page 62):

rR External demand, load-dependent

rT External changeover of staged/modulating burners

rZ External demand burner stage 2

rU External demand burner stage 1

System Accessories

wI Contactor relay

wO Downstream heating circuit controller, contact closed: Signal for mixing valve ”Close”

eR Central fault message system S

rP Extension EA1

rQ 1 analog input (0 – 10VDC): Boiler water setpoint temperature via 3rd party control

rW 3 digital inputs: External blocking External blocking with fault message Fault message input

rE 1 switching output (dry contact switching relay): Switching a feed pump to a substation

rO KM BUS distributor, for several KM BUS participants

tQ LON communication module for communication with external control

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Electrical Installation Scheme


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Wiring DiagramClosing of system mixing valves installed downstream of the boiler via the Therm-Control temperature sensor. These 3rd party heating circuit control units are not connected to the boiler control units.

Required Code

Category Function

0d:1 2 “Boiler” Therm-Control temperature sensor affects the mixing valves of downstream heating circuits.

4C:2 1 “General” Connection at plug sÖ affects the mixing valves of downstream heating circuits

Legend A Contactor relayB Downstream heating circuit, switching contact closed: signal for mixing valve closed.

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System Example 2

Single Boiler System: Boiler with Shunt Pump and 3-way Mixing Valve for Return Temperature Raising

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Equipment RequiredPos. Designation

1 Boiler



5 Shunt pump (on site)

6 3-way mixing valve

7 Temperature sensor T2


tP ON/OFF switch

qP DHW tank


qW DHW pump

qE Heating Circuits

Boiler Accessories











System Accessories

eR Central fault message system

rP Extension EA1





tQ LON communication module for communication with external control


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Required Code

Category Function

0C:1 2 “Boiler” Constant return temperature control.

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System Example 3

Single Boiler System with Vitocrossal


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Equipment Required

Pos. Designation

1 Boiler



5 Neutralizing system

tP ON/OFF switch

qP DHW tank


qW Circulation pump for DHW tank heating UPSB

qE Heating Circuits

Boiler Accessories










System Accessories


rP Extension EA1

rQ 1 analog input (0 – 10VDC): Boiler water setpoint temperature via 3rd party controls




tQ LON communication module for communication with external cascade control

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Required Code

Category Function

0C:0 2 “Boiler” Without Therm-Control temperature sensor.

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System Example 4

Multi Boiler System: Boiler with Therm-Control


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Equipment Required

Pos. Designation

1 Boiler



4 Therm-Control temperature sensor

5 Motorized isolation valve

6 Supply temperature sensor (connection to higher third party control unit)

tP ON/OFF switch

9 Boiler II

qP Vitotronic 100, type GC1B

qQ Boiler water temperature sensor KTS

qW Therm-Control temperature sensor

qE Motorized isolation valve

tP ON/OFF switch

qR DHW tank

qT DHW tank temperature sensor (connection to higher third party control unit)

qZ DHW pump (connection to higher third party control unit)

qI Heating Circuits

Boiler Accessories







rR Enable boiler, isolation valve open/closed




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Equipment Required

Pos. Designation

System Accessories

eR Central fault message system S

rP Extension EA1








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Required Code

Category Function

01:2 2 “Boiler” Multi boiler system with external cascade control via LON.

01:3 2 “Boiler” Multi boiler system with external cascade control via 0 –10VDC input or switching relay.

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System Example 5

Multi Boiler System: Any Boiler with Shunt Pump for Return Temperature Raising


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Equipment Required

Pos. Designation

1 Boiler I



tP Supply temperature sensor (connection to higher third party control unit)

7 Motorized isolation valve


9 Shunt pump (on site)

qP Temperature sensor T1

tP ON/OFF switch

qQ Boiler II

qW Vitotronic 100, type GC1B

qE Boiler water temperature sensor KTS

qR Motorized isolation valve

qT Temperature sensor T2

qZ Shunt pump (on site)

qU Temperature sensor T1

tP ON/OFF switch

qI DHW tank

qO DHW tank temperature sensor (connection to higher third party control unit)

wP DHW pump (connection to higher third party control unit)

wW Heating Circuits

Boiler Accessories












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Equipment Required

Pos. Designation

System Accessories


rP Extension EA1








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Required Code

Category Function

01:2 2 2 “Boiler” Multi boiler system with external cascade control via LON.

01:2 2 2 “Boiler” Multi boiler system with external cascade control via 0 –10VDC input or switching relay.

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System Example 6

Multi Boiler System: Any Boiler with Boiler Circuit Pump and 3-way Mixing Valve for Return Temperature Raising


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Technical Data System Example 6 (continued)

Equipment Required

Pos. Designation

1 Boiler I




7 3-way mixing valve


9 Boiler circuit pump (on site)

tP ON/OFF switch

qP Boiler II

qQ Vitotronic 100, type GC1B

qW Boiler water temperature sensor KTS

qE 3-way mixing valve

qR Temperature sensor T1

qT Boiler circuit pump (on site)

tP ON/OFF switch

qZ DHW tank

qU DHW tank temperature sensor (connection to higher third party control unit)

qI DHW pump (connection to higher third party control unit)

wP Heating Circuits

Boiler Accessories







rR Dry contact for boiler enable, 3-way mixing valve operates in control mode




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Equipment Required

Pos. Designation

System Accessories


rP Extension EA1






Technical Data System Example 6 (continued)



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Required Code

Category Function


01:3 2 “Boiler” Multi boiler system with external cascade control via 0 –10VDC input or switching relay.

0C:1 2 “Boiler” Constant return temperature control.

4d:2 1 “General” Boiler circuit pump at plug sL

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System Example 7

Multi Boiler System: Vitocrossal or Vitorond with Therm-Control (with a low temperature heating circuit)


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Equipment Required

Pos. Designation

1 Boiler I





tP ON/OFF switch

9 Boiler II



qW Motorized isolation valve

qE Therm-Control temperature sensor

tP ON/OFF switch

qR DHW tank

qT DHW tank temperature sensor (connection to higher third party control unit)

qZ DHW pump (connection to higher third party control unit)

wP Heating Circuit

wQ Low Temperature Heating Circuit

Boiler Accessories





eT Flue gas temperature sensor AGS (not for Vitocrossal)






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Equipment Required

Pos. Designation

System Accessories


rP Extension EA1









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Required Code

Category Function


01:3 2 “Boiler” Multi boiler system with external cascade control via 0 – 10VDC input or switching relay.

0d:0 2 “Boiler” Only with the Vitotronic 100 for Vitocrossal:Without Therm-Control.

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System Example 8

Multi Boiler System: Vitocrossal and Low Temperature Boiler with Shunt Pump for Raising the Return Temperature (with a low temperature heating circuit)


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Equipment Required

Pos. Designation

1 Boiler I





tP ON/OFF switch

9 Boiler II



qW Temperature sensor T2

qE Temperature sensor T1

qR Motorized isolation valve

qT Shunt pump (on site)

tP ON/OFF switch

qZ DHW tank

qU DHW tank temperature sensor (connection to higher third party control unit)

qI DHW pump (connection to higher third party control unit)

wP Heating Circuit


Boiler Accessories












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Equipment Required

Pos. Designation

System Accessories


rP Extension EA1









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Required Code

Category Function


01:3 2 “Boiler” Multi boiler system with external cascade control via 0 – 10VDC input or switching relay.


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System Example 9

Multi Boiler System: Vitocrossal and Low Temperature Boiler with 3-way Mixing Valve and Boiler Circuit Pump (with a low temperature heating circuit)


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Equipment Required

Pos. Designation

1 Boiler I





tP ON/OFF switch

9 Boiler II



qW Boiler circuit pump

qE 3-way mixing valve

qR Temperature sensor T1

tP ON/OFF switch

qT DHW tank

qZ DHW tank temperature sensor (connection to higher third party control unit)

qU DHW pump (connection to higher third party control unit)

wP Heating Circuit


Boiler Accessories







rR Dry contact for boiler enable, 3-way mixing valve operates in control mode




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Equipment Required

Pos. Designation

System Accessories


rP Extension EA1



rE 1 switching output (dry contact switching relay: Switching a feed pump to a substation





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Required Code

Category Function


01:3 2 “Boiler” Multi boiler system with external cascade control via 0–10VDC input or switching relay.

0C:1 2 “Boiler” Only with the Vitotronic 100 for low temperature boilers:Constant return temperature control.


4d:2 1 “General” Only with the Vitotronic 100 for low temperature boilers:Boiler circuit pump at plug sL

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Vitotronic 100, GC1B Installation and Service Control Unit Installation

1. Fasten the metal back plate to the boiler jacket with four fasteners.

Refer to the installation instructions of

the relevant boiler for mounting location.

2. Install the mid plate and junction box to the back plate.

3. Fasten the junction box and mid plate to the back plate with two fasteners.

4. Install the control rear section to the junction box housing. Hook the control to the back plate tabs and pivot downwards.

5. Fasten the control rear section to the junction box with two fasteners.

Mounting the Control Unit

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Fitting the Control Unit Front

Legend A Cable retaining tab

1. Snap on the control cover to the control housing.

2. Snap on the interface cover to the control cover.

3. Release the stay bar and lock in position.

4. Verify the coding plug installed (see page 52). Note: Route the ribbon cable through retainer A.

5. Return the stay bar to the control cover and lock in position.

6. Close the control cover.

7. Secure the control cover to the front housing with supplied fasteners.

8. Install the junction box cover and support with a supplied screws.

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1. Remove the junction box cover screws and remove the cover.

2. Remove the front housing screws.

3. Swing up the front part of the control housing.

4. Position the stay bar so that it supports the front housing.

Opening the Control Unit

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Overview of Electrical Connections

Note: When making connection to plugs aVD and aVH, bundle the individual wires of the cables closely to the terminals.

This prevents the wires from drifting into the adjacent voltage area.

Legend Main PCB, low voltage§ Boiler water temperature sensor%A DHW tank temperature sensor%B DHW tank temperature sensor 2 for primary store

system (optional accessory, not used)) Supply temperature sensor, low loss header (accessory)aG Flue gas temperature sensor (accessories)aJA Therm-Control temperature sensor or Return temperature sensor T1 (supplied with VD2 and VD2A, accessory for CT3) aJB Return temperature sensor T2 (accessory) or Temperature sensor primary store system (optional accessory, not used)aVD External connectionaVG KM BUS participant (accessory)aVH External connection


Main PCB 120V~sÖA1 Switching output or Primary pump for primary store system (optional accessory, not used)sA DHW pumpsL Shunt pump or boiler circuit pump (on site)fÖ Power supplyfA Burner stage 1gÖ Central fault messagegSA1 Motorized isolation valve or Mixing valve, return temperature raising facility or 3-way mixing valve, primary store system (optional accessory not used)lÖ Burner stage 2/mod.aBÖ External connections, e.g. supplementary safety

equipmentaBA Safety chain, potential freeaBH Power supply for accessories

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Overview of Electrical Connections (continued)


Legend A Vitotronic 100B Junction boxC Burner motor power supply (refer to page 73)fÖ Vitotronic 100 GC1B power supply

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Vitotronic 100, GC1B Installation and Service Installation Sequence

Pump Connection Overview

Pumps 120V

Rated current: 2A~* Maximum output 6FLA shared between all 120V outputs.

Legend A 120V pump outputB To the Vitotronic control unit C Junction box

Available pump connections

sÖA1 Switching contact/shunt pumpsL Boiler pumpsA DHW Pump

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Inserting Cables and Applying Strain Relief

Legend A Cables with moulded strain reliefB On-site cables; strip up to 4 in. (100 mm) insulation


Control unit fitted to the side of the boiler Route the cables from the junction box below into the control unit.

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Inserting the LON Communication Module (if required)

Connecting the control unit to the LON, see page 79.

A

B

Legend A LON communication module (accessory)B Vitotronic 100 GC1B

Inserting the Boiler Coding Card

Only use the boiler coding card designated for the installed boiler (also see table on page 114).

Insert the boiler coding card through the recess in the cover into slot “X7”.

Boiler Coding card Identification Spare parts no.

Vitocrossal 300, CT3 1040 7841118 7841118

Vitorond 200, VD2, VD2A 1020 7841111 7841111

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Adjusting the Fixed High Limit (if required)

When adjusting the fixed high limit, the adjustable high limit and the electronic temperature limiter must also be adjusted (see chart below).

Changing the Adjustable High Limit (if required)

Note: Excessive DHW temperatures can damage the DHW tank. If the system is operated in conjunction with a DHW tank, ensure that the maximum permissible water temperature of the tank is not exceeded. If necessary, install suitable safety equipment for this purpose.

1. Remove rotary selector A.

2. Using a pair of pointed pliers, break the restraining tab B or C out of the stop dial as shown.

3. Install rotary selector A. Turn rotary selector A to the required temperature. The slot should line up to the selected temperature.

LegendA Rotary selectorB Break required tab orC Break required tab

1. Unclip the fuse box and swing upwards.

2. Turn the slotted screw on the rear of the fixed high limit until the slot points to desired temperature.

3. Re-fi t the fuse box.

WARNINGDisconnect power to the control and burner!

Non-condensing boiler (VD2/VD2A) °F (°C)

Condensing boiler (CT3) °F (°C)

Factory set at; Adjustable to; Factory set at;

Fixed high limit 230°F (110°C)

210°F (99°C)

248°F (120°C)

210°F (99°C)

Adjustable high limit 212°F (100°C)

203°F (95°C)

230°F (110°C)

203°F (95°C)

Coding address for the electronic maximum temperature limit of Vitotronic 100; set coding address 06 (see boiler coding section) to the temperature as shown or less

200°F (93°C)

188°F (87°C)

223°F (106°C)

188°F (87°C)

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Connecting Sensors

Main PCB, low voltage

§ Boiler water temperature sensor%A DHW tank temperature sensor%B DHW tank temperature sensor 2 for primary store system (optional accessory, not used)) Supply temperature sensor, low loss header (accessory)aG Flue gas temperature sensor (accessory)aJA Therm-Control temperature sensor or Return temperature sensor T1 (supplied with VD2 and VD2A - optional accessory for CT3) aJB Temperature sensor T2 (accessory) or Temperature sensor primary store system (optional accessory, not used)


Power Supply

WARNINGThe control must be grounded.Ensure that “L”, “N” and “G” are not interchanged.

1. Ensure that the main power supply to the control contains over current protection with a minimum rating of 12A and 2-pole disconnect.

2. Connect power supply wire to the connection fÖ terminals 11, N and G on the DIN rail inside the junction box.

LegendL: LineN: NeutralG: Ground

A Power supply 120VAC, 1PH, 60Hz, provide disconnect means and over current protection as per local codes

B Terminals N, G and 11 (in junction box)

C Junction box

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120V External Connection

120V pumps with an amperage draw of >2FLA

240V single phase pumps

Contactor specification 120VAC 1A

LegendA DIN rail B Contactor/relay (field supplied)C PumpD Power supply w/disconnect and protection

Contactor specification 120VAC 1A


120V pumps with an amperage draw of <2FLA

LegendA DIN rail B Pump


208/460/575V 3 phase pumps Contactor specification 120VAC 1A


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Connecting Actuators

Legend A 24V Mixing Valve AdaptorB DIN Rail (in junction box) C 24V Valve ActuatorD Valve

Legend A 120V Mixing Valve AdaptorB DIN Rail (in junction box) C 24V Valve ActuatorD Valve


1. Disconnect power to control.

2. Install 120V or 24V valve adaptor on DIN rail inside junction box.

3. Insert the plug gS into socket gSA1 on the Vitotronic control.

4. Fasten cable with tie.

5. Connect black wire of the adaptor to terminals 8,9 or 10 on the Din rail.

6. Connect valve actuator wires to the adaptor terminals

120V Valve AdaptorRated voltage: 120VACRated current: max. 0.1 FLA

24V Valve AdaptorRated voltage: 24VACRated current: max. 0.15 FLA

gS A1: for boiler protection (via 100% low temperature protection package) or motorized isolation valve.Operating time: 5 to 199 sec. selected via coding address “40”.

Refer to the valve adaptor Installation Instructions.

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Connecting the Central Fault Message Facility

Rated voltage: 120V~Rated current: max. 2A~


Connection of Low Water Cut-off Device 150

CAUTIONThe diagram shown is only a simplified conceptualdrawing of a typical low water cut off (LWCO) device. Refer to the manual specific to the device for interconnection details.

1. Remove jumper between terminals 12 and 15.

2. Make connection as shown in diagram.

Legend aBH Power supply for accessories.aBÖ Connection for external equipment.A Low water cut-off (typical)

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Connections to Safety Equipment 150

Connections to Terminal aBA

WARNINGThe terminals should be used for safety switch-off purposes only (e.g. through a high limit thermostat).During switch-off, there is no frost protection of the heating system and the boiler is not kept at the minimum boiler water temperature.

External shut-off1. Remove jumper between terminals 19 and 20.

2. Connect dry contact. Controlled switch-off takes place when the contact is opened.

Note: The heating system has no frost protection while it is blocked. The boiler is not held at the lower boiler water temperature.

Legend A DIN railB Low water cutoffC Other safety controls

1. Connect the external safety equipment in series.


Legend A Dry contactB DIN rail

B

A

A

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External Blocking – Single Boiler System


Connection options (dry contact) at: Plug aBÖ Extension EA1 (accessory, see page 117)

Note: The heating system has no frost protection during blocking. The boiler is not held at the lower boiler water temperature.

CodeSet “5d”, “5E” or “5F” in category 1 “General” to 3 or 4.

ConnectionNote: ‘Live’ contacts lead to short circuits or phase failure.

The external connection must be potential-free.


Plug aBÖ Extension EA1

Legend A Dry contactB Extension EA1

Opening this contact leads to a controlled burner shutdown.Note: Connect only safety shutdown equipment, e.g. temperature limiter, to these terminals.

Closing this contact leads to a controlled burner shutdown. Any connected shunt or boiler circuit pump is stopped.

B

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Vitotronic 100, GC1B with 30% LTP Package (VD2 only)

30% LTP Package consists of:- 1 circulation pump- 1 cast iron flange set- 2 full port ball valves- 1 flow check valve- 1 17B sensor (strap -on)

IMPORTANT

Each pump output: 120V single phaseMax. pump current: 2 FLA

Mandatory Coding Address Changes0C:5 - Modulating isolation valve (independant of boiler water temperature).0d:2 - Switching contact4A:1 - 17A Sensor installed4b:1 - 17B Sensor installed4C:2 - Connections at plug 20A1 Therm-control switch contact4d:2 - Boiler circuit pump

Pump current larger than 2 FLA will require a contactor or isolation relay (see page 55).

Legend A Vitotronic 100 controlB Junction boxC Return temperature 2 aJBD Return temperature 1 aJAE Shunt pump sÖA1F Boiler pump sL

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External Changeover of Staged/Modulating Burners

Connection at Plug aVH.

Note: ‘Live’ contacts lead to short circuits or phase failure. The external connection must be potential-free.

Note: When scanning the burner version, the address for modulation appears even after an external changeover.Legend

A External changeover (dry contact)

Contact open: modulating modeContact closed: two stage mode


CodeSet code “02:2” in group 2 “Boiler”.

Connection of Combustion Air Device

IMPORTANT

Connection of the Combustion Air Device Adaptor1. Disconnect power to control and burners.

2. Install Combustion Air Device Adaptor, on DIN Rail inside connection enclosure (refer to installation manual of Combustion Air Device Adaptor).

3. Remove jumper between terminals 16 and 17.

4. Make connection as shown in the diagram.

Wire BK2 must be connected to terminal 16 and BK3 to terminal 17 - DO NOT reverse.

LegendA Combustion Air Device AdaptorB DIN Rail in connection enclosure

For more detail, refer to the combustion air device Installation Instructions.

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Single Boiler System – Connecting an External Control Unit

Settings Codes in category 2 “Boiler”:– “02:1” for two-stage burner– “02:2” for modulating burner– “01:1” for single boiler system (delivered condition)

The boiler water temperature must be set to the lower value. The boiler is held at the required minimum temperature.

The DHW tank adjustable high limit is activated when a DHW tank temperature sensor is connected.

The fixed high limit settings and other settings depend on the system equipment.


Provisional Burner Operation 150

Remove jumper across terminals 16 and 17 (not shown) and connect terminals 16 and 18 external control via dry contact (heat demand on close). Upon heat demand the boiler will maintain low fire until modulation is externally controlled through BMS.

Temperature control is limited by the adjustable high limit.

For connection points refer to the burner Installation Instructions.


B





210°F (99°C)

248°F (120°C)

210°F (99°C)


203°F (95°C)

230°F (110°C)

203°F (95°C)


200°F (93°C)

188°F (87°C)

223°F (106°C)

188°F (87°C)

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Single Boiler System – Connecting an External Control Unit (continued)

External Demand Via 0 – 10VDC Input

Connection at 0 – 10VDC input at extension EA1 (see page 117).

0 - 1VDC “No default set boiler water temperature”1VDC Set value 50°F (10°C)10VDC Set value 212°F (100°C)Observe coding address “1E” in the “General” category.

“1E:1” ≙ temperature demand adjustable in the range from 86 to 248°F (30 to 120°C) 1V ≙ 86°F (30°C) set value10V ≙ 248°F (120 C) set value

External Demand Via Switching ContactsConnection at plug aVD/aVH of the control unit. The set boiler water temperature is adjusted via code “9b” in category 1”General”.

Two-stage BurnerA, B and C are dry contacts of the higher control unit.


External Burner Start – Burner Stage 1Contact at terminals “1” and “2” of plug aVD:

Contact closed:Burner stage 1 is switched on. Burner stage 2 is switched ON only for maintaining the minimum temperature. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R. Contact open:Burner stage 1 is switched off.

External Burner Start – Burner Stage 1 and 2 Contact at terminals “2” and “3” of plug aVD

Contact closed:Both burner stages are switched ON. The boiler water temperature is limited by the electronic maximum temperature limiter, if it is set below that of mechanical control thermostat “R”.Burner stage 2 is switched OFF 2 K sooner.

Contact open:Burner stages 1 and 2 are switched OFF.

External Starting Subject to LoadThe burner is started, subject to load, when the zero volt contact across terminals “2” and “3” at plug-in connector aVH closes. The boiler will be constantly operated at the set temperature. The boiler water temperature is limited via the maximum set boiler water temperature or via the mechanical control thermostat. The set value is adjusted via code “9b”.

Legend A Burner stage 1 “ON”B Burner stage 2 “ON”C External load-dependent starting

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Low Temperature Boiler With Modulating Burner (on-site modulation controller)

Burner Connection: Connect plug fA of Vitotronic 100 to the burner.

Plug lÖ from the Vitotronic 100 via modulation controller (on site) to modulation terminals on the burner.

Set the minimum temperature at the higher control unit with the modulation controller 5 K higher than the lower boiler water temperature.

Dry contact from BMS system triggers burner activation via aVD at base load.

Modulation control via dry contact from BMS points F and E.

Temperature limited by the adjustable high limit.


Legend A Control unit B Junction boxC Burner control unitD Burner activation (base load)E Burner modulation upF Burner modulation down

For connection points refer to the burner Installation Instructions.

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Vitocrossal With Modulating Burner (on-site modulation controller)

Burner Connection: Connect plug fA of Vitotronic 100 to the burner. Plug lÖ of the Vitotronic 100 remains unallocated. Connect modulation terminals of the burner to the on-site modulation controller.


External Burner Start – Base LoadContact at terminals “1” and “2” of plug aVD

Contact closed: The burner is started with base load. An external modulation controller regulates the load-dependent modulation.

The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R.

Contact open:The burner is switched OFF.

Legend A Control unit B Junction boxC Burner control unitD Burner activation (base load)E BMS - Burner modulation control

Refer to the burner Installation Instructions.

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Multi Boiler System – Connecting an External Control Unit

Settings Codes in category 2 “Boiler”:– “02:1” for two-stage burner– “02:2” for modulating burner – “01:3” for multi boiler system with on-site cascade

control (third party control unit)– “01:2” with on-site cascade control (third party

control unit) via LON

The cascade and DHW tank control must be provided by the higher third party control unit.

Note: A boiler enable contact is essential to prevent boiler damage. This contact must always be closed on the lead boiler.

The fixed high limit safety settings and other settings depend on the system equipment.


External Demand Via 0 – 10VDC InputConnection at 0 – 10VDC input at extensionEA1 on each Vitotronic 100 (accessory, see page 115).

Enable Boiler Without an Additional Enable Contact 0 to 1VDC

Boiler blocked. Motorized isolation valve closed. Boiler circuit pump or shunt pump OFF.

1 to 10VDC Boiler water temperature default

1VDC Set value 50°F (10°C)10VDC Set value 212°F (100°C)

Observe coding address “1E” in the “General” category. Boiler enabled and held at its minimum temperature. Isolation valve open. Boiler circuit pump or shunt pump enabled.

Note: Only for low temperature boilers: On the lead boiler, the voltage must be higher than 1VDC.

Enable Boiler With an Additional Enable Contact0-1VDC “No default set boiler water temperature”1VDC Set value 50°F (10°C)10VDC Set value 212°F (100°C)

Observe coding address “1E” in the “General” category.





210°F (99°C)

248°F (120°C)

210°F (99°C)


203°F (95°C)

230°F (110°C)

203°F (95°C)


200°F (93°C)

188°F (87°C)

223°F (106°C)

188°F (87°C)

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Make connection at plug aVH.

Note: This contact must always be closed on the lead boiler.

Closed Contact Open

A Boiler enabled and held at its minimum temperature. The isolation valve opens.

The isolation valve is closed after approx. 5 min. External burner start not possible.Legend

A Boiler enable (dry contact)

Multi Boiler System – Connecting an External Control Unit (continued)

External Demand Via Switching ContactsConnection at plug aVD/aVH of the control unit.The set boiler water temperature is adjusted via code “9b” in category 1 ”General”.

Two-Stage BurnerA, B and C are dry contacts of the higher control unit.

Legend A Burner stage 1 “ON”B Burner stage 2 “ON”C Boiler enable

Motorized isolation valve “Open” or “Close”

External Burner Start – Burner Stage 1Contact at terminals “1” and “2” of plug aVD:

Contact closed:Burner stage 1 is switched on. Burner stage 2 is switched ON only for maintaining the minimum temperature. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R.

Contact open:Burner stage 1 is switched off.

External Burner Start – Burner Stage 1 and 2Contact at terminals “2” and “3” of plug aVD:

Contact closed:Both burner stages are switched ON. The boiler water temperature is limited by the electronic maximum temperature limiter, if it is set below that of mechanical control thermostat “R”.Burner stage 2 is switched OFF 2 K sooner.

Contact open:Burner stages 1 and 2 are switched OFF.

Enable Boiler, Isolation ValveContact at terminals “2” and “3” of plug aVH:

Contact closed:– Vitocrossal:The isolation valve opens.– Low temperature boiler:Initially, the preheat function for lag boilers is activated. After the preheat function has expired, the minimum boiler water temperature will be maintained and the burner stages can be controlled externally.The isolation valve opens.

Contact open:The isolation valve is closed after approx. 5 min. Burner stages cannot be switched ON externally; a minimum temperature will not be maintained.


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Low Temperature Boiler With Modulating Burner (on-site modulation controller)Burner Connection:

Connect plug fA of Vitotronic 100 to the burner. Plug lÖ from the Vitotronic 100 via modulation controller (on site) to plug lÖ on the burner. Via external demand aVD, the on-site modulation controller starts the burner with base load.

External Burner Start – Base LoadContact at terminals “1” and “2” of plug aVD:

Contact closed:The burner is started with base load. To maintain the minimum temperature, the burner is switched to full load via the Vitotronic 100. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R.



Contact closed: Initially, the preheat function for lag boilers is activated. After the preheat function has expired, the minimum boiler water temperature is maintained and the burner is controlled by the on-site modulation controller.

Contact open:The isolation valve is closed after approx. 5 min. The burner cannot be switched ON externally; a minimum temperature will not be maintained.

Vitocrossal With Modulating Burner (on-site modulation controller)Burner Connection:

Connect plug fA of Vitotronic 100 to the burner. Plug lÖ of the Vitotronic 100 remains unallocated. Via external demand aVH, the on-site modulation controller starts the burner with base load.

Legend A Control unit B Junction boxC Burner control unitD Burner activation (base load)E Isolation valve openF Burner Modulation upG Burner Modulation down Refer to the burner Installation Instructions.

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External Burner Start – Base LoadContact at terminals “1” and “2” of plug aVD:

Contact closed:The burner is started with base load. An external modulation controller regulates the load-dependent modulation.

The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R.



Contact closed:The isolation valve opens.

Contact open:The isolation valve is closed after approx. 5 min. The burner cannot be switched ON externally; a minimum temperature will not be maintained.


Legend A Control unit B Junction boxC Burner control unitD Burner activation - base loadE Isolation valve openF BMS - Burner modulation control

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Legend A Boiler blockingB Start boiler as the last one in the boiler sequenceC External changeover of stepped/ modulating burners

Hooking Up On-site Control Devices Via LON

Boiler BlockingContact at terminals “1” and “2” of plug aVD:

Contact closed: The boiler is blocked and has been removed from the boiler sequence. The isolation valve or the 3-way mixing valve for constant return temperature raising, the shunt pump or the boiler circuit pump are switched OFF.The other boilers provide the required heating.

Note: If all boilers are blocked or there is no other boiler ready for operation, then there will be no frost protection for the heating system.

Contact open:The boiler is reinstated into the current boiler sequence.

Start Boiler as the Last One in the Boiler SequenceContact at terminals “2” and “3” of plug aVD:

Contact closed: The boiler is started as the last one in the boiler sequence. This boiler is started if the other boilers in the heating system cannot provide sufficient heat.

Contact open:The boiler is reinstated into the current boiler sequence.



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Burner Connection, Burner Control Wiring

For burners with plug-in connectionThe burner cables are included in the standard delivery of the Vitotronic. Connect the burner in accordance withapplicable codes.

Terminal codesL Phase via fixed high limit to the burner? Ground connectionN Neutral connection to the burnerT1,T2 Control circuitS3 Connection for burner fault indicatorB4 Connection for burner hours counter

1. Disconnect power to burner and boiler control.

2. Connect plugs fA and plug lÖ to respective counter plugs in boiler control unit.

3. Connect the 7-pole plug fA and the 3-pole plug lÖ to the burner.

Terminal codes

1,2,3 Control circuit ”2nd stage burner or modulation controller” (via two-point controller with 2-stage operation; via three-point controller with modulating operation)1 From burner2 Modulating down3 Modulating up/2nd stage ON

Color codes as applicableBK BlackBN BrownBU Blue

LegendA To plug-in connection in the Vitotronic boiler control junction boxB To burner

LegendA To boiler control unitB To burner

CAUTIONThis is a generic connection drawing only! Follow the burner manufacturer’s connection drawings for Viessmann controls.

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Burner Connection, Burner Control Wiring (continued)

LegendA Vitotronic 100 controlB Junction boxC BurnerfA Burner, 1st stagelÖ Burner, 2nd stage/modulation

CAUTIONThis is a generic connection drawing only! Follow the burner manufacturer’s connection drawings for Viessmann controls. Note: Write the terminal numbers or markings on the

drawing for future reference.

For burner without plug-in connectionThe burner cables are included in the standard delivery of the Vitotronic. Connect the burner in accordance with applicable codes.

Refer to burner manufacturer’s instruction on detailed connections for Viessmann controls.

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CAUTIONThe control must be grounded. Ensure that “L”, “N” and “G” are not interchanged.

1. Ensure that the main power supply to the control contains over current protection with a maximum rating of 15A and 2 pole disconnect.

2. Connect power supply wire to the Connection fÖ terminals 11, N and G on the DIN rail inside the connection enclosure.

Burner Connection, Motor Power Supply

Supply power must be sufficient to cover both the 12A control plus the required motor amperage.

LegendA Burner motor power supply 120 VAC, 1PHB Connection terminals and plug inside connection enclosureC Cable and conduit- factory suppliedD BurnerE Motor starterF Burner motorG Connection enclosure on boiler control

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Burner Connection, Motor Power Supply (continued)

For burners with 240VAC, 1PH power supply.

See burner manual for correct fuse and wire gauge sizing, and specifi c connections for Viessmann controls.


2. Connect 240VAC power to the terminals 21, 22 and 23 on the DIN rail inside the connection enclosure. Provide fuseable disconnect means according to local codes.

3. Connect supplied power cable to the motor terminals on the burner.

4. Connect cable plug to the socket on the DIN rail in the connection enclosure.

LegendA Burner motor power supply 240VAC, 1PHB Connection terminals and plug inside connection enclosureC Cable and conduit- factory suppliedD BurnerE Motor starterF Burner motorG Connection enclosure on boiler control

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Burner Connection, Motor Power Supply (continued)

For burners with 3PH 208, 460 or 575V power supply.

See burner manual for correct fuse and wire gauge sizing, and specific connections for Viessmann controls.


2. Connect 3PH power to the terminals 21, 22, 23 and 24 on the DIN rail inside the connection enclosure. Provide fuseable disconnect means according to local codes.

3. Connect supplied power cable to the motor terminals on the burner.

4. Connect cable plug to the socket on the DIN rail in the connection enclosure.

LegendA Burner motor power supply 3PH 208, 460 or 575V B Connection terminals and plug inside connection enclosureC Cable and conduit - factory suppliedD BurnerE Motor starterF OverloadG Burner motorH Connection enclosure

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Vitotronic 100, GC1B Installation and Service Commissioning

Testing the Fixed High Limit

Matching the Coding Addresses to the System Version

The minimum circulation volume should be 10% of the circulation volume at rated load.Reduce the heat consumption as far as possible.

1. Hold down the “TEST” key until the burner has shut down: Thermostat is bridged. The fixed high limit must shut down the burner at the latest when the safety temperature has been reached.

2. Release the “TEST” key.

3. Wait until the boiler water temperature has dropped approx. 15 to 20 K below the selected safety temperature.

4. Reset the fixed high limit by pressing reset button.

Refer to the Operating Instructions.

Check and adjust accordingly all addresses in Code 1.

Check the following coding addresses and adjust accordingly in Code 2:

Category Function

0C:__ 2 “Boiler” Return temperature control

0d:__ 2 “Boiler” Therm-Control

4C:__ 1 “General” Function at plug sÖ

4d:__ 1 “General” Function at plug sL

4E:__ 1 “General” Function at plug gS

98:__ 1 “General” Viessmann system number

9C:__ 1 “General” Monitoring LON participants

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Matching the Coding Addresses to the System Version (continued)

Matching the Control Unit to the Two-stage Burner

Matching coding addresses according to the burner used

Address Meaning Setting

03:__ Fuel Gas operation: 0 (delivered condition)Oil operation: 1 (irreversible)

08:__ Units and tens of the maximum burner output

Example: Max. burner output:225 kW – select: 25

Note: Values up to and including 199 kW can be entered directly.

09:__ Hundreds of the maximum burneroutput

Example: Max. burner output: 225 kW – select: 2

0A:__ Ratio of output burner stage 1 tomaximum burner output in percent

Example: Output burner stage 1135 kWMax. burner output: 225 kW(135 kW: 225 kW) · 100% = 60%

Matching coding addresses according to the burner used

Address Meaning Setting

03:__ Fuel Gas operation: 0 (delivered condition)Oil operation: 1 (irreversible)

08:__ Units and tens of the maximum burner output

Example: Max. burner output: 225 kW – select: 25

Note: Values up to and including 199 kW can be entered directly.

09:__ Hundreds of the maximum burner output Example: Max. burner output: 225 kW – select: 2

15:__ Modulation range runtime Calculate servomotor runtime(s) between base load and max. burner output

0A:__ Ratio of output base load to maximum burner output in percent

Example: Output burner stage 1135 kWMax. burner output: 225 kW (135 kW: 225 kW) · 100% = 60%

05:__ Ratio of partial output at g of the servomotor runtime to maximum burner output in percent

Example: Partial output 171 kWMax. burner output: 225 kW (171 kW: 225 kW) · 100% = 76%

Matching the Control Unit to the Modulating Burner

Note: The burner must be fully adjusted. To achieve a wide modulating range, set the minimum output as low as possible (take the chimney and flue system into account).

Commissioning

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Checking Actuators and Sensors

The following actuators (relay outputs) can be switched subject to system equipment level:

Display Explanation

0 All actuators are switched off

1 Burner ON or burner stage 1 ON or modulation controller ramps up (modul. burner)

2 Burner stages 1 and 2 ON or modulation controller neutral (modul. burner)

3 Modulation controller ramps down (modul. burner).

5 Output sÖ On

6 Output sL On

7 Output gS Open

8 Output gS Neutral

9 Output gS Close

10 Output circulation pump for DHW tank heating sA ON

11 Output central fault message gÖ ON

15 Solar circuit pump output sF at solar control module SM1 enabled

16 Solar circuit pump output sF at solar control module SM1 switched to minimum speed

17 Solar circuit pump output sF at solar control module SM1 switched to maximum speed

18 Output sS at solar control module SM1 enabled

19 Contact P - S on plug aBJ for extension EA1 closed

20 Output A1 at extension AM1 enabled

21 Output A2 at extension AM1 enabled

Note: During burner operation, the connected pumps are started.

Checking SensorsActual temperatures can be scanned in the “i” menu.


Commissioning

Testing Relays1. Press OK and simultaneously for approx. 4 sec.

flashes on the display.

2. With select and confirm with OK.

3. Select required actuator with (see following table). The display shows the number for the activated actuator and “ON”.

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Connecting the Control Unit to the LON

The LON communication module (accessory) must be plugged in.

Installation Instructions LON communication module

Note: The data transfer via LON can take several minutes.

Single boiler system with Vitotronic 200-H and Vitocom 100 LAN 1 (example)Set the LON participant numbers and further functions via code 2 (see the following table).

Note: In the same LON system, the same participant number must not be allocated twice. Only one Vitotronic may be programmed as fault manager.

All coding addresses in the table are listed in the “General” group.

Boiler control unit Vitotronic 200-H Vitotronic 200-H Vitocom

Participant no. 1.Code “77:1”.

Participant no. 10.Code “77:10”.

Participant no. 11.Set code “77:11”.

Participant no. 99.

Control unit is fault manager.Code “79:1”.

Control unit is not fault manager.Code “79:0”.

Control unit is not fault manager.Code “79:0”.

Device is fault manager.

Control unit transmitsthe time.Code “7B:1”.

Control unit receives the time.Set code “81:3”.

Control unit receives the time.Set code “81:3”.

Device receives the time.

Control unit transmitsoutside temperature.Set code “97:2”.

Control unit receives outside temperature.Set code “97:1”.

Control unit receivesoutside temperature.Set code “97:1”.

--

Viessmann systemnumber.Code “98:1”.



--

LON participant faultmonitoringCode “9C:20”.



--

A A

LegendA Terminal end resistor

Commissioning

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Integrating a Control Unit into the LON

Carrying out a LON participant check The participant check is used to test communication with the system devices connected to the fault manager.

Preconditions: The control unit must be programmed as fault manager

(code “79:1” in the “General” group). The LON participant number must be programmed in

all control units. The LON participant list in the fault manager must

be up to date.

Service menu:1. Press OK and simultaneously for approx. 4 sec.

2. “Service functions”

3. “Participant check”

4. Select participant (e.g. participant 10).

5. Start the participant check with “OK”.

Successfully tested participants are designated with “OK”.

Unsuccessfully tested participants are designated with “Not OK”.

Note: To carry out a new participant check, create a new participant list with “Delete list?” (participant list is updated).

Note: During the participant check, the display for the relevant participant shows the participant no. and “Wink” for approx. 1 min.

Commissioning

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Vitotronic 100, GC1B Installation and Service Commissioning

Making the LON Connection

The Viessmann LON system is designed for the “Line” BUS topology with a terminator at both ends (accessories). The transfer distances for LON are subject to the electrical properties of the respective cabling. For this reason, only use the stated cable types. Use only one type of cable within the LON.

Observe the cabling requirements for the operation of the LON interface FTT 10-A (see www.echelon.com). The line may be up to ≤ 23 ft. (7 m) long

LegendA Control unit or VitocomB LON cable, 23 ft. (7 m) longC Terminator

All Viessmann equipment is connected via RJ45 plugs. The Viessmann LON system always requires the cores “1” and “2” and the screen. The cores are interchangeable. The installation is therefore safe from pole errors.

Connection with Viessmann LON cable and coupling Connection with on-site cable and LON plug

The line may be up to ≤ 3000 ft. (900 m)(with LON plug)

LegendA Control unit or VitocomB On-site cableC TerminatorD LON plugE Up to 99 participants

Installation spacing 23 to 69 ft. (7 to 21 m)

LegendA Control unit or VitocomB LON cable, 23 ft. (7 m) long Max. 3 cables between 2 appliancesC TerminatorD LON coupling

Connection with Viessmann LON cable

Connection with LON cable, on-site cable and LON junction box

LegendA Control unit or VitocomB LON cable, 23 ft. (7 m) longC TerminatorD LON junction boxesE On-site cableF Up to 99 participants

The line may be up to ≤ 3000 ft. (900 m) (with LON junction boxes)

≤ 3000 ft.

≤ 3000 ft.

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Entering a Service PIN for LON Participants

Integration of the Vitotronic 100 into a higher LON system, e.g. in conjunction with a third party control unit.The LON participant is identified with the service PIN.

1. Press OK and simultaneously for approx. 4 sec.

2. Press to select 6. “PIN” is displayed.

3. Enable PIN with OK.

4. Exiting the input function: Press .

Commissioning

Entering a PIN Code for Vitocom 100

The PIN code of a connected Vitocom 100 can be entered at the Vitotronic 100.

Vitocom 100 installation instructions


2. Press to select 8. “00 00” is displayed for the entry of the PIN code and the number of remaining entry attempts.

3. Select the position for the entry with .

4. Select the relevant figures with .

5. Confirm the PIN code with OK.The entered PIN code is checked (figures flashing). If the PIN code entered is correct, “FrEE” is displayed and the entry is automatically left.

6. Exiting the input function: Press .

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Calling Up the Service Level

1. Press OK and simultaneously for approx. 4 sec. flashes on the display.

2. Select required function. See the following pages.

Leaving the Service Level

Scanning Operating Data

Brief Scan

1. Press to select 9.

2. Confirm with OK. “OFF” flashes.

3. Confirm with OK.

Operating data can be scanned in the “i” menu.


2. Confirm with OK.

3. Select the required scan with . For example, “b” for “Boiler coding card” (see following table)

4. Confirm selected scan with OK.

For explanations of individual scans, see the following table:

Brief Scan Display

8 8 8 8 8 8

0 -- Systemscheme

Software versionControl unit

Software versionProgramming unit

2 -- Maximum flue gas temperature

3 -- Set boiler water temperature

4 -- Common demand temperature

5 -- Set DHW tank temperature

Note: The service level is automatically exited after 30 min.


Service Scans

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Brief Scan (continued)

Brief Scan Display

8 8 8 8 8 8

6 Number of KM BUS participants Number of LON participants

7 SNVT configuration0:Auto1:Tool

Software version communicationcoprocessor

Software version LON module

8 -- Subnet address/system no. Node address

9 -- Burner type Appliance type

b -- Boiler coding card

L Burner:

0: OFF1: Burner stage 1/base load2: Burner stage 2/full load

Isolationvalve:0: OFF1: Preheating2: Control Close3: Control4: Control Open5: Open6: Run-on

Output reduction in %0: OFF

E1

Software version solar control module, type SM1

-- -- -- Software versioncascade module

E3

-- -- Software version plug-in adaptor for external safety equipment

Extension AM1

F2

Software version Output A1configuration(value corresponds to code 33 setting)

Output A1switching state0: OFF1: ON

Output A2configuration(value correspondsto code 34 setting)

Output A2switching state0: OFF1: ON

Extension EA1

F3

Output 157 configuration(value corresponds to code 5C setting)

Output 157switching state0: OFF1: ON

Input DE1switching state0: open1: closed



F4

Softwareversion

-- External hook-up 0 - 10VDisplay in %

Solar Control Module SM1

F5

Stagnation time of the solar thermal system in hrs.

F6

Night DHW circulation, solar thermal system (number)

F7

Monitoring of differential temperature, solar thermal system

F8

-- -- -- Reheatingsuppression0: disabled1: enabled

Output 22switching state0: OFF1: ON

Service Scans

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When the limits specified in coding addresses “21”, “23” or “1F” in category 2 “Boiler” are reached, the red fault indicator flashes and the following appears on the programming unit display (subject to the setting):

The specified hours run and . The defaulted interval with clock symbol u and . The defaulted max. flue gas temperature and .

Scanning and Resetting Service Display

Acknowledging and Resetting ServicePress OK to acknowledge a service message.

Note: An acknowledged service message that was not reset reappears after 7 days.

After a Service Has Been Carried Out (resetting service)Reset code “24:1” to “24:0” in category 2 “Boiler”.

Note: The selected service parameters for hours run and time interval restart at 0.

Service Scans/ Troubleshooting

Fault Display

In the event of a fault, the red fault display flashes at the control unit. On the programming unit display, the 2-digitfault code and flash.Output gÖ (central fault message) is switched ON.Other current faults can be displayed with . For an explanation of the fault codes, see the following pages.

Acknowledge FaultPress OK; the standard display is shown again.A fault message facility, if connected, will be switched off.

If an acknowledged fault is not remedied, the fault message will be re-displayed the following day and the fault message facility restarted.

Calling up Acknowledged FaultsPress OK for approx. 4 sec. The 10 most recent faults (including resolved ones) can be scanned.

Calling Up Fault Codes From the Fault Memory (fault history)The 10 most recent faults (including those remedied) are saved and can be called up.Faults are sorted by date.


2. Select with and activate fault history with OK.

3. Select fault messages with .

Example: Fault code “50”

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Vitotronic 100, GC1B Installation and Service Troubleshooting

Fault Display (continued)

Fault Codes

Displayed Fault Code

System Characteristics Cause Measures

0F Control mode. Service “0F” is only displayed in fault history.

Service required

Note: After servicing, set code “24:0”.

30 With DHW tank: Circulation pump for DHW tank heating on; boiler is maintained at set DHW tank temperature. Without DHW tank: Boiler is regulated by the adjustable high limit.

Short circuit, boiler water temperature sensor.

Check the boiler water temperature sensor (see page 116).

38 With DHW tank: Circulation pump for DHW tank heating on; boiler is maintained at set DHW tank temperature. Without DHW tank: Boiler is regulated by the adjustable high limit.

Lead break, boiler water temperature sensor.


50 DHW tank primary pump “ON”:Set DHW temperature= Set boiler water temperaturePriority control is cancelledorWith primary store system:DHW tank heating is started and stopped via DHW tank temperature sensor 2.

Short circuit, DHW tanktemperature sensor 1.

Check the DHW tank temperature sensor (see page 116).

51 With primary store system:DHW tank heating is started and stopped via DHW tank temperature sensor 1.

Short circuit, DHW tanktemperature sensor 2.


52 Control mode. Short circuit, supplytemperature sensor.


58 DHW tank primary pump “ON”:Set DHW temperature= Set boiler water temperaturePriority control is cancelledorWith primary store system:DHW tank heating is started and stopped via DHW tank temperature sensor 2.

Lead break, DHW tanktemperature sensor 1.


59 With primary store system:DHW tank heating is started and stopped by DHW tank temperature sensor 1.

Lead break, DHW tank temperature sensor 2.


5A Control mode. Lead break, supply temperature sensor.

Check the supply temperature sensor (see page 116).

60 Boiler with maximum temperature, no output reduction, mixing valve return temperature control “Open”.

Short circuit, temperature sensor aJA.

Check temperature sensor (see page 116).

68 Boiler with maximum temperature, no output reduction, mixing valve return temperature control “Open”.

Lead break, temperaturesensor aJA.

Check temperature sensor (see page 116).Without temperature sensor:Set code “4A:0” in group 1“General”.

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Fault Codes

DisplayedFault Code


70 Shunt pump constantly “ON”.With primary store system:Mixing valve primary circuit “Close”; no DHW heating.

Short circuit, temperaturesensor aJB.

Check temperature sensor (see page 116).

78 Shunt pump constantly “ON”.With primary store system:Mixing valve primary circuit “Close”; no DHW heating.

Lead break, temperaturesensor aJB.

Check temperature sensor (see page 116).Without temperature sensor:Set code “4b:0” in group 1“General”.

90 Control mode. Short circuit, temperature sensor /,Connection at the solar control module.

Check temperature sensor /.

Solar control module

installation and service instructions

91 Control mode. Short circuit, temperature sensor aÖ,Connection at the solar control module.

Check temperature sensor aÖ.

Solar control module installation and service instructions

92 No solar DHW heating. Short circuit, collector temperature sensor, Connection of temperature sensor & at solar control module.

Check solar control unit sensor.

Solar control unit installation and service instructions

93 Control mode. Short circuit, temperature sensor, connection at S3 of the Vitosolic.



94 No solar DHW heating. Short circuit, DHW tank temperature sensor, connection of temperature sensor % at solar control module.



98 Control mode. Lead break, temperature sensor /, connection to the solar control module.

Check temperature sensor /.

Solar control module installation and service instructions

99 Control mode. Lead break, temperature sensor aÖ, connection to the solar control module.

Check temperature sensor aÖ.

Solar control module

installation and service instructions


Troubleshooting

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Fault Codes

DisplayedFault Code


9A No solar DHW heating. Lead break, collector temperature sensor, connection of temperaturesensor & at solar control module.


Solar control unit installation

and service instructions

9b No solar DHW heating. Lead break, temperature sensor, connection of sensor at S3 of the Vitosolic.



9C Control mode. Lead break, DHW tank temperature sensor, connection of temperature sensor % at solar control module.



9E Control mode. No flow rate in solar circuit or flow rate too low, or temperature limiter has responded.

Check solar circuit pump and solar circuit.Acknowledge fault message.


9F Control mode. Solar control module or Vitosolic fault.Displayed if a fault occurs at these appliances that has no fault code in the Vitotronic.

Check solar control unit.

Solar control unit installation

and service instructions

A0 Boiler cools down. Fault, safety equipment at “X7” of plug-in adaptor 2 for external safety equipment.

Check safety equipment, and reset if required.


Check safety equipment, and reset if required.


Check safety equipment,and reset if required.


Check safety equipment,and reset if required.

AA Control mode. Therm-Control configuration fault:Plug aJA not plugged in.

Insert plug aJA.For Vitocrossal, code “0d:0” in group 2 “Boiler” must be selected.

Ab Control operation;DHW tank may be cold.

Primary store system configuration error:Code “55:3” has been selected, but plug aJB is not plugged in and/or Codes “4C:1” and “4E:2” in the “General” category have not been set.

Insert plug aJB and check codes.

Troubleshooting

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Fault Codes

DisplayedFault Code


AC Control mode. Return temperature control configuration error:Code “0C:1” in group 2 “Boiler” has been set, but plug aJA is not plugged in and/or code “4E:0” in group 1 “General” is not set.

Insert plug aJA and checkcodes.

Ad Control mode. Isolation valve configuration error:Code “0C:2”, “0C:3” or “0C:4” in group 2 “Boiler” is set andcode “4E:1” in group 1 “General” is set.

With isolation valve:

Set code “4E:0” in group 1“General”.Without isolation valve:Set code “0C:1” in group 2“Boiler”.

b0 Control mode. Short circuit, flue gas temperature sensor. Check the flue gas temperature sensor (see page 116).

b1 Control mode. Communication error, programming unit. Check connections and replace the programming unit if required.

b5 Control mode. Internal fault. Check PCB and plug-in connection; replace PCB if required.

b6 Constant mode. Invalid hardware recognized. Check coding address “92”; “92:161” must be selected.

b7 Boiler is regulated by the adjustable high limit.

Boiler coding card fault. Plug in or replace boiler coding card.

b8 Control mode. Lead break, flue gas temperature sensor. Check the flue gas temperature sensor (see page 116).Without flue gas temperature sensor:Set code “1F:0” in group 2 “Boiler”.

bF Control mode.No communication via LON.

Incorrect LON communication module. Replace LON communication module.

C1 Boiler cools down. External safety equipment at plug aBÖ. Check connection andexternal safety equipment.

C2 No solar DHW heating. Lead break, KM BUS to solar control module or Vitosolic.

Check KM BUS cable and appliance.Without solar control unit:Set code “54:0” in group 1“General”.

C3 Control mode. Communication error, extension AM1. Check connections.Without extension AM1:Set code “32:0” in group 1“General”.

C8 Boiler cools down. Fault, low water indicator at “X7” of plug-in adaptor 1 for external safety equipment.

Check the system water level; reset low water indicator.


Troubleshooting

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Fault Codes

DisplayedFault Code


C9 Boiler cools down. Fault, maximum pressure limiter at “X3” of plug-in adaptor 1 for external safety equipment.

Check system pressure; reset maximum pressure limiter.

CA Boiler cools down. Fault, minimum or maximum pressure limiter 2 at “X2” of plug-in adaptor 1 for external safety equipment.

Check system pressure, reset minimum or maximum pressure limiter 2.

Cb Boiler cools down. Additional fixed high limit faultorTemperature limiter at “X1” of plug-in adaptor 1 for external safety equipment.

Check system temperature; reset fixed high limit.

Cd Control mode. Vitocom 100 communication fault. Check connections and the Vitocom 100.

Installation and service instructions Vitocom 100

Without Vitocom 100: Set code “95:0” in group 1“General”.

CE Control mode. Communication fault, plug-in adaptor 1 for external safety equipment.

Check plug-in adaptor.Without plug-in adaptor:Set code “30:0” in group 1“General”.

CF Control mode.No communication via LON.

Communication error, LON communication module of control unit.

Check LON communication module and replace if required.If no LON communication moduleis installed, set code “76:0” in category 1“General”.

d1 Boiler cools down. Burner fault. Check burner.

d2 Control mode. Communication fault, plug-in adaptor 2 for external safety equipment.

Check plug-in adaptor).Without plug-in adaptor:Set code “31:0” in group 1“General”.

d3 Control mode. Communication error, extension EA1. Check connections (see page 115).Without extension EA1:Set code “5b:0” in category 1 “General”.

d4 Boiler cools down. The fixed high limit has responded or fuse F2 has blown.

Check the fixed high limit or the burner, burner loop and fuse F2.

d6 Control mode. Input DE1 at extension EA1 reports a fault.

Remove fault at appliance concerned.






Troubleshooting

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Boiler Water Temperature Control

Brief Description The boiler water temperature is regulated by starting and stopping the burner or through modulation.

The set boiler water temperature is determined from the following parameters:– Set supply temperature of the heating circuit A1

(system circuit) or the heating circuits connected via the LON

– External demand– Set DHW temperature The set boiler water temperature is subject to the boiler and the heating/control versions. The boiler coding card defaults a minimum boiler water temperature that must be maintained to protect the boiler. In conjunction with Therm-Control: The set boiler water temperature will be increased when the actual temperature at the Therm-Control sensor falls below the set temperature. For heating the DHW tank, a set boiler water temperature is defaulted that lies 20 K above the set DHW temperature (change in coding address “60” in category 3 “DHW”).

FunctionsThe boiler water temperature is captured by the following equipment:

Fixed high limit STB (liquid expansion) Adjustable high limit TR (liquid expansion) Boiler water temperature sensor (change in resistance)

Upper Control Range Limits

Fixed high limit STB 230/210ºF (110/99ºC) Adjustable high limit TR 203/189ºF (95/87ºC) Electronic maximum temperature limit:– Setting range: 68/260ºF (20 to 127ºC)– Changed via coding address “06” in the “Boiler”

category. Lower control range limits

Lower Control Range Limits In standard mode and when frost protection is enabled, the boiler water temperature will be regulated subject to the respective boiler


Boiler Protection FunctionTherm-Control

(Start-up system) For heating systems with distributor installed close to the boiler.

Requirement: The boiler water flow rate in the startup phase (e.g. after a weekend shutdown) must be able to be reduced by at least 50%. Also affects the heating circuits.

FunctionSingle Boiler Systems

The Therm-Control sensor, installed near the return connector, captures the return temperature.

The burner is ramped up to full load if the factory-selected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the mixing valve.

When the set temperature is exceeded, the mixing valves are opened and the flow rate gradually increased to 100%.

Multi Boiler Systems The Therm-Control sensor, installed near the return connector, captures the return temperature.

The burner is ramped up to full load if the factory-selected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the isolation valve. Where the Therm-Control sensor cannot affect the isolation valves it must, instead, regulate the downstream heating circuits.

When the set temperature is exceeded, the isolation valve is opened and the flow rate gradually increased to 100%.

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Boiler Water Temperature Control (continued)

Connection in Heating Systems Without LON

Single Boiler System Plug sÖA1 of the Vitotronic is used as switching contact for the Therm-Control. Required code: “4C:2” in category 1

“General”

Multi Boiler System Plug sÖA1 of the Vitotronic is used as switching contact for the Therm-Control. Required code: “0d:1” in category 2 “Boiler” and “4C:2” in category 1 “General”

Legend sÖA1 Closing the mixing valvesA Contactor relayB Downstream heating circuit controller, switching contact closed: Signal for mixing valve “Close”

Raising the Return Temperature Via Shunt Pump or/and 3-way Mixing Valve

With shunt pump: For heating systems with distributor installed close to the boiler. With 3-way mixing valve: For heating systems where downstream heating circuits cannot be controlled, e.g. older heating systems or commercial green houses.


Legend sÖA1 Closing the mixing valves Contactor relay connection to boiler #1 Contactor relay connection to boiler #2B Downstream heating circuit controller, switching contact closed: Signal for mixing valve “Close”C Power supply, 120V/60 HzD Junction box, on site

A1A2

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Requirement:– The boiler water flow rate must be able to be reduced

by at least 50%.– With shunt pump:

Size the shunt pump to approx. 30% of the total throughput.

– With 3-way mixing valve: Size the boiler circuit pump at each boiler to approx. 110% of the total throughput.

Also affects the heating circuits.

FunctionSingle boiler systems and multi boiler systems with a common shunt pump

Temperature sensors T1 and T2 capture the return temperature at different test points. The shunt pump is started via temperature sensor T2 if the factory-selected minimum return temperature (defaulted by the boiler coding card) is not being achieved. The flow rate will be reduced via the mixing valve if the minimum return temperature captured by temperature sensor T1 is not achieved despite the return temperature raising.

Single boiler systems with shunt pump and 3-way mixing valve

Temperature sensors T1 and T2 capture the return temperature at different test points. The shunt pump is started via temperature sensor T2 if the factory-selected minimum return temperature (defaulted by the boiler coding card) is not being achieved. The flow rate will be reduced via the 3-way mixing valve if, in spite of the return temperature raising facility, the minimum return temperature captured by temperature sensor T1 is not achieved.

Multi boiler systems with shunt pumps for every boiler Temperature sensors T1 and T2 capture the return temperature at different test points. The shunt pump is started via temperature sensor T2 if the factory-selected minimum return temperature (defaulted by the boiler coding card) is not being achieved. If the minimum return temperature captured by temperature sensor T1 is not achieved despite the return temperature raising, the flow rate will be reduced via the isolation valve. Where temperature sensor T1 cannot affect the isolation valves it must, instead, regulate the downstream heating circuits.


Multi boiler systems with boiler circuit pump and 3-way mixing valve

Temperature sensor T1 records the return temperature. The flow rate is proportionally reduced via the 3-way mixing valve on the boilers if the factory-selected set temperature (defaulted by the boiler coding card) is not achieved.

When the set temperature is exceeded, the 3-way mixing valve is opened and the flow rate is gradually increased to 100%.

Multi boiler systems with boiler circuit pump, low loss header and 3-way mixing valve

Temperature sensor T1 records the return temperature. The flow rate is proportionally reduced via the 3-way mixing valve on the boilers if the factory-selected set temperature (defaulted by the boiler coding card) is not achieved.

When the set temperature is exceeded, the 3-way mixing valve is opened and the flow rate is gradually increased to 100%.

Downstream heating circuits are hydraulically separated.

The flow temperature is controlled by the temperature sensor (cascade control unit) in the low loss header.

Connection in Heating Systems Without LONSingle Boiler System

Plug sÖA1 of the Vitotronic is used as switching contact. Required code: “4C:2” in category 1 “General”

Legend sÖA1 Closing the mixing valvesA Contactor relayB Downstream heating circuit controller, switching contact closed: Signal for mixing valve “Close”

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Multi Boiler System Plug sÖA1 of the Vitotronic is used as switching contact.

Required code: “0d:1” in category 2 “Boiler” and “4C:2” in category 1 “General”

Distribution Pump For heating systems with remote substation (> 20 m). Requirement:

The heat transfer must be able to be reduced. Also affects the heating circuits. The distribution pump must be started by a higher third party control unit if a boiler is enabled.

Size the distribution pump to approx. 110% of the total throughput.

With injection control: For heating circuits that require heat immediately a heat demand is issued (e.g. air heaters).

FunctionMulti boiler systems with distribution pump and low pressure distributor

Temperature sensor T1 records the return temperature. The burner is ramped up to full load if the factory-selected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the mixing valve. The mixing valves are fully closed upon demand.


Multi boiler systems with distribution pump and injection control

Temperature sensor T1 records the return temperature. The burner is ramped up to full load if the factory-selected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the mixing valve. For this, the mixing valves are proportionally or fully closed.


Connection in Heating Systems Without LONMulti Boiler System

Plug sÖA1 of the Vitotronic is used as switching contact. Required code: “0d:1” in category 2 “Boiler” and “4C:2” in category 1 “General”


A1A2


A1A2

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Switching Hysteresis, BurnerPermanent Switching Hysteresis

Code “04:0”

Heat Demand-dependent Switching HysteresisThe heat demand-dependent switching hysteresis takes the boiler load into account.


The switching hysteresis, i.e. the burner runtime varies subject to actual heat demand.

ERB50 FunctionCode “04:1”

Subject to heat demand, values between 6 and 12 K result.

ERB80 FunctionCode “04:2”

Subject to heat demand, values between 6 and 20 K result.

Control SequenceBoiler Goes Cold (set value −2 K)The burner start signal is set as the set boiler water temperature minus 2 K, and the burner starts its own monitoring program.

The burner start may be delayed by a few minutes subject to the number of auxiliary circuits and the combustion type.

Boiler Heats UpThe burner stopping point is determined by the shutdown differential (coding address “13” in category 2 “Boiler”).

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DHW Tank Control

Brief Description The DHW tank adjustable high limit functions as a constant temperature controller. This is achieved by starting and stopping the circulation pump for DHW tank heating.The switching differential is ±2.5 K. For heating the DHW tank, a set boiler water temperature is defaulted that lies 20 K above the set DHW temperature (change in coding address “60” in category 3 “DHW”).

During DHW tank heating, central heating is switched off (optional DHW tank priority control).

FunctionsFrost ProtectionThe DHW tank will be heated to 68ºF (20ºC) if the DHW temperature falls below 41ºF (5ºC).

Auxiliary Function for DHW HeatingThis function is activated by providing a second set DHW temperature via coding address “58” in category 3 “DHW” and activating the fourth DHW phase for DHW heating.

Set DHW TemperatureThe set DHW temperature can be adjusted between 50/140ºF (10/60ºC).The set range can be extended up to 203ºF (95ºC) via coding address “56” in category 3 “DHW”.

System With Primary StoreThe above functions also apply in conjunction with primary store systems.

Set the following codes: “4C:1”, “4E:2” in category 1 “General”, “55:3” in category 3 “DHW” (see coding overview).

System With Solar DHW HeatingA third set DHW temperature can be defaulted via coding address “67” in category 3 “DHW”.

Reheating by the boiler will be suppressed above this value. The DHW tank is heated exclusively by the solar thermal system.


Control SequenceCoding “55:0” in Category 3 “DHW”, tank HeatingThe DHW tank Goes Cold (set value −2.5 K; change via coding address “59” in category 3 “DHW”):

The set boiler water temperature is adjusted 20 K higher than the set DHW temperature (adjustable via coding address “60”).

Pump on:– Starting the circulation pump for DHW tank heating

subject to the boiler water temperature (code “61:0”): The circulation pump starts when the boiler water

temperature is 7 K higher than the DHW temperature.– Immediate start of the circulation pump for DHW tank

heating (code “61:1”).

The DHW tank is Hot (set value +2.5 K): The set boiler water temperature is returned to the selected set value.

Pump run-on: The circulation pump runs on after DHW tank heating until one of the following criteria is met:– The differential between the boiler water and the

DHW temperature is less than 7 K.– The weather-compensated set flow temperature

has been reached.– The set DHW temperature is exceeded by 5 K.– The set max. run-on time has been reached (coding

address “62”). Without pump run-on (code “62:0”)

Coding “55:1” in Category 3 “DHW”, Adaptive DHW tank HeatingWith adaptive DHW tank heating, the speed of the temperature rise during DHW heating is taken into account.

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DHW Tank Control (continued)

The DHW tank Goes Cold (set value −2.5 K; change via coding address “59”):


Pump on:– Starting the circulation pump for DHW tank heating

subject to the boiler water temperature (code “61:0”): The circulation pump starts when the boiler water

temperature is 7 K higher than the DHW temperature.– Immediate start of the circulation pump for DHW tank

heating (code “61:1”).

The DHW tank is hot: The control unit checks whether the boiler will still be required to supply heating energy after the DHW tank has been heated up or whether residual boiler heat should be transferred to the DHW tank. Accordingly, the control unit determines the burner and circulation pump stop times to prevent the set DHW temperature being substantially exceeded after the DHW tank has been heated up.

Code “55:2” in category 3 “DHW”, tank temperature control with 2 DHW tank temperature sensors DHW tank temperature sensor 1 enables the circulation pump for DHW tank heating and is evaluated for stop conditions during the pump run-on time. DHW tank temperature sensor 2:

DHW tank heating will start early if a lot of hot water is drawn off. DHW tank heating will terminate early if no hot water is drawn off.

DHW tank goes cold: Set value −2.5 K, adjustable via coding address “59” or

Actual DHW temperature at sensor 2 < set DHW temperature x factor for start time (adjustment via coding address “69”).

The DHW tank is hot: Set value +2.5 K and

Actual DHW temperature at sensor 2>set DHW temperature x factor for stop time (adjustment via coding address “68”).

Coding “55:3” in category 3 “DHW”, tank temperature control, primary store system

The DHW tank Goes Cold (set value −2.5 K; change via coding address “59”):


The primary pump in the primary store system starts. The 3-way mixing valve opens and then regulates to the defaulted set DHW temperature.

The circulation pump for DHW tank heating cycles (short term ON and OFF) until the set supply temperature has been reached (set DHW temperature + 5 K). Then it runs constantly. If, during heating, the actual value falls below the required set temperature, the circulation pump for DHW tank heating will temporarily cycle again.

The DHW tank is Hot: DHW tank temperature sensor 1:Actual value ≥ set valueandDHW tank temperature sensor 2:Actual value > set value −1.5 K: The set boiler water temperature is returned to the weather-compensated set value.

The circulation pump for DHW tank heating stops immediately when the 3-way mixing valve is fully opened or The circulation pump for DHW tank heating stops after expiry of the run-on time that is selected via coding address “62”.


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Calling Up Coding Level 1

Note: Codes that have not been assigned due to the heating system equipment level or the setting of other codes are not displayed.


2. With , select 1 for coding level 1 and confirm with OK. “I” flashes on the display for the coding addresses in category 1.

3. Select the category of the required coding address with :1: “General”2: “Boiler”3: “DHW”4: “Solar”6: “All codes std device”. In this category, all coding

addresses of coding level 1 are displayed in ascending order.

Confirm selected category with OK.

4. Select coding address with .

5. Select value according to the following tables with and confirm with OK.

6. If you want to reset all codes to their delivered condition:Select “7” with and confirm with OK.When D flashes, confirm with OK.

Note: This also resets codes from coding level 2.

7. Exit coding level 1: Press .

8. Exit the service level: Press to select 9.


10. Confirm with OK.


Coding Level 1

Category 1 “General”

Coding in the Delivered Condition Possible Change

System Design

00:1 One heating circuit without mixing valve (heating circuit 1), without DHW heating.

00:0 Set automatically if “01:2” or “01:3” has been selected.

00:2 One heating circuit without mixing valve A1 (heating circuit 1), with DHW heating (code is adjusted automatically).

Servomotor Runtime

40:... Runtime, servomotor at plug gSA1 in conjunction with return temperature raising.Delivered condition specified by the boiler coding card.

40:5to40:199

Runtime adjustable from 5 to 199 sec.

Boiler Circuit Pump Function

53:1 System with low loss header: Boiler circuit pump only runs when there is demand if the burner is running (with run-on time).

53:0 System with low loss header: Boiler circuit pump always runs when there is demand

User No.

77:1 LON participant number. 77:1to77:99

LON participant number, adjustable from 1 to 99.

Note: Allocate each number only once.

Set Supply Temperature for External Demand

9b:0 No set minimum boiler water temperature for external demand.

9b:0to9b:127

Set value for external demand adjustable from 32 to 260ºF (0 to 127°C) (limited by boiler specific parameters).

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Category 2 “Boiler”


System Design

01:1 Single boiler system. 01:2 Multi boiler system with cascade control via LON(e.g. Vitotronic 300-K, type MW1B).

01:3 Multi boiler system with on site cascade control (third party control unit) via switching contacts (input avD and avH) or 0 – 10VDC input.

Burner Type

02:1 Two-stage burner. 02:0 Single stage burner.

02:2 Modulating burner.

Gas/Oil Operation

03:0 Gas operation. 03:1 Oil operation (irreversible).

Boiler/Burner.

05:... Modulating burner:Burner curve.Delivered condition specified by the boiler coding card.

05:0 Linear burner curve.

05:1to05:99

Non-linear burner curve(PT: Pmax)·100PT in kW: Partial output atg of the servomotor runtimePmax in kW: Maximum output.

Boiler Water Temperature Maximum Limit

06:87 Set to 188ºF (87ºC). 06:20to06:127

Adjustable from 68 to 260ºF (20 to 127°C).Observe the adjustable high limit settings.

Boiler

07:1 Sequential boiler number in a multi boiler system (in conjunction with coding address “01”).

07:2to07:4

Consecutive boiler number in multi boiler system.

Coding Level 1

100

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Vitotronic 100, GC1B Installation and Service Coding Level 1

Category 2 “Boiler” (continued)


Flue Gas Monitor

1F:0 With flue gas temperature sensor:Flue gas temperature is not monitored for service display.

1F:1to1F:250

When the limit for the flue gas temperature is exceeded, is displayed. Flue temperaturemeasured in diagram C - e.g. IF:50 is displayed when flue gas temperature reaches or exceeds 50°C (122ºF)

Burner Service in 100 hours

21:0 No service interval (hours run) selected. 21:1to21:100

The number of hours run before the burner should be serviced is adjustable from 100 to 10000 h;1 step 100 h.

Service Interval in Months

23:0 No interval for service. 23:1to23:24

Interval adjustable from 1 to 24 months.

Service Status

24:0 No display. 24:1 display (the address is automatically set and must be manually reset after a service has been carried out).

Category 3 “DHW”


Set DHW Temperature Reheating Suppression

67:40 For solar DHW heating:Set DHW temperature 104ºF (40°C).Reheating is suppressed above the selected set temperature (DHW heating by the boiler only if solar energy is not sufficient).

67:0to67:95

Set DHW temperature adjustable from 32 to 203ºF (0 to 95°C)(limited by boiler-specific parameters).

101

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Category 4 “Solar”


Speed control solar circuit pump

02:0 Solar circuit pump (multi stage) without speed control by solar control module SM1.

02:1 Solar circuit pump (multi stage) is speed-controlled with wave pack control.

02:2 Solar circuit pump is speed-controlled with PWM control.

DHW tank Maximum Temperature

08:60 The solar circuit pump stops when the actual DHW temperature reaches the maximum DHW tank temperature 140ºF (60°C).

08:10to08:90

The maximum DHW tank temperature is adjustable from 50 to 194ºF (10 to 90°C).

Stagnation Time Reduction

0A:5 To protect system components and heat transfer medium:the speed of the solar circuit pump is reduced if the actual DHW temperature is 5 K below the maximum DHW tank temperature

0A:0 Stagnation time reduction is disabled.

0A:1to0A:40

Value for stagnation time reduction is adjustable from 1 to 40 K.

Flow Rate Solar Circuit

0F:70 The solar circuit flow rate at maximum pump speed is 7 L/min.

0F:1to0F:255

Flow rate adjustable from 0.1 to 25.5 L/min;1 step 0.1 L/min.

Extended Solar Control Functions

20:0 No extended control functions enabled. 20:1 Additional function for DHW heating.

20:2 Differential temperature control 2.

20:3 Differential temperature control 2 and auxiliary function.

20:4 Differential temperature control 2 for central heating backup.

20:5 Thermostat function.

20:6 Thermostat function and auxiliary function.

20:7 Solar heating via external heat exchanger without additional temperature sensor.

20:8 Solar heating via external heat exchanger with additional temperature sensor.

20:9 Solar heating of two DHW tanks.

Only in conjunction with solar control module, type SM1.

Coding

Coding Level 1

102

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Calling Up Coding Level 2

Note: At coding level 2, all codes are accessible, including the codes in coding level 1. Codes that have not been assigned due to the heating system equipment level or the setting of other codes are not displayed.



3. With , select 2 for coding level 2 and confirm with OK. “I” flashes on the display for the coding addresses in category 1.

4. Select the category of the required coding address with :1: “General”2: “Boiler”3: “DHW”4: “Solar”6: “All codes std device”. In this category, all coding

addresses of coding level 2 are displayed in ascending order.

Confirm selected category with OK.

5. Select coding address with .

6. Select value according to the following tables with and confirm with OK.

7. If you want to reset all codes to their delivered condition:Select “7” with and confirm with OK.When D flashes, confirm with OK.

Note: This also resets codes from coding level 1.

8. Exit coding level 2: Press .

9. Exit the service level: Press to select 9.


11. Confirm with OK.


Coding Level 2

103

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00:1 Heating circuit without mixing valve A1, without DHW heating.

00:0 Set automatically, if codes “01:2” or “01:3” are selected.

00:2 Heating circuit without mixing valve A1, and with DHW heating.

1E:0 With extension EA1 (analog input 0-10V):Temperature demand from 32 to 212°F (0 to 100°C):1V 50°F (10°C)10V 212°F 100°C.

1E:1 Temperature demand from 86 to 248°F (30 to 120°C):1V 86°F (30°C)10V 248°F (120°C).

20:... Controller integral time for low loss header in sec.Delivered condition specified by the boiler coding card.The greater the integral action time, the more accurate but slower the controller.

20:10to20:199

Controller integral time adjustable from 10 to 1990 sec;1 step 10 sec.

22:... Controller integral time for low loss header in min.Time between burner start and controller start.Delivered condition specified by the boilercoding card.

22:1to22:199

Controller integral time adjustable from 1 to 199 min.

30:0 Without plug-in adaptor for external safety equipment 1.

30:1 With plug-in adaptor for external safety equipment1 (automatic recognition).

31:0 Without plug-in adaptor for external safety equipment 2.

31:1 With plug-in adaptor for external safety equipment2 (automatic recognition).

32:0 Without extension AM1. 32:1 With extension AM1; automatic recognition.

33:1 Function output A1 at extension AM1:Heating circuit pump, heating circuit without mixing valve A1 (heating circuit 1).

33:0 DHW recirculation pump.

33:2 DHW tank primary pump.

33:3 Circulation pump for neutralising system or flue gas/ water heat exchanger.

34:1 Function output A2 at extension AM1:Heating circuit pump, heating circuit without mixing valve A1 (heating circuit 1).

34:0 DHW recirculation pump.

34:2 DHW tank primary pump.

34:3 Circulation pump for neutralising system or flue gas/ water heat exchanger.

40:... Runtime, servomotor at plug gSA1 in conjunction with return temperature raising.Delivered condition specified by the boiler coding card.

40:5to40:199

Runtime adjustable from 5 to 199 sec.

4A:0 Sensor aJA not available. 4A:1 Sensor aJA available (e.g. Therm-Control temperature sensor); automatic recognition.

4b:0 Sensor aJB not installed. 4b:1 Sensor aJB installed (e.g. temperature sensor T2) (automatic recognition).

4C:2 Connection at plug sÖ:Switching contact,Therm-Control.

4C:1 Primary pump, primary store system.

4C:3 Circulation pump – flue gas/water heat exchanger.

Category 1 “General”

Coding

Coding Level 2

104

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Category 1 “General” (continued)

Coding in the Delivered Condition Possible Change4d:1 Connection at plug sL:

Shunt pump.

4d:2 Boiler circuit pump.

4d:3 Boiler circuit pump with isolation valve function.

4E:0 Connection at plug gS:Motor for isolation valve.

4E:1 Motor for 3-way mixing valve for return temperature control.

4E:2 Motor for 3-way mixing valve, primary store system.

4F:5 Run-on time shunt or boiler circuit pump 5 min. 4F:0 No pump run-on.4F:1to4F:60

Run-on time adjustable from 1 to 60 min.

52:0 Without supply temperature sensor for low loss header.

52:1 With supply temperature sensor for low loss header; automatic recognition.

53:1 System with low loss header: Boiler circuit pump only runs when there is demand if the burner is running (with run-on time).

53:0 System with low loss header: Boiler circuit pump always runs when there is demand.

54:0 Without solar thermal system. 54:1 With Vitosolic 100; automatic recognition.54:2 With Vitosolic 200; automatic recognition.54:3 With solar control module, type SM1, without

auxiliary function; automatic recognition.54:4 With solar control module, type SM1, with auxiliary

function, e.g. central heating backup (automatic recognition).

5b:0 Without extension EA1. 5b:1 With extension EA1; automatic recognition.

5C:0 Function output abJ at extension EA1: Central fault message.

5C:1 Feed pump.5C:2 Never adjust.5C:3 Never adjust.5C:4 Never adjust.5C:5 Never adjust.

5d:0 Function input DE1 at extension EA1:Not assigned.

5d:1 Not assigned.5d:2 External demand with set minimum boiler water

temperature.Set value selected in coding address “9b”.

5d:3 External blocking.5d:4 External blocking with fault message input.5d:5 Fault message input.5d:6 Not assigned.

5E:0 Function input DE2 at extension EA1:Not assigned.

5E:1 Not assigned.5E:2 External demand with set minimum boiler water


5E:3 External blocking.5E:4 External blocking with fault message input.5E:5 Fault message input.5E:6 Not assigned.

Coding Level 2

105

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Category 1 “General” (continued)

Coding in the Delivered Condition Possible Change5F:0 Function input DE3 at extension EA1:

Not assigned.5F:1 Not assigned.5F:2 External demand with set minimum boiler water


5F:3 External blocking.5F:4 External blocking with fault message input.5F:5 Fault message input.5F:6 Not assigned.

6C:0 Run-on time for circulation pump, neutralizing system at output A1 at extension AM1: None.

6C:1to6C:255

Run-on time adjustable from 1 to 255 sec.

6d:0 Run-on time for circulation pump, neutralizing system at output A2 at extension AM1: None.

6d:1to6d:255

Run-on time adjustable from 1 to 255 sec.

6E:50 Do Not Adjust. -- --76:0 Without LON communication module. 76:1 With LON communication module; automatic

recognition.77:1 LON participant number. 77:1

to77:99

LON participant number, adjustable from 1 to 99.

Note: Allocate each number only once.

78:1 LON communication enabled. 78:0 LON communication disabled.79:0 Control unit is not fault manager. 79:1 Control unit is fault manager.

80.6 A fault message is issued if a fault occurs for at least 30 sec.

80:0 Immediate fault message.

80:2to80:199

The minimum fault duration until a fault message is issued is adjustable from 10 to 995 sec.;1 step 5 sec.

88:0 Temperature displayed in °C (Celsius). 88:1 Temperature displayed in °F (Fahrenheit).8A:175 Do Not Adjust. -- --8b:0 Do Not Adjust. -- --8F:0 Do Not Adjust. -- --93:0 Fault messages during emissions test

function/service display do not affect central fault messages.

93:1 Fault messages during emissions test function/service display affect central fault messages.

94:0 System with low loss header:Primary circuit pump and DHW tank primary pump always run when there is demand.

94:1 Primary circuit pump only runs when there is demand if the burner is running (with run-on time).

94:2 DHW tank primary pump only runs when there isdemand if the burner is running (with run-on time).

95:0 Without Vitocom 100 communication interface.

95:1 With Vitocom 100 communication interface; automatic recognition.

98:1 Viessmann system number (in conjunction with monitoring several systems via Vitocom 300).

98:1to98:5

System number adjustable from 1 to 5.

9b:0 No set minimum boiler water temperature for external demand.

9b:0to9b:127

Set value for external demand adjustable from 32 to 260°F (0 to 127°C) (limited by boiler specific parameters).

9C:20 Monitoring LON participants:If there is no response from a participant, values defaulted by the control unit are used 20 min. later, and a fault message is issued.

9C:0 No monitoring.

9C:5to9C:60

Time adjustable from 5 to 60 min.

9d:0 Do Not Adjust. -- --

Coding Level 2

106

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Category 2 “Boiler”


01:1 Single boiler system. 01:2 Multi boiler system with cascade control via LON (e.g. Vitotronic 300-K, type MW1B).

01:3 Multi boiler system with on site cascade control (third party control unit) via switching contacts (input avD and avH) or 0 – 10V input.

02:1 Two-stage burner. 02:0 Single stage burner.

02:2 Modulating burner.

03:0 Gas operation. 03:1 Oil operation (irreversible).

03:2 Set automatically if no boiler coding card or an incorrect boiler coding card is inserted.

04:... Switching hysteresis, burner:Delivered condition specified by the boiler coding card.

04:0 Switching hysteresis 4 K (see page 95)

04:1 Switching hysteresis, heat demand-dependent (see page 95).ERB50 function (values from 6 to 12 K).

04:2 ERB80 function (values from 6 to 20 K).

05:... Modulating burner:Burner curve.Delivered condition specified by the boiler coding card.

05:0 Linear burner curve.

05:1to05:99

Non-linear burner curve.(PT: Pmax)·100PT in kW: Partial output at g of the servomotor runtimePmax in kW: Maximum output.

06:87 Maximum limit of the boiler water temperature set to 189°F (87°C).

06:20to06:127

Maximum limit adjustable from 68 to 260°F (20 to 127°C).Observe the adjustable high limit settings.

07:1 Sequential boiler number in a multi boiler system (in conjunction with coding address “01”).

07:2to07:4

Consecutive boiler number in multi boiler system.

08:... Maximum burner output in kW.Delivered condition specified by the boiler coding card.

08:0to08:199

Maximum output adjustable from 0 to 199 kW.

09:... Maximum burner output in kW.Delivered condition specified by the boiler coding card.

09:0to09:199

Maximum output adjustable from 0 to 19,900 kW;1 step 100 kW.

0A:... Burner base load in kW.Delivered condition specified by the boiler coding card.

0A:0to0A:100

Non-linear burner curve(PG:Pmax)·100%PG in kW: Base outputPmax in kW: Maximum output.

Coding Level 2

Coding

107

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0C:5 Modulating isolation valve, independent of the set boiler water temperature.

0C:0 No function.

0C:1 Constant return temperature control.

0C:2 Time-controlled isolation valve.

0C:3 Isolation valve switching subject to the boiler water temperature.

0C:4 Isolation valve modulating subject to the set boiler water temperature.

0d:2 With Therm-Control, affects the isolation valve (function disabled with code “0C:1”).

0d:0 Without Therm-Control.

0d:1 With Therm-Control, affects the mixing valves of downstream heating circuits.

13:... Shutdown differential in K.The burner is switched off when the set boiler water temperature is exceeded.Delivered condition specified by the boiler coding card.

13:0 Without stop differential.

13:2to13:20

Stop differential adjustable from 2 to 20 K.

14:... Minimum burner runtime in min.Delivered condition specified by the boiler coding card.

14:0to14:15

Minimum runtime adjustable from 0 to 15 min.

15:10 Runtime servomotor modulating burner 10 sec. 15:5to15:199

Runtime adjustable from 5 to 199 sec.For the Vitocrossal, see separate service instructions.

16:... Burner offset with start optimization in K (temporary reduction of the set boiler water temperature after burner start).Delivered condition specified by the boiler coding card.

16:0to16:15

Offset adjustable from 0 to 15 K.

1A:... Start optimization in min.Delivered condition specified by the boiler coding card.

1A:0to1A:60

Duration of start optimization adjustable from 0 to 60 min.

1b:60 Time from burner ignition before control starts 60 sec.

1b:0to1b:199

Control delay adjustable from 1 to 199 sec.

1C:120 Signal B4 at plug fA is not available:Compensation of signal delay for hours run meter.Time from burner start signal initiation at T2 in plug fA to opening of the solenoid valve. At each burner start, 120 sec. will be taken off the runtime.

1C:1to1C:199

Delay adjustable from 1 to 199 sec.This time is deducted from the operating time for every burner start.E.g. operating situations in which the burner is shut down via the mechanical adjustable high limit, but a burner demand is still present (hours run continue to be counted).If required, change coding address “06”.

1F:0 With flue gas temperature sensor:Flue gas temperature is not monitored for service display.

1F:1to1F:250

When the flue gas temperature limit is exceeded, is displayed. Flue temperaturemeasured in diagram C - e.g. IF:50 is displayed when flue gas temperature reaches or exceeds 50°C (122ºF)

Coding Level 2

108

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21:0 No service interval (hours run) selected. 21:1to21:100

The number of hours run before the burner should be serviced is adjustable from 100 to 10,000 h; One adjusting step 100 h.

23:0 No interval for service. 23:1to23:24

Interval adjustable from 1 to 24 months.

24:0 No display. 24:1 display (the address is automatically set and must be manually reset after a service has been carried out).

26:0 Burner fuel consumption (stage 1):No count if “26:0” and “27:0” are programmed.

26:1to26:99

Input of 0.1 to 9.9;1 step 0.1 L/h or USG/h.

Note: Values of coding addresses “26” and “27” are added together.

27:0 Burner fuel consumption (stage 1):No count if “26:0” and “27:0” are programmed.

27:1to27:199

Input of 10 to 1990;1 step 10 L/h or USG/h.

28:0 No burner interval ignition. 28:1to28:24

Interval adjustable from 1 to 24 h. Burner is force started for 30 sec. respectively.

29:0 Burner fuel consumption (stages 1 and 2):No count if “29:0” and “2A:0” are programmed.

29:1to29:99

Input of 0.1 to 9.9;1 step 0.1 L/h or USG/h.

Note: Values of coding addresses “29” and “27” are added together.

2A:0 Burner fuel consumption (stages 1 and 2); No count if “29:0” and “2A:0” are programmed.

2A:1to2A:199

Input of 10 to 1990;1 step 10 L/h or USG/h.

2b:5 Maximum preheating time of the isolation valve 5 min.

2b:0 No preheating time.

2b:1to2b:60

Preheating adjustable from 1 to 60 min.

2C:5 Maximum run-on time of the isolation valve 5 min. 2C:0 No run-on time.

2C:1to 2C:60


2d:0 Shunt pump control function only “ON” if the boiler is enabled.

2d:1 Shunt pump control function permanently “ON”.


Coding Level 2

109

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55:0 DHW tank heating, hysteresis ± 2.5 K. 55:1 Adaptive DHW tank heating enabled (see page 96).

55:2 DHW tank temperature control with 2 DHW tank temperature sensors (see page 97).

55:3 DHW tank temperature control, primary store system (see page 97).

56:0 Set DHW temperature adjustable from 50 to 140°F (10 to 60°C).

56:1 Set DHW temperature adjustable from 50 to203°F (10 to 95°C).

Note: Observe the max. permissible DHW temperature. Reset the adjustable high limit “R”.

58:0 Without auxiliary function for DHW heating. 58:1to58:95

Input of a second set DHW temperature, adjustable from 34 to 203°F (1 to 95°C). (observe coding address “56”).

59:0 DHW tank heating:Start point: Set value −2.5 KShutdown point: Set value +2.5 K

59:1to59:10

Start point adjustable from 1 to 10 K below the set value.

5A:0 For DHW heating: The set boiler water temperature is determined by the highest system supply temperature demand.

5A:1 For DHW heating: The set boiler water temperature is determined by the DHW tank supply temperature demand.

60:20 During DHW heating, the boiler water temperature is up to 20 K higher than the set DHW temperature.

60:5to60:50

The differential between the boiler water temperature and the set DHW temperature is adjustable from 10 to 50 K.

61:1 The circulation pump for DHW tank heating is started immediately.

61:0 The circulation pump for DHW tank heating is started depending on the boiler water temperature.

62:10 Circulation pump with a run-on time after DHW tank heating of up to 10 min.

62:0 Circulation pump without run-on.

62:1to62:15


63:0 Without auxiliary function for DHW heating. 63:1 Auxiliary function: 1 x daily.

63:2to63:14

Every 2 days to every 14 days.

63:15 2 x daily.

67:40 For solar DHW heating:Set DHW temperature 104° F (40° C). Reheating is suppressed above the selected set temperature (DHW heating by the boiler only if solar energy is not sufficient).

67:0to67:95

Set DHW temperature adjustable from 32 to 203°F (0 to 95°C). (limited by boiler-specific parameters).

68:8 With 2 DHW tank temperature sensors (code “55:2”):DHW tank heating stop point at set value x 0.8.

68:2to68:10

Factor adjustable from 0.2 to 1;1 step 0.1.

69:7 With 2 DHW tank temperature sensors (code “55:2”): DHW tank heating start point at set value x 0.7.

69:1to69:9

Factor adjustable from 0.1 to 0.9;1 step 0.1.

6A:75 Runtime, servomotor, mixing valve, heat exchanger set, Vitotrans 222, 80 and 120 kW: 75 sec.

6A:10to6A:255

For heat exchanger setVitotrans 222, 240 kW: set 113 sec.Runtime adjustable from 10 to 255 sec.

Category 3 “DHW”

Coding

Coding Level 2

110

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Category 4 “Solar”


00:8 The solar circuit pump starts when the collector temperature exceeds the actual DHW temperature by 8 K.

00:2to00:30

The differential between the actual DHW temperature and the start point for the solar circuit pump is adjustable from 2 to 30 K.

01:4 The solar circuit pump stops when the differential between the collector temperature and the actual DHW temperature is less than 4 K.

01:1to01:29

The differential between the actual DHW temperature and the stop point of the solar circuit pump is adjustable from 1 to 29 K.

02:0 Solar circuit pump (multi stage) without speed control by solar control module SM1.

02:1 Solar circuit pump (multi stage) is speed-controlled with wave pack control.

02:2 Solar circuit pump is speed-controlled with PWM control.

03:10 The temperature differential between the collector temperature and actual DHW temperature is regulated to 10 K.

03:5to03:20

The differential temperature control between the collector temperature and actual DHW temperature is adjustable from 5 to 20 K.

04:4 Controller amplification of the speed control 4%/K.

04:1to04:10

Controller amplification adjustable from 1 to 10%/K.

05:10 Minimum speed of the solar circuit pump 10% of the maximum speed.

05:2to05:100

Minimum speed of the solar circuit pump is adjustable from 2 to 100%.

06:75 Maximum speed of the solar circuit pump 75% of the maximum possible speed.

06:1to06:100

Maximum speed of the solar circuit pump is adjustable from 1 to 100%.

07:0 Interval function of the solar circuit pump switched off.

07:1 Interval function of the solar circuit pump switched on.To capture the collector temperature more accurately, the solar circuit pump starts for short cycles.

08:60 The solar circuit pump stops when the actual DHW temperature reaches the maximum DHW tank temperature 140°F (60°C).

08:10to08:90

The maximum DHW tank temperature is adjustable from 50 to 194° F (10 to 90° C).

09:130 The solar circuit pump stops if the collectortemperature reaches 266°F (130°C) (maximum collector temperature to protect the system components).

09:20to09:200

The temperature is adjustable from 68 to 392°F (20 to 200°C).

0A:5 To protect system components and heat transfer medium:The solar circuit pump speed is reduced when the actual DHW tank temperature is 5 K below the maximum DHW tank temperature.

0A:0 Stagnation time reduction is disabled.

0A:1to0A:40

Value for stagnation time reduction is adjustable from 1 to 40 K.

Only in conjunction with solar control module, type SM1.

Coding

Coding Level 2

111

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Category 4 “Solar” (continued)


0b:0 Frost protection function for solar circuit switched off.

0b:1 Frost protection function for solar circuit switched on (not required with Viessmann heat transfer medium).

0C:1 nt monitoring switched on.No flow rate captured in the solar circuit, or flow rate too low.

0C:0 nt monitoring switched off.

0d:1 Night circulation monitoring switched on.Unintentional flow rate is captured in the solar circuit (e.g. at night).

0d:0 Night circulation monitoring switched off.

0E:1 Calculation of solar yield with Viessmann heat transfer medium.

0E:2 Calculation of solar yield with water as heat transfer medium (never adjust, as operation is only possible with Viessmann heat transfer medium).

0E:0 Calculation of solar yield switched off.

0F:70 The solar circuit flow rate at maximum pump speed is 7 L/min.

0F:1to0F:255

Flow rate adjustable from0.1 to 25.5 L/min.1 step 0.1 L/min.

10:0 Target temperature control switched off (see coding address “11”).

10:1 Target temperature control switched on.

11:50 Set solar DHW temperature 122°F (50°C). Target temperature control switched on

(code “10:1”): Temperature at which the solar heated water in the DHW tank is to be stratified. Extended control functions set to heat two DHW tanks (code “20:8”):

The second DHW tank is heated when one DHW tank reaches its set DHW temperature.

11:10to11:90

The set solar DHW temperature is adjustable from 50 to 194°F (10 to 90°C).

12:10 Minimum collector temperature 50°F (10°C).The solar circuit pump will only start when the set minimum collector temperature is exceeded. Controller amplification of the speed control 4%/K.

12:0 Minimum collector temperature function switched off.

12:1to12:90

The minimum collector temperature is adjustable from 34 to 194°F (1 to 90°C).

20:0 No extended control functions enabled. 20:1 Additional function for DHW heating.

20:2 Differential temperature control 2.

20:3 Differential temperature control 2 and auxiliary function.

20:4 Differential temperature control 2 for central heating backup.

20:5 Thermostat function.

20:6 Thermostat function and auxiliary function.

20:7 Solar heating via external heat exchanger without additional temperature sensor.

20:8 Solar heating via external heat exchangerwith additional temperature sensor.

20:9 Solar heating of two DHW tanks.

22:8 Start temperature differential for central heating backup: 8 K.Switching output sS is switched on when the temperature at sensor / exceeds the temperature at sensor aÖ by the selected value.

22:2to22:30

Start temperature differential for central heating backup is adjustable from 2 to 30 K.

Coding Level 2

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Category 4 “Solar” (continued)

Coding Level 2


23:4 Stop temperature differential for central heating backup: 4 K.Switching output sS is switched off when the temperature at sensor / falls below the stop point. The stop point is the sum of the temperature at sensor aÖ and the value selected for the stop temperature differential.

23:2to23:30

Stop temperature differential for central heating backup is adjustable from 1 to 29 K.

24:40 Start temperature for thermostat function 104°F (40°C).

Start temperature for thermostat function ≤ stop temperature for thermostat function:Thermostat function, e.g. for reheating. Switching output sS is switched on when the temperature at sensor / falls below the start temperature for the thermostat function.

Start temperature for thermostat function > stop temperature for thermostat function:Thermostat function, e.g. for utilizing excess heat.Switching output sS is switched on when the temperature at sensor / exceeds the start temperature for the thermostat function.

24:0to24:100

Start temperature for thermostat function is adjustable from 0 to 100 K.

25:50 Stop temperature for thermostat function 122°F (50°C).

Start temperature for thermostat function ≤ stop temperature for thermostat function:Thermostat function e.g. for reheating. Switching output sS is switched off when the temperature at sensor / exceeds the start temperature for the thermostat function.

Start temperature for thermostat function > stop temperature for thermostat function:Thermostat function e.g. for utilizing excess heat.Switching output sS is switched off when the temperature at sensor / falls below the start temperature for the thermostat function.

25:0to25:100

Start temperature for thermostat function is adjustable from 0 to 100 K.

26:1 Priority for DHW tank1 – with alternate heating.

26:0 Priority for DHW tank 1– without alternate heating.

Only when setting code “20:8”. 26:2 Priority for DHW tank 2– without alternate heating

26:3 Priority for DHW tank 2– without alternate heating

26:4 Alternate heating without priority for one of the DHW tanks.

27:15 Alternate heating time 15 min.The DHW tank without priority is heated at most for the duration of the set alternate heating time if the DHW tank with priority is heated up.

27:5to27:60

The alternate heating time is adjustable from 5 to 60 min.

28:3 Alternate pause time 3 min.After the selected alternate heating time for the DHW tank without priority has expired, the rise in collector temperature is captured during the alternate pause time.

28:1to28:60

The alternate pause duration is adjustable from 1 to 60 min.

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Connection and Wiring Diagram

Overview

Designs

Legend A2 Main PCB low voltageA3 Main PCB 120V~A6 Programming unitA7 Optolink PCB/emissions test switchA8 PCBA9 Boiler coding cardA10 LON communication module (accessory)A11 Power supply unit PCBA12 ON/OFF switchX Electrical interfaces

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Connection and Wiring Diagram (continued)

Main PCB Low Voltage

Legend § Boiler water temperature sensor%A DHW tank temperature sensor%B DHW tank temperature sensor 2 for primary store

system (optional accessory)) Supply temperature sensoraG Flue gas temperature sensoraJA Therm-Control temperature sensor or Return temperature sensor T1aJB Return temperature sensor T2 or Temperature sensor primary store system (optional accessory)

Designs

avD External hook-upavG KM BUS participantavH External hook-upLON Cable for data exchange between control units

(accessories)S3 Emissions test switchV1 Fault indicator (red)V2 ON indicator (green)X Electrical interfaces

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Connection and Wiring Diagram (continued)

Main PCB 120V~

Designs

Legend sÖ Primary pump or primary store system (optional accessory) or DHW pump or Switching outputsA Circulation pump for DHW tank heating (accessory)sK No functionsL Shunt pump or boiler circuit pump (on site)fÖ Power supply, 120V/60 HzfA Oil/gas burnersgÖ Central fault messagegS Isolation valve or Mixing valve motor, return temperature raising facility or Motor for 3-way mixing valve, primary store system

(optional accessory not used)

lÖ Burner stage 2/modulating abÖ External connections (remove jumper when

connecting) a External safety equipment b External blocking

abA Safety chain (potential-free)abH Power supply for accessoriesF1, F2 FuseF6 Fixed high limitF7 Adjustable high limitK1-K10 RelayS1 ON/OFF switchS2 TEST keyX Electrical interfaces

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Boiler Coding Card

Boiler Boiler Coding Card

Service Menu Display “Diagnosis” Category ”General” Identification Spare Part No.

Vitocrossal 300, type CT3 1040 7435 870 7837 015

Vitorond 200, type VD2, VD2A 1020 7435 867 7837 012

Boiler, DHW tank, Supply (Therm-Control Sensor) and Return Temperature SensorChecking Sensors

Note: The supply temperature sensor can be used as a strap on or immersion temperature sensor.

Sensors

Components

1. Pull corresponding plug.

2. Check the sensor resistance and compare it with the curve.

3. In the case of severe deviation, check the installation and replace the sensor if required.

Flue Gas Temperature SensorA service message appears when a set limit has been reached (see coding address “1F” in category 2 “Boiler”).

Checking the Flue Gas Temperature Sensor

Viessmann NTC 10 kΩ (blue identification)

1. Disconnect plug aG.

2. Check the sensor resistance and compare it with the curve.

3. In the case of severe deviation, check the installation and replace the sensor if required.

Viessmann NTC 20 kΩ (orange identification)

Res

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Temperature

Temperature

Res

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in k

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s

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Extension EA1 Accessory (optional)

Components

The DHW recirculation pump is started by closing the contact at DE1, DE2 or DE3 by means of a push button. The runtime is adjusted via coding address “3D” in the“General” group.

Analog input 0–10VDCThe 0–10VDC hook-up provides an additional set boiler water temperature:0–1VDC Is taken as “no default for set boiler water temperature”.Note: Ensure DC separation between the LV output and the earth conductor of the on site voltage source.

Coding address “1E” in the “General” group: “1E:0” ≙ temperature demand adjustable in the

range from 32 to 212°F (0 to 100°C) 1VDC ≙ 50°F (10°C) set value change 10VDC ≙ 212°F (100°C) set value change

“1E:1” ≙ temperature demand adjustable in the range from 86 to 248°F (30 to 120°C) 1VDC ≙ 86°F (30°C) set value change 10VDC ≙ 248°F (120°C) set value change

Output aBJConnection of a central fault messaging facility or signalling reduced mode (reduction of the heating circuit pump speed).Select the function of output aBJ via coding address “5C” in the “General” group.

Digital data inputs DE1 to DE3Functions:

External heating program changeover, separate for heating circuits 1 to 3

External blocking External blocking with fault message input External demand with minimum boiler water

temperature Fault message input Brief operation of the DHW recirculation pump

When connecting external contacts, observe the requirements of safety category II, i.e. 8.0 mm air-gap and creep path or maintain a 2.0 mm insulation thickness against ‘live’ parts.

Input function assignmentSelect the input functions by means of the following codes in the “General” group at the boiler control unit:

DE1: Coding address “5D” DE2: Coding address “5E” DE3: Coding address “5F”

Assigning the heating program changeover function to the heating circuitsThe allocation of the heating program changeover to the relevant heating circuit is selected via coding address “D8” in the “Heating circuit...” group:

Code “D8:1”: Changeover via input DE1 Code “D8:2”: Changeover via input DE2 Code “D8:3”: Changeover via input DE3

The effect of the heating program changeover is selected via coding address “D5” in the “Heating circuit...” group.

Duration of the heating program changeover Contact constantly closed:

The changeover is active as long as the contact is closed.

Contact only closed briefly via push button: The changeover is enabled for the time selected in coding address “F2” in the “Heating circuit...” group.

DHW recirculation pump runtime for brief operationThe DHW recirculation pump can be started outside the times when it is enabled according to the time program.

Refer to the EA1 module Installation Instructions

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When Ordering Spare PartsQuote the part and serial no. (see type plate A) and the item no. of the required part (as per this parts list).Standard parts are available from your local supplier.

Parts0001 Hinges0004 Adjustable high limit rotary selector0006 Adjustable high limit stop dial0008 Supporting stay0011 Safety valve with wiring0013 Casing front with frame (see 001)0014 PCB cover0015 Front flap0016 Casing, rear panel0018 Programming unit0019 Fascia left0020 Fascia right0021 Ribbon cable, 10-PIN0023 Connecting cable, emissions test switch0024 Fuse holder cap for control fuse0025 Fuse holder for control fuse0030 Fixed high limit0031 Adjustable high limit0037 Emissions test switch, single-pole0038 ON/OFF switch, 2-pole0039 “TEST” key, single-pole0042 Temperature sensor (boiler water temperature sensor or DHW tank temperature sensor)0049 Main PCB low voltage0050 PCB0051 Optolink PCB and emissions test switch0052 Main PCB 120V~0054 Power supply unit PCB0056 LON communication module0057 LON cable0058 LON terminator0065 Burner connecting cable with plug fA and burner connecting cable with plug lÖ0066 Burner connecting cable with plug fA and burner connecting cable with plug lÖ for Vitocrossal0074 Connection line0080 Installation and service instructions0081 Operating instructions0092 Fuse, 6.3A (slow), 250V~0100 Plug for LV (7 pieces)0101 Plug for pumps (3 pieces)0102 Plug gS (3 pieces)0103 Plug abH (3 pieces)0104 Power supply plug fÖ (3 pieces)0105 Plug abÖ0106 Plug gÖ (3 pieces)0108 3 Pole Plug avD, avG, avH0109 Burner plugs fA, lÖ, abA and a.AA Type plate

Parts ListParts List

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Rated voltage 120V~Rated frequency 60 HzRated current 2 x 6 A~Power consumption 10 WSafety category I

Permiss. ambient temperature: During operation 32 to 104°F (0 to +40°C)

Installation in living spaces or boiler rooms (standard ambient conditions)

During storage and transport -4 to 149°F (−20 to +65°C)

Rated relay output breaking capacity at 120V~sÖA1 Primary pump, primary store system or Circulation pump – flue gas/water heat exchanger or Switching output 2 A~*1

sA Circulation pump for DHW tank heating 2 A~*1

sL Shunt pump or boiler circuit pump 2 A~*1

gÖ Central fault message 2 A~*1

gSA1 Isolation valve Mixing valve motor, return temperature raising facility or Motor, 3-way mixing valve, primary store system 0.1 A~*1

fA Burner 3 A~lÖ Burner (two-stage) 0.5 A~lÖ Burner (modulating) 0.1 A~

*1 Total max. 6 A~

SpecificationsSpecifications

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installation and service instructions - viessmann...viessmann maintenance schedule of the boiler...

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