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Installation, Start-up
and Service Instructions
Vitotronic 100
Model KW10
Boiler control unit
for modulating temperature heating systems
Part No. 7133 375
VITOTRONIC 100
Certified as a component part
of Viessmann boilers only
5167 483 v1.4 08/2010
IMPORTANT
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Summary of Contents for Viessmann KW10
- Page 1 Vitotronic 100 Model KW10 Boiler control unit for modulating temperature heating systems Part No. 7133 375 VITOTRONIC 100 IMPORTANT Read and save these instructions Certified as a component part for future reference. of Viessmann boilers only 5167 483 v1.4 08/2010...
- Page 2 Safety, Installation and Warranty Requirements Safety, Installation and Warranty Requirements Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
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Page 3: Table Of Contents
Contents Page Important Precautions Safety ....................Important Regulatory and Installation Requirements . -
Page 4: Safety
- Technical Data Manual literature can be found. Contact - Installation, Start-up Viessmann for additional copies. and Service Instructions - Operating Instructions and User’s Information Manual - Instructions of other Viessmann products utilized and installed - Installation codes mentioned in this manual... -
Page 5: Important Regulatory And Installation Requirements
This symbol indicates that other instructions must be referenced. Valid for ... Applies to Vitotronic 100, Model KW10: Order No. 7133 375, starting with serial no. V00101 This control shall only be installed with the Vitola 200, Vitorond 200, Vitogas 050, RS Series, or with a Vitogas 100 hot water heating boiler. -
Page 6: System Configuration
Vitogas 100 boilers only) Required equipment Description Quantity Order No. Vitotronic 100, Model KW10 7133 375 Optional equipment Description Quantity Order No. DHW Pump Module for domestic hot water production using a 9543 431 Viessmann Vitocell indirect-fired domestic hot water storage tank... -
Page 7: Opening The Control
Electrical Connections Opening the Control 1. Open front cover. 2. Carefully unlock control top cover using a screw driver and flip open top cover. -
Page 8: Overview
Electrical Connections Overview The control is pictured from the rear. 120 VAC connections for power supply cord 120 VAC, 60 Hz for burner connection Pump connection FHL test connection A B Test 24 VAC connections Room thermostat connection X2.1, X2.2 Dip switches Outdoor temperature sensor (field wired) and... -
Page 9: Routing Cabling
Electrical Connections Routing Cabling Strain relief clamps are located in the fittings package supplied with the control. 1. Remove breakouts as necessary. 2. Mount lower portion of strain relief clamp. 3. Cut rubber grommet (if applicable). 4. Insert rubber grommet in strain relief and mount strain relief. -
Page 10: Burner Connection
Electrical Connections Burner Connection The Vitotronic 100 is prewired with the Viessmann quick-connect plug-in system. 1. Connect the RAST-5 plug to the main circuit board of the control (see page 8) 2. Connect 7-pole plug to the counter plug of the burner... -
Page 11: Pump Connection
Electrical Connections Pump Connection The main circuit board is pictured from the top. The Vitotronic 100, KW10 incorporates a 120 VAC pump output. The output is activated when the boiler water temperature exceeds the minimum boiler temperature limit. The Pump... -
Page 12: Installation Of Outdoor Temperature Sensor
Electrical Connections Installation of Outdoor Temperature Sensor To mount outdoor temperature sensor, Installation experience has shown that the north or 1.Remove cover north-west outside wall of the building is the best location. If, however, the 2.Mount housing base (cable inlet boiler is intended to supply heat to the opening to bottom). -
Page 13: Fixed High Limit
Altering Settings Fixed High Limit The default setting of the fixed high limit (FHL) is 230°F / 110°C. The FHL deactivates the burner control circuit if abnormally high temperatures occur. If tripped, it may be reset by pushing in the pin, labelled with a “ ”... -
Page 14: Adjustable High Limit
Altering Settings Adjustable High Limit The default setting of the adjustable high limit (AHL) is 167°F / 75°C. The AHL must not be set higher than 167°F / 75°C if the FHL is set to 212°F / 100°C. The AHL sets the maximum boiler water temperature. -
Page 15: Dip Switch Settings
Altering Settings Dip Switch Settings The “sequence of operation” of the Vitotronic 100, Model KW10 can be CAUTION customized depending upon the boiler it is installed with, or the characteristics of the heating system itself. Ensure power switch on boiler control is deactivated before attempting to Dip switch settings are to be altered by a qualified heating contractor only. -
Page 16: Altering The Indoor/Outdoor Control Settings
Altering Settings Altering the Indoor/Outdoor Control Settings The adjustable high limit determines the maximum available boiler (supply) temperature. Therefore, it functions as a high limit. The room thermostat (if used) enables and disables the outdoor reset processor in order to add indoor control (fine tuning) to the outdoor reset function. The curve for the outdoor reset function can be adjusted by opening the front flip-down cover. -
Page 17: Warm Weather Shut-Down Adjustment
Altering Settings Altering the Indoor/Outdoor Control Settings (Continued) Warm weather shut-down adjustment The reset function starts at the warm weather shut-down (WWSD) point and supplies increasingly more heat to a building to make up for the greater heat loss as outdoor temperatures get colder. When the outdoor temperature rises above the setting of the WWSD dial, no more heat is required by the control, and... -
Page 18: After Installation
Appendix / Start-up After Installation ... Checklist Please verify the following points (check with a pen) and take corrective actions as necessary: j Have all limit capillaries and sensors j Did all plug-in connectors engage been completely inserted into the with a “click”... -
Page 19: Diagnostics
Troubleshooting Diagnostics (for qualified service personnel only) Failure, Cause, Correction j Are all controls operating properly (i.e. thermostats, low water cut-off, etc.)? j Are all wire connections tight and secure? Failure Cause Correction Heating system does not activate Power switch “ “ is in “ “ Ensure power switch “... -
Page 20: Electrical Connections And Sequence Of Operation
(for qualified service personnel only) Electrical connections and sequence of operation plug of the Vitotronic 100, Model KW10 boiler control supplies power to the RAST-5 connection on the main circuit board. This plug connector has L1, G and N markings on its terminals. - Page 21 Troubleshooting Diagnostics (for qualified service personnel only) Electrical connections and sequence of operation Using a volt-ohm meter, place one probe onto neutral test point terminal (TPN). Use the remaining probe to touch the individual test points to diagnose the problem. Follow the steps below through the individual test points. Test point 1 Is 120 VAC present? Check main 6.3A fuse and replace as necessary.
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Page 22: Replacement Components (For Qualified Service Personnel Only)
Additional Information Replacement Components (for qualified service personnel only) Fuse, Part No. 7815 580 F1: T 6.3 A / 250 V, slow blow for control operation Fixed high limit, Part No. 7819 411 H Electro-mechanical temperature limit with liquid filled capillary H Safety feature: if capillary is not liquid tight (leaks), switch deactivates IMPORTANT... - Page 23 Other replacement components (not shown) Description Quantity Part No. Temperature gage, °F 7334 598 Temperature gage, °C 7334 599 Temperature gage, °C / °F 9543 566 Vitotronic 100 main circuit board, KW10 9544 170 LED circuit board Indoor/outdoor control Pump aquastat 9525 828...
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Page 24: Boiler Protection
– activation of the burner – deactivation of the space heating pump. The Vitotronic 100, KW10 control uses a pump aquastat (PA) in conjunction with an Outdoor Reset Control (ORC) to maintain a minimum boiler temperature. The aquastat uses a probe-type mechanical limit which monitors the boiler water temperature. - Page 25 Operation of the PA or the burner can be modified by changing the DIP switch settings. Refer to the table in subsection “Minimum Boiler Temperature Settings” for the Vitotronic 100, KW10 control. The ORC can maintain two alternate minimum boiler water temperatures.
- Page 26 When the Vitotronic 100, KW10 control is used with DHW Pump Module, the factory default setting will allow the space heating pump and the DHW pump to turn off below minimum boiler water temperature. This function can be disabled by changing the S1.6 DIP switch setting from the OFF position to the ON position (upwards movement of DIP switch).
- Page 27 Vitogas 100, GS10 120 ºF/49 ºC To adjust the minimum temperature for the Vitotronic 100, KW10 control, select an alternate DIP switch setting. The table below outlines the three DIP switch settings for the three various temperatures. Select the temperature which best suits your application.
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Page 28: Parts List
007 Flip-down cover 039 Indoor/outdoor control parts. Order replacement components 010 Control housing cover, top 040 Outdoor temperature sensor from your Viessmann distributor. 011 Control housing, front 042 Boiler sensor 016 Control housing, bottom 065 Burner cable with 017 Control housing, rear... -
Page 29: Wiring Diagram
DHW pump module connection X4 Outdoor reset control connection 2nd stage cable connection 1/3 Sensors connection This wiring diagram applies only to installations where Viessmann products are used. Technical information subject to change without notice. Wire color code BK black... -
Page 30: Technical Data
Additional Information Technical Data Power: 120 VAC 1 Phase 60 Hz 15 A pre-fuse Burner switching capacity: 120 VAC 2.5 FLA Room thermostat: 24 VAC Anticipator setting: 0.1 A Fixed high limit: 230°F / 110°C max. (fixed) Adjustable high limit: 167 to 239°F max. - Page 31 5167 483 v1.4...
- Page 32 +60 +140 +70 +158 +80 +176 +90 +194 +100 +212 +110 +230 Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc. 45 Access Road 750 McMurray Road Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada Tel.
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