Viessmann Vitotronic 100 GC1 Installation And Service Instructions Manual Download

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Installation and

Service Instructions

for use by heating contractor

Vitotronic 100, Model GC1

Digital boiler control unit

VITOTRONIC 100, GC1

Certified as a component part

of Viessmann boilers only

Read and save these instructions
for future reference.

IMPORTANT

5351 338 v1.8 10/2013

Summary of Contents for Vitotronic 100 GC1

Page 1: ... contractor Vitotronic 100 Model GC1 Digital boiler control unit VITOTRONIC 100 GC1 Certified as a component part of Viessmann boilers only Read and save these instructions for future reference IMPORTANT 1 Please file in Service Binder 5351 338 v1 8 10 2013 ...

Page 2: ...itled Important Regulatory and Installation Requirements Product documentation Read all applicable documentation before commencing installation Store documentation near boiler in a readily accessible location for reference in the future by service personnel For a listing of applicable literature please see section entitled Important Regulatory and Installation Requirements Advice to owner Once the...

Page 3: ... operation or maintenance which pertain to the product 5351 338 v1 8 Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial product property damage DANGER Indicates an imminently hazardous situation which if not avoided could result in death serious injury or substantial product property damage WARNING Indicates an imminently hazardous s...

Page 4: ... from Serial No 7143 002 This document describes the Vitotronic 100 GC1 as used in a single boiler application and a multi boiler system with an external building automation system These instructions are not required for the Vitotronic 100 GC1 used in multi boiler systems with the Vitocontrol S VD2 CT3 CM2 Product Information 5351 338 v1 8 ...

Page 5: ...ction of Return Mixing Valve or Isolation Modulating Valve VD2 VD2A CT3 only 56 Connection of Return Mixing Valve or Isolation Modulating Valve CM2 only 57 Making Space for Accessory Adaptors on the Din Rail CM2 only 58 Vitotronic 100 GCI with 30 LTP Package 59 Connection of External Controls 60 Connection of External Controls VD2 VD2A only 62 Connection of External Controls CT3 only 64 Connection...

Page 6: ...ion 97 Scanning and Resetting the Service Display 98 Troubleshooting Troubleshooting Steps 99 Diagnosis 100 Functional Description Boiler Temperature Control 105 Heating Circuit Control 106 DHW Tank Temperature Control 106 Additional Information Overview 108 Technical Data 109 System Components 109 Coding 1 115 Coding 2 117 Wiring Diagrams 125 Parts List 130 5351 338 v1 8 ...

Page 7: ...perature protection 19 8 Multi boiler system Vitorond 200 VD2 Low loss header and return valve for elevating the return temperature 21 9 Single boiler system Vitocrossal 300 Several heating circuits and one mixing valve heating circuit 23 10 Single boiler system Vitocrossal 300 Several heating circuits and one mixing valve heating circuit 25 11 Multi boiler system Vitocrossal 300 Several heating c...

Page 8: ... the Vitotronic 100 aJA Therm Control temperature sensor sÖM2 Heating circuit pump mixing valve only for Vitotronic 300 sÖM3 Heating circuit pump mixing valve only for Vitotronic 300 sÖA1 Closing the mixing valves with external heating circuit control units sA DHW primary pump sK DHW circulation pump only for the Vitotronic 300 fÖ Power supply 120 VAC 60 Hz Install the main isolator in accordance ...

Page 9: ...e Wiring diagram Wiring of the Therm Control in heating systems with heating circuit control units are not connected to the boiler control unit via the LON Required coding Change 4C to 2 use the plug in connector 20 A1 to close the downstream mixing valve Change 0D to 1 the Therm Control acts on the mixing valve of the downstream heating circuits for Vitotronic 200 and 300 delivered condition 5351...

Page 10: ...00 H Boiler water temperature sensor DHW tank temperature sensor only for Vitotronic 300 K aJA Therm Control temperature sensor sÖM2 Heating circuit pump mixing valve only for Vitotronic 300 K sÖM3 Heating circuit pump mixing valve only for Vitotronic 300 K sÖ Heating circuit pump Vitotronic 200 H sK DHW circulation pump only for the Vitotronic 300 K fÖ Power supply 120 VAC 60 Hz Install the main ...

Page 11: ...ture sensor accessory aJ A Temperature sensor T1 aJ B Temperature sensor T2 sÖ A1 Close mixing valves with external heating circuit controls sA DHW pump sL Shunt pump fÖ Power supply connection 120 VAC fA Burner 1st stage lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 1 On the Vitorond the boiler supply and return ar...

Page 12: ... the total supply rate of the boiler Temperature sensor T1 Wiring of the temperature sensor T1 in heating systems with heating circuit control units which are not connected via the LON BUS to the boiler control unit Coding required 4C 2 use plug sÖ for closing the mixing valves of the heating circuits connected downstream sÖ A1 Close mixing valves A Contactor relay field supplied B Heating circuit...

Page 13: ...ank temperature sensor accessory aJ A Temperature sensor T1 aJ B Temperature sensor T2 sA DHW pump sL Shunt pump fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Mixing valve motor for raising the return temperature lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 1 On the Vitorond the boiler supply and ret...

Page 14: ...witches on the shunt pump If as a result the required minimum return temperature is not reached the return valve is proportionally closed via the temperature sensor T1 and the minimum return temperature is assured Available system accessories Flue gas temperature sensor Coding of system type Change required Automatic change 00 1 With DHW tank Coding is automatically changed to 00 2 02 1 Set coding...

Page 15: ...it with mixing valve Plugs Boiler temperature sensor aJ A Temperature sensor T1 aJ B Temperature sensor T2 sL Shunt pump fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Motorized isolation valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B C C A A 3 17B 90 41 40 146 143 52 A1 T1 17A T2 ...

Page 16: ...ply rate of the boiler The boiler is assured optimum protection in conjunction with control of the heating circuits via the Vitotronic 050 connected to the boiler control unit No further protective measures are required on site Temperature sensor T1 Wiring of the temperature sensor T1 in heating systems with heating circuit control units which are not connected via the LON BUS to the boiler contro...

Page 17: ...ing circuit with mixing valve D Common supply pump Plugs Boiler temperature sensor aJ A Temperature sensor T1 fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Motorized isolation valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B 3 17A 90 41 40 146 143 52 A1 A A 3 17A 90 41 40 146 143 52...

Page 18: ...nic 050 connected to the boiler control unit No further protective measures are required on site Temperature sensor T1 Wiring for reducing the supply via temperature sensor T1 in heating systems with heating circuit control units which are not connected via the LON BUS to the boiler control unit Coding required 4C 2 use plug sÖ for closing the mixing valves of the heating circuits connected downst...

Page 19: ... Heating circuit with mixing valve Plugs Boiler temperature sensor aJ A Temperature sensor T1 sL Boiler circuit pump fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Return valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B 3 17A A A 3 17A T1 C C 90 41 40 146 143 52 A1 29 T1 90 41 40 146...

Page 20: ... the 3 port mixing valve on the boilers is proportionally closed via the temperature sensor T1 thereby assuring protection of the boiler The boiler and the heating circuits downstream are hydraulically decoupled The supply temperature is controlled via the common temperature sensor Available system accessories Flue gas temperature sensor Coding of system type Change required Automatic change 01 1 ...

Page 21: ...C Heating circuit with mixing valve D Low loss header Plugs Boiler temperature sensor aJ A Temperature sensor T1 sL Boiler circuit pump fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Return valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B 3 17A A A 3 17A T1 C C 90 41 40 146 143 52 A1...

Page 22: ...valve on the boilers is proportionally closed via the temperature sensor T1 thereby assuring protection of the boiler The supply temperature is controlled by the temperature sensor in the low loss header Available system accessories Flue gas temperature sensor Coding of system type Change required Automatic change 01 1 Set coding 01 3 for multi boiler system with external cascade control via switc...

Page 23: ...tic hot water tank C Heating circuit with mixing valve D Neutralizing unit Plugs Boiler temperature sensor DHW tank temperature sensor accessory sA DHW pump fÖ Power supply connection 120 VAC fA Burner 1st stage lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 3 5 21 B C C A 90 41 40 146 143 D ...

Page 24: ...iler water temperature by means of the boiler control unit Two stage or modulating burners can be controlled The boiler water temperature which is established in the heating mode is higher than the maximum heating system supply temperature by an adjustable difference Available system accessories Flue gas temperature sensor Coding of system type Change required Automatic change 00 1 With DHW tank C...

Page 25: ...t or E Underfloor heating circuit with mixing valve F Limit thermostat max limit G Neutralizing unit Plugs Boiler temperature sensor DHW tank temperature sensor accessory sÖ A1 Close mixing valves with external heating circuit controls sA DHW pump fÖ Power supply connection 120 VAC fA Burner 1st stage lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of...

Page 26: ...return connections The heating circuits with the higher return temperature are connected to the return connection at the top those with the lower temperatures to the return connection at the bottom Please note At least 15 of the take off from the rated output must be connected to the return connection at the bottom The boiler water temperature which is established in the heating mode is higher tha...

Page 27: ...omestic hot water tank C Heating circuit with mixing valve D Neutralizing unit Plugs Boiler temperature sensor fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Motorized isolation valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B C A C A D D 3 90 41 40 146 143 52 A1 3 90 41 40 146 143 5...

Page 28: ... return connection at the top those with the lower temperatures to the return connection at the bottom Please note At least 15 of the take off from the rated output must be connected to the return connection at the bottom The boiler water temperature which is established in the heating mode is higher than the maximum heating circuit supply temperature by an adjustable difference Motorized isolatio...

Page 29: ...tank C Heating circuit with mixing valve D Neutralizing unit Plugs Boiler temperature sensor aJ A Temperature sensor T1 aJ B Temperature sensor T2 sL Shunt pump fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 Motorized isolation valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B A A D 3...

Page 30: ...n temperature are connected to the return connection at the top those with the lower temperatures to the return connection at the bottom Please note At least 15 of the take off from the rated output must be connected to the return connection at the bottom The return temperature raising functionality of the Vitorond modulating boiler is available as an accessory or must be provided on site The retu...

Page 31: ...hot water tank C Heating circuit with mixing valve D Neutralizing unit Plugs Boiler temperature sensor aJ A Temperature sensor T1 sL Boiler circuit pump fÖ Power supply connection 120 VAC fA Burner 1st stage gS A1 3 port mixing valve lÖ Burner 2nd stage modulating aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 B A A D 3 90 41 40 146 ...

Page 32: ...g circuits with the higher return temperature are connected to the return connection at the top those with the lower temperatures to the return connection at the bottom Please note At least 15 of the take off from the rated output must be connected to the return connection at the bottom The T1 temperature sensor measures the return temperature The return valve is activated via the boiler control u...

Page 33: ...ng valve D Mixing valve heating circuit or E Underfloor heating circuit with mixing valve F Limit thermostat max limit G Neutralizing unit Plugs Boiler temperature sensor DHW tank temperature sensor accessory sÖ A1 Close mixing valves with external heating circuit controls sA DHW pump fÖ Power supply connection 120 VAC fA Burner lÖ Burner modulation aVD Connection of external equipment see page 60...

Page 34: ... to check that this recommendation is complete and fully functional The Vitocrossal 200 is operated with constant boiler water temperature by means of the boiler control unit and the Viessmann fully modulating burner Coding of system type Change required Automatic change 00 1 With DHW tank Coding is automatically changed to 00 2 02 1 Set coding 02 2 for operation with modulating burner 0C 4 Set co...

Page 35: ...ossal 200 A Boiler with Vitotronic 100 GC1 B Domestic hot water tank C Heating circuit with mixing valve D Neutralizing unit Plugs Boiler temperature sensor fÖ Power supply connection 120 VAC fA Burner gS A1 Motorized isolation valve lÖ Burner modulation aVD Connection of external equipment see page 60 aVH Connection of external equipment see page 60 5351 338 v1 8 ...

Page 36: ...ed with constant boiler water temperature by means of the boiler control unit and the Viessmann fully modulating burner Motorized isolation valve Connect motorized 120V isolation valve adaptor Part No 7511 367 or 24V valve adaptor Part No 7511 366 installed in connection enclosure in parallel Use electric junction box if necessary Coding of system type Change required Automatic change 01 1 Set cod...

Page 37: ...lock in position at point A 3 Insert the flat cable from the Optolink into plug X20 4 Insert the plug of the programming unit into socket X10 Use cable guides in cover for routing 5 Engage the stay bar in the front housing 6 Close the front of the housing 7 Secure front housing with supplied screws 8 Install cover of the connection enclosure and support with supplied screw 5351 338 v1 8 1 2 3 4 5 ...

Page 38: ... VD2 VD2A CT3 only 1 Remove the cover of the connection enclosure 2 Unscrew the screws from the front housing 3 Swing up the front part of the control housing 4 Position the stay bar so that it supports the front housing 5351 338 v1 8 4 3 1 2 ...

Page 39: ...low cables to come in contact with hot metal components 2 Mount the control to the control panel 3 Secure the control to the control panel with screws Note Screws to secure control are included with the cosmetic cover in the boiler jacketing package 4 Install the junction box to the rear panel either right or left Secure the junction box with 4 x 4 8 metal screws Note The ground screw and ground w...

Page 40: ... stay bar open it up and lock in position at point A 3 Insert the flat cable from the Optolink into plug X20 4 Insert the plug of the programming unit into socket X10 Use cable guides in cover for routing 5 Engage the stay bar in the front housing 6 Close the front of the housing 7 Secure front housing with supplied screws 8 Install control cosmetic cover 5351 338 v1 8 A ...

Page 41: ...e Control Unit CM2 only 1 Remove the control cosmetic cover 2 Unscrew the screws from the front housing 3 Swing up the front part of the control housing 4 Position the stay bar so that it supports the front housing 5351 338 v1 8 ...

Page 42: ... external equipment Line voltage connections motherboard sÖ A1Control output sA DHW pump sL Shunt pump or boiler circuit pump fÖ Power supply connection fA Burner 1st stage gÖ Compiled failure alarm gS A1Return valve or Isolation modulating valve lÖ Burner 2nd stage modulating aBÖ Connection of external equipment e g additional safety equipment aBA Safety circuit potential free aBH Power supply co...

Page 43: ...Installation 43 Overview of Electrical Connections VD2 VD2A CT3 only continued 5351 338 v1 8 29 20 A1 ...

Page 44: ...Installation 44 Overview of Electrical Connections CM2 only continued 5351 338 v1 8 ...

Page 45: ... 1 Run the cables from the connection enclosure into the control unit 2 Apply strain relief to cables see below Cables with moulded strain relief clamp Connect cable and strain relief clamp OR Fasten cable to the cable lead with cable tie 5351 338 v1 8 ...

Page 46: ...0 7820 144 Vitorond 200 VD2 VD2A 1020 7820 142 Vitocrossal 200 CM2 1041 7820 145 1 Push the boiler coding card through the recess in the cover and insert it in plug in location X7 5351 338 v1 8 For matching the operation of the control unit to the boiler the boiler coding card which is supplied as part of the standard delivery of the boiler may be used CAUTION ...

Page 47: ... CM2 of 99 C 210 F No adjustment Disconnect power to control and burner 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 99 C 210 F once adjusted the fixed high limit cannot be reset to 110 C 230 F 3 Re fit the fuse box Non condensing boiler VD2 VD2A C F Condensing boiler CT3 C F Condensing boiler CM2 C F Fixed high limit...

Page 48: ...a pair of pointed pliers break off the cams identified by the shaded areas in the Fig from the stop dial A 75 to 1100 C 167 to 212 F 4 Fit the selector knob R so that the marking is in the centre of the selected range Note the setting of coding address 06 5351 338 v1 8 1 2 A 3 IMPORTANT If the system is operated in conjunction with a domestic hot water tank ensure that the maximum permissible dome...

Page 49: ...Installation 49 Sensor Connection ATemperature sensor T2 BTemperature sensor T1 CBoiler temperature sensor DFlue gas temperature sensor 5351 338 v1 8 17B 17A 3 15 1 2 3 1 2 3 1 2 3 1 2 3 D A B C ...

Page 50: ...ture in C F Resistance in Ω Ω Ω Ω 40 104 50 122 60 140 578 597 616 3 Compare the value measured with the current temperature If the value differs significantly check installation and if necessary replace sensor Technical data Degree of protection IP 32 Ambient temperature during operation 0 to 130 C 32 to 266 F during storage and transport 20 to 170 C 4 to 158 F Electrical connection The sensors a...

Page 51: ...oiler water temperature of the boiler The boiler temperature sensor is installed at the same time as the boiler insulation Check the sensor 1 Disconnect plug in the terminal compartment 2 Measure resistance of sensor at terminals 1 and 2 of the plug or 2 and 3 if a second DHW tank temperature sensor is connected DHW tank temperature in C F Resistance in Ω Ω Ω Ω 40 104 50 122 60 140 578 597 616 3 C...

Page 52: ...t terminals 1 and 2 of the plug Return temperature in C F Resistance in Ω Ω Ω Ω 30 86 40 104 60 140 569 592 643 3 Compare the value measured with the current temperature If the value differs significantly check installation and if necessary replace sensor Technical data Degree of protection IP 32 Ambient temperature during operation 0 to 100 C 32 to 212 F during storage and transport 20 to 70 C 4 ...

Page 53: ... of the plug Flue gas temperature in C F Resistance in Ω Ω Ω Ω 180 176 160 320 200 392 650 800 880 3 Compare the value measured with the current temperature If the value differs significantly check installation and if necessary replace sensor Technical data Degree of protection IP 60 Ambient temperature during operation 0 to 600 C 32 to 1112 F during storage and transport 20 to 670 C 4 to 158 F 53...

Page 54: ...ecommended connection cable AWG 14 Use contactor for pumps with higher current rating Connect the 3 wire cable from the pump to the corresponding terminals 240 VAC or 3 PH pumps Please note Use contactor and or motor starter to power pump For activating the contactor Rated current max 2 FLA Recommended connection wire size AWG 14 Please ensure that all connections and wire sizes comply with local ...

Page 55: ... connection cable AWG 14 Use contactor for pumps with higher current rating Connect the 3 wire cable from the pump to the corresponding terminals 240 VAC or 3 PH pumps Please note Use contactor and or motor starter to power pump For activating the contactor Rated current max 2 FLA Recommended connection wire size AWG 14 Please ensure that all connections and wire sizes comply with local and nation...

Page 56: ...15 FLA Recommended connection wire size AWG 14 Part No 7134 559 Operating time 5 to 199 sec selected via coding address 40 1 120V Valve Adaptor 2 120V valve actuator 1 24V Valve Adaptor 2 24V valve actuator 1 Disconnect power to control 2 Install 120V or 24V Valve Adaptor on DIN rail inside connection enclosure 3 Insert the plug gS into socket gS on the control 4 Fasten cable with tie see page 45 ...

Page 57: ...ecommended connection wire size AWG 14 Part No 7511366 Operating time 5 to 199 sec selected via coding address 40 1 120V Valve Adaptor 2 120V valve actuator 1 24V Valve Adaptor 2 24V valve actuator 1 Disconnect power to control 2 Install 120V or 24V Valve Adaptor on DIN rail inside connection enclosure 3 Insert the plug gS into socket gS on the control 4 Fasten cable with tie see page 45 5 Connect...

Page 58: ...pare DIN terminals 23 24 25 and 26 one at a time Place the screwdriver between the rail and the base of the terminal and turn the screwdriver clockwise Discard the removed terminals 3 Re install the DIN rail clamp by hooking the latch of the clamp around the top of the rail and then push down on the front of the clamp Note See separate Installation Instructions for accessory adaptors 5351 338 v1 8...

Page 59: ...Installation 59 Vitotronic 100 GC1 with 30 LTP Package VD2 VD2A only 5351 338 v1 8 VD2 VD2A 1 17B Sensor strap on 5 2 ...

Page 60: ...et on the mechanical adjustable high limit R The 2nd stage burner is switched off 2 K sooner Contact open The 1st and 2nd stage burner are switched off C External changeover of staged modulating burners Connect dry contact at terminals 1 and 2 of the plug aVH Contact closed Modulating operation Contact open Two stage operation Coding 02 2 modulating burner must be set Note Even if contact is close...

Page 61: ...rature as shown or less 93 200 87 188 87 188 88 190 Single boiler systems Coding 01 1 factory setting When a building automation system is connected only the connections on plug aVD are required The DHW tank control unit is activated when the DHW tank temperature sensor is connected The boiler water temperature must be set to the minimum value Multi boiler systems Set coding 01 3 When a building a...

Page 62: ...r stages modulation can be switched externally The boiler water temperature is limited by the preset maximum boiler water temperature or via the mechanical adjustable high limit The set point value is selected via the coding address 9b Contact open The isolation valve is closed after approx 5 minutes coding address 2C External override of the burner stages is not possible and no minimum temperatur...

Page 63: ...de 06 to the temperature as shown or less 93 200 87 188 87 188 88 190 Single boiler systems Coding 01 1 factory setting When a building automation system is connected only the connections on plug aVD are required The DHW tank control unit is activated when the DHW tank temperature sensor is connected The boiler water temperature must be set to the minimum value Multi boiler systems Set coding 01 3...

Page 64: ...s modulation can be switched externally The boiler water temperature is limited by the preset maximum boiler water temperature or via the mechanical adjustable high limit The set point value is selected via the coding address 9b Contact open The isolation valve is closed after approximately 5 minutes coding address 2C External override of the burner stages is not possible and no minimum temperatur...

Page 65: ...set code 06 to the temperature as shown or less 93 200 87 188 87 188 88 190 Single boiler systems Coding 01 1 factory setting When a building automation system is connected only the connections on plug aVD are required The DHW tank control unit is activated when the DHW tank temperature sensor is connected The boiler water temperature must be set to the minimum value Multi boiler systems Set codin...

Page 66: ...n Air Device Adaptor B DIN Rail in connection enclosure Connection of the combustion air blower to adaptor Rated voltage 120 VAC Rating current max 5 FLA Recommended connection wire size AWG 14 Ensure that combustion air blower device is suitable for this application For detailed instruction on adaptor installation please refer to the adaptor s installation manual 1 Make connection as shown in the...

Page 67: ...50 plug and DIN rail connections as shown in the diagram Wire BK2 must be connected to terminal 18 and BK3 to terminal 19 DO NOT reverse Connection of the combustion air blower to adaptor Rated voltage 120 VAC Rating current max 5 FLA Recommended connection wire size AWG 14 Ensure that combustion air blower device is suitable for this application For detailed instruction on adaptor installation pl...

Page 68: ...rner 2 Make connection as shown in the diagram A Combustion Air Device Adaptor in connection enclosure B Relay 120 VAC coil field supplied C Combustion air damper D End switch rated for 120 VAC wired to normally open terminal on device adaptor board E Power supply 120 VAC Safety instruction Provide disconnect means and overcurrent protection as required by local codes Note Spring return air damper...

Page 69: ...stall Combustion Air Device Adaptor on each boiler Part No 7134 563 2 Install Common Combustion Air Device Interface Part No 7134 604 as per supplied manual 3 Make connection as shown in the diagram at left A Common Combustion Air Device Interface wall mount B Combustion Air Device Adaptor in connection enclosure on each boiler C Interconnecting wiring field supplied and connected Refer to Istalla...

Page 70: ... C Proving switch rated for 120 VAC D Power supply 120 VAC Safety instruction Provide disconnect means and overcurrent protection as required by local codes See blower manual for current rating to correctly select the fuse See Common Combustion Air Device Interface manual for Installation and Operating details 1 Disconnect power to control and burner 2 Make the connections as shown in the diagram ...

Page 71: ...h rated for 120 VAC D Power supply 120 VAC Safety instruction Provide disconnect means and overcurrent protection as required by local codes See damper manual for current rating to correctly select the fuse See Common Combustion Air Device Interface manual for Installation and Operating details 1 Disconnect power to control and burner 2 Make the connections as shown in the diagram 5351 338 v1 8 ...

Page 72: ... plug from the Vitotronic control and discard 3 Install new 150 plug supplied attached to flue gas temperature switch 5351 338 v1 8 Please note that the diagram shown is only a simplified conceptual drawing of a flue gas temperature switch Refer to the manual specific to the device for interconnection details CAUTION ...

Page 73: ...on for external equipment 1 Remove jumper between terminals 12 and 15 2 Make connection as shown in diagram 5351 338 v1 8 Please note that the diagram at left is only a simplified conceptual drawing of a typical low water cut off LWCO device Refer to the manual specific to the device for interconnection details CAUTION ...

Page 74: ...er between terminals 21 and 22 2 Make connection as shown in diagram 5351 338 v1 8 Please note that the diagram shown is only a simplified conceptual drawing of a typical low water cut off LWCO device Refer to the manual specific to the device for interconnection details CAUTION ...

Page 75: ...hen the contact is opened WARNING Emergency operation Move jumper from terminals 16 and 17 to terminals 17 and 18 5351 338 v1 8 The terminals should be used for safety switch off purposes only e g through a limit thermostat See pages 52 to 59 for details of controlled switch off During switch off there is no frost protection of the heating system and the boiler is not kept at the minimum boiler wa...

Page 76: ...VAC 60 Hz Rated current max 2 FLA Recommended connection wire size AWG 14 1 Disconnect power to control and burner 2 Connect the compiled failure alarm as shown in the diagram A Connect terminal strip in connection enclosure of boiler control B Visual and or audible alarm device 120 VAC 5351 338 v1 8 A B ...

Page 77: ... Hz Rated current max 2 FLA Recommended connection wire size AWG 14 1 Disconnect power to control and burner 2 Connect the compiled failure alarm as shown in the diagram A Connect terminal strip in connection enclosure of boiler control B Visual and or audible alarm device 120 VAC 5351 338 v1 8 A B 9 ...

Page 78: ... fault indicator B4 Connection for burner hours counter A To plug in connection in connection enclosure B To burner 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 p...

Page 79: ...upply connection of control unit 120 VAC fA Burner 1st stage lÖ Burner 2nd stage aBÖ Plugs for external equipment a External safety devices remove jumper when connecting b External controlled switch off remove jumper when connecting aBA Safety circuit Emergency shut off 1 Refer to burner manufacturer s instruction on detailed connections for Viessmann controls 5351 338 v1 8 This is a generic conne...

Page 80: ...ontrol 2 Connect 240 VAC 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 A Burner motor power supply 240 VAC 1PH B Connection terminals and plug inside connec...

Page 81: ...de 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 A Burner motor power supply 3PH 208 460 or 575V B Connection terminals and plug inside connection enclosure C Cable and conduit factory supplied D Burner E Motor starter F Overload G Burner motor H C...

Page 82: ...ocal codes B Terminals 40 C Connection enclosure 1 Ensure that the main power supply to the control contains overcurrent protection with a maximum rating of 15 A 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 5351 338 v1 8 The control must be grounded Ensure that L N and G are not interchanged CAUTION ...

Page 83: ...fault indicator B4 Connection for burner hours counter A To plug in connection in connection enclosure B To burner interface 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 ...

Page 84: ... limit 86 3 Integrate the control unit in the LON BUS system in conjunction with heating circuits connected downstream 87 4 Carry out participant check 88 5 Match the control unit to the system type 89 6 Check outputs actuators and sensors 89 7 Match the coding addresses 90 5351 338 v1 8 ...

Page 85: ...unction on multi boiler systems Value selection buttons Information Confirmation Basic setting Display window Heating program selector buttons w without function on multi boiler systems Adjustable high limit Fixed high limit reset button Control on off switch Fuses TUV button Operating status indicator green Fault indicator red 5351 338 v1 8 F1 T6 3 A F2 T6 3 A TUV ...

Page 86: ...the rated load The amount of heat consumed should be reduced as far as possible The adjustable high limit R is bridged The burner is switched on until the boiler water temperature reaches the safety temperature and the fixed high limit operates When the burner is switched off by the fixed high limit release the TUV button wait until the boiler water temperature has fallen 15 to 20 C 27 to 36 F bel...

Page 87: ...cipant check is initiated see also page 88 The participant list is updated after approx 2 minutes The participant check is terminated Example of single boiler system with Vitotronic 050 heating circuit controls and Vitocom connected downstream Participant No 1 Coding 77 1 Participant No 10 Coding 77 10 Participant No 11 Set coding 77 11 Participant No 100 Control unit is error manager Coding 79 1 ...

Page 88: ...e required participant with or 3 Activate the check with If communication between the two units is verified the arrows in the display window stop flashing If communication is not verified the display shown on the left appears 4 To check further participants follow the steps described in points 2 and 3 5 Press w and simultaneously for approx 1 second The participant check is initiated All 7 arrows ...

Page 89: ...r approx 2 seconds 2 Select relay outputs with the or button 3 Press Relay test is activated Relay test is terminated The following relay outputs can be selected depending on the system equipment installed Display Relay function 11 Burner stage 1 ON 12 Burner stage 1 and 2 ON modulation open 13 Burner modulation neutral 14 Burner modulation closed 15 Output 20 ON 16 Output 29 ON 17 Output 52 open ...

Page 90: ... burner output through the fuel consumption 5 With activate the function Modulating burner closed display 4 and measure the time it takes for the actuating drive of the burner to reach the minimum output 6 Establish the minimum burner output basic output through the fuel consumption 7 With activate the function Modulating burner open display 2 and after one third of the time measured in point 5 ac...

Page 91: ...ns digits of the maximum output established in point 4 e g max output 210 kW here set 10 09 hundreds digit of the maximum output established in point 4 e g max output 210 kW here set 2 0A the basic output see point 6 as a percentage proportion of the max output e g basic output 70 kW max output 210 kW 70 kW 210 kW x100 33 15 the operating time in seconds established in point 5 Please note You will...

Page 92: ...rw simultaneously for approx 2 seconds Press OK 93 Relay test Press 9 and OK simultaneously for approx 2 seconds Press OK 89 Participant check in conjunction with LON Press w and OK simultaneously for approx 2 seconds Press w and OK simultaneously for approx 1 second 88 Operating status information Press Press 97 Service display Press OK 98 5351 338 v1 8 ...

Page 93: ...see page 94 18888 Scan 1 Only in conjunction with LON communication module see page 94 28888 Scan 2 Only in conjunction with LON communication module see page 94 3 65 C Set point boiler water tempera ture effective set point value including boiler protection h 70 C Maximum request temperature 48888 Scan 4 See page 95 5 55 C Set point domestic hot water temperature 8230 C Maximum flue gas temperatu...

Page 94: ...sion Communication coprocessor Scan 0 LON participant number SNVT configuration Auto Tool 0 to F 0 to 9 0 to 9 0 0 1 8 8 8 1 8 Node address System number only with self binding Subnet address Scan 1 0 to F 0 to F 0 to F 1 0 to F 8 8 8 2 8 Software version LON communication module Number of LON participants Scan 2 0 to 9 2 0 to 9 0 to F 0 to F ...

Page 95: ...338 v1 8 8 8 8 4 8 Software version Control unit System type Free Software version Programming unit Scan 4 4 1 or 2 0 to F 0 to F Isolation valve 0 Closed 1 Preheating 2 Closing 3 Regulating 4 Opening 5 Open 6 Run on d 0 1 2 b 8 8 8 b d Scan d Free Scan b Burner OFF 1st stage basic load 2nd stage full load ...

Page 96: ...emperatures Boiler Coding Cards and Scans continued Scan L Scan o o o o 5351 338 v1 8 0 0 0 or to to 1 9 9 L 8 8 8 l 8 Scan L Free Output reduction 0 to 100 0 OFF 0 0 to to F F o 8 8 8 o 8 Free Equipment identification code Scan o Free ...

Page 97: ...HW tank temperature 2nd DHW tank temperature sensor Only displayed if DHW tank temperature sensor is connected 6 55 C Return temperature 17A 1st return temperature sensor Only displayed if return temperature sensor is connected 8 190 C Flue gas temperature Only displayed if flue gas temperature sensor is connected 9 60 C Return temperature 17B 2nd return temperature sensor Only displayed if return...

Page 98: ... the service messages with the or button 2 Press The service display is turned off Please note An acknowledged service message can be displayed again by pressing for approx 3 seconds After carrying out maintenance 1 Reset coding 24 1 see page 120 to 24 0 Please note If coding address 24 is not reset the service display will re appear on Monday morning 2 If necessary Press Reset burner hours run an...

Page 99: ...ault message or ascertain behaviour of system 2 Look for the corresponding cause of the fault in the diagnosis tables 101 Please note Retrieve fault codes from the fault memory 100 3 Establish the action required in the table Correction 4 Correct the fault 5351 338 v1 8 ...

Page 100: ...t can be acknowledged by pressing The fault message in the display 1 is blanked out the red fault indicator 2 continues to flash The central fault indicator connected to plug gÖ is switched off If an acknowledged fault is not rectified within 24 hours the fault message will re appear in the display Vitotronic 100 as error manager A fault on another LON participant is displayed as shown Fault symbo...

Page 101: ... In conjunction with DHW heating Tank heating is switched on and off by Tank temperature sensor 2 Open circuit DHW tank temperature sensor 1 Check DHW tank temperature sensor see page 51 59 In conjunction with DHW heating Tank heating is switched on and off by DHW tank temperature sensor 1 Open circuit DHW tank temperature sensor 2 Check DHW tank temperature sensor see page 51 60 No output reducti...

Page 102: ...ly valve is installed Set coding 0C 0 or 0C 1 b0 Controlled operation Short circuit Flue gas temperature sensor Check flue gas temperature sensor see page 53 b1 Controlled operation Communication error Programming unit Check connections if necessary replace programming unit b4 Emissions test mode Internal fault Check electronics board b5 Controlled operation Internal fault Check electronics board ...

Page 103: ... high limit or limit thermostat or flue gas damper Check system pressure reset fixed high limit or flue gas damper cd Controlled operation Communication error Vitocom Check connections and Vitocom cEe Controlled operation Communication error Plug in adaptor for external safety equipment cf Controlled operation Error LON communication module Replace communication module d1 Boiler cools down Burner ...

Page 104: ...ith the most recently stored fault code 1 Press and simultaneously for approx 2 seconds Scanning of error history is activated 2 Access the individual fault codes by pressing the or button Sequence of stored fault codes Fault code 1 Last most recent fault code 10 Last fault code 3 Press All stored fault codes can be deleted by pressing Scanning of error history is terminated 5351 338 v1 8 1 2 3 4 ...

Page 105: ...rs separately Fixed high limit FHL liquid expansion Adjustable high limit AHL liquid expansion Boiler temperature sensor BTS change in resistance PT 500 Upper limits of control range Fixed high limit FHL 110 C 230 F can be adjusted to 100 C 212 or 230 F Adjustable high limit AHL 95 C 203 F can be adjusted to 100 C 212 F Electronic maximum limit Setting range 20 to 127 C 68 to 261 F The maximum lim...

Page 106: ... constant maximum boiler water temperature is set 20 C 36 F above the set point DHW tank temperature variable via coding address 60 and space heating is switched off DHW tank priority control optional Functions Frost protection function If the domestic hot water temperature falls below 10 C 50 F the domestic hot water DHW tank is heated to 20 C 68 F Additional function for domestic hot water heati...

Page 107: ...perature difference between the boiler water and domestic hot water is less than 7 C 13 F or the set point boiler water temperature selected through the set point supply temperature of the boiler circuit is reached or the set point domestic hot water temperature is exceeded by 5 C 9 F The max run on time is 15 minutes selectable via coding address 62 DHW pump without run on time Coding 62 00 The c...

Page 108: ...munication module 107 Boiler coding card 108 Fuses 108 TUV button 109 Fixed high limit 109 Adjustable high limit 109 Input module 0 to 10V 110 Resetting codings to the factory setting 110 Coding 1 Call up coding level 1 115 Codings 115 Coding 2 Call up coding level 2 117 Reset codings to factory settings 117 Overview of all codings 117 Wiring Diagrams Overview 121 Low voltage motherboard 121 Line ...

Page 109: ...lt indicator gÖ 2 FLA 120 VAC 1 boiler isolation valve gS 0 1 FLA 120 VAC 1 or return valve 0 15 FLA 24 VAC burner connection fA 4 FLA 120 VAC connection lÖ 2 stage 0 5 FLA 120 VAC modulating 0 1 FLA 120 VAC 1 Total max 6 A 120 VAC System Components Line voltage motherboard Part No 7165 792 The motherboard contains relays and outputs for activating the pumps the control elements and the burner plu...

Page 110: ...od ing address 92 not listed in the overview to 92 160 Optolink override switch board Part No 7820 165 The circuit board contains Operating status indicator Fault indicator Optolink laptop interface Override switch Override switch for flue gas measurements with the boiler operated with constant boiler water temperature for a short time The following functions are triggered in the h setting The bur...

Page 111: ...ating system switch TUV button LON communication module Part No 7172 173 Accessory The communication module is inserted in the control unit Interruption of communication is indicated 1 terminal resistor is inserted on each of the first and last control unit A Control unit or Vitocom B Connecting cable for data transfer between the control units part of standard delivery or accessory C Terminal res...

Page 112: ... Part No Vitocrossal 300 Type CT3 1040 7820 144 Vitorond 200 Type VD2 VD2A 1020 7820 142 Vitocrossal 200 Type CM2 1041 7820 145 Fuses F1 6 3 A 250 V for protecting the control elements pumps and electronics Mounting location see drawing F2 T6 3 A 250 V for protecting the burner Mounting location see drawing 5351 338 v1 8 F2 F1 ...

Page 113: ...t if the temperature has fallen approx 15 K below the shut down temperature Central fastening M 10 capillary 3600 mm long Tests Electrical to VDE 0701 standard Functional check via TEST button Adjustable high limit Part No 7817 531 Type TR 55 18029 020 make EGO DIN TR 110397 or EM 1 V TK b1 60002846 make Juchheim DIN TR 77798 The adjustable high limit has a factory setting of 95 C 203 F Electromec...

Page 114: ...e output contact A Power supply provide disconnect if required by code B DIP switch see table DIP switch Function 1 to 3 1 2 3 4 4 OFF ON ON ON ON OFF Switch for pre set value Reduced mode system circuit A1 Reduced mode mixing valve circuit M2 Reduced mode mixing valve circuit M3 Pre set value default 10 to 100 C 50 to 212 F Pre set value default 30 to 120 C 86 to 248 F Please note Amongst switche...

Page 115: ...estic hot water heating 01 1 System type Single boiler system 01 2 Multi boiler system with cascade control via LON BUS e g Vitotronic 333 Type MW1 01 3 Multi boiler system with cascade control via switch contacts input aVD and aVH or 0 10V input module 02 1 Boiler burner Operation with two stage burner 02 0 Operation with single stage burner 02 1 Boiler burner Operation with two stage burner 02 2...

Page 116: ... to 19900 kW 1 increment 100 kW 0A 1 Burner mod Basic output of burner in 0A 0 to 0A 100 Basic output in Basic output in kW Max output in kW x100 15 10 2 Burner mod Operating time of actuating drive 15 5 to 15 199 Operating time variable from 5 to 199 seconds 40 125 General Operating time of actuating drive boiler isolation valve 3 port mixing valve or mixing valve motor in conjunction with return...

Page 117: ...cond Exit coding level 2 Reset codings to factory settings 1 Press and simultaneously for approx 2 seconds 2 Press Access coding level 2 The codings are reset to their factory settings The display changes and shows the boiler water temperature Overview of all codings Coding as per factory setting Address Value Function New coding Address Value Possible change 00 1 System type System circuit A1 wit...

Page 118: ...heat demand The heat demand controlled switching differential takes into account the boiler load The switching differential i e the burner operating time is varied in relation to the actual heat demand Burner Burner Burner Set point Set point Set point Low heat demand Medium heat demand High heat demand Time Time Time Low heat demand Medium heat demand High heat demand Low heat demand Medium heat ...

Page 119: ...temperature controlled 0C 4 Boiler isolation valve controlled on a modulating basis as a function of the set point boiler water temperature 0d 2 Boiler With Therm Control effective for boiler isolation valve function not 0d 0 Without Therm Control 0d 2 Boiler With Therm Control effective for boiler isolation valve function not active if 0C 1 is coded 0d 1 With Therm Control effective for mixing va...

Page 120: ...and 24 months 24 0 Boiler burner No service display 24 1 The service display appears address is set automatically and must be reset manually after maintenance has been carried out 26 0 Boiler burner 2 stage Fuel consumption of burner 1st stage not metered if 26 0 and 27 0 are coded 26 1 to 26 99 Input from 0 1 to 9 9 1 increment 10 litres or gallons hour 27 0 Boiler burner 2 stage Fuel consumption...

Page 121: ...nstalled 4b 1 Plug aJB installed e g temperature sensor T2 automatically recognized 4C 2 General Connections at plug sÖ A1 Therm Control switch contact 4C 1 Primary pump of DHW heating 4C 2 General Connections at plug sÖ A1 Therm Control switch contact 4C 3 Circulation pump of flue gas water heat exchanger 4d 1 General Connections at plug sL Shunt pump 4d 2 Boiler circuit pump 4d 1 General Connect...

Page 122: ... 95 C 34 and 203 F note coding address 56 CAUTION Set the adjustable high limit R to a value which is at least 10 C 18 F higher than the maximum domestic hot water temperature the temperature which is reached by activating the additional function The temperature set on the adjustable high limit R must not exceed the maximum permissible tank temperature See installation instructions for the DHW tan...

Page 123: ... 2 days to Every 14 days 68 8 DHW In conjunction with 2 tank temperature sensors with the DHW heating Switch off point of tank heating at setpoint value x 0 8 68 2 to 68 10 Factor adjustable from 0 2 to 1 per 1 increment 0 1 69 7 DHW In conjunction with 2 tank temperature sensors with the DHW heating Switch on point of tank heating at setpoint value x 0 7 69 1 to 69 9 Factor adjustable from 0 1 to...

Page 124: ...tral fault 94 0 General Without plug in adaptor for external safety equipment 94 2 With plug in adaptor for external safety equipment recognized automatically 98 1 General Viessmann system number in conjunction with monitoring of several systems within one LON BUS system 98 2 to 98 5 System number selectable from 1 to 5 9b 0 General Input aVH released 9b 1 to 9b 127 Set point supply temperature se...

Page 125: ...rboard A3 Line voltage motherboard A6 Programming unit A7 Optolink override switch board A8 Electronics board A9 Boiler coding card A10 LON communication module or Viessmann 2 wire BUS communication module A11 Power supply unit board A12 Boiler control section 5351 338 v1 8 ...

Page 126: ...Additional information 126 Wiring Diagrams continued Low voltage motherboard 5351 338 v1 8 A11 A8 A9 A6 A7 A2 A10 34 pole ...

Page 127: ...ue gas temperature sensor accessory aJA Temperature sensor T1 aJB Temperature sensor T2 aVD Connection of external equipment aVG KM BUS participant accessory aVH Connection of external equipment LON Connecting cable for data transfer between the control units S3 Override switch S V1 Fault indicator red V2 Operating status indicator green 5351 338 v1 8 ...

Page 128: ...Additional information 128 Wiring Diagrams continued Line voltage motherboard 5351 338 v1 8 A11 A3 floating ON ON ...

Page 129: ...r 2nd stage modulating aBÖ External equipment a External safety equipment remove jumper when connecting b External controlled switch off remove jumper when connecting c External burner activation aBA Safety circuit emergency shut off aBH Power supply connection for accessories F1 F2 Fuses F6 Fixed high limit E 120 C 99 C or 110 C 248 F 210 C or 230 F F7 adjustable high limit R 95 C 100 C or 110 C ...

Page 130: ...38 Switch 2 pole power on off 042 Sensor 3 for boiler 043 Sensor 5 for domestic hot water production 049 Motherboard control low voltage 050 Circuit board control software 051 Diagnostics module Optolink 052 Motherboard control line voltage 054 Circuit board 120V power supply 055 Communication module 2 wire BUS 056 LON module 065 Burner cable Nr 41 90 l 3470 067 Sensor immersion NI500 068 Sensor 2...

Page 131: ...Additional information 131 Parts List 5351 338 v1 8 ...

Page 132: ...w viessmann us com info viessmann us com Additional information 132 Quick Reference C F 40 40 35 31 25 13 20 4 18 0 16 3 14 7 12 10 10 14 9 16 8 18 7 19 6 21 5 23 4 25 3 27 2 28 1 30 0 32 1 34 2 36 3 37 4 39 5 41 6 43 7 45 8 46 9 48 10 50 12 54 14 57 16 61 18 64 20 68 25 77 30 86 35 95 40 104 50 122 60 140 70 158 80 176 90 194 100 212 110 230 Printed on environmentally friendly recycled and recycl...

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Viessmann Vitotronic 100 GC1, Installation And Service Instructions Manual

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