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

Type gc1 digital boiler control unit
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See also: Technical Data Manual
Installation and
service instructions
for heating engineers
Vitotronic 100
Type GC1
Digital boiler control unit
See applicability, page 168.
VITOTRONIC 100
Please keep safe
5862 730 GB
3/2005

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Summary of Contents for Viessmann VITOTRONIC 100

  • Page 1 Installation and service instructions for heating engineers Vitotronic 100 Type GC1 Digital boiler control unit See applicability, page 168. VITOTRONIC 100 Please keep safe 5862 730 GB 3/2005...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions ¨ Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Regulations ¨ Danger Observe the following when working This symbol warns against the on this system H all legal instructions regarding the risk of injury.
  • Page 3 For replacements, use only original spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index General information Product information ....................... Heating system designs Summary of system versions .
  • Page 5 Index Index (cont.) Service scans Service level summary ......................Temperatures, boiler coding card and brief scans .

  • Page 6: General Information

    General information Product information This document describes Vitotronic 100 when used H in a single boiler system and H in a multi−boiler system with higher third party control unit. These instructions are not required in multi−boiler systems with Vitotronic 333.

  • Page 7: Heating System Designs

    Heating system designs Summary of system versions Boiler Characteristics Page Single boiler systems 1 Vitoplex Therm Control 2 Vitogas, Vitomax, Shunt pump for raising the return temperature Vitoplex, Vitorond Shunt pump and three−way mixer for raising the return temperature 11 Vitocrossal 300 Several heating circuits and one low temperature heating circuit Multi−boiler systems...

  • Page 8: System Versions 1 To 17

    System version 1 System with Therm−Control Vitoplex 100, type SX1, up to 460 kW, Vitoplex 200, type SX2, up to 560 kW and Vitoplex 300, type TX3 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 9 Heating system designs System version 1 (cont.) Required coding 02 : 2 Modulating burner operation 03 : 1 Oil fired operation (irreversible) 0d : 1 Therm−Control controls the mixers of downstream heating circuits Automatic changeover 00 : 2 With DHW cylinder Connecting the Therm Control temperature sensor to plug aJA 4A: 1 If required.
  • Page 10 Heating system designs System version 1 (cont.) Possible applications Therm−Control Heating systems with distributor Wiring in heating systems with installed close to the boiler. The heating circuit control units which boiler water volume flow must be are not connected to the boiler able to be reduced.
  • Page 11 Raising the return temperature with a shunt pump Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 B DHW cylinder C Heating circuit with mixer Plug §...
  • Page 12 Heating system designs System version 2 (cont.) Required coding 02 : 2 Modulating burner operation 03 : 1 Oil fired operation (irreversible) The temperature sensor on plug aJA controls the mixers of 0d : 1 downstream heating circuits Automatic changeover 00 : 2 With DHW cylinder Connecting temperature sensor T1 to plug aJA...
  • Page 13 Heating system designs System version 2 (cont.) Possible applications Temperature sensor T1 Heating systems with distributor Wiring in heating systems with installed close to the boiler. The heating circuit control units which boiler water volume flow must be are not connected to the boiler able to be reduced.
  • Page 14 Raising the return temperature with shunt pump and three−way mixer Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 B DHW cylinder C Heating circuit with mixer Plug §...
  • Page 15 Heating system designs System version 3 (cont.) Required coding 02 : 2 Modulating burner operation 03 : 1 Oil fired operation (irreversible) 0C : 1 Constant return temperature control Automatic changeover 00 : 2 With DHW cylinder Connecting temperature sensor T1 to plug aJA 4A: 1 Connecting temperature sensor T2 to plug aJB 4b : 1...
  • Page 16 Heating system designs System version 4 System with Therm−Control Vitoplex 100, type SX1, to 460 kW, Vitoplex 200, type SX2, to 560 kW, and Vitoplex 300, type TX3 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 17 Heating system designs System version 4 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 18 Heating system designs System version 4 (cont.) Possible applications Therm−Control Heating systems with distributor Wiring in heating systems with installed close to the boiler. The heating circuit control units which boiler water volume flow will be are not connected to the boiler reduced by the motorised butterfly control unit via the LON BUS.
  • Page 19 Raising the return temperature for each boiler with a shunt pump Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 B DHW cylinder C Heating circuit with mixer Plug §...
  • Page 20 Heating system designs System version 5 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 21 Heating system designs System version 5 (cont.) Possible applications Temperature sensor T1 Heating systems with distributor Wiring in heating systems with installed close to the boiler. The heating circuit control units which boiler water volume flow will be are not connected to the boiler reduced by the motorised butterfly control unit via the LON BUS.
  • Page 22 System version 6 Raising the return temperature with a common shunt pump Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 A Boiler with Vitotronic 100 Plug B DHW cylinder §...
  • Page 23 Heating system designs System version 6 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 24 Heating systems with distributor shunt pump must be connected to installed close to the boiler. The one of the Vitotronic 100 if an boiler water volume flow must be external cascade control unit is used. able to be reduced via the heating circuits.
  • Page 25 Distribution pump and low pressure distributor Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 26 Heating system designs System version 7 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 27 Heating system designs System version 7 (cont.) Possible applications Temperature sensor T1 If the distributor is located in remote Wiring for reducing the volume flow sub−stations (> 20 m). The heat in heating systems with heating transfer to the heating circuits must circuit control units, which are not be able to be reduced.
  • Page 28 Distribution pump and injection control Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water tempe. sensor...
  • Page 29 Heating system designs System version 8 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 30 Heating system designs System version 8 (cont.) Possible applications Temperature sensor T1 If the distributor is located in remote Wiring for reducing the volume flow sub−stations (>20 m), and the heating in heating systems with heating circuits require heat immediately circuit control units, which are not after a demand is present, e.g.
  • Page 31 Raising the return temperature with a three−way mixing valve Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 32 Heating system designs System version 9 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 33 Vitogas 100 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 200 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature C Heating circuit with mixer...
  • Page 34 Heating system designs System version 10 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 35 Heating system designs System version 11 System with Vitocrossal 300 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature C Heating circuit with mixer sensor D Neutralising system Cylinder temperature sensor (accessories) Cylinder primary pump (accessories) fÖ...
  • Page 36 Heating system designs System version 11 (cont.) Required coding 02 : 2 Modulating burner operation 0d : 0 Without Therm−Control Automatic changeover 00 : 2 With DHW cylinder Vitocrossal 300 is operated via the boiler control unit two−stage or modulating burners are regulated. If required.
  • Page 37 Heating system designs System version 12 Several heating circuits and one low temperature heating circuit Vitocrossal 300 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature C Heating circuit with mixer sensor D Low temperature heating circuit...
  • Page 38 Heating system designs System version 12 (cont.) Required coding 02 : 2 Modulating burner operation 0d : 0 Without Therm−Control Automatic changeover 00 : 2 With DHW cylinder Possible applications Vitocrossal 300 is operated via the For heating circuits with varying boiler control unit two−stage or temperatures.
  • Page 39 Heating system designs System version 13 Several heating circuits and one low temperature heating circuit Vitocrossal 300 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature C Heating circuit with mixer sensor D Neutralising system fÖ...
  • Page 40 Heating system designs System version 13 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 41 Heating system designs System version 14 Several heating circuits and one low temperature heating circuit Vitocrossal 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, Vitoplex 300, type TX3 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 42 Heating system designs System version 14 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 43 Heating system designs System version 14 (cont.) Possible applications Vitocrossal 300 is equipped with two The cascade and cylinder control return connectors. The heating must be provided by a higher control circuits with the higher return unit. temperature are connected to the upper return connector and those The Vitocrossal 300 (lead boiler) and with lower return temperatures to...
  • Page 44 Vitocrossal 300 Vitogas 100 Vitomax 100 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 Vitorond 100 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature C Heating circuit with mixer...
  • Page 45 Heating system designs System version 15 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 46 Heating system designs System version 15 (cont.) Possible applications Vitocrossal 300 is equipped with two The cascade and cylinder control return connectors. The heating must be provided by a higher control circuits with the higher return unit. temperature are connected to the upper return connector and those The Vitocrossal 300 (lead boiler) and with lower return temperatures to...
  • Page 47 Several heating circuits, one low temperature heating circuit plus Vitoplex with Therm−Control and boiler circuit pump Vitocrossal 300 Vitoplex 100 (90 to 500 kW), Vitoplex 200 and Vitoplex 300, type TX3 (80 to 1750 kW) A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 48 Heating system designs System version 16 (cont.) Codes must be set on every Vitotronic 100. Required coding 01 : 2 Multi−boiler system with cascade control via LON BUS 01 : 3 Multi−boiler system with external cascade control via switching contacts...
  • Page 49 Heating system designs System version 16 (cont.) Possible applications Vitocrossal 300 are equipped with For heating circuits with temperature two return connectors. The heating differentials y 20 K. circuits with the higher return temperature are connected to the The cascade and cylinder control upper return connector and those must be provided by a higher control with lower return temperatures to...
  • Page 50 Three−way mixing valve, several heating circuits and one low temperature heating circuit Vitocrossal 300 Vitomax 100, Vitomax 200 and Vitomax 300 Vitoplex 100, type SX1, Vitoplex 200, type SX2, and Vitoplex 300, type TX3 A Boiler with Vitotronic 100 Plug B DHW cylinder § Boiler water temperature...
  • Page 51 03 : 1 Only with Vitotronic 100 for low temperature boilers: Oil fired operation (irreversible) 0C : 1 Only with Vitotronic 100 for low temperature boilers: Constant return temperature control 0d : 0 Only with Vitotronic 100 for Vitocrossal 300: Without Therm−Control...
  • Page 52 Heating system designs System version 17 (cont.) Possible applications Vitocrossal 300 are equipped with For heating circuits with temperature two return connectors. The heating differentials y 20 K. circuits with the higher return The cascade and cylinder control temperature are connected to the must be provided by a higher control upper return connector and those unit.

  • Page 53: System Extension

    System extension DHW heating with a cylinder storage system Only in conjunction with single boiler systems 21 17B A Boiler with Vitotronic 300 Plug B Vitocell−L 300 Terminals 1 and 2: C Vitotrans 222 Cylinder temperature sensor 1 (top) Terminals 2 and 3: Cylinder temperature sensor 2 (bottom) aJB Temperature sensor...
  • Page 54 System extension DHW heating with a cylinder storage system (cont.) Required coding 4C : 1 Primary pump connection on plug sÖ A1 Motor connection for three−way mixing valve on plug gS A1 4E : 1 55 : 3 Cylinder thermostat cylinder storage system Automatic changeover Connection of temperature sensor Vitotrans 222 on plug aJB...

  • Page 55: System With Flue Gas/Water Heat Exchanger

    System extension System with flue gas/water heat exchanger With shunt pump With boiler circuit pump...
  • Page 56 System extension System with flue gas/water heat exchanger (cont.) Boiler with Vitotronic 100 Required coding: Vitotrans 333 (flue gas/water Adjust on every Vitotronic 100 with heat exchanger) Vitotrans 333 "4C : 3". Circulation pump Vitotrans 333 Circulation pump and motorised...

  • Page 57: Installation

    Installation Summary of electrical connections A1/M1 A1/M1...
  • Page 58 Installation Summary of electrical connections (cont.) Main PCB low voltage Main PCB 230V~ § sÖ A1 Cylinder primary pump Boiler water temperature sensor Cylinder temperature sensor Circulation pump flue Cylinder temperature sensor 2 gas/water heat exchanger for cylinder storage system (accessories) switching output Flue gas temperature sensor...

  • Page 59: Inserting Cables And Applying Strain Relief

    Installation Inserting cables and applying strain relief Installing the control unit on the boiler Route cables from below through the front panel of the boiler into the wiring chamber of the control unit. Installing the control unit on the boiler side Route cables from below, out of the cable channel into the control unit.

  • Page 60: Inserting The Boiler Coding Card

    Installation Inserting the boiler coding card Only use the boiler coding card included with the boiler. Boiler Coding card Part no. Vitocrossal 300, type CM3 1042 7820 146 Vitocrossal 300, type CR3 1041 7820 145 Vitocrossal 300, type CT3 1040 7820 144 Vitocrossal 300, type CU3 1042...

  • Page 61: Changing The High Limit Safety Cut−Out Setting

    Installation Changing the high limit safety cut−out setting (if required) The high limit safety cut−out is supplied with a factory setting of 120 ºC. Please note If the high limit safety cut−out is to remain set to 120 ºC, also install a minimum pressure limiter (see page 84 and 136), to prevent injury and material losses.
  • Page 62 Installation Changing the high limit safety cut−out setting (cont.) Conversion to 110 or 100 ºC (make T&G)
  • Page 63 Installation Changing the high limit safety cut−out setting (cont.) Change to 110 or 100 ºC make EGO A Slotted screw 1. Release the safety assembly and 2. Turn the slotted screw until the slot points to 110 or 100 ºC (once pivot it up.
  • Page 64 Installation Changing the high limit safety cut−out setting (cont.) Conversion to 110 or 100 ºC, make JUMO 1. Release the safety assembly. 4. Remove the high limit safety cut−out. 2. Remove reset button cover "E". 5. Turn the screw until the indicator points to 110 or 100 ºC.

  • Page 65: Changing The Control Thermostat Setting

    Installation Changing the control thermostat setting (if required) Conversion to 100 or 110 ºC In the delivered condition, the control thermostat is set to 95 ºC. 1. Lever out and remove rotary selected range. selector "R". Turn rotary selector "R" clockwise to the end stop.

  • Page 66: Sensor Connection

    Installation Sensor connection 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 A Temperature sensor T2 or Temperature sensor cylinder storage system B Therm−Control temperature sensor or temperature sensor T1 C Cylinder temperature sensor (accessories) D Cylinder temperature sensor 2 in conjunction with a cylinder...

  • Page 67: Pump Connection

    Installation Pump connection Available pump connections sÖ Cylinder primary pump Circulation pump flue gas/water heat exchanger sA Cylinder primary pump sL Shunt pump or boiler circuit pump Pumps 230 V~ L N PE L N PE External ON/OFF Pumps 400 V~ Rated current: 4 (2) A~ Recommended L1 L2 L3 N PE...

  • Page 68: Connecting An Actuator With Three Point Output

    Installation Connecting an actuator with three−point output Use as: H Butterfly valve H Mixer motor H Three−way mixing valve Rated voltage: 230 V~ Rated current: max. 0.2 (0.1) A Recommended connecting cable: H05VV−F4G 0.75 mm H05RN−F4G 0.75 mm Run−time: 5 to 199 s, adjustable via coding address "40"...

  • Page 69: External Hook−Up In Single Boiler Systems

    Installation External hook−up in single boiler systems Operation with a two−stage burner The connections on plug aVD and Zero volt contacts of the higher aVH are required when connecting control unit: an external hook−up. The cylinder Burner stage 1 ON thermostat is activated when the cylinder temperature sensor (accessories) is connected.
  • Page 70 Installation External hook−up in single boiler systems (cont.) Starting burner stage 1 Starting burner stage 1 and 2 Contact closed: Contact closed: Burner stage 1 is started. Burner Both burner stages are switched ON. stage 2 will only be started for The boiler water temperature is maintaining the minimum temperature.
  • Page 71 External hook−up in single boiler systems (cont.) Low temperature boiler operation with a modulating burner Connection modulating burner: H Burner stage 1 fA of Vitotronic 100 H Plug−in connector lÖ from Vitotronic 100 via the modulation controller (on site) to burner plug−in connector lÖ.
  • Page 72 Code "02: 1" the minimum temperature, the (delivered condition) burner is switched to full load via Vitotronic 100. An external The boiler water temperature must modulation controller regulates the be set to the lower value. The boiler load−dependent modulation. is held at the required minimum The boiler water temperature is temperature.
  • Page 73 External hook−up in single boiler systems (cont.) Vitocrossal 300 operation with a modulating burner Connection modulating burner: H Burner stage 1 fA of Vitotronic 100 H Plug−in connector lÖ of Vitotronic 100 remains unused H Burner stage 2 lÖ modulating under the control of the on−site...
  • Page 74 Installation External hook−up in single boiler systems (cont.) Control unit settings Starting burner stage 1 Code "01: 1" Contact closed: (delivered condition) Burner stage 1 is started. An external modulation controller regulates the The boiler water temperature must load−dependent modulation. The be set to the lower value.

  • Page 75: External Hook−Up In Multi−Boiler Systems Without Lon

    Installation External hook−up in multi−boiler systems without LON Operation with a two−stage burner The connections on plug aVD and Zero volt contacts of the higher aVH are required when connecting control unit: an external hook−up. The DHW cylinder temperature and the Burner stage 1 ON load−dependent cascade control must be regulated by an external...
  • Page 76 Installation External hook−up in multi−boiler systems without LON (cont.) Starting burner stage 1 and 2 Enable boiler, butterfly valve Contact closed: Contact closed: H Vitocrossal 300: Both burner stages are switched ON. The boiler water temperature is The butterfly valve opens. H Low temperature boiler: limited by the electronic maximum temperature limiter, if it is set below...
  • Page 77 External hook−up in multi−boiler systems without LON (cont.) Low temperature boiler operation with a modulating burner Connection modulating burner: H Burner stage 1 fA of Vitotronic 100 H Plug−in connector lÖ from Vitotronic 100 via the modulation controller (on site) to burner plug−in connector lÖ.
  • Page 78 (cont.) Zero volt contacts of the higher control unit with modulation controller: Enable boiler, open or close the butterfly valve Burner stage 1 (base load) ON Modulation controller: Reduce burner output Increase burner output A Vitotronic 100 B Burner control...
  • Page 79 Installation External hook−up in multi−boiler systems without LON (cont.) Adjustments on every control unit Starting burner stage 1 Set code "01: 3" Contact closed: code "02: 1" Burner stage 1 is started. Full load is (delivered condition) switched ON only for maintaining the minimum temperature.
  • Page 80 External hook−up in multi−boiler systems without LON (cont.) Vitocrossal 300 operation with a modulating burner Connection modulating burner: H Burner stage 1 fA of Vitotronic 100 H Plug−in connector lÖ of Vitotronic 100 remains unused H Burner stage 2 lÖ modulating under the control of the on−site...
  • Page 81 Zero volt contacts of the higher control unit with modulation controller: Enable boiler, open or close the butterfly valve Burner stage 1 (base load) ON Modulation controller: Reduce burner output Increase burner output A Vitotronic 100 B Burner control C unused...
  • Page 82 Installation External hook−up in multi−boiler systems without LON (cont.) Adjustments on every control unit Starting burner stage 1 Set code "01: 3". Contact closed: Burner stage 1 is started. The boiler The high limit safety cut−out settings water temperature is limited by the and other settings are subject to the electronic maximum temperature system equipment and the safety...

  • Page 83: External Hook−Up In Multi−Boiler Systems With Lon

    Installation External hook−up in multi−boiler systems with LON Zero volt contacts of the higher Boiler blocking control unit: Contact closed: Boiler blocking The boiler is blocked. It is taken out of the boiler sequence, Start boiler as last i.e. the butterfly valve or the one in boiler three−way mixing valve for constant sequence...

  • Page 84: External Connections On Plug Abö

    Installation External connections on plug aBÖ Please note ’Live’ contacts lead to short circuits or phase failure. The external connections must be zero volt. Plug aBÖ must remain plugged in, even if no connection is made. The plug−in adaptor for external safety equipment can be used for connecting several pieces of safety equipment (see page 136).

  • Page 85: Connecting Central Fault Messaging To Plug Gö

    Installation External connections on plug aBÖ (cont.) Please note When the heating system is Connecting an external control shut down, the heating system unit can damage the boiler. is not protected against frost, Connect only safety shutdown and the boiler is not held at the equipment, e.g.

  • Page 86: Plugging In The Lon Communication Module

    Installation Plugging in the LON communication module (if required) Plug in the LON communication module in accordance with the illustration in the control unit.

  • Page 87: Making The Lon Connection

    Installation Making the LON connection The Viessmann LON system is designed for "Line" BUS topology, i.e. with terminators at both ends. Connection with Viessmann LON cable A Control unit or Vitocom B LON cable C Terminator Connection with H Viessmann LON cable and...
  • Page 88 Vitotronic 333) D Up to 99 users and the Note corresponding number of junction boxes and cables The Viessmann LON system always E Viessmann junction boxes, requires the cores "1" (orange) and part no. 7171 784 "2" (orange/white) and the screen.

  • Page 89: Connecting An Ac Burner

    High limit safety cut−out of control unit Control thermostat of the control unit Burner fault signal Hours run meter A To control unit B To burner Burner without plug Install the mating plug supplied by Viessmann or the burner manufacturer; connect the burner cable.
  • Page 90 Installation Connecting an AC burner (cont.) Terminal codes T6, T8 Control chain Burner stage 2 ON Modulation controller open T6, T7 Control chain Burner stage 2 OFF Modulation controller closed Signal pass direction: Control unit → burner Signal pass direction: Burner →...
  • Page 91 Installation Connecting an AC burner (cont.) Atmospheric burner The burner cables are included in the standard boiler delivery. Max. power consumption 6 (3) A. BK* BU BK ³ B4 Colour coding to DIN IEC 60 757 BK* ³ S3 black BU ³...

  • Page 92: Connecting A Three−Phase Burner Zero Volt Safety Chain

    Installation Connecting a three−phase burner zero volt safety chain Please note A jumper in the burner may possibly have to be removed from the external conductor to the control voltage. Observe the details of the burner supplier. T6 T7 T8 A Control unit fÖ...

  • Page 93: Connecting A Three−Phase Burner Safety Chain Not Zero Volt

    Installation Connecting a three−phase burner safety chain not zero volt Please note A jumper in the burner may possibly have to be removed from the external conductor to the control voltage. Observe the details of the burner supplier. T6 T7 T8 A Control unit fÖ...

  • Page 94: Power Supply

    Installation Power supply Regulations Carry out the power supply connection and all earthing measures (e.g. fault current circuit) in accordance with IEC 364, the requirements of your local electricity supplier, VDE regulations or local regulations. Protect the power supply cable to the control unit with an appropriate fuse. Mains isolator requirements (if necessary) For combustion equipment to DIN VDE 0116, the mains isolator fitted on site must comply with the requirements of DIN VDE 0116 "Section 6"...

  • Page 95: Installing The Control Unit Front

    Installation Installing the control unit front...

  • Page 96: Opening The Control Unit

    Installation Opening the control unit...

  • Page 97: Commissioning

    Commissioning Controls and display elements F1 6.3A (slow) F2 6.3A (slow) A Emissions test switch a/b Adjusting values B User interface: Information Confirmation Boiler water temperature (N/A for multi−boiler Standard settings C Control thermostat systems) D Excess temperature reset DHW temperature E ON/OFF switch (N/A for multi−boiler F Fuses F1, F2...

  • Page 98: Checking The High Limit Safety Cut−Out

    Commissioning Checking the high limit safety cut−out Hold down the "TÜV" test key After the burner has been shut down during this test (position "h"). There by the high limit safety cut−out, H Release the "TÜV" test key, must be a minimum flow. H wait until the boiler water The minimum circulation volume temperature has fallen 15 to 20 K...
  • Page 99 The user list is updated after User check initiated (see page 100). approx. 2 min. User check completed. Example of a single boiler system with Vitotronic 050 and Vitocom 300 Vitotronic 100 Vitotronic 050 Vitotronic 050 Vitocom User no. 1 User no.

  • Page 100: Carrying Out A User Check

    Commissioning Carrying out a user check (in conjunction with the LON system) Communication with the system devices connected to the fault manager is tested with a user check. Preconditions: H The control unit must be programmed as fault manager (code "79: 1").

  • Page 101: Matching The Coding Addresses To The System Version

    "4d" Function plug sL "4E" Function plug gS "77" LON user number "79" Fault manager "98 Viessmann system number "9C" Monitoring LON users Note The control unit must be matched to the system equipment. See codes 1 and 2 from page 139.
  • Page 102 Commissioning Matching the coding addresses to the system version (cont.) Matching the control unit to a two−stage burner 1. Start up the burner. 6. Activate the "Burner stage 1 ON" function with a (display: 1). 2. Set the emissions test switch to "h"...
  • Page 103 Commissioning Matching the coding addresses to the system version (cont.) Matching the control unit to a modulating burner Note The burner must be fully adjusted. To achieve a wide modulating range, set the minimum output as low as possible (take the chimney and flue gas system into account).

  • Page 104: Checking Outputs (Actuators) And Sensors

    Commissioning Matching the coding addresses to the system version (cont.) Address Setting of Units and tens of the determined maximum output; e.g. max. output: 225 kW select: 25 Values up to and including 199 kW can be entered directly. Hundreds of the determined maximum output; e.g.
  • Page 105 Commissioning Checking outputs (actuators) and sensors (cont.) The following relay outputs can be controlled subject to system design: Display Relay function indication Burner or stage1 ON Burner stage 1 and 2 ON or modulation open Burner modulation neutral Burner stage 1 ON (modulation closed) Output 20 ON Output 29 ON Output 52 open...

  • Page 106: Service Scans

    Service scans Service level summary Function Entry Exit Page Press L and d Press L and d User check in conjunction with a simultaneously for approx. simultaneously for LON system approx. 1 s Press K and d Press d Relay test simultaneously for approx.

  • Page 107: Temperatures, Boiler Coding Card And Brief Scans

    Service scans Temperatures, boiler coding card and brief scans 1. Press K and G simultaneously 3. Press d. for approx. 2 s. Leaving the diagnostics level. Entering the diagnostics level. 2. Select the required scan with a or b. Subject to the system equipment level, the following values can be scanned: (for brief scans, see page 108): Display indication Description...
  • Page 108 2 = Stage 2/ closed full load 3 = Control 4 = Control open 5 = Open 6 = Run−on Output reduction 0 = Off; 1 to 100 % Equipment recognition Test code for Viessmann hexadecimal: A0 service engineer decimal: 160...

  • Page 109: Scanning Operating Conditions

    Service scans Scanning operating conditions 1. Press c. 3. Press c. Scanning operating conditions is Scanning operating conditions is active. completed. 2. Select the required operating condition scan with a or b. The following operating conditions can be scanned subject to the actual equipment level: Display indication Description...
  • Page 110 Service scans Scanning operating conditions (cont.) Display indication Description Notes Hours run, burner (stage 2) The hours run can be reset to "0" with e. 0 0 9 5 7 2 Hours run are only approximate values P P P Burner starts The burner starts can be reset to "0"...

  • Page 111: Scanning And Resetting Maintenance Displays

    Service scans Scanning and resetting maintenance displays After limits set up via coding addresses "1F", "21" and "23" (see page 144) have been reached, the programming unit display flashes one of the following messages, and the red fault indicator flashes. Note Set code "24:1"...

  • Page 112: Troubleshooting

    Troubleshooting Faults which are displayed at the programming unit The red fault indicator flashes for every fault. A fault code flashes in the display if a fault message has been issued (see page 113). Call up further fault codes with a or b. A fault can be acknowledged with d.
  • Page 113 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Control mode Maintenance Carry out "0F" is only maintenance Note displayed in fault history. Set code "24:0" after maintenance. Burner is started Short circuit Check boiler water and stopped via a Boiler water...
  • Page 114 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Cylinder primary Lead broken Check cylinder temp. pump ON: Cylinder temp. sensor Set cylinder water sensor 1 (see page 130) temperature = set boiler water temperature, priority control is cancelled...
  • Page 115 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Control mode Short circuit Check solar control Only solar control Collector unit sensor unit fault codes will temperature sensor, be displayed connects to S1 (Vitosolic) Short circuit Cylinder...
  • Page 116 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Insert plug aJA Control mode Therm Control configuration error Code "0d:0" must Plug aJA of be set for Therm Control Vitocrossal temperature sensor not inserted Insert plug aJB Controlled Cylinder storage...
  • Page 117 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Control mode Communication Check connections error and replace Programming unit programming unit if necessary (see page 128) Emissions test Internal electronics Check electronics mode fault PCB.
  • Page 118 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Control mode Communication Check connections with function and cables/leads; if extension 0−10 V required replace faulty function extension (see page 133). Without function extension, set code "9d : 0"...
  • Page 119 Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Control mode Communication Check plug−in fault plug−in adaptor for external adaptor for external safety equipment safety equipment (see page 135) and connecting cable. Without plug−in adaptor, set code "94 : 0"...
  • Page 120 Troubleshooting Faults which are displayed at the programming unit (cont.) LON users fault messages Only if the control unit is the fault manager (code "79:1"). Fault Cause Remedy System code characteristics Control mode A user fault has Download fault code occurred, e.g.

  • Page 121: Downloading Fault Codes From The Fault Memory (Fault History)

    Troubleshooting Faults which are displayed at the programming unit (cont.) Fault Cause Remedy System code characteristics Control mode Fault message active Check external at Vitocom 300 connections at Vitocom 300 No connection to Check coding Vitocom 300 (see page 99) Check connecting LON cable Update user list...

  • Page 122: Function Description

    Function description Boiler water temperature control Brief description The boiler water temperature is Coding addresses which influence regulated by controlling the the boiler water temperature control two−stage or modulating burner. 02 to 06, 08 to 0A, 13 to 1C Several defaults determine the set For a description, see page 140.
  • Page 123 Function description Boiler water temperature control (cont.) Functions The boiler water temperature is recorded by three sensors separately, which are inserted into a multiple sensor well: H High limit safety cut−out (STB) (liquid expansion) H Control thermostat TR (liquid expansion) H Boiler water temperature sensor KTS (change in resistance PT 500) Upper control range limits...

  • Page 124: Cylinder Temperature Control

    Function description Cylinder temperature control (only for single boiler systems) Brief description The cylinder thermostat operates Coding addresses which influence with a constant temperature. It is the the cylinder thermostat result of starting and stopping the 4E, 54, 55, 56, 58 to 5A, 60 to 63, cylinder primary pump.
  • Page 125 Function description Cylinder temperature control (only for single boiler systems) (cont.) Control sequence H The cylinder primary pump runs on The DHW cylinder is hot after cylinder heating, until (set value +2.5 K) the difference between the boiler water and the DHW temperature The set boiler water temperature is is less than 7 K or returned to the programmed set...
  • Page 126 Function description Cylinder temperature control (only for single boiler systems) (cont.) H The three−way mixing valve opens Code "55:2": Cylinder temperature control with and then regulates to the defaulted 2 cylinder temperature sensors set value. H The cylinder primary pump cycles Cylinder temperature sensor 1 (short term ON and OFF) until the enables the cylinder primary pump,...

  • Page 127: Components

    Components Components from the parts list For parts list, see page 153. Main PCB 230 V~ Electronics PCB The main PCB comprises: Microprocessor with software H Relays and outputs for controlling pumps, actuators and the burner When replacing the PCB: H Slot for power supply unit and 1.

  • Page 128: Programming Unit

    Components Components from the parts list (cont.) Programming unit LON communication module (accessories) Setting the: H Heating program Electronics PCB for data exchange H Set values with additional control units or H Coding Vitocom 300. A communications interruption will Displaying: be indicated.
  • Page 129 Components Components from the parts list (cont.) TEST key For testing the high limit safety cut−out. For a description, see page 98. Control thermostat H Type TR 55.18029.020, make EGO, DIN TR 110302 EM 1 TK/b1 60002846, make JUMO, DIN TR 77703 Type 751.X32X6.01A, make T&G, DIN TR 96803 H Set to 95 ºC in the delivered...
  • Page 130 Components Components from the parts list (cont.) Boiler water temperature sensor and cylinder temperature sensor Connection See page 66. Checking sensor 1. Pull plug § or %. 2. Check the sensor resistance at terminals "1" and "2" or "2" and "3"...
  • Page 131 Components Components from the parts list (cont.) Contact temperature sensor and immersion temperature sensor For recording the return temperature. Connection See page 66. Checking sensor 1. Pull plug aJ. 2. Check the sensor resistance at terminals "1" and "2" of the plug. 3.

  • Page 132: Flue Gas Temperature Sensor

    Components Flue gas temperature sensor, part no. 7450 630 The sensor records the flue gas temperature and monitors the set limit. Connection See page 66. Checking the flue gas temperature sensor 1. Pull plug aG. 1020 2. Check the sensor resistance at terminals "1"...

  • Page 133: Boiler Coding Card

    Components Boiler coding card To match the control unit function to the boiler (see page 60). Function extension 0−10 V, part no. 7174 718 To default an additional set system temperature via a 0−10 V input for a range from 10 to 100 ºC or 30 to 120 ºC. For signalling reduced mode.
  • Page 134 0−10 V hook−up creates an additional set value Multi−boiler system with Function Preconditions external cascade Vitotronic 100 with Boiler control via 0−10 V Code "01:3" at enable command via hook−up: Vitotronic 100 0−10 V signal 0 to 1 V...

  • Page 135: Plug−In Adaptor For External Safety Equipment

    Components Plug−in adaptor for external safety equipment, part no. 7143 526 For the connection of external safety equipment to DIN 4751−2 H Low water indicator H Maximum pressure limiter H Minimum pressure limiter H Additional high limit safety cut−out In addition for the connection of H Controlled external burner shutdown H Three external fault messages.
  • Page 136 Components Plug−in adaptor for external safety equipment (cont.) Lower part of the plug−in adaptor X7 D X2 D X1 E X3 D 6 5 4 3 2 1 6 5 4 3 2 1 A Wiring chamber H Remove the corresponding jumper B External safety equipment when connecting the external X1 Additional high limit safety...

  • Page 137: Vitoair Draught Stabiliser

    Components Vitoair draught stabiliser, part no. 7338 725 and 7339 703 A To the burner Colour coding to DIN IEC 60 757 B To the control unit black GN/YE green/yellow Function check H Burner OFF → Press the motor rotary selector and turn it to its central position.

  • Page 138: Motorised Flue Gas Damper

    Components Motorised flue gas damper, part no. 9586 973 and 9586 974 When connecting, remove jumper ON ON "TR" "ON/TR". N STB TR TR 1 2 3 A To control unit B Flue gas damper motor C Limit switch Function check The burner may only start after the You can check the switch function by flue gas damper has opened 90% of...

  • Page 139: Coding

    Coding Resetting codes to the delivered condition 1. Press L and G simultaneously 2. Press e. for approx. 2 s, until the first two arrows appear in the display. Code 1 Calling up code 1 1. Press K and L simultaneously 3.
  • Page 140 Coding Code 1 (cont.) Coding in the delivered condition Possible change Boiler/burner 02 : 1 Two−stage burner 02 : Single stage burner 02 : Modulating burner 03 : 0 Gas fired operation 03 : Oil fired operation (irreversible) 03 : Set automatically, if incorrect boiler coding card inserted Burner (mod.) (see page 103)

  • Page 141: Code 2

    Coding Code 2 Calling up code 2 1. Press L and G simultaneously 3. Change the value with a or b; confirm with d. for approx. 2 s, until the first two arrows appear in the display; The value is saved and does not confirm with d.
  • Page 142 Coding Code 2 (cont.) Coding in the delivered condition Possible change Boiler/burner (cont.) 04 : Switching hysteresis 04 : Switching hysteresis 4 K (Note see page 151) Heat demand−dependent switching hysteresis: 04 : ERB50 function (values from 6 to 12 K) 04 : ERB80 function (values from 6 to 20 K)
  • Page 143 Coding Code 2 (cont.) Coding in the delivered condition Possible change Burner (two−stage/mod.) (see page 102) (cont.) 09 : Maximum burner output 09 : Maximum output in kW adjustable from 0 to 09 : 199 19 900 kW; 1 step ¢ 100 kW 0A : Burner base output in 0A :...
  • Page 144 Coding Code 2 (cont.) Coding in the delivered condition Possible change Boiler/burner (mod.) (see page 103) 15 : 10 Actuator operating time 15 : Operating time adjustable 10 s from 5 to 199 s; for 15 : 199 Vitocrossal 300, type CV3, with MatriX burner set "15 : 19"...
  • Page 145 Coding Code 2 (cont.) Coding in the delivered condition Possible change Boiler/burner 23 : No time interval for burner 23 : Adjustable time interval maintenance from 1 to 24 months 23 : 24 24 : No maintenance display 24 : Maintenance indication in display (address is automatically set and must...
  • Page 146 Coding Code 2 (cont.) Coding in the delivered condition Possible change Boiler 2d : Shunt pump control 2d : Shunt pump control function only ON if boiler is function ON, independent enabled of whether boiler is enabled or not General 40 : 125 Operating time for butterfly 40 :...
  • Page 147 Coding Code 2 (cont.) Coding in the delivered condition Possible change 55 : Cylinder heating, 55 : Adaptive cylinder heating hysteresis ± 2.5 K active (speed of temp. rise for cylinder temperature is taken into account during DHW heating) 55 : Cylinder temperature control with 2 cylinder temperature sensors...
  • Page 148 Coding Code 2 (cont.) Coding in the delivered condition Possible change DHW (cont.) 61 : The cylinder primary pump 61 : The cylinder primary pump starts immediately will be switched ON subject to the boiler water temperature 62 : Cylinder primary pump 62 : 10 The cylinder primary pump without run−on...
  • Page 149 Coding Code 2 (cont.) Coding in the delivered condition Possible change General 76 : Without communication 76 : With LON communication module module; will be recognised automatically 76 : Do not adjust. 77 : LON user number 77 : LON user number, adjustable from 1 to 99 Note 77 : 99...
  • Page 150 Coding Code 2 (cont.) Coding in the delivered condition Possible change General (cont.) 98 : Viessmann system number 98 : System number adjustable (in conjunction with from 1 to 5 monitoring of several 98 : systems via Vitocom 300) 9b :...

  • Page 151: Burner Switching Hysteresis

    Coding Burner switching hysteresis Switching hysteresis 4 K (04:0) Time −2 average high heat demand heat demand heat demand Heat−demand dependent switching hysteresis (only with outside temp. sensor) ERB50 function (04:1) Subject to heat demand, values between 6 and 12 K result. Time −3 average...
  • Page 152 Coding...

  • Page 153: Parts List

    Parts list Parts list When ordering spare parts 052 Main PCB 230V~ Quote the part no. and serial no. (see 054 Power supply unit PCB type plate A) as well as the item no. 056 Communication module LON of the required parts (as per this 065 Burner supply cable with plug fA (for boilers with parts list).
  • Page 154 Parts list Parts list (cont.)
  • Page 155 Parts list Parts list (cont.)

  • Page 156: Connection And Wiring Diagrams

    Connection and wiring diagrams Summary...
  • Page 157 Connection and wiring diagrams Summary (cont.) A2 Main PCB low voltage A3 Main PCB 230 V~ A6 Programming unit A7 Optolink/emissions test switch PCB A8 Electronics PCB A9 Boiler coding card A10 LON communication module A11 Power supply unit PCB A12 Boiler control unit...
  • Page 158 Connection and wiring diagrams Main PCB low voltage...
  • Page 159 Connection and wiring diagrams Main PCB low voltage (cont.) § Boiler water temperature sensor Cylinder temperature sensor (accessories) / cylinder temperature sensor 2 for a cylinder storage system Flue gas temperature sensor (accessories) aJA Temperature sensor of Therm−Control Temperature sensor T1 aJB Temperature sensor T2 Temperature sensor cylinder storage system...
  • Page 160 Connection and wiring diagrams Main PCB 230 V~...
  • Page 161 Connection and wiring diagrams Main PCB 230 V~ (cont.) sÖ Switching output Fuse for electronics, pumps and accessories (via plug aBH) Primary pump, cylinder storage system Fuse for burner High limit safety cut−out "E" 120 ºC Circulation pump, flue (100 or 110 ºC) gas/water heat exchanger Cylinder primary pump Control thermostat "R"...

  • Page 162: Specification

    Specification Specification Rated voltage: 230 V~ Rated capacity of relay outputs Rated frequency: 50 Hz at 230 V~ for H Switching output Rated current: 2 (6) A ~ Power consumption: Primary pump Safety class: cylinder storage Protection level: IP 20 D to EN 60529, system safeguard through appropriate design...

  • Page 163: Keyword Index

    Keyword index Keyword index Coding, H Matching to system version, 101 AC burner connection, 89 H Overview, 141 Actuators, 68 H Resetting to the delivered Actuators, checking, 104 Adaptive cylinder heating, 125, 147 condition, 139 Additional function for DHW heating, Collector temperature, 109 124, 147 Communication module LON, 86, 128...
  • Page 164 Keyword index Keyword index (cont.) Danger, 2 Gas smell, 2 DHW heating, 124 Diagnostics, 112 Draught stabiliser, Vitoair, 137 Hiding a fault display, 112 High limit safety cut−out H Additional, 135 H Changing, 61 Electrical connections, 57 H Checking, 98 Electronics PCB, 127 H Component, 128 Emissions test switch, 127...
  • Page 165 Keyword index Keyword index (cont.) Main PCB 230 V~, 127, 160 Parts list, 153 Main PCB low voltage, 127, 158 PCB Optolink/emissions test Mains isolator requirements, 94 switch, 127 Maintenance display, Plug−in adaptor for external safety H Resetting, 111 equipment, 135 H Scanning, 111 Plug sÖ, 57, 67 Plug sA, 57, 67...
  • Page 166 Keyword index Keyword index (cont.) System versions, 7 Safety, 2 Safety equipment, 84, 135 Safety assembly, 127 Terminator, 87, 128 Scanning, 107 TEST key, 129 Scanning actual temperatures, 109 Therm Control, 66, 143 Scanning operating conditions, 109 Three−way mixing valve, 68 Scanning temperatures, 107, 109 Troubleshooting, 112 Sensors, checking, 104...

  • Page 168: Applicability

    Applicability Applicability Vitotronic 100, type GC1 Only for integration/installation on/in Viessmann boilers. For control unit Part no. 7187 094 Viessmann Werke GmbH & Co KG D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de...

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Vitotronic 100 gc1

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