Viessmann VITOTRONIC 100 GC1 Installation And Service Instructions Manual
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Viessmann VITOTRONIC 100 GC1 Installation And Service Instructions Manual

Viessmann VITOTRONIC 100 GC1 Installation And Service Instructions Manual

Digital boiler control unit
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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
5351 338 v1.8 10/2013
IMPORTANT
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for future reference.
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Summary of Contents for Viessmann VITOTRONIC 100 GC1

  • Page 1 Service Instructions for use by heating contractor Vitotronic 100, Model GC1 Digital boiler control unit VITOTRONIC 100, GC1 IMPORTANT Read and save these instructions Certified as a component part for future reference. of Viessmann boilers only 5351 338 v1.8 10/2013...

  • Page 2: General Information

    General information Safety, Installation and Warranty Requirement 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.
  • Page 3 General information Safety, Installation and Warranty Requirement (continued) Safety Terminology Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial product / property damage.

  • Page 4: Product Information

    Product Information Vitotronic 100, GC1 For installation on Viessmann Applicable to the following control units: boilers only. Part No. 7134 553/7134 554/7511361, 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.

  • Page 5: Table Of Contents

    Index Page Safety Instructions and Warranty Requirements General Information ....... . Product Information .

  • Page 6: System Components

    Start-up Procedure (overview) ..................Steps .

  • Page 7: Heating System Types

    Heating system types Overview Circuit System type Boiler Key features Page diagram Single-boiler Vitorond 200, VD2A With Therm-Control, single-boiler with 3-way mixing system valve Multi-boiler Vitorond 200, VD2A With Therm-Control, multi-boiler with 3-way mixing system valve Single-boiler Vitorond 200, VD2 Shunt pump for elevating the return temperature system Single-boiler...
  • Page 8 Heating system types Circuit Diagram 1 Single-boiler system with Therm-Control and three-way mixing valve in conjunction with Vitorond 200, VD2A A Heating circuit with mixing valves B DHW tank fÖ Power supply, 120 VAC Plug sÖM2 Outdoor temperature sensor Heating circuit pump, mixing 60 Hz (only for Vitotronic 300) valve (only for Vitotronic 300)
  • Page 9 Heating system types Circuit Diagram 1 (continued) 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.
  • Page 10 Heating system types Circuit Diagram 2 Multi-boiler system with Therm-Control and three-way mixing valve in conjunction with Vitorond 200, VD2A LON LON connection (available connections with terminator) A Heating circuit with mixing valves B DHW tank gSM2 Therm-Control temperature Mixing valve motor (only for Plug Outdoor temperature sensor sensor...
  • Page 11 Heating system types Circuit Diagram 3 Single-boiler system with shunt pump for elevating the return temperature in conjunction with Vitorond 200, VD2 Plugs A Boiler with Vitotronic 100, GC1 § Boiler temperature sensor Shunt pump B Domestic hot water tank fÖ...
  • Page 12 Heating system types Circuit Diagram 3 (continued) When the return temperature falls Possible applications Temperature sensor T1 Heating systems with manifold below the required minimum value, Wiring of the temperature sensor T1 arranged close to the boiler. The boiler the temperature sensor T2 switches in heating systems with heating water supply is required to be reduced.
  • Page 13 Heating system types Circuit Diagram 4 Single-boiler system with shunt pump and return valve for elevating the return temperature in conjunction with Vitorond 200, VD2 Plugs A Boiler with Vitotronic 100, GC1 § fÖ Boiler temperature sensor Power supply connection, B Domestic hot water tank DHW tank temperature sensor 120 VAC...
  • Page 14 Heating system types Circuit Diagram 4 (continued) When the return temperature falls Possible applications Heating systems in which there is no below the required minimum value, facility for making modifications or the temperature sensor T2 switches adjustments to the heating circuits on the shunt pump.
  • Page 15 Heating system types Circuit Diagram 5 Multi-boiler system with shunt pump for elevating the return temperature for each boiler in conjunction with Vitorond 200, VD2 Plugs A Boiler with Vitotronic 100, GC1 § gS A1 Motorized isolation valve Boiler temperature sensor B Domestic hot water tank aJ A Temperature sensor T1 lÖ...
  • Page 16 Heating system types Circuit Diagram 5 (continued) When the return temperature falls Possible applications Temperature sensor T1 Heating systems with manifold below the required minimum value, Wiring of the temperature sensor T1 arranged close to the boiler. The boiler the temperature sensor T2 switches in heating systems with heating water supply is reduced via the on the shunt pump.
  • Page 17 Heating system types Circuit Diagram 6 Multi-boiler system with common supply pump and low-pressure manifold in conjunction with Vitorond 200, VD2 Plugs A Boiler with Vitotronic 100, GC1 § lÖ Boiler temperature sensor Burner (2nd stage/modulating) B Domestic hot water tank aJ A Temperature sensor T1 Connection of external C Heating circuit with mixing valve...
  • Page 18 Heating system types Circuit Diagram 6 (continued) When the return temperature falls Possible applications Temperature sensor T1 Where the manifold is arranged in below the required minimum value, Wiring for reducing the supply via distant substations (> 20 m). The the mixing valves are partially or fully temperature sensor T1 in heating heat transferred to the heating circuits...
  • Page 19 Heating system types Circuit Diagram 7 Multi-boiler system with return valve for return temperature protection in conjunction with Vitorond 200, VD2 Plugs A Boiler with Vitotronic 100, GC1 § lÖ Boiler temperature sensor Burner (2nd stage/modulating) B Domestic hot water tank aJ A Temperature sensor T1 Connection of external C Heating circuit with mixing valve...
  • Page 20 Heating system types Circuit Diagram 7 (continued) When the return temperature falls Possible applications E.g. old systems or systems in market below the required minimum value, gardens and/or systems in which there the 3-port mixing valve on the boilers is no facility for making modifications is proportionally closed via the or adjustments to the heating circuits temperature sensor T1, thereby...
  • Page 21 Heating system types Circuit Diagram 8 Multi-boiler system with low-loss header and return valve for elevating the return temperature in conjunction with Vitorond 200, VD2 Plugs A Boiler with Vitotronic 100, GC1 § lÖ Boiler temperature sensor Burner (2nd stage/modulating) B Domestic hot water tank aJ A Temperature sensor T1 Connection of external...
  • Page 22 Heating system types Circuit Diagram 8 (continued) When the return temperature falls Possible applications E.g. old systems or systems in market below the required minimum value, gardens as well as systems in which the return valve on the boilers is there is a lack of clarity in the hydraulic proportionally closed via the installation and/or systems where there...
  • Page 23 Heating system types Circuit Diagram 9 Several heating circuits and one mixing valve heating circuit Single-boiler system with Vitocrossal 300 Plugs A Boiler with Vitotronic 100, GC1 § Boiler temperature sensor Burner (1st stage) B Domestic hot water tank lÖ DHW tank temperature sensor Burner (2nd stage/modulating) C Heating circuit with mixing valve...
  • Page 24 Heating system types Circuit Diagram 9 (continued) IMPORTANT The Vitocrossal 300 is operated with constant boiler water temperature by means of the boiler control unit. This circuit diagram represents a Two-stage or modulating burners recommendation only. It is the can be controlled. responsibility of the customer and/or heating contractor to check that this The boiler water temperature which is...
  • Page 25 Heating system types Circuit Diagram 10 Single-boiler system with several heating circuits and one mixing valve heating circuit in conjunction with Vitocrossal 300 Plugs A Boiler with Vitotronic 100, GC1 § fÖ Boiler temperature sensor Power supply connection, B Domestic hot water tank DHW tank temperature sensor 120 VAC C Heating circuit with mixing valve...
  • Page 26 Heating system types Circuit Diagram 10 (continued) The Vitocrossal 300 is operated with Possible applications For heating circuits with different constant boiler water temperature by temperatures. means of the boiler control unit. Two-stage or modulating burners can be controlled. IMPORTANT The Vitocrossal 300 has two return connections.
  • Page 27 Heating system types Circuit Diagram 11 Multi-boiler system with several heating circuits and one mixing valve heating circuit in conjunction with Vitocrossal 300 Plugs A Boiler with Vitotronic 100, GC1 § Boiler temperature sensor Connection of external B Domestic hot water tank fÖ...
  • Page 28 Heating system types Circuit Diagram 11 (continued) The Vitocrossal 300 is operated with Possible applications Motorized isolation valve The cascade and DHW tank control constant boiler water temperature by Connect motorized isolation valve must be activated by a building means of the boiler control unit. adaptor (Part No.
  • Page 29 Heating system types Circuit Diagram 12 Multi-boiler system with several heating circuits, one mixing valve heating circuit and Vitorond with shunt pump in conjunction with Vitocrossal 300 and Vitorond 200 Plugs A Boiler with Vitotronic 100, GC1 § gS A1 Motorized isolation valve Boiler temperature sensor B Domestic hot water tank aJ A Temperature sensor T1...
  • Page 30 Heating system types Circuit Diagram 12 (continued) The Vitocrossal 300 (lead boiler) and The Vitocrossal 300 boilers have Possible applications The cascade and DHW tank control the Vitorond lag boilers are operated two return connections. The heating must be activated by a building with modulating boiler water circuits with the higher return automation system.
  • Page 31 Heating system types Circuit Diagram 13 Multi-boiler system with return valve, several heating circuits and one mixing valve heating circuit in conjunction with Vitocrossal 300 and Vitorond 200 A Boiler with Vitotronic 100, GC1 Plugs B Domestic hot water tank §...
  • Page 32 Heating system types Circuit Diagram 13 (continued) The Vitocrossal 300 (lead boiler) and The Vitocrossal 300 boilers have Possible applications For heating circuits with temperature the Vitorond lag boilers are operated two return connections. The heating differences ≥20 K. with modulating boiler water circuits with the higher return The cascade and DHW tank control temperature and load-dependent...

  • Page 33: Circuit Diagrams 1 To

    Heating system types Circuit Diagram 14 (CM2 only) Single-boiler system with several heating circuits and one mixing valve heating circuit in conjunction with Vitocrossal 200 Plugs A Boiler with Vitotronic 100, GC1 § fÖ Boiler temperature sensor Power supply connection, B Domestic hot water tank DHW tank temperature sensor 120 VAC...
  • Page 34 Possible applications For heating circuits with different constant boiler water temperature by temperatures. means of the boiler control unit and the Viessmann fully modulating burner. IMPORTANT This circuit diagram represents a recommendation only. It is the responsibility of the customer and/or...
  • Page 35 Heating system types Circuit Diagram 15 (CM2 only) Multi-boiler system with several heating circuits and one mixing valve heating circuit in conjunction with Vitocrossal 200 Plugs A Boiler with Vitotronic 100, GC1 § Boiler temperature sensor Connection of external B Domestic hot water tank fÖ...
  • Page 36 (Part No. 7511 367) automation system. the Viessmann fully modulating burner. or 24V valve adaptor (Part No. 7511 366), installed in connection enclosure, in parallel.

  • Page 37: Installation

    Installation Mounting the Front Part of the Control Unit (VD2/VD2A/CT3 only) 1. Position the front part of the housing and clip hinges to counter-parts on main housing. 2. Release the stay bar, open it up and lock in position at point A. 3.

  • Page 38: Opening The Control Unit (Vd2/Vd2A/Ct3 Only)

    Installation Opening the Control Unit (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.

  • Page 39: Control And Junction Box Installation Instructions (Cm2 Only)

    Installation Control and Junction Box Installation Instructions (for CM2 only) 1. Route cables and capillaries from control through the opening in the control panel. Guide the cables to the junction box through the opening in the rear panel and along the top rail to the control.

  • Page 40: Mounting The Front Part Of The Control Unit (Cm2 Only)

    Installation Mounting the Front Part of the Control Unit (CM2 only) 1. Position the front part of the housing and clip hinges to counter-parts on main housing. 2. Release the stay bar, open it up and lock in position at point A. 3.

  • Page 41: Opening The Control Unit (Cm2 Only)

    Installation Opening the 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.

  • Page 42: Overview Of Electrical Connections

    Installation Overview of Electrical Connections A1/M1 A1/M1 Low voltage connections (motherboard) Line voltage connections (motherboard) § sÖ A1Control output Boiler temperature sensor (KTS) DHW tank temperature sensor DHW pump Flue gas temperature sensor Shunt pump or aJA Return temperature sensor T1 boiler circuit pump aJB Return temperature sensor T2 fÖ...

  • Page 43: Overview Of Electrical Connections (Vd2/Vd2A/Ct3 Only)

    Installation Overview of Electrical Connections (VD2/VD2A/CT3 only) (continued) [29] [20] A1...

  • Page 44: Overview Of Electrical Connections (Cm2 Only)

    Installation Overview of Electrical Connections (CM2 only) (continued)

  • Page 45: Routing And Strain Relief Of Cables

    Installation Routing and Strain Relief of Cables 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. Fasten cable to the cable lead with cable tie.

  • Page 46: Inserting The Boiler Coding Card

    Installation Inserting the Boiler Coding Card CAUTION 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. Only use the boiler coding card included with the boiler. Boiler Coding card Part no.

  • Page 47: Setting Of The Fixed High Limit (If Required)

    Installation Setting of the Fixed High Limit (if required) Settings on the control unit The setting for the fixed high limit and the other settings are dependent on the The fixed high limit is supplied with safety equipment installed in a factory setting of 110°C / 230°F.

  • Page 48: Setting Of The Adjustable High Limit (If Required)

    Installation Setting of the Adjustable High Limit (if required) The adjustable high limit is supplied with a factory setting of 95°C / 203°F Adjustment to 100°C / 212°F 1. Disconnect power to control and burner. 2. Using a suitable screwdriver, lever out and remove the selector knob ”R”...

  • Page 49: Sensor Connection

    Installation Sensor Connection 1 2 3 1 2 3 1 2 3 1 2 3 ATemperature sensor T2 BTemperature sensor T1 CBoiler temperature sensor DFlue gas temperature sensor...

  • Page 50: Connection Of The Boiler Temperature Sensor

    Installation Connection of the Boiler Temperature Sensor Electrical connection See page 42. The sensor measures the boiler 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.

  • Page 51: Connection Of The Dhw Tank Temperature Sensor

    Installation Connection of the DHW Tank Temperature Sensor The sensor measures the domestic hot Heating systems with domestic hot Electrical connection See page 42. water tank temperature. water heating (single-boiler systems only) The sensor measures the boiler 1. Install the DHW tank temperature water temperature of the boiler.

  • Page 52: Connection Of The Return Temperature Sensor

    Installation Connection of the Return Temperature Sensor Strap-on temperature sensor and immersion temperature sensor For measuring the boiler return and return temperature. Electrical connection The sensor is inserted in socket 17A or 17B ”17A” or ”17B” on the boiler control. Check the sensor 1.

  • Page 53: Connection Of The Flue Gas Temperature Sensor

    Installation Connection of the Flue Gas Temperature Sensor (VD2/VD2A/CT3 only) The sensor measures the flue gas temperature and monitors the selected limit value. Electrical connection The sensor is inserted in socket ”15” on the control unit. Check flue gas temperature sensor 1.

  • Page 54: Connection Of The Pumps (Vd2/Vd2A/Ct3 Only)

    Installation Connection of the Pumps (VD2/VD2A/CT3 only) Available pump connections 20A1/M1 sÖ A1/M1Heating circuit high 120 VAC pumps 240 VAC or 3 PH pumps temperature (without mixing valve) Terminals 5 - L, - G , - N Note: Please note: The maximum power consumption of Use contactor and/or motor starter to Circulation pump for heating...

  • Page 55: Connection Of The Pumps (Cm2 Only)

    Installation Connection of the Pumps (CM2 only) Available pump connections sÖ A1/M1Heating circuit high 120 VAC pumps 240 VAC or 3 PH pumps temperature (without mixing valve) Terminals 7 - L, - G , - N Note: Please note: The maximum power consumption Use contactor and/or motor starter Circulation pump for heating of all pumps is 4A .

  • Page 56: Isolation/Modulating Valve (Vd2/Vd2A/Ct3 Only)

    Installation Connection of Boiler Return Mixing Valve or Isolation/Modulating Valve actuator (VD2/VD2A/CT3 only) 1 120V or 24V Valve Adaptor 1 120V Valve Adaptor 1 24V Valve Adaptor 2 DIN rail in connection enclosure 2 120V valve actuator 2 24V valve actuator 3 aBH Terminals 1.

  • Page 57: Isolation/Modulating Valve (Cm2 Only)

    Installation Connection of Boiler Return Mixing Valve or Isolation/Modulating Valve actuator (CM2 only) 10 11 12 1 120V or 24V Valve Adaptor 1 120V Valve Adaptor 1 24V Valve Adaptor 2 DIN rail in connection enclosure 2 120V valve actuator 2 24V valve actuator 3 120V L out power supply 1.
  • Page 58 Installation Making Space for Accessory Adaptors on the DIN Rail (CM2 only) 1. Push up on the bottom front of the DIN rail clamp to remove and set aside. 2. Using a flat head screwdriver, remove the 4 ’spare’ DIN terminals 23, 24, 25 and 26 one at a time.

  • Page 59: Vitotronic 100, Gci With 30% Ltp Package

    Installation Vitotronic 100, GC1 with 30% LTP Package (VD2/VD2A only) 1 - 17B Sensor (strap-on) VD2/VD2A...

  • Page 60: Connection Of External Controls

    Installation Connection of External Controls Operation with two-stage burner Dry contacts of the building automation system: 1st stage burner ON 2nd stage burner ON External changeover of staged/modulating burners Boiler activation, isolation valve open or closed (on multi-boiler system only) Switch on 2nd stage burner Boiler activation, isolation valve Connect dry contact at terminals ”2”...
  • Page 61 Installation Connection of External Controls (continued) Operation with two-stage burner Settings on the control unit The settings for the fixed high limit and the other settings are dependent on the safety equipment installed in accordance with applicable codes. Non-condensing boiler Condensing boiler Condensing boiler (VD2/VD2A) °C / °F...

  • Page 62: Connection Of External Controls (Vd2/Vd2A Only)

    Installation Connection of External Controls (VD2/VD2A only) (continued) Modulating boilers – operation with external modulation controller (continued) 1st stage burner fA from Boiler activation, isolation valve open Vitotronic 100. or closed Connect dry contact at terminals ”2” Plug lÖ from Vitotronic 100 via and ”3”...
  • Page 63 Installation Connection of External Controls (VD2/VD2A only) (continued) Modulating boilers – operation with external modulation controller Settings on the control unit The settings for the fixed high limit and the other settings are dependent on the safety equipment installed in accordance with applicable codes.

  • Page 64: Connection Of External Controls (Ct3 Only)

    Installation Connection of External Controls (CT3 only) (continued) Vitocrossal 300 – operation with external modulation controller 1st stage burner fA from Boiler activation, isolation valve open Vitotronic 100. or closed Connect dry contact at terminals ”2” Connection lÖ from Vitotronic 100 and ”3”...
  • Page 65 Installation Connection of External Controls (CT3 only) (continued) Vitocrossal 300 – operation with external modulation controller (continued) Settings on the control unit The settings for the fixed high limit and the other settings are dependent on the safety equipment installed in accordance with applicable codes.

  • Page 66: Connection Of Combustion Air Device (Vd2/Vd2A/Ct3 Only)

    Installation Connection of Combustion Air Device (VD2/VD2A/CT3 only) Connection of the Combustion Air Device Adaptor 1. Disconnect power to control and burners. 2. Install Combustion Air Device Adaptor, Part No. 7134 563 on DIN Rail inside connection enclosure (refer to installation manual of Combustion Air Device Adaptor).

  • Page 67: Connection Of Combustion Air Device (Cm2 Only)

    Installation Connection of Combustion Air Device (CM2 only) Connection of the Combustion Air Connection of the combustion air Device Adaptor blower to adaptor 1. Disconnect power to control and Rated voltage: 120 VAC burners. Rating current: max 5 FLA Recommended connection 2.

  • Page 68: Connection Of Combustion Air Device

    Installation Connection of Combustion Air Device (continued) Connection of the combustion air damper See damper manual for correct installation. Ensure that the combustion air damper is suitable for this application. 1. Disconnect power to control and burner. 2. Make connection as shown in the diagram.

  • Page 69: Connection Of Combustion Air Device On Multiple Boiler Systems

    Installation Connection of Combustion Air Device on Multiple Boiler Systems If a single combustion air device is required for a multiple boiler system, a Common Combustion Air Interface must be installed. Rated voltage: 120 VAC Rating current: max 5 FLA Recommended connection wire size: AWG 14...

  • Page 70: Connection Of Single Air Device On Multiple Boiler Systems

    Installation Connection of Single Combustion Air Device on Multiple Boiler Systems Connection of the combustion air blower A Common Combustion Air Device Interface B Combustion air device motor 120VAC, 5 FLA max. C Proving switch rated for 120 VAC D Power supply, 120 VAC ¨...

  • Page 71: Connection Of Combustion Air Damper

    Installation Connection of Combustion Air Damper Connection of the combustion air damper A Common Combustion Air Device Interface B Combustion air device motor 120VAC, 5 FLA max 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.

  • Page 72: Gas Flue Temp. Sensor (Optional For Cm2 Equipped With Ss Flue Collector)

    Installation Flue Gas Temp. Switch (mandatory for PP(s) material collectors) (CM2 only) 1. Disconnect power. CAUTION 2. Remove 150 plug from the Vitotronic control and discard. Please note that the diagram shown is only a simplified conceptual 3. Install new 150 plug supplied drawing of a flue gas temperature (attached to flue gas temperature switch.

  • Page 73: Connection Of Low Water Cut-Off Device (Vd2/Vd2A/Ct3 Only)

    Installation Connection of Low Water Cut-off Device (VD2/VD2A/CT3 only) 1. Remove jumper between terminals 12 and 15. 2. Make connection as shown in diagram. CAUTION Please note that the diagram at left is only a simplified conceptual drawing of a typical low water cut-off (LWCO) device.

  • Page 74: Connection Of Low Water Cut-Off Device (Cm2 Only)

    Installation Connection of Low Water Cut-off Device (CM2 only) 1. Remove jumper between terminals 21 and 22. 2. Make connection as shown in diagram. CAUTION Please note that the diagram shown is only a simplified conceptual drawing of a typical low water cut-off (LWCO) device.

  • Page 75: Connections To Terminal Abö (Vd2/Vd2A/Ct3 Only)

    Installation Connections to Terminal aBÖ (VD2/VD2A/CT3 only) External shut-off 1. Remove jumper between terminals 16 and 17. 2. Connect dry contact. Controlled switch-off takes place when the contact is opened. CAUTION The terminals should be used for safety switch-off purposes only (e.g. through a limit thermostat).

  • Page 76: Connection Of The Compiled Failure Alarm Indicator (Vd2/Vd2A/Ct3 Only)

    Installation Connection of the Compiled Failure Alarm Indicator (VD2/VD2A/CT3 only) Rated voltage: 120 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.

  • Page 77: Connection Of The Compiled Failure Alarm Indicator (Cm2 Only)

    Installation Connection of the Compiled Failure Alarm Indicator (CM2 only) Rated voltage: 120 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.

  • Page 78: Burner Connection, Burner Control Wiring (Vd2/Vd2A/Ct3 Only)

    Installation Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) For burners with plug-in connection The burner cables are included in the standard delivery of the Vitotronic. Connect the burner in accordance with applicable codes. ATo boiler control unit 1.Disconnect power to burner and BTo burner boiler control.
  • Page 79 Burner, 2nd stage b External controlled switch-off D Burner fault indicator * (remove jumper when connecting) E Control circuit, stage 1/ aBA Safety circuit. Emergency basic load * shut-off F Burner Refer to burner manufacturer’s instruction on detailed connections for Viessmann controls.
  • Page 80 (continued) See burner manual for correct fuse and wire gauge sizing, and specific For burners with 240 VAC, 1PH power connections for Viessmann controls. supply and connection in conduit. 1.Disconnect power to burner and boiler control. 2.Connect 240 VAC power to the...
  • Page 81 (continued) Burner motor power supply connection See burner manual for correct fuse (continued) and wire gauge sizing, and specific connections for Viessmann controls. For burners with 3PH 208, 460 or 575V power supply. 1.Disconnect power to burner and boiler control.

  • Page 82: Power Supply Connection To Boiler Control (Vd2/Vd2A/Ct3 Only)

    Installation Power Supply Connection, Boiler Control (VD2/VD2A/CT3 only) 1. Ensure that the main power supply Legend L: Line to the control contains overcurrent N: Neutral protection with a maximum rating G: Ground of 15 A and 2 pole disconnect. A Power supply 120 VAC, 1 PH . Provide disconnect means and CAUTION overcurrent protection as per local...

  • Page 83: Burner Connection, Burner Control Wiring (Cm2 Only)

    Installation Burner Connection, Burner Control Wiring (CM2 only) For burners with plug-in connection The burner cables are included in the standard delivery of the Vitotronic. Connect the burner in accordance with applicable codes. ATo boiler control unit 1.Disconnect power to burner and BTo burner interface boiler control.
  • Page 84 Start-up Procedure (overview) Page 1. Controls and indicators ................2.
  • Page 85 Start-up Steps 1. Controls and indicators Override switch Boiler water temperature (without function on multi-boiler systems) Domestic hot water temperature (without function 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...
  • Page 86 Start-up Steps (continued) 2. Check the fixed high limit The check is made via the ”TUV button” (see page 85). When making the check, the ”TUV” button must be kept continuously pressed. A minimum supply is required during the check. The minimum amount of recirculated water should be 10% of the amount recirculated at the rated load.
  • Page 87 Start-up Steps (continued) 3. Integrate the control unit in the LON BUS system Single-boiler system only The LON communication module (accessory) must be inserted (see page 111). Set the LON participant number Set the LON participant number via See page 115 for coding 1. coding address ”77”...
  • Page 88 Start-up Steps (continued) 4. Carry out participant check Single-boiler system only The participant check is used to verify the communication of the system units connected to the error manager. Requirements: The control unit must be coded as the error manager (coding ”79: 1”) The LON participant number must be coded in all control units (see page 87) The participant list must be updated in the error manager (see page 87) 1.
  • Page 89 Start-up Steps (continued) 5. Match the control unit to the system type Set the following coding addresses in See page 117 for coding 2. coding 2: ”00” System type ”01” Single or multi-boiler system ”02” Burner type ”03” Oil or gas-fired operation ”07”...
  • Page 90 Start-up Steps (continued) 7. Match the coding addresses Match control unit to modulating burner Please note: The burner must be adjusted. In order to achieve a wide modulation range, the minimum output should be set as low as possible (take chimney/flue system into account).
  • Page 91 Start-up Steps (continued) 7. Match the coding addresses (continued) 10. Set the established values in coding See page 115 for coding 1. level 1. Address Setting of the partial output (see point 8) as a percentage proportion of the max. output; e.g. partial output: 170 kW max.
  • Page 92 Scanning service information Overview of Service Levels Function Button combination To exit Page Temperatures, boiler coding Press 9 and rw simultaneously Press OK cards and scans for approx. 2 seconds Relay test Press 9 and OK simultaneously for Press OK approx.
  • Page 93 Scanning service information Temperatures, Boiler Coding Cards and Scans 1. Press simultaneously for Access diagnosis level. approx. 2 seconds. 2. Select the required data for scanning with the button. Exit diagnosis level. 3. Press The following values can be scanned depending on the system equipment installed: Display Meaning...
  • Page 94 Scanning service information Temperatures, Boiler Coding Cards and Scans (continued) Scan 0 SNVT configuration Auto Tool Software version Communication coprocessor LON participant number Scan 0 Scan 1 Node address System number (only with self-binding) Subnet address Scan 1 Scan 2 Software version LON communication module Number of LON...
  • Page 95 Scanning service information Temperatures, Boiler Coding Cards and Scans (continued) Scan 4 Software version Control unit Software version Programming unit System type Free Scan 4 Scan b/d Isolation valve Closed Preheating Closing Regulating Opening Open Run-on Scan d Burner 1st stage/basic load 2nd stage/full load Free Scan b...
  • Page 96 Scanning service information Temperatures, Boiler Coding Cards and Scans (continued) Scan L Output reduction (0 to 100 %; 0 = OFF) Free Scan L o o o o Scan Free Free Equipment identification code Scan...
  • Page 97 Scanning service information Scanning Service Information 1. Press Operating status scanning mode is activated. 2. Select the required operating status data for scanning with the button. 3. Press Exit the operating status scanning mode. The following operating status information can be scanned depending on the system equipment installed: Display Meaning...
  • Page 98 Scanning service information Scanning and Resetting the Service Display Please note: If a service is carried out before the service display appears, set the coding address ”24: 1” and then coding address ”24: 0”. When the limit values selected via coding addresses ”1F”, ”21”...
  • Page 99 Troubleshooting Troubleshooting Steps Page Diagnosis 1. Establish fault message or ascertain behaviour of system 2. Look for the corresponding cause of the fault in the diagnosis tables ................... . . Please note: Retrieve fault codes from the fault memory .
  • Page 100 Troubleshooting Diagnosis Faults with fault display on the programming unit The red fault indicator 2 flashes whenever there is a fault. 1 2 3 4 5 6 7 When a fault message is transmitted, The meaning of the fault code is a fault code flashes in the display 1 explained in the table on page 101 of the programming unit.
  • Page 101 Troubleshooting Diagnosis (continued) Faults with fault display on the programming unit (continued) Fault Cause of fault Action Behaviour of system code in display Burner is switched on and off by Short circuit Check boiler temperature sensor (see the adjustable high limit Boiler temperature sensor page 50) Burner is switched on and off by...
  • Page 102 Troubleshooting Diagnosis (continued) Faults with fault display on the programming unit (continued) Fault Cause of fault Action Behaviour of system code in display Insert plug aJA Controlled operation Therm-Control configuration error: On Vitocrossal: plug aJA of Check that coding ”0d: 0” is set. Therm-Control temperature sensor not inserted Insert plug aJB and check coding...
  • Page 103 Troubleshooting Diagnosis (continued) Faults with fault display on the programming unit (continued) Fault Cause of fault Action Behaviour of system code in display Control mode Faulty communication with Input Check connections and Module cables/leads; replace Input 0 to 10 V Module, if required (see page 126) Without Input Module:...
  • Page 104 Troubleshooting Diagnosis (continued) Retrieving fault codes from the fault memory (error history) All faults which have occurred are stored and can be retrieved by scanning. The scanning sequence starts with the most recently stored fault code. 1. Press simultaneously Scanning of error history is for approx.
  • Page 105 Functional description Boiler Temperature Control Brief description The boiler water temperature is In conjunction with Therm-Control: Coding addresses which influence controlled by switching the burner on The set-point boiler water temperature the boiler temperature control and off. is increased when the temperature falls 02 to 06, 08 to 0b, 13 to 1C.
  • Page 106 Functional description Heating Circuit Control Brief description The supply temperature of the boiler Coding addresses which influence the circuit (A1) corresponds to the boiler heating circuit control water temperature. 55, 56, 58, 5A to 63, 6A, 6b. Functions The boiler circuit (A1) is dependent on Upper limit of control range Domestic hot water temperature the boiler water temperature and its...
  • Page 107 Functional description DHW Tank Temperature Control (continued) Control sequence DHW tank temperature falls DHW tank temperature rises (Set-point value –2.5°C / - 4.5°F, (Set-point value +2.5°C / 4.5°F) selectable via coding address ”59”) The boiler water temperature set-point The set-point boiler water temperature value is reset to the value is set 20°C / 36°F higher than the determined by the set-point supply...
  • Page 108 Additional information Overview Page Technical Data System Components Line voltage motherboard ................Low-voltage motherboard .

  • Page 109: Low-Voltage Motherboard

    Low-voltage motherboard, Part No. 7820 290 The motherboard contains: plugs for sensors, communication connections and external equipment plug-in locations for electronics board, LON communication module, Viessmann 2-wire BUS communication module, programming unit, boiler coding card and Optolink board.

  • Page 110: Power Supply Unit Board

    Additional information System Components (continued) Power supply unit board, 120 VAC Part No. 7823 991 The power supply unit board contains the low-voltage supply for the entire electronics. Electronics board, Part No. 7828 193 The board contains the microprocessor with the software. When replacing the board: 1.

  • Page 111: Programming Unit

    Additional information System Components (continued) Programming unit, Part No. 7823 990 The programming unit is inserted in the control unit. For setting: heating program set-point values For displaying: temperatures operating status information faults Fuse box, Part No. 7820 175 The fuse box contains: fixed high limit adjustable high limit fuses...
  • Page 112 Additional information System Components (continued) Boiler coding card Vitotronic 200 Boiler coding Part No. in conjunction with card 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.
  • Page 113 Additional information System Components (continued) TUV button, Part No. 7819 314 For checking the fixed high limit. See description on page 86. Fixed high limit, Part No. 7820 036 Type STW 56.10525.570, make: EGO, DIN STB (STW) 106095 EM-80-V-TK/b7-1 60002843, make: Juchheim, DIN STB 82699 The fixed high limit has a factory setting of 120°C / 248°F.

  • Page 114: Input Module 0 To 10V

    Additional information System Components (continued) Input Module 0 to 10 V, Part No. 7134 561 From software version 7 of Vitocontrol-S, VD2/CT3, the Input Module can be connected (software version via scan 2: 1st digit, display ≥7). For external control of the boiler/supply temperature via a 0 to 10VDC signal 10 to 100˚C or 30 to 120˚F 50 to 212˚C or 86 to 248˚F to signal reduced mode and regulate a heating circuit pump to a lower speed.

  • Page 115: Coding 1

    Additional information Coding 1 Call up coding level 1 1. Press simultaneously for Access coding level 1. approx. 2 seconds. The first arrow appears in the display. 2. Call up the required coding address Address flashes. with the button; press to confirm.

  • Page 116: Coding 1

    Additional information Coding 1 (continued) Codings (continued) Coding as per Function New coding Possible change factory setting Address: Value Address:Value 07: 1 Boiler sequence number in multi- 07: 2 Boiler sequence number in multi-boiler Boiler boiler system (in conjunction with system (in conjunction with coding coding address ”01”) 07: 4...

  • Page 117: Call Up Coding Level 2

    Additional information Coding 2 Call up coding level 2 The overview lists all possible coding addresses. However, only those coding addresses are displayed which correspond to the system type and equipment concerned and can be changed accordingly. Access coding level 2. 1.
  • Page 118 Additional information Coding 2 (continued) Overview of all codings (continued) Coding as per Function New coding Possible change factory setting Address: Value Address: Value 03: 0 Gas-fired operation 03: 1 Oil-fired operation Boiler/ (coding cannot be reset) burner Switching differential 04: 0 Switching differential 4°C / 7°F Boiler/...
  • Page 119 Additional information Coding 2 ((continued) Overview of all codings (continued) Coding as per Function New coding Possible change factory setting Address: Address: Value Value 06: 87 Max. limit of boiler water 06: 20 Maximum boiler water temperature limit Boiler/ temperature set to variable between 20 and 127 burner 87°C / 189°F...
  • Page 120 Additional information Coding 2 (continued) Overview of all codings (continued) Coding as per Function New coding Possible change factory setting Address: Address: Value Value 1b: 60 Time from ignition of burner to 1b: 0 Control delay adjustable Burner start of control 60 seconds from 0 to 199 seconds 1b:199 1C:120...
  • Page 121 Additional information Coding 2 (continued) Overview of all codings (continued) Coding as per Function New coding Possible change factory setting Address: Address: Value Value 2C: 0 No run-on time 2C: 5 2C: 5 Maximum run-on time of boiler isolation Maximum run-on time of boiler isolation General General valve 5 minutes...
  • Page 122 Additional information Coding 2 (continued) Overview of all codings (continued) Coding as per Function New coding Possible change factory setting Address: Address: Value Value 55: 1 Adaptive tank heating active 55: 0 Tank heating, (takes into account the rate at differential +/- 2.5°C / 4.5°F which the tank temperature increases during domestic hot...
  • Page 123 0.7 76: 1 With LON communication module; 76: 0 Without LON communication module General recognized immediately 76: 2 With Viessmann 2-wire BUS communication module; recognized immediately 77: 1 LON participant number 77: 2 LON participant number selectable General...
  • Page 124 94: 2 With plug-in adaptor for external General safety equipment safety equipment; recognized automatically 98: 1 Viessmann system number 98: 2 System number General (in conjunction with monitoring of selectable from 1 to 5 several systems within one LON BUS...

  • Page 125: Wiring Diagrams

    A2 Low-voltage motherboard 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...

  • Page 126: Low-Voltage Motherboard

    Additional information Wiring Diagrams (continued) Low-voltage motherboard...
  • Page 127 Additional information Wiring Diagrams (continued) Low-voltage motherboard (continued) § aJA Temperature sensor T1 Boiler temperature sensor S3 Override switch ”S” aJB Temperature sensor T2 Tank temperature sensor V1 Fault indicator (red) aVD Connection of external (accessory) V2 Operating status indicator (green) Flue gas temperature sensor equipment aVG KM BUS participant (accessory)

  • Page 128: Line Voltage Motherboard

    Additional information Wiring Diagrams (continued) Line voltage motherboard...
  • Page 129 Additional information Wiring Diagrams (continued) Line voltage motherboard (continued) sÖ Control output lÖ Burner (2nd stage/modulating) F1, F2 Fuses sA DHW pump aBÖ External equipment Fixed high limit ”E” sL Shunt pump or boiler circuit pump a External safety equipment 120°C (99°C or 110°C) / fÖ...

  • Page 130: Parts List

    7248247 Ordering Replacement Parts: Please provide product Model and Serial Number from rating plate when ordering replacement parts. Order replacement parts from your Viessmann distributor. Parts Hinges Circuit board (control software) Other Parts (not illustrated) Optic link Diagnostics module (Optolink)
  • Page 131 Additional information Parts List...
  • Page 132 +176 +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. (401) 732-0667 • Fax (401) 732-0590 Tel.

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