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Installation, Start-up
and Service Instructions
Vitotronic 100
Model KK10
Boiler control unit
for high temperature heating systems
Part No. 7133 374
VITOTRONIC 100
Certified as a component part
of Viessmann boilers only
5167 481 v1.2 08/2010
IMPORTANT
Read and save these instructions
for future reference.
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Table of Contents
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Summary of Contents for Viessmann KK10
- Page 1 Vitotronic 100 Model KK10 Boiler control unit for high temperature heating systems Part No. 7133 374 VITOTRONIC 100 IMPORTANT Read and save these instructions Certified as a component part for future reference. of Viessmann boilers only 5167 481 v1.2 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 KK10: Order No. 7133 374, 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 KK10 7133 374 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 or DHW pump module connection Dip switches 2nd stage adaptor connection, 191 plug... -
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: Room Thermostat Connection
5. Set thermostat anticipator to 0.1 A. Pump Connection The main circuit board is pictured from the top. The Vitotronic 100, Model KK10 incorporates a 120 VAC pump output. The output is activated when the boiler water temperature exceeds the minimum boiler temperature limit. -
Page 12: 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 13: 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 14: Dip Switch Settings
Altering Settings Dip Switch Settings The “sequence of operation” of the Vitotronic 100, Model KK10 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 15: 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 16 Appendix / Start-up Notes...
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Page 17: 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 18: Electrical Connections And Sequence Of Operation
(for qualified service personnel only) Electrical connections and sequence of operation plug of the Vitotronic 100, Model KK10 boiler control supplies power to the RAST-5 connection on the main circuit board. This plug has L1, G and N markings on its terminals. - Page 19 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 20: 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 21 Additional Information Replacement Components (for qualified service personnel only) Adjustable high limit, Part No. 7819 316 H Electro-mechanical temperature limit with liquid filled capillary H Controls maximum boiler water temperature (Factory setting 167°F / 75°C) H Adjustable to 189, 203 and 212°F / 87, 95 and 100°C by breaking off tabs enabling dial to rotate right to...
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Page 22: Boiler Protection
When the boiler temperature drops below the setpoint of the pump aquastat, the burner activates and the space heating pump is deactivated. The space heating pump may be connected to the KK10 control in one of two ways: –using a boiler-mounted pump junction box –using a DHW pump module (accessory). - Page 23 The Vitola 200 boiler does not have a boiler-mounted pump junction box. When the Vitotronic, KK10 control is used with the DHW pump module, the factory default setting will allow the space heating pump and the DHW pump to turn off when the boiler water temperature is below the minimum boiler temperature setpoint.
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Page 24: Parts List
065 Burner cable with plugs parts. Order replacement components 010 Control housing cover, top (shipped with burner or boiler) from your Viessmann distributor. 011 Control housing, front 091 Fuse 016 Control housing, bottom T 6.3 A / 250 V, slow blow... -
Page 25: Wiring Diagram
24 VAC Connections X2 Room thermostat connection or DHW pump module connection 2nd stage cable 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 26: 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 27 5167 481 v1.2...
- Page 28 +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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