Datasheet | Viessmann VITOTRONIC 100 GC1B Technical data

Installation and
Service Instructions
Please file in Service Binder
for use by heating contractor
Vitotronic 100, Model GC1
Digital boiler control unit
VITOTRONIC 100, GC1
IMPORTANT
Certified as a component part
of Viessmann boilers only
5351 338 v1.6 05/2012
Read and save these instructions
for future reference.
1
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. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
Licensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
Please see section
entitled “Important
Regulatory and
Installation
Requirements.”
Product documentation
Read all applicable documentation
before commencing installation. Store
documentation near boiler in a readily
accessible location for reference in the
future by service personnel.
Advice to owner
Once the installation work is complete,
the heating contractor must familiarize
the system operator/ultimate owner
with all equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before the
heating season begins.
Warranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
5351 338 v1.6
For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and
Installation Requirements.”
2
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.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product / property damage.
CAUTION
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or product /
property damage.
IMPORTANT
5351 338 v1.6
Helpful hints for installation, operation
or maintenance which pertain to the
product.
3
Product Information
Vitotronic 100, GC1
For installation on Viessmann
boilers only.
Applicable to the following control units:
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.
5351 338 v1.6
These instructions are not required for the Vitotronic 100, GC1 used in multi-boiler
systems with the Vitocontrol-S, VD2/CT3/CM2.
4
Index
Page
General Information
Heating System Types
2
4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagrams 1 to 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
Mounting the Front Part of the Control Unit (VD2/VD2A/CT3 only) 37
Opening the Control Unit (VD2/VD2A/CT3 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control and Junction Box Installation Instructions (CM2 only) . . . . . . . . . . . 39
Mounting the Front Part of the Control Unit (CM2 only) . . . . . . . . . . . . . . . . . . . . . . 40
Opening the Control Unit (CM2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overview of Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Overview of Electrical Connections (VD2/VD2A/CT3 only) . . . . . . . . . . . . . 43
Overview of Electrical Connections (CM2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Routing and Strain Relief of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inserting the Boiler Coding Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Setting of the Fixed High Limit (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Setting of the Adjustable High Limit (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Sensor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connection of the Boiler Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Connection of the DHW Tank Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connection of the Return Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connection of the Flue Gas Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connection of the Pumps (VD2/VD2A/CT3 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connection of the Pumps (CM2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Connection of Return Mixing Valve or
Isolation/Modulating Valve (VD2/VD2A/CT3 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connection of Return Mixing Valve or
Isolation/Modulating Valve (CM2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Making Space for Accessory Adaptors on the Din Rail (CM2 only) . 58
Vitotronic 100, GCI with 30% LTP Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection of External Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connection of External Controls (VD2/VD2A only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connection of External Controls (CT3 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connection of Combustion Air Device (VD2/VD2A/CT3 only) . . . . . . . 66
Connection of Combustion Air Device (CM2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connection of Combustion Air Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connection of Combustion Air Device on Multiple Boiler Systems 69
Connection of Single Air Device on Multiple Boiler Systems . . . . . . . . 70
Connection of Combustion Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Gas Flue Temp. Sensor (Optional for CM2 equipped with
SS Flue Collector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Connection of Low Water Cut-off Device (VD2/VD2A/CT3 only) 73
Connection of Low Water Cut-off Device (CM2 only) . . . . . . . . . . . . . . . . . . . . . . 74
Connections to Terminal aBÖ (VD2/VD2A/CT3 only) . . . . . . . . . . . . . . . . . . . . . . . . 75
Connection of the Compiled Failure Alarm Indicator
(VD2/VD2A/CT3 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connection of the Compiled Failure Alarm Indicator (CM2 only) . 77
Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only)
78
Power Supply Connection to Boiler Control (VD2/VD2A/CT3 only) . . 82
Burner Connection, Burner Control Wiring (CM2 only)
83
5351 338 v1.6
Installation
Safety Instructions and Warranty Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Start-up
Scanning Service Information
Troubleshooting
Procedure (overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
85
Overview of Service Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperatures, Boiler Coding Cards and Scans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning and Resetting the Service Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
93
97
98
Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Functional Description
Boiler Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Heating Circuit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DHW Tank Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Additional Information
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coding 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coding 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5351 338 v1.6
108
109
109
115
117
125
130
6
Heating system types
Overview
Circuit
diagram
System type
Boiler
Key features
Page
11
Single-boiler
system
Vitorond 200, VD2A
With Therm-Control, single-boiler with 3-way mixing
valve
12
Multi-boiler
system
Vitorond 200, VD2A
With Therm-Control, multi-boiler with 3-way mixing
valve
10
13
Single-boiler
system
Vitorond 200, VD2
Shunt pump for elevating the return temperature
11
14
Single-boiler
system
Vitorond 200, VD2
Shunt pump and return valve for elevating the
return temperature
13
15
Multi-boiler
system
Vitorond 200, VD2
Shunt pump for elevating the return temperature for
each boiler
16
16
Multi-boiler
system
Vitorond 200, VD2
Common supply pump and low-pressure manifold
17
17
Multi-boiler
system
Vitorond 200, VD2
Return valve for return temperature protection
19
8
Multi-boiler
system
Vitorond 200, VD2
Low-loss header and return valve for elevating
the return temperature
21
9
Single-boiler
system
Vitocrossal 300
Several heating circuits and one mixing valve heating
circuit
23
10
Single-boiler
system
Vitocrossal 300
Several heating circuits and one mixing valve heating
circuit
25
11
Multi-boiler
system
Vitocrossal 300
Several heating circuits and one mixing valve heating
circuit
27
12
Multi-boiler
system
Vitocrossal 300 and
Vitorond 200
Several heating circuits, one mixing valve heating
circuit and Vitorond with shunt pump
29
13
Multi-boiler
system
Vitocrossal 300 and
Vitorond 200
Return valve, several heating circuits and one mixing
valve heating circuit
31
14
Single-boiler
system
Vitocrossal 200
Several heating circuits and one mixing valve heating
circuit
33
15
Multi-boiler
system
Vitocrossal 200
Several heating circuits and one mixing valve heating
circuit
35
5351 338 v1.6
8
7
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
?M2
?M3
§
%
aJA
8
fÖ
Outdoor temperature sensor
(only for Vitotronic 300)
Flow temperature sensor,
mixing valve (only for the
Vitotronic 300)
Flow temperature sensor,
mixing valve (only for
Vitotronic 300)
Boiler water temperature
sensor
DHW tank temperature sensor
(accessory for the Vitotronic
100)
Therm-Control temperature
sensor
sÖM2
sÖM3
sÖA1
sA
sK
Heating circuit pump, mixing
valve (only for Vitotronic 300)
Heating circuit pump, mixing
valve (only for Vitotronic 300)
Closing the mixing valves with
external heating circuit control
units
DHW primary pump
DHW circulation pump (only
for the Vitotronic 300)
Power supply, 120 VAC
60 Hz
Install the main isolator in
accordance with regulations
fA
Burner (stage 1)
gSM2
Mixing valve motor (only for
Vitotronic 300)
gSM3
Mixing valve motor (only for
Vitotronic 300)
lÖ
Burner
(burner stage 2 / mod.)
aVD/aVH External connections
Please refer to the control
manual Vitotronic 300 GW2.
5351 338 v1.6
Plug
!
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. Change “0D”
to “1” - the Therm-Control acts on the
mixing valve of the downstream heating
circuits (for Vitotronic 200 and 300,
delivered condition).
5351 338 v1.6
sÖ A1 Close mixing valves
A
Contactor relay, field supplied
B
Heating circuit controls
connected downstream
Switch contact closed: signal
for ”close mixing valve”.
9
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
?Flow
?M2
?M3
?
§
%
10
aJA
Outdoor temperature sensor
(only for Vitotronic 300-K)
Flow temperature sensor,
common heating flow (only for
the Vitotronic 300-K)
Flow temperature sensor,
mixing valve (only for the
Vitotronic 300-K)
Flow temperature sensor,
mixing valve (only for the
Vitotronic 300-K)
Flow temperature sensor
Vitotronic 200-H
Boiler water temperature
sensor
DHW tank temperature sensor
(only for Vitotronic 300-K)
sÖM2
sÖM3
sÖ
sK
fÖ
fA
gSA1
Therm-Control temperature
sensor
Heating circuit pump, mixing
valve (only for Vitotronic
300-K)
Heating circuit pump, mixing
valve (only for Vitotronic
300-K)
Heating circuit pump Vitotronic
200-H
DHW circulation pump (only
for the Vitotronic 300-K)
Power supply, 120 VAC
60 Hz
Install the main isolator in
accordance with regulations
Burner (stage 1)
Motorized butterfly valve
gSM2
Mixing valve motor (only for
Vitotronic 300-K)
gSM3
Mixing valve motor (only for
Vitotronic 300-K)
gSM3
Mixing valve motor, Vitotronic
200-H
lÖ
Burner
(burner stage 2 / mod.)
aVD/aVH External connections
Please refer to the control
manual for the Vitocontrol-S,
VD2/CT3.
5351 338 v1.6
Plug
!
Heating system types
Circuit Diagram 3
29
A1
20
Single-boiler system with shunt pump for elevating the return temperature
in conjunction with Vitorond 200, VD2
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
143
146
41
90
40
B
5351 338 v1.6
C
sL
fÖ
Shunt pump
Power supply connection,
120 VAC
Burner (1st stage)
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
T2
17B
17A
3
21
5
*1
C
T1
*1
A
Plugs
§
Boiler temperature sensor
%
DHW tank temperature sensor
(accessory)
aJ A Temperature sensor T1
aJ B Temperature sensor T2
sÖ A1 Close mixing valves with
external heating circuit
controls
sA
DHW pump
fA
lÖ
aVD
aVH
On the Vitorond the boiler supply and return are at the rear of the boiler.
11
Heating system types
Circuit Diagram 3
(continued)
Possible applications
Heating systems with manifold
arranged close to the boiler. The boiler
water supply is required to be reduced.
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
When the return temperature falls
below the required minimum value,
the temperature sensor T2 switches
on the shunt pump. If the minimum
return temperature is not reached
despite raising the return temperature,
the supply must be reduced by at
least 50% via the temperature
sensor T1.
Temperature sensor T1
Wiring of the temperature sensor T1
in heating systems with heating
circuit control units which are not
connected via the LON BUS to the
boiler control unit.
Coding required: ”4C: 2” – use plug
sÖ for closing the mixing valves of
the heating circuits connected
downstream.
The shunt pump must be sized so
that bypassed water accounts for
approx. 30% of the total supply rate
of the boiler.
sÖ A1 Close mixing valves
A
Contactor relay, field supplied
B
Heating circuit controls
connected downstream
Switch contact closed: signal
for ”close mixing valve”.
Available system accessories
Flue gas temperature sensor
00: 1
Change required
Automatic change
–––
With DHW tank:
Coding is automatically changed to ”00: 2”
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
03: 0
Set coding ”03: 1” for oil-fired operation
(re-setting is not possible)
–––
4A: 0
–––
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
4b: 0
–––
Connection of the temperature sensor T2 at
plug aJB;
Coding is automatically changed to ”4b: 1”
12
5351 338 v1.6
Coding of
system type
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
29
A1
52
C
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
143
146
41
90
40
B
5351 338 v1.6
T2
17B
17A
3
21
5
*1
C
T1
*1
A
Plugs
§
Boiler temperature sensor
%
DHW tank temperature sensor
(accessory)
aJ A Temperature sensor T1
aJ B Temperature sensor T2
sA
DHW pump
sL
Shunt pump
fÖ
Power supply connection,
120 VAC
fA
Burner (1st stage)
gS A1 Mixing valve motor for raising
the return temperature
lÖ
Burner (2nd stage/modulating)
aVD
Connection of external
equipment (see page 51)
aVH
Connection of external
equipment (see page 51)
On the Vitorond the boiler supply and return are at the rear of the boiler.
13
Heating system types
Circuit Diagram 4
(continued)
Possible applications
Heating systems in which there is no
facility for making modifications or
adjustments to the heating circuits
connected downstream, e.g. old
systems or market gardens.
IMPORTANT
When the return temperature falls
below the required minimum value,
the temperature sensor T2 switches
on the shunt pump. If, as a result,
the required minimum return
temperature is not reached, the return
valve is proportionally closed via the
temperature sensor T1 and the
minimum return temperature is
assured.
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
Available system accessories
Flue gas temperature sensor
Coding of
system type
00: 1
Change required
Automatic change
–––
With DHW tank:
Coding is automatically changed to ”00: 2”
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
03: 0
Set coding ”03: 1” for oil-fired operation
(re-setting is not possible)
–––
0C: 4
Set coding ”0C: 1” for continuous
return temperature control
–––
–––
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
4b: 0
–––
Connection of the temperature sensor T2 at
plug aJB;
Coding is automatically changed to ”4b: 1”
5351 338 v1.6
4A: 0
14
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
C
3
17B
17A
T1
B
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
T2
40
41
90
29
52 A1
143
146
T2
40
41
90
29
52 A1
143
146
3
17B
17A
C
T1
A
Plugs
§
aJ A
aJ B
sL
fÖ
gS A1 Motorized isolation valve
lÖ
Burner (2nd stage/modulating)
aVD
Connection of external
equipment (see page 51)
aVH
Connection of external
equipment (see page 51)
5351 338 v1.6
fA
Boiler temperature sensor
Temperature sensor T1
Temperature sensor T2
Shunt pump
Power supply connection,
120 VAC
Burner (1st stage)
A
15
Heating system types
Circuit Diagram 5
(continued)
Possible applications
Heating systems with manifold
arranged close to the boiler. The boiler
water supply is reduced via the
motorized isolation valve.
On multi-boiler systems without the
Vitotronic 333, the cascade and DHW
tank control must be activated by a
building automation system.
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
When the return temperature falls
below the required minimum value,
the temperature sensor T2 switches
on the shunt pump. If the minimum
return temperature is not reached
despite raising the return temperature,
the supply must be reduced by at
least 50% via the temperature
sensor T1, through the isolation
valve or the heating circuit controls.
Temperature sensor T1
Wiring of the temperature sensor T1
in heating systems with heating
circuit control units which are not
connected via the LON BUS to the
boiler control unit.
Coding required: ”4C: 2” – use plug
sÖ for closing the mixing valves of
the heating circuits connected
downstream.
The shunt pump must be sized so
that bypassed water accounts for
approx. 30% of the total supply rate
of the boiler.
The boiler is assured optimum
protection in conjunction with control
of the heating circuits via the
Vitotronic 050 connected to the
boiler control unit. No further
protective measures are required on
site.
sÖ A1 Close mixing valves
A
Contactor relay, field supplied
B
Heating circuit controls
connected downstream
Switch contact closed: signal
for ”close mixing valve”.
Available system accessories
Flue gas temperature sensor
Change required
Automatic change
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
03: 0
Set coding ”03: 1” for oil-fired operation
(re-setting is not possible)
–––
4A: 0
–––
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
4b: 0
–––
Connection of the temperature sensor T2 at
plug aJB;
Coding is automatically changed to ”4b: 1”
16
5351 338 v1.6
Coding of
system type
Heating system types
Circuit Diagram 6
Multi-boiler system with common supply pump and low-pressure manifold
in conjunction with Vitorond 200, VD2
C
C
D
B
52 A1
143
146
41
90
40
A
Plugs
§
Boiler temperature sensor
aJ A Temperature sensor T1
fÖ
Power supply connection,
120 VAC
fA
Burner (1st stage)
gS A1 Motorized isolation valve
T1
A
lÖ
aVD
aVH
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Common supply pump
3
17A
T1
52 A1
143
146
41
90
40
3
17A
17
Heating system types
Circuit Diagram 6
(continued)
Possible applications
Where the manifold is arranged in
distant substations (> 20 m). The
heat transferred to the heating circuits
is required to be reduced.
On multi-boiler systems without
Vitotronic 333, the boiler staging and
DHW tank control must be activated by
a building automation system.
The common supply pump is activated
by the master control of the building
management system. It must be
switched on when a boiler is engaged.
IMPORTANT
When the return temperature falls
below the required minimum value,
the mixing valves are partially or fully
closed via the temperature sensor T1.
The common supply pump must be
sized on the basis of 110% of the total
supply Btu/hr output rate of the heating
system.
The boiler is assured optimum
protection in conjunction with control
of the heating circuits via a Vitotronic
050 connected to the boiler control
unit. No further protective measures
are required on site.
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
Temperature sensor T1
Wiring for reducing the supply via
temperature sensor T1 in heating
systems with heating circuit control
units which are not connected via
the LON BUS to the boiler control unit.
Coding required: ”4C: 2” – use plug
sÖ for closing the mixing valves of
the heating circuits connected
downstream.
sÖ A1 Close mixing valves
A
Contactor relay, field supplied
B
Heating circuit controls
connected downstream
Switch contact closed: signal
for ”close mixing valve”
C
Power supply connection,
120 VAC
D
Junction box, field supplied
If an external cascade control unit is
used, the distributor pump must be
connected to the external control unit.
Available system accessories
Flue gas temperature sensor
Change required
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
03: 0
Set coding ”03: 1” for oil-fired operation
(re-setting is not possible)
–––
0d: 2
Set coding ”0d: 1”
Therm-Control is effective for the mixing
valves of the heating circuits connected
downstream
–––
4A: 0
18
Automatic change
–––
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
5351 338 v1.6
Coding of system type
Heating system types
Circuit Diagram 7
Multi-boiler system with return valve for return temperature protection
in conjunction with Vitorond 200, VD2
C
40
41
90
29
52 A1
143
146
3
17A
41
90
29
52 A1
143
146
40
3
17A
T1
B
T1
A
Plugs
§
aJ A
sL
fÖ
Boiler temperature sensor
Temperature sensor T1
Boiler circuit pump
Power supply connection,
120 VAC
fA
Burner (1st stage)
gS A1 Return valve
A
lÖ
aVD
aVH
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
C
19
Heating system types
Circuit Diagram 7
(continued)
Possible applications
E.g. old systems or systems in market
gardens and/or systems in which there
is no facility for making modifications
or adjustments to the heating circuits
connected downstream.
The cascade and DHW tank control
must be activated by a building
automation system.
IMPORTANT
When the return temperature falls
below the required minimum value,
the 3-port mixing valve on the boilers
is proportionally closed via the
temperature sensor T1, thereby
assuring protection of the boiler.
The boiler and the heating circuits
downstream are hydraulically
decoupled. The supply temperature
is controlled via the common
temperature sensor.
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
Available system accessories
Flue gas temperature sensor
Coding of
system type
Change required
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
03: 0
Set coding ”03: 1” for oil-fired operation
(re-setting is not possible)
–––
0C: 4
Set coding ”0C: 1” for continuous return
temperature control
–––
4A: 0
–––
Set coding ”4d:
at plug sL
2” for boiler circuit pump
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
–––
5351 338 v1.6
4d: 1
Automatic change
20
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
C
C
D
40
41
90
29
52 A1
143
146
3
17A
41
90
29
52 A1
143
146
40
3
17A
T1
B
A
Plugs
§
aJ A
sL
fÖ
Boiler temperature sensor
Temperature sensor T1
Boiler circuit pump
Power supply connection,
120 VAC
fA
Burner (1st stage)
gS A1 Return valve
A
lÖ
aVD
aVH
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Low-loss header
T1
21
Heating system types
Circuit Diagram 8
(continued)
Possible applications
E.g. old systems or systems in market
gardens as well as systems in which
there is a lack of clarity in the hydraulic
installation and/or systems where there
is no facility for making modifications
or adjustments to the heating circuits
connected downstream.
The cascade and DHW tank control
must be activated by a building
automation system.
When the return temperature falls
below the required minimum value,
the return valve on the boilers is
proportionally closed via the
temperature sensor T1, thereby
assuring protection of the boiler.
The supply temperature is controlled
by the temperature sensor in the
low-loss header.
CAUTION
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
The boiler circuit pumps on each
boiler must be sized so that their
supply is at least equal to the
maximum possible total heating
circuit supply.
Recommendation: 110%.
Available system accessories
Flue gas temperature sensor
Coding of
system type
Change required
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
03: 0
Set coding ”03: 1” for oil-fired operation
(re-setting is not possible)
–––
0C: 4
Set coding ”0C: 1” for continuous return
temperature control
–––
4A: 0
–––
Set coding ”4d: 2” for boiler circuit pump
at plug sL
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
–––
5351 338 v1.6
4d: 1
Automatic change
22
Heating system types
Circuit Diagram 9
Several heating circuits and one mixing valve heating circuit
Single-boiler system with Vitocrossal 300
21
5
C
C
fA
lÖ
aVD
Burner (1st stage)
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
B
D
A
Plugs
§
Boiler temperature sensor
%
DHW tank temperature sensor
(accessory)
sA
DHW pump
fÖ
Power supply connection,
120 VAC
aVH
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Neutralizing unit
143
146
41
90
40
3
23
Heating system types
Circuit Diagram 9
(continued)
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
The Vitocrossal 300 is operated with
constant boiler water temperature by
means of the boiler control unit.
Two-stage or modulating burners
can be controlled.
The boiler water temperature which is
established in the heating mode is
higher than the maximum heating
system supply temperature by an
adjustable difference.
Available system accessories
Flue gas temperature sensor
Coding of
system type
Change required
00: 1
Automatic change
–––
With DHW tank:
Coding is automatically changed to ”00: 2”
Set coding ”02: 2” for operation with
modulating burner
–––
0C: 4
Set coding ”0C: 0”
–––
0d: 2
Set coding ”0d: 0”
–––
5351 338 v1.6
02: 1
24
Heating system types
Circuit Diagram 10
Single-boiler system with several heating circuits and one mixing valve heating circuit
in conjunction with Vitocrossal 300
E
C
D
21
5
41
90
143
146
3
40
B
or
A1
20
F
G
Plugs
§
Boiler temperature sensor
%
DHW tank temperature sensor
(accessory)
sÖ A1 Close mixing valves with
external heating circuit controls
sA
DHW pump
fÖ
fA
lÖ
aVD
aVH
Power supply connection,
120 VAC
Burner (1st stage)
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Mixing valve heating circuit
or
E Underfloor heating circuit with
mixing valve
F Limit thermostat (max. limit)
G Neutralizing unit
A
25
Heating system types
Circuit Diagram 10
(continued)
Possible applications
For heating circuits with different
temperatures.
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
The Vitocrossal 300 is operated with
constant boiler water temperature by
means of the boiler control unit.
Two-stage or modulating burners can
be controlled.
The Vitocrossal 300 has two return
connections. The heating circuits with
the higher return temperature are
connected to the return connection at
the top, those with the lower
temperatures to the return connection
at the bottom.
Please note:
At least 15% of the take-off from the
rated output must be connected to the
return connection at the bottom.
The boiler water temperature which is
established in the heating mode is
higher than the maximum heating
circuit supply temperature by an
adjustable difference.
Available system accessories
Flue gas temperature sensor
Coding of
system type
Change required
00: 1
Automatic change
–––
With DHW tank:
Coding is automatically changed to ”00: 2”
Set coding ”02: 2” for operation with
modulating burner
–––
0C: 4
Set coding ”0C: 0”
–––
0d: 2
Set coding ”0d: 0”
–––
5351 338 v1.6
02: 1
26
Heating system types
Circuit Diagram 11
Multi-boiler system with several heating circuits and one mixing valve heating circuit
in conjunction with Vitocrossal 300
C
B
Plugs
§
fÖ
Boiler temperature sensor
Power supply connection,
120 VAC
fA
Burner (1st stage)
gS A1 Motorized isolation valve
lÖ
Burner (2nd stage/modulating)
D
aVD
aVH
A
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Neutralizing unit
A
52 A1
143
146
40
D
41
90
3
52 A1
143
146
41
90
40
3
C
27
Heating system types
Circuit Diagram 11
(continued)
Possible applications
The cascade and DHW tank control
must be activated by a building
automation system.
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
The Vitocrossal 300 is operated with
constant boiler water temperature by
means of the boiler control unit.
Two-stage or modulating burners can
be controlled.
The Vitocrossal 300 has two return
connections. The heating circuits
with the higher return temperature
are connected to the return
connection at the top, those with
the lower temperatures to the return
connection at the bottom.
Motorized isolation valve
Connect motorized isolation valve
adaptor (Part No. 7134 560) or 24V
valve adaptor (Part No. 7134 559),
installed in connection enclosure, in
parallel.
Use electric junction box if necessary.
Please note:
At least 15% of the
take-off from the rated output must
be connected to the return connection
at the bottom.
The boiler water temperature which
is established in the heating mode is
higher than the maximum heating
circuit supply temperature by an
adjustable difference.
Available system accessories
Flue gas temperature sensor
Change required
Automatic change
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
0d: 2
Set coding ”0d: 0”
–––
5351 338 v1.6
Coding of
system type
28
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
C
C
3
17B
17A
T2
40
41
90
29
52 A1
143
146
143
146
41
90
40
3
T1
B
D
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Neutralizing unit
A
Plugs
§
aJ A
aJ B
sL
fÖ
gS A1 Motorized isolation valve
lÖ
Burner (2nd stage/modulating)
aVD
Connection of external
equipment (see page 51)
aVH
Connection of external
equipment (see page 51)
5351 338 v1.6
fA
Boiler temperature sensor
Temperature sensor T1
Temperature sensor T2
Shunt pump
Power supply connection,
120 VAC
Burner (1st stage)
A
29
Heating system types
Circuit Diagram 12
(continued)
Possible applications
The cascade and DHW tank control
must be activated by a building
automation system.
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
The Vitocrossal 300 (lead boiler) and
the Vitorond lag boilers are operated
with modulating boiler water
temperature and load-dependent
sequential control by means of the
outdoor-reset logic control system.
Two-stage or modulating burners can
be controlled.
Through the control system which is
linked via the LON BUS, the boiler
supply temperature which is
established is higher than the
maximum heating circuit supply
temperature by an adjustable
difference. The heating system can
be operated in accordance with a
separate heating curve.
The Vitocrossal 300 boilers have
two return connections. The heating
circuits with the higher return
temperature are connected to the
return connection at the top, those
with the lower temperatures to the
return connection at the bottom.
Please note:
At least 15% of the
take-off from the rated output must
be connected to the return
connection at the bottom.
The return temperature raising
functionality of the Vitorond
modulating boiler is available as an
accessory or must be provided on
site.
The return temperature is raised by
means of the shunt pump and by
closing the isolation valve.
The temperature sensor T1 activates
the isolation valve. The temperature
sensor T2 switches the shunt pump.
Available system accessories
Flue gas temperature sensor
Coding of
system type
Change required
Automatic change
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
0C: 4
Only with Vitotronic 100 for the Vitocrossal
300:
Set coding ”0C: 0”
–––
0d: 2
Set coding ”0d: 0”
–––
–––
Only with Vitotronic 100 for the Vitorond:
Connection of the temperature sensor T1 at
plug aJA;
Coding is automatically changed to ”4A: 1”
4b: 0
–––
Only with Vitotronic 100 for the Vitorond:
Connection of the temperature sensor T2 at
plug aJB;
Coding is automatically changed to ”4b: 1”
5351 338 v1.6
4A: 0
30
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
C
40
41
90
29
52 A1
143
146
3
17A
143
146
41
90
40
3
C
T1
B
D
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Neutralizing unit
A
A
Plugs
§
aJ A
sL
fÖ
Boiler temperature sensor
Temperature sensor T1
Boiler circuit pump
Power supply connection,
120 VAC
fA
Burner (1st stage)
gS A1 3-port mixing valve
lÖ
aVD
aVH
Burner (2nd stage/modulating)
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
31
Heating system types
Circuit Diagram 13
(continued)
Possible applications
For heating circuits with temperature
differences ≥20 K.
The cascade and DHW tank control
must be activated by a building
automation system.
IMPORTANT
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional. Three-phase equipment
must be connected via additional
power contactors.
The Vitocrossal 300 (lead boiler) and
the Vitorond lag boilers are operated
with modulating boiler water
temperature and load-dependent
sequential control by means of the
outdoor-reset logic control system.
Two-stage or modulating burners
can be controlled.
Through the control system which is
linked via the LON BUS, the boiler
supply temperature which is
established is higher than the
maximum heating circuit supply
temperature by an adjustable
difference. The heating system can
be operated in accordance with a
separate heating curve.
The Vitocrossal 300 boilers have
two return connections. The heating
circuits with the higher return
temperature are connected to the
return connection at the top, those
with the lower temperatures to the
return connection at the bottom.
Please note:
At least 15 % of the
take-off from the rated output must
be connected to the return connection
at the bottom.
The T1 temperature sensor measures
the return temperature.
The return valve is activated via the
boiler control unit so as to ensure that
the return temperature does not fall
below the minimum value.
Available system accessories
Flue gas temperature sensor
Coding of
system type
Change required
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
0C: 4
Only with Vitotronic 100 for the Vitocrossal
300:
Set coding ”0C: 0”
Only with Vitotronic 100 for the Vitorond
300: Set coding ”0C: 1” for continuous
return temperature control
–––
0d: 2
Only with Vitotronic 100 for the Vitocrossal
300:
Set coding ”0d: 0”
–––
4d: 1
32
–––
Only with Vitotronic 100 for the Vitocrossal
300:
Set coding ”4d: 2” for boiler circuit pump at
plug sL
Only with Vitotronic 100 for the Vitorond:
Connection of the Therm-Control temperature
sensor at plug aJA;
Coding is automatically changed to ”4A: 1”
5351 338 v1.6
4A: 0
Automatic change
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
§
Boiler temperature sensor
%
DHW tank temperature sensor
(accessory)
sÖ A1 Close mixing valves with
external heating circuit controls
sA
DHW pump
fÖ
fA
lÖ
aVD
aVH
Power supply connection,
120 VAC
Burner
Burner modulation
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Mixing valve heating circuit
or
E Underfloor heating circuit with
mixing valve
F Limit thermostat (max. limit)
G Neutralizing unit
33
Heating system types
Circuit Diagram 14 (CM2 only)
Possible applications
For heating circuits with different
temperatures.
(continued)
The Vitocrossal 200 is operated with
constant boiler water temperature by
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
heating contractor to check that this
recommendation is complete and fully
functional.
Coding of
system type
Change required
00: 1
Automatic change
–––
With DHW tank:
Coding is automatically changed to ”00: 2”
Set coding ”02: 2” for operation with
modulating burner
–––
0C: 4
Set coding ”0C: 0”
–––
0d: 2
Set coding ”0d: 0”
–––
5351 338 v1.6
02: 1
34
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
§
fÖ
Boiler temperature sensor
Power supply connection,
120 VAC
fA
Burner
gS A1 Motorized isolation valve
lÖ
Burner modulation
aVD
aVH
Connection of external
equipment (see page 51)
Connection of external
equipment (see page 51)
5351 338 v1.6
A Boiler with Vitotronic 100, GC1
B Domestic hot water tank
C Heating circuit with mixing valve
D Neutralizing unit
35
Heating system types
Circuit Diagram 15 (CM2 only)
Possible applications
The cascade and DHW tank control
must be activated by a building
automation system.
(continued)
The Vitocrossal 200 is operated with
constant boiler water temperature by
means of the boiler control unit and
the Viessmann fully modulating burner.
IMPORTANT
Motorized isolation valve
Connect motorized 120V isolation
valve adaptor (Part No. 7511 367)
or 24V valve adaptor (Part No.
7511 366), installed in connection
enclosure, in parallel.
Use electric junction box if necessary.
This circuit diagram represents a
recommendation only. It is the
responsibility of the customer and/or
heating contractor to check that this
recommendation is complete and fully
functional.
Change required
Automatic change
01: 1
Set coding ”01: 3” for multi-boiler system
with external cascade control via switch
contacts
–––
02: 1
Set coding ”02: 2” for operation with
modulating burner
–––
0d: 2
Set coding ”0d: 0”
–––
5351 338 v1.6
Coding of
system type
36
Installation
Mounting the Front Part of the Control Unit (VD2/VD2A/CT3 only)
1.
7.
8.
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.
6.
3. Insert the flat cable from the
Optolink into plug ”X20”.
4. Insert the plug of the programming
unit into socket ”X10”. Use cable
guides in cover for routing.
5. Engage the stay bar in the front
housing.
6. Close the front of the housing.
2.
A
7. Secure front housing with supplied
screws.
8. Install cover of the connection
enclosure and support with supplied
screw.
5.
4.
5351 338 v1.6
3.
37
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.
2.
3. Swing up the front part of the
control housing.
4. Position the stay bar so that it
supports the front housing.
1.
3.
5351 338 v1.6
4.
38
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. Secure
all cables to the rail with cable ties.
Insert capillaries into the sensor well.
Note: Never allow cables to come
in contact with hot metal
components.
WARNING
Do not bend or kink the capillaries.
Damaging the capillaries leads to
malfunction.
2. Mount the control to the control
panel.
3. Secure the control to the control
panel with screws.
Note: Screws to secure control are
included with the cosmetic
cover in the boiler jacketing
package.
5351 338 v1.6
4. Install the junction box to the rear
panel either right or left. Secure the
junction box with 4 x 4.8 metal
screws.
Note: The ground screw and ground
wire can be reinstalled with the
boiler back panel attached.
39
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.
A
3. Insert the flat cable from the
Optolink into plug ”X20”.
4. Insert the plug of the programming
unit into socket ”X10”. Use cable
guides in cover for routing.
5. Engage the stay bar in the front
housing.
6. Close the front of the housing.
7. Secure front housing with supplied
screws.
5351 338 v1.6
8. Install control cosmetic cover.
40
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.
5351 338 v1.6
4. Position the stay bar so that it
supports the front housing.
41
Installation
Overview of Electrical Connections
145
17 B
17 A
5
151
3/2
15
90
21
143
52 A1/M1
146
20 A1/M1
41
29
50
150
40
156
Low voltage connections (motherboard)
§
Boiler temperature sensor (KTS)
%
DHW tank temperature sensor
aG
Flue gas temperature sensor
aJA Return temperature sensor T1
aJB Return temperature sensor T2
aVD Connection of external
equipment
aVG KM BUS participant
aVH Connection of external
equipment
42
Line voltage connections (motherboard)
sÖ A1Control output
sA
DHW pump
sL
Shunt pump or
boiler circuit pump
fÖ
Power supply connection
fA
Burner (1st stage)
gÖ
Compiled failure alarm
gS A1Return valve
or
Isolation/modulating valve
lÖ
Burner (2nd stage/modulating)
aBÖ Connection of external
equipment, e.g. additional
safety equipment
aBA Safety circuit, potential free
aBH Power supply connection for
accessories
5351 338 v1.6
156
Installation
Overview of Electrical Connections (VD2/VD2A/CT3 only)
(continued)
5351 338 v1.6
[29]
[20] A1
43
Installation
(continued)
5351 338 v1.6
Overview of Electrical Connections (CM2 only)
44
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.
OR
5351 338 v1.6
Fasten cable to the cable lead with
cable tie.
45
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.
Vitocrossal 300, type CT3
1040
7820 144
Vitorond 200, VD2 / VD2A
1020
7820 142
Vitocrossal 200, CM2
1041
7820 145
5351 338 v1.6
1. Push the boiler coding card through
the recess in the cover and insert
it in plug-in location ”X7”.
46
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
safety equipment installed in
accordance with applicable codes.
A
The fixed high limit is supplied with
a factory setting of 110°C / 230°F.
- On Vitotronic 100, GC1 for
Vitorond 200, VD2 of
110°C / 230°F
- Adjustment to 99°C / 210°F
- On Vitotronic 100, GC1 for
Vitocrossal 300, CT3
Vitocrossal 200, CM2
of 99°C / 210°F
No adjustment
3.
¨ Disconnect power to control and
burner!
1. Unclip the fuse box and swing
upwards.
2. Turn the slotted screw on the rear
of the fixed high limit until the slot
points to 99°C / 210°F (once
adjusted, the fixed high limit cannot
be reset to 110°C / 230°F).
1.
3. Re-fit the fuse box.
2.
Non-condensing boiler
(VD2/VD2A) °C / °F
Condensing boiler
(CT3) °C / °F
Condensing boiler
(CM2) °C / °F
Fixed high limit
110 / 230
99 / 210
99 / 210
99 / 210
Adjustable high limit
100 / 212
95 / 203
95 / 203
95 / 203
93 / 200
87 / 188
87 / 188
88 / 190
5351 338 v1.6
Coding for the electronic maximum
temperature limiter of Vitotronic 100;
set code 06 to the temperature as
shown or less
47
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.
A
2. Using a suitable screwdriver,
lever out and remove the selector
knob ”R” behind the hinged cover.
3.
3. Using a pair of pointed pliers, break
off the cams identified by the
shaded areas in the Fig. from the
stop dial.
A
2.
75 to 1100°C
167 to 212°F
4. Fit the selector knob ”R” so that
the marking is in the centre of the
selected range.
IMPORTANT
Note the setting of coding address
”06”!
WARNING
If the system is operated in
conjunction with a domestic hot
water tank, ensure that the
maximum permissible domestic
hot water temperature is not
exceeded. If necessary, install a
suitable safety device for this
purpose.
5351 338 v1.6
1.
48
Installation
Sensor Connection
17B
17A
3
15
1 2 3
1 2 3
1 2 3
1 2 3
A
B
C
D
5351 338 v1.6
ATemperature sensor T2
BTemperature sensor T1
CBoiler temperature sensor
DFlue gas temperature sensor
49
Installation
Connection of the Boiler Temperature Sensor
Electrical connection
See page 35.
The sensor measures the boiler
water temperature of the boiler.
3
The boiler temperature sensor is
installed at the same time as the
boiler insulation.
Check the sensor
1. Disconnect plug § in the
terminal compartment.
2. Measure resistance of sensor at
terminals ”1” and ”2” of the plug
or ”2” and ”3” (if a second DHW
tank temperature sensor is
connected).
760
Boiler water
temperature
in °C / °F
Resistance
in Ω
40 / 104
50 / 122
60 / 140
578
597
616
3. Compare the value measured with
the current temperature. If the
value differs significantly, check
installation and, if necessary,
replace sensor.
740
720
700
Technical data
Degree of protection: IP 32
Ambient temperature
during operation:
0 to + 130°C
32 to + 266°F
during storage and transport:
-20 to + 170°C
- 4 to + 158°F
680
660
640
620
Electrical connection
The sensors are ready to plug in.
Insert the boiler temperature sensor
in socket ”3” of the boiler control.
580
560
400
540
50
0
32
20
68
40
104
60
141
80
176
Boiler temperature in °C / °F
100
212
120
248
140
284
5351 338 v1.6
Resistance in
600
Installation
Connection of the DHW Tank Temperature Sensor
The sensor measures the domestic hot
water tank temperature.
Heating systems with domestic hot
water heating (single-boiler systems
only)
1. Install the DHW tank temperature
sensor.
5
See installation instructions
for domestic hot water tank
Please note:
When installing the sensor in DHW
tanks of other makes, make sure
that the sensor is pressed against
the sensor well of the DHW tank by
means of a suitable device.
2. Ensure that the maximum
permissible domestic hot water
temperature is not exceeded. If
necessary, install a suitable safety
device for this purpose.
Heating systems without domestic hot
water heating
Do not connect the DHW tank
temperature sensor.
760
740
720
Electrical connection
See page 35.
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.
2. Measure resistance of sensor at
terminals ”1” and ”2” of the plug
or ”2” and ”3” (if a second DHW
tank temperature sensor is
connected).
DHW tank
temperature
in °C / °F
Resistance
in Ω
40 / 104
50 / 122
60 / 140
578
597
616
3. Compare the value measured with
the current temperature. If the
value differs significantly, check
installation and, if necessary,
replace sensor.
Technical data
Degree of protection: IP 32
Ambient temperature
during operation:
0 to + 130°C
32 to + 266°F
during storage and transport:
-20 to + 170°C
- 4 to + 158°F
700
680
660
640
Electrical connection
The sensors are ready to plug in.
Insert the DHW temperature sensor
in socket ”5” of the boiler control.
620
Resistance in
5351 338 v1.6
600
580
560
400
540
0
32
20
68
40
104
60
141
80
176
DHW temperature in °C / °F
100
212
120
248
140
284
51
Installation
Connection of the Return Temperature Sensor
Strap-on temperature sensor and immersion temperature sensor
For measuring the boiler return
and return temperature.
17A or 17B
Electrical connection
The sensor is inserted in socket
”17A” or ”17B” on the boiler
control.
Check the sensor
1. Disconnect plug aJA or aJB
in the terminal compartment of
the boiler control.
2. Measure resistance of sensor at
terminals ”1” and ”2” of the plug.
17A or 17B
Return
temperature
in °C / °F
Resistance
in Ω
30 / 86
40 / 104
60 / 140
569
592
643
3. Compare the value measured with
the current temperature. If the
value differs significantly, check
installation and, if necessary,
replace sensor.
740
720
Technical data
Degree of protection: IP 32
Ambient temperature
during operation: 0 to + 100°C
32 to + 212°F
during storage and transport:
-20 to + 70°C
-4 to + 158°F
700
680
660
640
620
580
560
540
20
68
52
30
86
40
104
50
122
60
70
140 158
Return temperature in °C / °F
80
176
90
100
194 212
5351 338 v1.6
Resistance in
600
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. Disconnect plug aG in the
terminal compartment.
2. Measure resistance of sensor at
terminals ”1” and ”2” of the
plug.
1020
980
Flue gas
temperature
in °C / °F
Resistance
in Ω
180 / 176
160 / 320
200 / 392
650
800
880
3. Compare the value measured
with the current temperature.
If the value differs significantly,
check installation and, if
necessary, replace sensor.
940
900
860
Technical data
Degree of protection: IP 60
Ambient
temperature
during operation:
0 to + 600°C
32 to + 1112°F
during storage and transport:
–20 to + 670°C
- 4 to + 158°F
820
780
740
700
660
5351 338 v1.6
Resistance in Ω
620
580
540
500
0
32
40
80 120 160 200 240
104 176 248 360 392 464
280
536
Flue gas temperature in °C / °F
53
Installation
Connection of the Pumps (VD2/VD2A/CT3 only)
Available pump connections
20A1/M1
29
sÖ
A1/M1Heating circuit high
temperature (without mixing valve)
Terminals 5 - L, - G , - N
sA
Circulation pump for heating
up the domestic hot water tank Terminals 4 - L, - G , - N
sL
Shunt pump, boiler circuit pump
Terminals 6 - L, - G, - N.
Install pumps: see
manufacturer’s
instructions.
120 VAC pumps
240 VAC or 3 PH pumps
Note:
The maximum power consumption of
all pumps is 4A .
Rated current: max. 2 FLA
Recommended connection
cable: AWG 14
Please note:
Use contactor and/or motor starter to
power pump.
For activating the contactor:
Rated current: max. 2 FLA
Recommended connection
wire size: AWG 14
Use contactor for pumps with higher
current rating
Connect the 3-wire cable from the
pump to the corresponding terminals.
Please ensure that all connections and
wire sizes comply with local and
national codes.
1.Select the contactor and the
connecting wire in accordance with
the rating of the pump that is to be
connected.
2.Connect pump and power supply to
the contactor.
5351 338 v1.6
3.Connect contactor coil to the
corresponding terminals.
54
Installation
Connection of the Pumps (CM2 only)
Available pump connections
sÖ
A1/M1Heating circuit high
temperature (without mixing valve)
Terminals 7 - L, - G , - N
sA
Circulation pump for heating
up the domestic hot water tank Terminals 6 - L, - G , - N
sL
Shunt pump, boiler circuit pump
Terminals 8 - L, - G, - N.
Install pumps: see
manufacturer’s
instructions.
120 VAC pumps
240 VAC or 3 PH pumps
Note:
The maximum power consumption
of all pumps is 4A .
Rated current: max. 2 FLA
Recommended connection
cable: AWG 14
Please note:
Use contactor and/or motor starter
to power pump.
For activating the contactor:
Rated current: max. 2 FLA
Recommended connection
wire size: AWG 14
Use contactor for pumps with higher
current rating
Connect the 3-wire cable from the
pump to the corresponding terminals.
Please ensure that all connections
and wire sizes comply with local and
national codes.
1.Select the contactor and the
connecting wire in accordance
with the rating of the pump that
is to be connected.
5351 338 v1.6
2.Connect pump and power supply
to the contactor.
3.Connect contactor coil to the
corresponding terminals.
55
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
120V Valve Adaptor
Rated voltage: 120 VAC
Rated current: max. 0.1 FLA
Recommended connection
wire size: AWG 14
Part No. 7134 560
24V Valve Adaptor
Rated voltage: 24 VAC
Rated current: max. 0.15 FLA
Recommended connection
wire size: AWG 14
Part No. 7134 559
Operating time:
5 to 199 sec. selected via coding
address “40”.
1. Disconnect power to control.
2. Install 120V or 24V Valve
Adaptor on DIN rail inside
connection enclosure.
3. Insert the plug gS into socket
gS on the control.
4. Fasten cable with tie
(see page.37).
5. Connect black wire of the
adaptor to connection aBH on
the DIN rail
- Terminal 8,9 or 10.
5351 338 v1.6
6. Connect valve actuator wires
to the adaptor terminals as
shown on figures.
56
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
120V Valve Adaptor
Rated voltage: 120 VAC
Rated current: max. 0.1 FLA
Recommended connection
wire size: AWG 14
Part No. 7511367
24V Valve Adaptor
Rated voltage: 24 VAC
Rated current: max. 0.15 FLA
Recommended connection
wire size: AWG 14
Part No. 7511366
Operating time:
5 to 199 sec. selected via coding
address “40”.
1. Disconnect power to control.
2. Install 120V or 24V Valve
Adaptor on DIN rail inside
connection enclosure.
3. Insert the plug gS into socket
gS on the control.
4. Fasten cable with tie
(see page.37).
5. Connect black wire of the
adaptor to connection 120V L
out the DIN rail
- Terminals 10,11 or 12.
5351 338 v1.6
6. Connect valve actuator wires
to the adaptor terminals as
shown on figures.
57
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. Place the screwdriver
between the rail and the base of
the terminal and turn the
screwdriver clockwise . Discard
the removed terminals.
3. Re-install the DIN rail clamp by
hooking the latch of the clamp
around the top of the rail and then
push down on the front of the
clamp.
5351 338 v1.6
Note: See separate Installation
Instructions for accessory
adaptors.
58
Installation
Vitotronic 100, GC1 with 30% LTP Package (VD2/VD2A only)
5351 338 v1.6
1 - 17B Sensor (strap-on)
VD2/VD2A
59
Installation
Connection of External Controls
Operation with two-stage burner
A
Dry contacts of the building automation
system:
1st stage burner ON
143
2nd stage burner ON
C
External changeover of
staged/modulating burners
D
Boiler activation, isolation valve open
or closed (on multi-boiler system only)
146
A
Switch on 1st stage burner
Connect dry contact at terminals ”1”
and ”2” of the plug aVD .
Contact closed:
The 1st stage burner is switched on.
The 2nd stage burner is only switched
on to maintain the minimum
temperature (not with Vitocrossal
300). The boiler water temperature is
limited by the electronic maximum
temperature limit (coding address ”06”)
if this is set below the value preset on
the mechanical adjustable high limit
”R”.
Contact open:
The 1st stage burner is switched off.
B
Switch on 2nd stage burner
Connect dry contact at terminals ”2”
and ”3”
of the plug aVD.
D
Boiler activation, isolation valve
open or closed
Connect dry contact at terminals ”2”
and ”3” of the plug aVH.
Contact closed:
Both burner stages are switched on.
The boiler water temperature is limited
by the electronic maximum
temperature limit (coding address ”06”)
if this is set below the value preset on
the mechanical adjustable high limit
”R”.
The 2nd stage burner is switched off
2 K sooner.
Contact closed:
First, the preheat function for
follow-up boilers is activated
(coding address ”2b”).
When the preheat function finishes,
the minimum temperature is
maintained for the boiler (not with
Vitocrossal 300), and the burner
stages can be switched externally.
The boiler water temperature is
limited by the preset electronic
maximum temperature limit or via
the mechanical adjustable high limit.
The setpoint value is selected via
the coding address ”9b”.
Contact open:
The 1st and 2nd stage burner are
switched off.
C
External changeover of
staged/modulating burners
Connect dry contact at terminals ”1”
and ”2” of the plug aVH.
Contact closed:
Modulating operation.
Contact open:
Two-stage operation. Coding “02: 2”
(modulating burner) must be set.
Note:
Even if contact is closed, scanning the
type of burner will continue to display
“modulating”.
60
Contact open:
The isolation valve is closed after
approximately. 5 minutes
(coding address ”2C”).
External override of the burner stages
is not possible, and no minimum
temperature is maintained.
5351 338 v1.6
B
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
(VD2/VD2A) °C / °F
Condensing boiler
(CT3) °C / °F
Condensing boiler
(CM2) °C / °F
Fixed high limit
110 / 230
99 / 210
99 / 210
99 / 210
Adjustable high limit
100 / 212
95 / 203
95 / 203
95 / 203
93 / 200
87 / 188
87 / 188
88 / 190
Coding for the electronic maximum
temperature limiter of Vitotronic 100;
set code 06 to the temperature as
shown or less
Single-boiler systems:
Coding ”01: 1”
(factory setting)
Multi-boiler systems:
Set coding ”01: 3”
When a building automation system is
connected, only the connections on
plug aVD are required. The DHW tank
control unit is activated when the DHW
tank temperature sensor is connected.
The boiler water temperature must be
set to the minimum value.
When a building automation system
is connected, the connections on
plugs aVD and aVH are required. The
DHW tank temperature and the
load-dependent cascade control must
be controlled through the bulding
automation system.
CAUTION
5351 338 v1.6
The boiler activation contact is
essential on multi-boiler systems.
The contact on the lead boiler must
be constantly closed.
61
Installation
Connection of External Controls (VD2/VD2A only) (continued)
Modulating boilers – operation with external modulation controller (continued)
1st stage burner fA from
Vitotronic 100.
Plug lÖ from Vitotronic 100 via
modulation controller (BAS).
On the building automation unit with
modulation controller set the minimum
temperatures 5°C / 9°F above the
minimum boiler water temperature of
the boiler.
Boiler activation, isolation valve open
or closed
Connect dry contact at terminals ”2”
and ”3” of the plug aVH.
Contact closed:
First, the preheat function for followup boilers is activated (coding
address ”2b”).
When the preheat function finishes,
the minimum temperature is
maintained for the boiler, and the
burner stages/modulation can be
switched externally.
The boiler water temperature is
limited by the preset maximum
boiler water temperature or via the
mechanical adjustable high limit.
The set-point value is selected via
the coding address ”9b”.
Contact open:
The isolation valve is closed after
approx. 5 minutes (coding address
”2C”).
External override of the burner stages
is not possible, and no minimum
temperature is maintained.
Switch on 1st stage burner (basic
load)
Connect dry contact at terminals ”1”
and ”2” of the plug aVD.
Contact closed:
The 1st stage burner is switched on.
The full load is only switched on to
maintain the minimum temperature
(not with Vitocrossal 300). The
boiler water temperature is limited
by the electronic maximum
temperature limit (coding address
”06”) if this is set below the value
preset on the mechanical adjustable
high limit ”R”.
5351 338 v1.6
Contact open:
The 1st stage burner is switched off.
62
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.
Non-condensing boiler
(VD2/VD2A) °C / °F
Condensing boiler
(CT3) °C / °F
Condensing boiler
(CM2) °C / °F
Fixed high limit
110 / 230
99 / 210
99 / 210
99 / 210
Adjustable high limit
100 / 212
95 / 203
95 / 203
95 / 203
93 / 200
87 / 188
87 / 188
88 / 190
Coding for the electronic maximum
temperature limiter of Vitotronic 100;
set code 06 to the temperature as
shown or less
Single-boiler systems:
Coding ”01: 1”
(factory setting)
Multi-boiler systems:
Set coding ”01: 3”
When a building automation system is
connected, only the connections on
plug aVD are required. The DHW tank
control unit is activated when the DHW
tank temperature sensor is connected.
The boiler water temperature must be
set to the minimum value.
When a building automation system
is connected, the connections on
plugs aVD and aVH are required. The
DHW tank temperature and the
load-dependent cascade control
must be controlled through the
external building automation system.
CAUTION
5351 338 v1.6
The boiler activation contact is
essential on multi-boiler systems.
The contact on the lead boiler must
be constantly closed.
63
Installation
Connection of External Controls (CT3 only)
(continued)
Vitocrossal 300 – operation with external modulation controller
1st stage burner fA from
Vitotronic 100.
Connection lÖ from Vitotronic 100
has no function.
Connection lÖ from building
automation system to the burner.
1st stage burner activated by the
modulation controller via connection
aVH.
Boiler activation, isolation valve open
or closed
Connect dry contact at terminals ”2”
and ”3” of the plug aVH.
Contact closed:
First, the preheat function for
follow-up boilers is activated
(coding address ”2b”).
When the preheat function finishes,
the burner stages/modulation can be
switched externally.
The boiler water temperature is
limited by the preset maximum boiler
water temperature or via the
mechanical adjustable high limit.
The set-point value is selected via the
coding address ”9b”.
Contact open:
The isolation valve is closed after
approximately 5 minutes (coding
address ”2C”).
External override of the burner
stages is not possible, and no
minimum temperature is maintained.
Switch on 1st stage burner (basic
load)
Connect dry contact at terminals ”1”
and ”2” of the plug aVD.
Contact closed:
The 1st stage burner is switched on.
The boiler water temperature is
limited by the electronic maximum
temperature limit (coding address
”06”) if this is set below the value
preset on the mechanical adjustable
high limit ”R”.
5351 338 v1.6
Contact open:
The 1st stage burner is switched off.
64
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.
Non-condensing boiler
(VD2/VD2A) °C / °F
Condensing boiler
(CT3) °C / °F
Condensing boiler
(CM2) °C / °F
Fixed high limit
110 / 230
99 / 210
99 / 210
99 / 210
Adjustable high limit
100 / 212
95 / 203
95 / 203
95 / 203
93 / 200
87 / 188
87 / 188
88 / 190
Coding for the electronic maximum
temperature limiter of Vitotronic 100;
set code 06 to the temperature as
shown or less
Single-boiler systems:
Coding ”01: 1”
(factory setting)
Multi-boiler systems:
Set coding ”01: 3”
When a building automation system is
connected, only the connections on
plug aVD are required. The DHW tank
control unit is activated when the DHW
tank temperature sensor is connected.
The boiler water temperature must be
set to the minimum value.
When a building automation system
is connected, the connections on
plugs aVD and aVH are required. The
DHW tank temperature and the
load-dependent cascade control must
be controlled through the building
automation system.
CAUTION
5351 338 v1.6
The boiler activation contact is
essential on multi-boiler systems.
The contact on the lead boiler must
be constantly closed.
65
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).
3. Remove jumper between terminals
16 and 17.
4. Make connection as shown in the
diagram.
IMPORTANT
Wire BK2 must be connected to
terminal 16 and BK3 to terminal 17 DO NOT reverse.
A Combustion Air Device Adaptor
B DIN Rail in connection enclosure
Connection of the combustion air
blower to adaptor
Rated voltage:
120 VAC
Rating current:
max 5 FLA
Recommended connection
wire size:
AWG 14
Ensure that combustion air blower
device is suitable for this application.
For detailed instruction on adaptor
installation please refer to the adaptor’s
installation manual.
D
1. Make connection as shown in the
diagram at left.
¨ Safety instruction!
Provide disconnect means and
overcurrent protection as required by
local codes.
66
5351 338 v1.6
A Combustion Air Device Adaptor in
connection enclosure
B Combustion air blower motor
C Proving switch - “normally open”
rated for 120 VAC.
D Power supply, 120 VAC
Installation
Connection of Combustion Air Device (CM2 only)
Connection of the Combustion Air
Device Adaptor
Connection of the combustion air
blower to adaptor
1. Disconnect power to control and
burners.
Rated voltage:
120 VAC
Rating current:
max 5 FLA
Recommended connection
wire size:
AWG 14
2. Install Combustion Air Device
Adaptor, Part No. 7134 563
on DIN Rail inside the boiler junction
box (refer to installation manual of
Combustion Air Device
Adaptor).
D
3. Remove plug 150 from Vitotronic
control. Remove jumper between
the 2 ’TR’ terminals. Using 14 AWG
(field supplied) connect plug
terminals TR(Left), TR(Right) and
neutral to the DIN rail.
Neutral to Terminal 16
TR(Left) to Terminal 18
TR(Right) to Terminal 19
Re-install the 150 plug and DIN rail
connections as shown in the diagram.
IMPORTANT
Ensure that combustion air blower
device is suitable for this application.
For detailed instruction on adaptor
installation please refer to the
adaptor’s installation manual.
1. Make connection as shown in the
diagram at left.
A Combustion Air Device Adaptor
in connection enclosure
B Combustion air blower motor
C Proving switch - “normally open”
rated for 120 VAC.
D Power supply, 120 VAC
¨ Safety instruction!
Provide disconnect means and
overcurrent protection as required
by local codes.
5351 338 v1.6
Wire BK2 must be connected to
terminal 18 and BK3 to terminal 19 DO NOT reverse.
67
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.
E
1. Disconnect power to control and
burner.
2. Make connection as shown in the
diagram.
A Combustion Air Device Adaptor
in connection enclosure
B Relay 120 VAC coil - field supplied
C Combustion air damper
D End switch rated for 120 VAC
wired to “normally open” terminal
on device adaptor board
E Power supply, 120 VAC
¨ Safety instruction!
Provide disconnect means and
overcurrent protection as required by
local codes.
5351 338 v1.6
Note:
Spring return air dampers do not
require field supplied relay.
68
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
1. Install Combustion Air Device
Adaptor on each boiler.
Part No. 7134 563
2. Install Common Combustion Air
Device Interface,
Part No. 7134 604
as per supplied manual.
3. Make connection as shown in the
diagram at left.
A Common Combustion Air Device
Interface (wall mount)
B Combustion Air Device Adaptor
in connection enclosure on each
boiler
C Interconnecting wiring
(field supplied and connected)
5351 338 v1.6
Refer to Istallation and Operating
Instructions of Common Combustion
Air Device Interface for details.
69
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
¨ Safety instruction!
Provide disconnect means and
overcurrent protection as required
by local codes.
See blower manual for current
rating to correctly select the fuse.
D
See Common Combustion Air
Device Interface manual for
Installation and Operating details.
1. Disconnect power to control and
burner.
5351 338 v1.6
2. Make the connections as shown
in the diagram.
70
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.
See damper manual for current
rating to correctly select the fuse.
See Common Combustion Air
Device Interface manual for
Installation and Operating details.
1. Disconnect power to control and
burner.
5351 338 v1.6
2. Make the connections as shown
in the diagram.
71
Installation
Flue Gas Temp. Switch (optional for CM2 equipped with SS flue collector)
(CM2 only)
1. Disconnect power.
CAUTION
Please note that the diagram shown
is only a simplified conceptual
drawing of a flue gas temperature
switch. Refer to the manual specific
to the device for interconnection
details.
2. Remove 150 plug from the
Vitotronic control.
3. Remove STB jumper from plug
150.
4. Using 14 AWG (field supplied)
connect STB(Left), STB(Right) and
ground to the DIN rail as shown
in the diagram.
STB(Left) to DIN 14
Ground to DIN 15
STB(Right) to DIN 17
5. Re-install the 150 plug into the
Vitotronic control.
5351 338 v1.6
6. Connect the Flue gas temperature
sensor to the DIN rail as shown in
the diagram.
72
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. Refer to the
manual specific to the device for
interconnection details.
aBH Power supply for accessories.
5351 338 v1.6
aBÖ Connection for external
equipment.
73
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
5351 338 v1.6
Please note that the diagram shown
is only a simplified conceptual
drawing of a typical low water
cut-off (LWCO) device. Refer to the
manual specific to the device for
interconnection details.
74
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). See
pages 44 to 49 for details of
controlled switch-off.
During switch-off, there is no frost
protection
of the heating system and
WARNING
the boiler is not kept at the minimum
boiler water temperature.
5351 338 v1.6
A Jumper
B External shut-off (dry contact)
Emergency operation
Move jumper from terminals 16 and 17
to terminals 17 and 18.
75
Installation
Connection of the Compiled Failure Alarm Indicator (VD2/VD2A/CT3 only)
A
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.
A Connect terminal strip in
connection enclosure of boiler
control
B Visual and/or audible alarm
device (120 VAC)
5351 338 v1.6
B
76
Installation
Connection of the Compiled Failure Alarm Indicator (CM2 only)
9
A
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.
A Connect terminal strip in
connection enclosure of boiler
control
B Visual and/or audible alarm
device (120 VAC)
5351 338 v1.6
B
77
Installation
Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only)
For burners with plug-in connection
A
The burner cables are included in the
standard delivery of the Vitotronic.
Connect the burner in accordance with
applicable codes.
ATo boiler control unit
BTo burner
1.Disconnect power to burner and
boiler control.
Terminal codes
2. Connect plugs fA and plug lÖ to
respective counter plugs in boiler
control unit.
L1
41
120 VAC
Phase via fixed high limit to the
burner
?
Ground connection
N
Neutral connection to the burner
T1,T2 Control circuit
S3
Connection for burner fault
indicator
B4
Connection for burner hours
counter
3. Connect the 7-pole plug fA and the
3-pole plug lÖ to the burner.
B
A To plug-in connection in connection
enclosure
B To burner
Terminal codes
1,2,3 Control circuit ”2nd stage
burner or modulation controller”
(via two-point controller with
2-stage operation;
via three-point controller with
modulating operation)
1
From burner
2
Modulating down
3
Modulating up/2nd stage ON
BK
BN
BU
78
Black
Brown
Blue
5351 338 v1.6
Colour codes as applicable
Installation
Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)
CAUTION
This is a generic connection drawing
only! Follow the burner
manufacturer’s connection drawings
for Viessmann controls.
Write the terminal numbers or
markings on the drawing for future
reference.
Plug connection
located on the
DIN rail. See page
35 for details.
a
b
5351 338 v1.6
Burner power supply not shown.
A Control unit
(Legend: see wiring diagram)
B 2nd stage or modulating *1
C Hours counter, stage 1 *1
D Burner fault indicator *1
E Control circuit, stage 1/
basic load *1
F Burner
*1
fÖ Power supply connection of control
unit 120 VAC
fA Burner, 1st stage
lÖ Burner, 2nd stage
aBÖ Plugs for external equipment
a External safety devices
(remove jumper when connecting)
b External controlled switch-off
(remove jumper when connecting)
aBA Safety circuit. Emergency
shut-off
Refer to burner manufacturer’s instruction on detailed connections for Viessmann controls.
79
Installation
Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)
Burner motor power supply connection
(continued)
For burners with 240 VAC, 1PH power
supply and connection in conduit.
See burner manual for correct fuse
and wire gauge sizing, and specific
connections for Viessmann controls.
1.Disconnect power to burner and
boiler control.
2.Connect 240 VAC power to the
terminals 21, 22 and 23 on the
DIN rail inside the connection
enclosure. Provide fuseable
disconnect means according to
local codes.
3.Connect supplied power cable to
the motor terminals on the burner.
4.Connect cable plug to the socket
on the DIN rail in the connection
enclosure.
5351 338 v1.6
A Burner motor power supply
240 VAC, 1PH
B Connection terminals and plug
inside connection enclosure
C Cable and conduit- factory supplied
D Burner
E Motor starter
F Burner motor
G Connection enclosure on boiler
control
80
Installation
Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only)
Burner motor power supply connection
(continued)
For burners with 3PH 208, 460 or
575V power supply.
(continued)
See burner manual for correct fuse
and wire gauge sizing, and specific
connections for Viessmann controls.
1.Disconnect power to burner and
boiler control.
2.Connect 3PH power to the
terminals 21, 22, 23 and 24 on
the DIN rail inside the connection
enclosure. Provide fuseable
disconnect means according to
local codes.
3.Connect supplied power cable to
the motor terminals on the burner.
4.Connect cable plug to the socket
on the DIN rail in the connection
enclosure.
CAUTION
During commissioning check for
correct motor rotation. If motor
rotates in opposite direction than
indicated on the burner, disconnect
power supply and reverse wires BK1
and BK2 on the burner terminals.
5351 338 v1.6
A Burner motor power supply 3PH
208, 460 or 575V
B Connection terminals and plug
inside connection enclosure
C Cable and conduit - factory
supplied
D Burner
E Motor starter
F Overload
G Burner motor
H Connection enclosure
81
Installation
Power Supply Connection, Boiler Control (VD2/VD2A/CT3 only)
Legend
L: Line
N: Neutral
G: Ground
A Power supply 120 VAC, 1 PH .
Provide disconnect means and
overcurrent protection as per local
codes
B Terminals [40]
C Connection enclosure
1. Ensure that the main power supply
to the control contains overcurrent
protection with a maximum rating
of 15 A and 2 pole disconnect.
CAUTION
The control must be grounded.
Ensure that “L”, “N” and “G” are not
interchanged.
5351 338 v1.6
2. Connect power supply wire to the
Connection fÖ terminals 11, N and
G on the DIN rail inside the
connection enclosure.
82
Installation
Burner Connection, Burner Control Wiring (CM2 only)
For burners with plug-in connection
A
The burner cables are included in the
standard delivery of the Vitotronic.
Connect the burner in accordance with
applicable codes.
ATo boiler control unit
BTo burner interface
1.Disconnect power to burner and
boiler control.
Terminal codes
2. Connect plugs fA and plug lÖ to
respective counter plugs in boiler
control unit.
L1
Phase via fixed high limit to the
burner
?
Ground connection
N
Neutral connection to the burner
T1,T2 Control circuit
S3
Connection for burner fault
indicator
B4
Connection for burner hours
counter
3. Connect the 7-pole plug fA and
the 3-pole plug lÖ to the burner.
B
A
A To plug-in connection in connection
enclosure
B To burner interface
Terminal codes
1,2,3 Control circuit ”2nd stage
burner or modulation controller”
(via two-point controller with
2-stage operation;
via three-point controller with
modulating operation)
1
From burner
2
Modulating down
3
Modulating up/2nd stage ON
5351 338 v1.6
Colour codes as applicable
BK
BN
BU
Black
Brown
Blue
B
83
Start-up
Procedure
(overview)
Page
1. Controls and indicators
..............................................................................
2. Check the fixed high limit
.....................................................................
3. Integrate the control unit in the LON BUS system
(in conjunction with heating circuits connected downstream)
4. Carry out participant check
86
.......
87
...................................................................
88
.....................................
89
...........................................
89
.................................................................
90
5. Match the control unit to the system type
6. Check outputs (actuators) and sensors
5351 338 v1.6
7. Match the coding addresses
85
84
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
F1 T6,3 A
TUV
F2 T6,3 A
Control on/off switch
Fuses
TUV button
5351 338 v1.6
Operating status indicator (green)
Fault indicator (red)
85
Start-up
Steps
(continued)
2. Check the fixed high limit
The check is made via the ”TUV button” (see page 85).
5351 338 v1.6
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.
The amount of heat consumed should
be reduced as far as possible.
The adjustable high limit ”R” is
bridged. The burner is switched on
until the boiler water temperature
reaches the safety temperature and
the fixed high limit operates.
When the burner is switched off by
the fixed high limit, release the ”TUV”
button, wait until the boiler water
temperature has fallen 15 to 20°C / 27
to 36°F below the selected safety
temperature and then reset the fixed
high limit by pressing the ”E” button.
86
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
coding address ”77” in coding 1
(factory setting: ”77: 1”).
See page 115 for coding 1.
Please note:
The same number must not be
assigned twice within a LON BUS
system.
Update the LON participant list
This is only possible when all participants are connected and the control unit is
coded as the error manager (coding ”79: 1”).
1234567
simultaneously for
1. Press w and
approx. 2 seconds.
The participant check is initiated
(see also page 88).
2. Press D.
The participant list is updated after
approx. 2 minutes.
The participant check is terminated.
Example of single-boiler system with Vitotronic 050 heating circuit controls and Vitocom connected downstream
Vitotronic 100
Vitotronic 050
5351 338 v1.6
LON
Vitotronic 050
LON
Vitocom
LON
Participant No. 1
Coding ”77: 1”
Participant No. 10
Coding ”77: 10”
Participant No. 11
Set coding ”77: 11”
Participant No. 100
Control unit is error
manager
Coding ”79: 1”
Control unit is not error
manager
Coding ”79: 0”
Control unit is not error
manager
Coding ”79: 0”
Unit is error manager
–––
Transmit time via LON
Set coding ”7b: 1”
Time is received via LON
Set coding ”81: 3”
Time is received via LON
–––
Transmit outdoor
temperature via LON
Set coding ”97: 2”
Outdoor temperature is
received via LON
Set coding ”97: 1”
–––
87
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)
1234567
simultaneously for
1. Press w and
approx. 2 seconds.
The participant check is initiated.
All 7 arrows appear in the display
window.
Participant number
Consecutive list number
1234567
2. Select the required participant with
or
.
3. Activate the check with
.
If communication between the two
units is verified, the arrows in the
display window stop flashing.
If communication is not verified, the
display shown on the left appears.
The arrows in the display will flash
until the check is completed. The
display window and all lit buttons of
the selected participant flash for
approx. 60 seconds.
Check the LON connection (see page
111).
4. To check further participants, follow
the steps described in points 2 and
3.
5. Press w and
simultaneously for
approx. 1 second.
The participant check is terminated.
5351 338 v1.6
1234567
88
Start-up
Steps (continued)
5. Match the control unit to the system type
Set the following coding addresses in
coding 2:
”00” System type
”01” Single or multi-boiler system
”02” Burner type
”03” Oil or gas-fired operation
”07” Boiler number
”0C” Return temperature raising
”0d” Therm-Control is effective for ...
”4C” plug sÖ function
”4d” plug sL function
”4E” plug gS function
See page 117 for coding 2.
6. Check outputs (actuators) and sensors
Carry out relay test
Relay test is activated.
1. Press and
simultaneously for
approx. 2 seconds.
1234567
2. Select relay outputs with the
button.
or
Relay test is terminated.
3. Press
.
The following relay outputs can be
selected depending on the system
equipment installed:
Display Relay function
11
12
13
14
15
16
17
18
19
10
11
Burner/stage 1 ON
Burner stage 1 and 2
ON/modulation open
Burner modulation neutral
Burner modulation closed
Output 20 ON
Output 29 ON
Output 52 open
Output 52 neutral
Output 52 closed
DHW pump ON
Central fault indicator ON
Check sensors
5351 338 v1.6
1. Press
Scanning of operating status
information is activated
(see page 97).
.
1234567
2. Scan sensors with
or
.
Scanning is terminated.
3. Press
.
89
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).
1. Start up the burner.
The relay test is activated.
simultaneously for
2. Press 9 and
approx. 2 seconds.
3. With
activate the function
”Modulating burner open” (display:
2) and wait until the actuating drive
of the burner is at maximum output.
Make a note of the value.
4. Establish the maximum burner
output through the fuel
consumption.
activate the function
5. With
”Modulating burner closed”
(display: 4) and measure the time it
takes for the actuating drive of the
burner to reach the minimum
output.
Make a note of the value.
Make a note of the value.
6. Establish the minimum burner output
(basic output) through the fuel
consumption.
7. With
activate the function
”Modulating burner open” (display:
2) and, after one-third of the time
measured in point 5, activate the
function ”Modulating burner neutral”
with
(display: 3).
Make a note of the value.
9. Press
90
.
The relay test is terminated.
5351 338 v1.6
8. Establish the partial output through
the fuel consumption.
Start-up
Steps
(continued)
7. Match the coding addresses (continued)
10. Set the established values in coding
level 1.
See page 115 for coding 1.
Address Setting of
05
the partial output (see point 8) as a percentage proportion of the
max. output; e.g.
partial output: 170 kW
max. output: 210 kW
170 kW x100 % = 81 %
210 kW
08
units and tens digits of the maximum output established in point
4: e.g. max. output: 210 kW – here set: 10
09
hundreds digit of the maximum output established in point 4: e.g.
max. output: 210 kW – here set: 2
0A
the basic output (see point 6) as a percentage proportion of the
max. output; e.g.
basic output: 70 kW
max. output: 210 kW
70 kW x100 % = 33 %
210 kW
15
the operating time in seconds established in point 5
5351 338 v1.6
Please note:
You will find details of other possible settings in the sections entitled
”Coding 1” and ”Coding 2” (see page 115 and 117).
91
Scanning service information
Overview of Service Levels
Function
Button combination
To exit
Temperatures, boiler coding
cards and scans
Press 9 and rw simultaneously
for approx. 2 seconds
Press OK
93
Relay test
Press 9 and OK simultaneously for Press OK
approx. 2 seconds
89
Participant check
(in conjunction with LON)
Press w and OK simultaneously for Press w and OK simultaneously for
approx. 1 second
approx. 2 seconds
88
Operating status information
Press Press 97
Press OK
98
5351 338 v1.6
Service display
Page
92
Scanning service information
Temperatures, Boiler Coding Cards and Scans
1. Press and
simultaneously for
approx. 2 seconds.
Access diagnosis level.
2. Select the required data for scanning
with the
or
button.
Exit diagnosis level.
.
3. Press
The following values can be scanned depending on the system equipment
installed:
Display
Meaning
Notes
08888
Scan 0
Only in conjunction with LON
communication module; see
page 94
18888
Scan 1
Only in conjunction with LON
communication module; see
page 94
28888
Scan 2
Only in conjunction with LON
communication module; see
page 94
3
65 °C
Set-point boiler water temperature (effective set-point value
including boiler protection)
–––
h 70 °C
48888
5 55 °C
Maximum request temperature
–––
8230
See page 95
Set-point domestic hot water
temperature
°C Maximum flue gas
temperature
–––
See coding address ”1F”; can
be reset to the actual value by
pressing D
Boiler coding card
See page 112
Scan b/d
See page 95
Scan L
See page 96
Scan o
See page 96
5351 338 v1.6
c1010
b 8d8
l8888
o8888
Scan 4
93
Scanning service information
Temperatures, Boiler Coding Cards and Scans
(continued)
Scan 0
0
8
8
8
8
0
1
0
to
9
0
0
to
9
0
to
F
SNVT configuration
Auto
Tool
Software version
Communication coprocessor
LON participant number
Scan 0
Scan 1
1
8
0
to
F
1
8
0
to
F
8
8
0
to
F
0
to
F
Node address
System number
(only with self-binding)
Subnet address
Scan 1
2
8
0
to
9
2
94
Scan 2
8
0
to
9
8
8
0
to
F
0
to
F
Number of LON
participants
Software version
LON communication module
5351 338 v1.6
Scan 2
Scanning service information
Temperatures, Boiler Coding Cards and Scans
(continued)
Scan 4
4
8
8
8
8
0
to
F
1
or
2
0
to
F
Software version
Control unit
Software version
Programming unit
System type
Free
4
Scan 4
Scan b/d
b
8
8
d
8
0
1
2
3
4
5
6
d
0
1
2
Free
Scan d
Burner
OFF
1st stage/basic load
2nd stage/full load
Scan b
5351 338 v1.6
b
Isolation valve
Closed
Preheating
Closing
Regulating
Opening
Open
Run-on
95
Scanning service information
Temperatures, Boiler Coding Cards and Scans
(continued)
Scan L
l
8
8
0
or
1
Free
L
Scan
8
8
0
to
9
0
to
9
8
8
Output reduction
(0 to 100 %; 0 = OFF)
Scan L
o
o
8
8
Free
0
to
F
0
to
F
Free
Equipment identification code
5351 338 v1.6
o Scan o
96
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
or
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
Notes
0
01
LON participant number
3
5
65
50
°C Boiler temperature
Only displayed if LON
communication module is
connected
––
°C DHW tank temperature
(1st DHW tank temperature
sensor)
Only displayed if DHW tank
temperature sensor is
connected
5o 45 °C
6
55
8 190
9
60
Y
63572
DHW tank temperature
(2nd DHW tank temperature
sensor)
°C Return temperature
17A (1st return temperature
sensor)
°C Flue gas temperature
°C Return temperature
17B (2nd return temperature
sensor)
Burner hours run
1st stage
h
YY
09572
YYY
Burner hours run
2nd stage
The hours run can be reset to
”0” by pressing D. The hours
run displayed are approximate
values only
Burner starts
The number of burner starts
can be reset to ”0” by
pressing D
5351 338 v1.6
30417
h
Only displayed if DHW tank
temperature sensor is
connected
Only displayed if return
temperature sensor is
connected
Only displayed if flue gas
temperature sensor is
connected
Only displayed if return
temperature sensor is
connected
The hours run can be reset to
”0” by pressing D. The hours
run displayed are approximate
values only
97
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” and ”23”
(see page 104) are reached, one of the
following displays flashes on the
programming unit:
Meaning
Display
a 245
35510 h
°C Max. flue gas
temperature reached
Number of burner hours
run reached
12 u
Time interval
(e.g. 12 months)
reached
1. Scan the service messages with the
or
button.
2. Press
.
The service display is turned off.
Please note:
An acknowledged service message
can be displayed again by pressing
(for approx. 3 seconds).
After carrying out maintenance
1. Reset coding ”24: 1”
(see page 104) to ”24: 0”.
Please note:
If coding address ”24” is not reset,
the service display will re-appear on
Monday morning.
2. If necessary:
Press
.
Reset burner hours run and
number of burner starts with
the button.
Press
.
See ”Temperatures, boiler coding
cards and scans” on page 77.
98
See ”Scanning operating status
information” on page 81.
5351 338 v1.6
3. If necessary:
Press and
simultaneously for approx.
4 seconds.
Reset maximum flue gas
temperature (8) to the actual
value by pressing .
Press
.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Please note:
Retrieve fault codes from the fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3. Establish the action required in the table
4. Correct the fault
5351 338 v1.6
Correction
99
Troubleshooting
Diagnosis
Faults with fault display on the programming unit
The red fault indicator 2 flashes whenever there is a fault.
1234567
When a fault message is transmitted,
a fault code flashes in the display 1
of the programming unit.
The meaning of the fault code is
explained in the table on page 101
onwards.
Other fault codes which may be
stored can be called up by pressing
or
button.
the
The fault can be acknowledged by
pressing
.The fault message in
the display 1 is blanked out; the
red fault indicator 2 continues to
flash. The central fault indicator
connected to plug gÖ is switched
off.
Fault symbol
Fault code
Fault number
If an acknowledged fault is not
rectified within 24 hours, the fault
message will re-appear in the
display.
Vitotronic 100 as error manager
A fault on another LON participant is
displayed as shown:
Fault symbol
LON participant number of the unit
with the fault
”EE” = External fault
Fault is displayed.
5351 338 v1.6
To retrieve an acknowledged
fault message
for approx. 2 seconds;
Press
select the acknowledged fault by
or
button.
pressing the
100
Troubleshooting
Diagnosis
(continued)
Faults with fault display on the programming unit (continued)
Fault
code in
display
Behaviour of system
Cause of fault
Action
30
Burner is switched on and off by
the adjustable high limit
Short circuit
Boiler temperature sensor
Check boiler temperature sensor (see
page 42)
38
Burner is switched on and off by
the adjustable high limit
Open circuit
Boiler temperature sensor
Check boiler temperature sensor (see
page 42)
50
DHW pump ON:
set-point boiler temperature =
set-point DHW tank temperature,
priority controls are cancelled
or
In conjunction with DHW heating:
Tank heating is switched on and off
by Tank temperature sensor 2
Short circuit
DHW tank temperature sensor 1
Check DHW tank temperature sensor
(see page 43)
51
In conjunction with DHW heating:
Tank heating is switched on and off
by Tank temperature sensor 1
Short circuit
DHW tank temperature sensor 2
Check DHW tank temperature sensor
(see page 43)
58
DHW pump ON:
set-point boiler temperature =
set-point DHW tank temperature,
priority controls are cancelled
or
In conjunction with DHW heating:
Tank heating is switched on and off
by Tank temperature sensor 2
Open circuit
DHW tank temperature sensor 1
Check DHW tank temperature sensor
(see page 43)
59
In conjunction with DHW heating:
Tank heating is switched on and off
by DHW tank temperature sensor 1
Open circuit
DHW tank temperature sensor 2
Check DHW tank temperature sensor
(see page 43)
60
No output reduction
Return control open
Boiler with maximum temperature
Short circuit
Temperature sensor aJA
Check temperature sensor
(see page 44)
68
No output reduction
Return control open
Boiler with maximum temperature
Open circuit
Temperature sensor aJA
Check temperature sensor
(see page 44)
70
Shunt pump ON continuously
Short circuit
Temperature sensor aJB
Check temperature sensor
(see page 44)
Open circuit
Temperature sensor aJB
Check temperature sensor
(see page 44)
In conjunction with DHW heating:
Mixing valve of primary circuit
closed, no domestic hot water
heating
78
Shunt pump ON continuously
5351 338 v1.6
In conjunction with DHW heating:
Mixing valve of primary circuit
closed, no domestic hot water
heating
101
Troubleshooting
Diagnosis
(continued)
Faults with fault display on the programming unit (continued)
Behaviour of system
Cause of fault
aa
Controlled operation
Therm-Control configuration
error:
plug aJA of
Therm-Control temperature
sensor not inserted
Insert plug aJA
On Vitocrossal:
Check that coding ”0d: 0” is set.
ab
Controlled operation, DHW tank
may be cold
DHW heating
configuration error:
Coding ”55: 3” is set, but
plug aJB is not inserted
and/or
coding ”4C: 1” and ”4E: 1”
not set
Insert plug aJB and check coding
aCc
Controlled operation
Return temperature sensor
configuration error:
Coding ”0C: 1” is set, but
plug aJA is not inserted
and/or
coding ”4E: 0” is not set
Insert plug aJA and check coding
aCd
Controlled operation
Butterfly valve
configuration error:
Coding ”0C: 2”, ”0C: 3” or
”0C: 4” is set,
and
coding ”4E: 1” is set
If butterfly valve is installed:
Set coding ”4E: 0”
If no butterfly valve is installed:
Set coding ”0C: 0” or ”0C: 1”
b0
Controlled operation
Short circuit
Flue gas temperature sensor
Check flue gas temperature sensor
(see page 45)
b1
Controlled operation
Communication error
Programming unit
Check connections, if necessary
replace programming unit
b4
Emissions test mode
Internal fault
Check electronics board
b5
b6
Controlled operation
Internal fault
Check electronics board
Operation at constant temperature
Invalid hardware code
Check the control software circuit
board and confirm the coding address:
- Enter coding 2 (see page 101
for instructions).
- Change code 8A to 176.
- Confirm coding 92:160
b7
Boiler controlled on basis of
adjustable high limit
Internal fault
Boiler coding card
Insert boiler coding card or replace
if defective (see page 35)
b8
Controlled operation
Open circuit
Flue gas temperature sensor
Check flue gas temperature sensor
(see page 45)
bf
Controlled operation
Incorrect LON communication
module
Replace LON communication
module
c1
Boiler cools down
External safety equipment
Check connection of plug
aBÖ
Check external safety
equipment
102
Action
5351 338 v1.6
Fault
code in
display
Troubleshooting
Diagnosis
(continued)
Faults with fault display on the programming unit (continued)
Fault
code in
display
Behaviour of system
Cause of fault
Action
c4
Control mode
Faulty communication with Input
Module
0 to 10 V
Check connections and
cables/leads; replace Input
Module, if required
(see page 110)
Without Input Module:
Set coding 9d: 0
c8
Boiler cools down
Error
Low water indicator
Check water level of system,
reset low water indicator
c9
Boiler cools down
Error
Maximum pressure limiter
Check system pressure, reset
maximum pressure limiter
ca
Boiler cools down
Error
Minimum pressure limiter or
maximum pressure limiter 2
Check system pressure, reset
minimum or maximum pressure
limiter
cb
Boiler cools down
Error
Additional fixed high limit or limit
thermostat or flue gas damper
Check system pressure, reset
fixed high limit or flue gas
damper
cd
Controlled operation
Communication error
Vitocom
Check connections and
Vitocom
cEe
Controlled operation
Communication error
Plug-in adaptor for external
safety equipment
cf
Controlled operation
Error
LON communication module
Replace communication
module
d1
d4
Boiler cools down
Burner fault
Check burner
Boiler cools down
Fixed high limit has operated
d6
Controlled operation
d7
Controlled operation
d8
Controlled operation
e0
Controlled operation
Fault at ”DE1” in the plug-in
adaptor for external safety
equipment
Fault at ”DE2” in the plug-in
adaptor for external safety
equipment
Fault at ”DE3” in the plug-in
adaptor for external safety
equipment
Open circuit
LON communication module
Check fixed high limit reset to
25° C (+/- 5.0° C)
Cooler than the high limit set
Check connection at inputs
”DE1” to ”DE3”
5351 338 v1.6
Check connection
103
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.
1234567
and
simultaneously
1. Press
for approx. 2 seconds.
Scanning of error history is
activated.
2. Access the individual fault codes
or
button.
by pressing the
All stored fault codes can be
deleted by pressing .
Sequence of
stored fault
codes
Fault code
1
Last (most recent)
fault code
..
.
..
.
10
.
Scanning of error history is
terminated.
5351 338 v1.6
3. Press
Last fault code
104
Functional description
Boiler Temperature Control
Brief description
The boiler water temperature is
controlled by switching the burner on
and off.
The set-point boiler water temperature
value is determined by the set-point
supply temperature values of the boiler
circuit (A1), the heating circuits with
mixing valve (from Vitotronic 050) and
the set-point supply temperature value
preset via coding address ”9b” as well
as the set-point domestic hot water
temperature, and is dependent on the
boiler and the heating and control
facilities installed.
In conjunction with Therm-Control:
The set-point boiler water temperature
is increased when the temperature falls
below the set-point value on the sensor
of the Therm-Control.
Coding addresses which influence
the boiler temperature control
02 to 06, 08 to 0b, 13 to 1C.
Upper limits of control range
Fixed high limit FHL
110°C / 230°F, can be adjusted to
100°C / 212 or 230°F
Adjustable high limit AHL
95°C/ 203°F, can be adjusted to
100°C / 212°F
Electronic maximum limit
Setting range: 20 to 127°C /
68 to 261°F
The maximum limit for the boiler
water temperature is defined in
coding address ”06”.
Lower limit of control range
The control unit regulates the boiler
water temperature in normal
operation and in the frost protection
mode according to the boiler
concerned (boiler coding card).
Functions
The boiler water temperature is
measured via a multiple sensor well by
three sensors separately:
Fixed high limit FHL
(liquid expansion)
Adjustable high limit AHL
(liquid expansion)
Boiler temperature sensor BTS
(change in resistance PT 500)
Control sequence
Boiler temperature rises
The switch-off point of the burner is
defined by the switch-off differential
(coding address ”13”).
5351 338 v1.6
Boiler temperature falls
The burner override signal is set for a
boiler water temperature setpoint value
of –2°C / -4°F, and the burner starts
its own monitoring program. Depending
on the range of additional control
facilities and the method of firing,
burner override can be delayed by a
few minutes.
105
Functional description
Heating Circuit Control
Brief description
The supply temperature of the boiler
circuit (A1) corresponds to the boiler
water temperature.
Coding addresses which influence the
heating circuit control
55, 56, 58, 5A to 63, 6A, 6b.
Functions
The boiler circuit (A1) is dependent on
the boiler water temperature and its
control range limits.
Upper limit of control range
Electronic maximum limit
Setting range: 1 to 127°C /
34 to 261°F.
Change via coding address ”C6”.
Lower limit of control range
Electronic minimum limit
Setting range: 1 to 127°C /
34 to 261°F.
Change via coding address ”C5”.
Domestic hot water temperature
With priority control:
While the DHW tank is being
heated, the set-point supply
temperature value is set to
0°C / 32°F.
Without priority control:
The heating circuit control
continues to operate as normal
with the setpoint value unchanged.
DHW Tank Temperature Control
Brief description
The DHW tank temperature control is a
constant value control. It operates on
the basis of switching the DHW pump
on and off.
The switching differential is ±2.5°C /
4.5°F.
During DHW tank heating, a constant
maximum boiler water temperature is
set (20°C / 36°F above the set-point
DHW tank temperature, variable via
coding address ”60”) and space
heating is switched off (DHW tank
priority control optional).
Heating with the additional function
takes place daily at the time of the
1st domestic hot water heating
period.
Additional control facilities
The domestic hot water supply
can be blocked and released via
change-over of the heating program.
Set-point domestic hot water
temperature
The set-point domestic hot water
temperature can be set in the range of
10 to 60°C / 50 to 140°F. The
setpoint range can be extended to
95°C / 203°F via coding address
”56”.
System with DHW heating
The functions described above also
apply in conjunction with DHW
heatings.
Functions
Additional function for domestic hot
water heating
For temporarily increasing the DHW
tank temperature at selectable intervals
→ this provides additional assurance
that bacteria are eliminated.
This function is activated when a
second DHW setpoint value is selected
via coding address ”58” and a time is
selected via coding address ”63”.
106
Set the following codings:
”4C: 1”, ”4E: 1”, ”55: 3”.
5351 338 v1.6
Frost protection function
If the domestic hot water temperature
falls below 10°C / 50°F, the domestic
hot water DHW tank is heated to
20°C / 68°F.
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,
selectable via coding address ”59”)
The set-point boiler water temperature
is set 20°C / 36°F higher than the
DHW temperature set-point value
(selectable via coding address ”60”).
(Set-point value +2.5°C / 4.5°F)
The boiler water temperature set-point
value is reset to the value
determined by the set-point supply
temperature of the boiler circuit.
The DHW pump is switched on
immediately (Coding ”61: 1”).
When the DHW tank has been
heated up, the DHW pump continues
to run (coding ”62: 10”) until
- the temperature difference
between the boiler water and
domestic hot water is less than
7°C / 13°F or
- the set-point boiler water
temperature selected through the
set-point supply temperature of the
boiler circuit is reached
or
- the set-point domestic hot water
temperature is exceeded by
5°C / 9°F.
The max. run-on time is 15 minutes
(selectable via coding address ”62”).
Boiler temperature-dependent switching
of the DHW pump
(Coding ”61: 0”):
The circulation pump is switched on
when the boiler water temperature is
7°C / 13°F higher than the domestic
hot water temperature.
5351 338 v1.6
DHW pump without run-on time
(Coding ”62: 00”):
The circulation pump is switched off
immediately.
With adaptive DHW tank heating
(Coding ”55: 1”):
Adaptive DHW tank heating takes
into account the rate at which the
temperature increases during
domestic hot water heating.
It also takes into account whether
the boiler must supply heat for space
heating purposes after heating up the
DHW tank or whether the residual
heat of the boiler should be
transferred to the DHW tank.
The control unit determines the
switch-off time of the burner and the
circulation pump accordingly so that
the set-point domestic hot water
temperature is not substantially
exceeded after DHW tank heating is
completed.
107
Additional information
Overview
Page
Technical Data
105
System Components
Line voltage motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Low-voltage motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Power supply unit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Electronics board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Optolink/override switch board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Programming unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
LON communication module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Boiler coding card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
TUV button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fixed high limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Adjustable high limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Input module 0 to 10V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Resetting codings to the factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Coding 1
Call up coding level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Codings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Coding 2
Call up coding level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Reset codings to factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Overview of all codings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Wiring Diagrams
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Low-voltage motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Line voltage motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
126
5351 338 v1.6
Parts List
GCI Series
108
Additional information
Technical Data
Rated voltage:
Rated frequency:
Rated actual:
Power
consumption:
Protection
class:
Degree of
protection:
120 V~
60 Hz
2 x 6 A~
Ambient
temperature
during
operation:
10 W
I
IP 20 D to EN
60 529, to be
guaranteed by
mounting/integration
during
storage and
transport:
0 to 40°C /
32 to 104°F
For use in boiler
rooms (normal
ambient conditions)
–20 to 65°C /
-4 to 149°F
Relay outputs at 120 V~ for
control
output sÖ:
2 FLA, 120 VAC*1
circulation pump
for heating the
DHW tank sA: 2 FLA, 120 VAC*1
shunt pump or
boiler circuit
pump sL:
2 FLA, 120 VAC*1
central fault
indicator gÖ:
2 FLA, 120 VAC*1
boiler isolation
valve gS:
0.1 FLA, 120 VAC*1
or
return valve
0.15 FLA, 24 VAC
burner
connection fA: 4 FLA 120 VAC
connection lÖ:
– 2-stage:
0.5 FLA, 120 VAC
– modulating: 0.1 FLA, 120 VAC
*1
Total max. 6 A 120 VAC
System Components
Line voltage motherboard, Part No. 7165 792
The motherboard contains:
relays and outputs for activating
the pumps, the control elements
and the burner
plug-in location for power supply
unit board and boiler control section.
Low-voltage motherboard, Part No. 7820 290
5351 338 v1.6
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.
109
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. Make a note of codings and settings
on the control unit.
2. Replace the board.
3. Set coding ”8A:176” and set
cod-ing address ”92” (not listed in
the overview) to ”92:160”.
Optolink/override switch board, Part No. 7820 165
The circuit board contains:
Operating status indicator
Fault indicator
Optolink laptop interface
Override switch
Override switch for flue gas
measurements with the boiler operated
with constant boiler water temperature
for a short time.
5351 338 v1.6
The following functions are triggered in
the ”h” setting:
The burner is switched on
(this can be delayed if the system
incorporates a fuel preheater or flue
gas damper)
All pumps are switched on
The boiler water temperature is
controlled by the adjustable high limit
”R”.
110
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
heating system switch
TUV button
LON communication module, Part No. 7172 173
Accessory
LON
LON
A
LON
LON
A
LON
D
LON
A
The communication module is inserted
in the control unit.
Interruption of communication is
indicated.
D
1 terminal resistor is inserted on each
of the first and last control unit.
5351 338 v1.6
C
B
B
C
A Control unit or Vitocom
B Connecting cable for data transfer
between the control units (part of
standard delivery or accessory)
C Terminal resistor,
(Part No. 7143 497, see Vitotronic
050 or Vitotronic 333)
D Plug-in locations for B and C
111
Additional information
System Components
(continued)
Boiler coding card
Vitotronic 200
in conjunction with
Boiler coding
card
Part No.
Vitocrossal 300, Type CT3
Vitorond 200, Type VD2/VD2A
1040
7820 144
1020
7820 142
Vitocrossal 200, Type CM2
1041
7820 145
Fuses
F1: 6.3 A, 250 V for protecting
the control elements, pumps and
electronics.
Mounting location: see drawing.
F2: T6.3 A, 250 V for protecting
the burner.
Mounting location: see drawing.
F1
5351 338 v1.6
F2
112
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
or
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.
Electromechanical temperature switch based on the liquid expansion principle
with interlock
Intrinsically safe; interlocking also takes place if the capillary tube is leaking or
if ambient temperatures are below –10°C / 14°F
Limits the boiler water temperature to the maximum permissible value by
cutting out and interlocking
Can be adjusted with the slotted screw A at the rear of the unit to 110 and
99 °C / 230 and 210 °F (cannot be reset to 120°C / 248 °F once adjusted)
Reset unit by pressing the reset button ”E” on the front of the programming
unit if the temperature has fallen approx. 15 K below the shut down temperature
Central fastening M 10, capillary 3600 mm long
Tests:
Electrical to VDE 0701 standard
Functional check via TEST button
Adjustable high limit, Part No. 7817 531
Type TR 55.18029.020, make: EGO, DIN TR 110397
or
EM-1-V-TK/b1 60002846, make: Juchheim, DIN TR 77798
The adjustable high limit has a factory setting of 95°C / 203°F
Electromechanical temperature switch based on the liquid expansion principle
Controls the maximum boiler water temperature (e.g. in emissions test mode)
Can be adjusted to 100 and 110°C / 212 and 230°F by altering the setting
of the stop dial or by removing the cams
5351 338 v1.6
IMPORTANT
Set the lower limit at least 20°C / 36°F higher than the domestic hot water
temperature, the upper limit at least 15°C / 27°F lower than the fixed high limit.
Adjusting shaft 6 mm / 0.27 inches, flat topped
Adjusting knob pushed onto shaft from front
Capillary 3600 mm / 141.7 inches long
Sensor 3 mm / 0.1inches thick, 180 mm / 7.1inches long
Tests:
Electrical to VDE 0701 standard
Functional check via emissions test mode
113
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).
24V
5V
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
or
to signal reduced mode and regulate a heating circuit pump to a lower speed.
Electronics
B
F1
50mA
(slow)
ON
OFF 1 2 3 4
L1
N
S Ö P
1 2 3
1 2 3
40
_
120 VAC
A
fÖ
aVF
aVG
aBJ
157
Power connection
0 to 10VDC input
KM BUS to control unit
Potential free output contact
144
145
A Power supply
(provide disconnect if required by
code)
B DIP switch (see table)
Function
DIP switch
1 to 3:
1:
2:
3:
4:
4:
+
OFF
ON
ON
ON
ON
OFF
Switch for pre-set value
Reduced mode – system circuit A1
Reduced mode – mixing valve circuit M2
Reduced mode – mixing valve circuit M3
Pre-set value default 10 to 100˚C / 50 to 212˚F
Pre-set value default 30 to 120˚C / 86 to 248˚F
Please note:
Amongst switches 1 to 3, only one switch may be set to ON.
1234567
1. Press w and rw simultaneously
for approx. two seconds, until the
first two arrows appear in the
display.
2. Press D.
114
5351 338 v1.6
Resetting codings to the factory setting
Additional information
Coding 1
Call up coding level 1
1. Press and
simultaneously for
approx. 2 seconds.
Access coding level 1.
The first arrow appears in the
display.
2. Call up the required coding address
or
button;
with the
press
to confirm.
Address flashes.
3. Change the value with the
or
button; press
to confirm.
The value is stored and stops flashing
for approx. 2 seconds. Then the
address flashes and further addresses
can now be selected with the
or
button.
4. Press and
simultaneously for
approx. 1 second.
Exit coding level 1.
Value flashes.
Codings
Coding as per Function
factory setting
Address: Value
Possible change
Address:Value
00: 1
System
type
System circuit A1
without domestic hot water
heating
00: 2
System circuit A1
with domestic hot water heating
01: 1
System
type
Single-boiler system
01: 2
Multi-boiler system with cascade control
via LON BUS (e.g. Vitotronic 333, Type
MW1)
01: 3
Multi-boiler system with cascade control
via switch contacts (input aVD and aVH)
or 0-10V input module
Boiler/
burner
Operation with two-stage
burner
02: 0
Operation with single-stage burner
02: 2
Operation with modulating burner
03: 0
Boiler/
burner
Gas-fired operation
03: 1
Oil-fired operation
(coding cannot be reset)
05: 70
Burner
(mod.)
Burner curve
05: 0
Burner curve linear
05: 1
to
05: 99
Burner curve not linear:
06: 20
to
06:127
Maximum boiler water temperature limit
variable between
20 and 127°C / 68°F and 261°F
02: 1
5351 338 v1.6
New coding
06: 87
Boiler/
burner
Max. limit of boiler water
temperature set to
87°C / 189°F
Partial output in kW (at g of the
Operating
time of the actuating drive)
x100%
Max. output in kW
= Partial output in %
115
Additional information
Coding 1 (continued)
Codings (continued)
Coding as per Function
factory setting
Address: Value
New coding
Possible change
Address:Value
07: 1
Boiler
Boiler sequence number in multiboiler system (in conjunction with
coding address ”01”)
07: 2
to
07: 4
Boiler sequence number in multi-boiler
system (in conjunction with coding
address ”01”)
08:*1
Burner
(mod.)
Max. output of burner in kW
08: 0
to
08: 99
Maximum output variable from
0 to 99 kW;
1 increment = 1 kW
09:*1
Burner
(mod.)
Max. output of burner in kW
09: 0
bis
09:199
Maximum output variable from
0 to 19900 kW:
1 increment = 100 kW
0A:*1
Burner
(mod.)
Basic output of burner in %
0A: 0
to
0A:100
Basic output in kW
x100% =
Max. output in kW
Basic output in %
15: 10*2
Burner
(mod.)
Operating time of actuating drive
15: 5
to
15:199
Operating time variable
from 5 to 199 seconds
40:125
General
Operating time of actuating drive,
boiler isolation valve, 3-port mixing
valve or mixing valve motor in
conjunction with return
temperature control 125 minutes
40: 5
to
40:199
Operating time adjustable
from 5 to 199
77: 1
General
LON participant number
77: 2
to
77: 99
LON participant number
selectable from 1 to 99
Please note:
Each number may be assigned once only.
*1 The
factory setting is determined by the boiler coding card.
This setting is matched to the Vitocrossal.
5351 338 v1.6
*2
116
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.
1234567
1234567
and
simultaneously
1. Press
for approx. 2 seconds;
press
to confirm.
Access coding level 2.
The first two arrows appear in
the display.
2. Select the required coding address
with the
or
button;
to confirm.
press
Coding address flashes.
3. Change the value with the
button;
to confirm.
press
The value is stored and stops
flashing for approx. 2 seconds.
Then the address flashes and
further addresses can now be
selected with the
or
button.
or
4. Press
and
simultaneously
for approx. 1 second.
Exit coding level 2.
1. Press
and
simultaneously
for approx. 2 seconds.
Access coding level 2.
Reset codings to factory settings
1234567
2. Press
The codings are reset to their
factory settings. The display
changes and shows the boiler
water temperature.
.
Overview of all codings
5351 338 v1.6
Coding as per Function
factory setting
Address: Value
New coding
Possible change
Address: Value
00: 1
System
type
System circuit A1 without
domestic hot water heating
00: 2
System circuit A1
with domestic hot water heating
01: 1
System
type
Single-boiler system
01:
Multi-boiler system with cascade
control via LON BUS (e.g.
Vitotcontrol-S, VD2/CT3, Model MW1)
01: 3
Multi-boiler system with cascade
control via switch contacts
02: 0
Operation with single-stage burner
02: 2
Operation with modulating burner
02: 1
Boiler/
burner
Operation with two-stage
burner
117
Additional information
Coding 2
(continued)
Overview of all codings (continued)
Function
New coding
Possible change
Address: Value
03: 0
Boiler/
burner
Gas-fired operation
03: 1
Oil-fired operation
(coding cannot be reset)
04:*1
Boiler/
burner
Switching differential
04: 0
Switching differential 4°C / 7°F
Burner
Coding as per
factory setting
Address: Value
ON
Time
OFF
Setpoint
Low
heat demand
Medium
heat demand
High
heat demand
Switching differential heat demandcontrolled
ERB50 function
Values from 6 to 12°C / 11 to 22°F are
set, depending on the heat demand.
Burner
04: 1
ON
Time
OFF
Setpoint
Low
heat demand
High
heat demand
ERB80 function
Values from 6 to 20°C / 11 to 36°F are
set, depending on the heat demand.
Burner
04: 2
Medium
heat demand
ON
Time
OFF
Setpoint
Low
heat demand
Medium
heat demand
High
heat demand
05: 70
*1 The
118
Burner
(mod.)
Burner curve
factory setting is determined by the boiler coding card.
05: 0
Burner curve linear
05: 1
to
05: 99
Burner curve not linear
Partial output in kW (at g of the
Operating
time of the actuating drive)
x100 %
Max. output in kW
= Partial output in %
5351 338 v1.6
The heat demand-controlled switching
differential takes into account the boiler
load. The switching differential, i.e. the
burner operating time, is varied in
relation to the actual heat demand.
Additional information
Coding 2 ((continued)
Overview of all codings (continued)
Coding as per Function
factory setting
Address: Value
Possible change
06: 87
Boiler/
burner
Max. limit of boiler water
temperature set to
87°C / 189°F
06: 20
to
06:127
Maximum boiler water temperature limit
variable between 20 and 127
07: 1
Boiler
Boiler sequence number in multiboiler system (in conjunction with
coding address ”01”)
07: 2
to
07: 4
Boiler sequence number in multi-boiler
system
(in conjunction with coding address ”01”)
08:*1
Burner
(mod.)
Max. output of burner in kW
08: 0
to
08: 99
Maximum output variable from
0 to 99 kW;
1 increment = 1 kW
09:*1
Burner
(mod.)
Max. output of burner in kW
09: 0
to
09:199
Maximum output variable from
0 to 19 900 kW;
1 increment = 100 kW
0A:*1
Burner
(mod.)
Basic output of burner in %
0A: 0
to
0A:100
Basic output in kW
x100% =
Max. output in kW
Basic output in %
0C: 5
Boiler
Boiler isolation valve controlled on 0C: 0
a modulating basis independently 0C: 1
of the set-point boiler water
0C: 2
temperature
0C: 3
Without function
Continuous return temperature control
Boiler isolation valve time-controlled
Boiler isolation valve temperature-controlled
0C: 4
Boiler isolation valve controlled on a
modulating basis as a function of the set
point boiler water temperature
With Therm-Control, effective for
boiler isolation valve (function not
active if ”0C: 1” is coded)
0d: 0
Without Therm-Control
0d: 1
With Therm-Control, effective for mixing
valve of heating circuits connected
downstream
Boiler/
burner
Switch-off differential in °C / °F
The burner is switched off when
the boiler water temperature rises
above the set-point value
13: 0
Without switch-off differential
13: 2
to
13: 20
Switch-off differential variable from
2 to 20°C / 4 to 36°F
14:*1
Burner
Minimum operating time in
minutes
14: 0
to
14: 15
Minimum operating time variable
from 0 to 15 minutes
15: 10*2
Boiler/
burner
(mod.)
Operating time of actuating drive
10 seconds
15: 5
to
15:199
Operating time variable
from 5 to 199 seconds
16:*1
Burner
(mod.)
Mod. burner offset in °C / °F
Temporary reduction of the boiler
set-point value after burner start
16: 0
to
16: 15
Offset during optimized start-up
adjustable from 0 to 15°C / 0 to 27°F
1A:*1
Burner
(mod.)
Optimized start-up in minutes
1A: 0
to
1A: 60
Duration of optimized start-up
adjustable from 0 to 60 minutes
0d: 2
13:*1
5351 338 v1.6
New coding
Address:
Value
*1
*2
Boiler
The factory setting is determined by the boiler coding card.
These settings are matched to the Vitocrossal.
119
Additional information
Coding 2
(continued)
Overview of all codings (continued)
New coding
Address:
Value
Possible change
1b: 60
Burner
Time from ignition of burner to
start of control 60 seconds
1b: 0
to
1b:199
Control delay adjustable
from 0 to 199 seconds
1C:120
Burner
Start delay 120 seconds (only
selectable if no operating signal
”B4” is available at plug fA of
the burner)
1C: 1
to
1C:199
Start delay adjustable
from 1 to 199 seconds
1F: 0
Boiler
No monitoring of flue gas
temperature
1F: 1
to
1F: 50
With flue gas temperature sensor
connected: When the flue gas
temperature exceeds the
preselected limit value (selectable
in the range from 10 to 500°C /
50 to 932°F), the service display
appears;
1 increment = 10°C / 50°F
21: 0
Boiler/
burner
No service display for burner
21: 1
to
21:100
The number of burner hours run
before the service display appears
can be set between 100 and
10000 hours; 1 increment = 100
hours
23: 0
Boiler/
burner
No time interval for burner
maintenance
23: 1
to
23: 24
Time interval variable between
1 and 24 months
24: 0
Boiler/
burner
No service display
24: 1
The service display appears
(address is set automatically and
must be reset manually after
maintenance has been carried out)
26: 0
Boiler/
burner
(2-stage)
Fuel consumption of burner
(1st stage); not metered if
”26: 0” and ”27: 0” are coded
26 : 1
to
26 : 99
Input from 0.1 to 9.9;
1 increment = 10 litres or gallons/hour
27: 0
Boiler/
burner
(2-stage)
Fuel consumption of burner
(1st stage); not metered if
”26: 0” and ”27: 0” are coded
27: 1
to
27:199
Input from 10 to 1990;
1 increment = 10 litres or gallons/hour
28: 0
Boiler/
burner
No intermittent ignition of burner
28: 1
The burner is automatically
switched on for 30 seconds
after 5 hours
29: 0
Boiler/
burner
(2-stage)
Fuel consumption of burner
29: 1
(2nd stage); not metered if ”29: 0” to
and ”2A: 0” are coded
29: 99
Input from 0.1 to 9.9;
1 increment = 0.1 litre or gallon/hour
2A: 0
Boiler/
burner
(2-stage)
Fuel consumption of burner
(2nd stage); not metered if
”29: 0” and ”2A: 0” are coded
2A: 1
to
2A:199
Input from 10 to 1990;
1 increment = 10 litres or gallons/hour
2b: 5
General
Maximum preheating time of
boiler isolation valve 5 minutes
2b: 0
No preheating time
2b: 1
to
2b: 60
Preheating time selectable from
1 to 60 minutes
120
5351 338 v1.6
Coding as per Function
factory setting
Address: Value
Additional information
Coding 2
(continued)
Overview of all codings (continued)
Coding as per Function
factory setting
Address: Value
2C: 5
General
New coding Possible change
Address:
Value
Maximum run-on time of boiler isolation
valve 5 minutes
2C: 0
No run-on time
2C: 1
to
2C: 60
Run-on time adjustable
from 1 to 60 minutes
2d: 0
Boiler
Shunt pump ON only when requested
2d: 1
Shunt pump ON continuously
40:125
General
Operating time of actuating drive, boiler
isolation valve, 3-port mixing valve or
mixing valve motor in conjunction with
return temperature raising facility
125 seconds
40: 5
to
40:199
Operating time adjustable
from 5 to 199 seconds
4A: 0
General
Plug aJA not installed
4A: 1
Plug aJA installed
(e.g. temperature sensor of
Therm-Control);
automatically recognized
4b: 0
General
Plug aJB not installed
4b: 1
Plug aJB installed
(e.g. temperature sensor T2);
automatically recognized
4C: 2
General
Connections at plug sÖ A1:
Therm-Control switch contact
4C: 1
Primary pump of DHW heating
4C: 3
Circulation pump of flue gas/water
heat exchanger
Connections at plug sL:
Shunt pump
4d: 2
Boiler circuit pump
4d: 3
Boiler circuit pump with boiler
isolation valve function
4d: 1
4E: 0
4F: 5
General
General
General
Connections at plug gS:
Boiler isolation valve or 3-port mixing
4E: 1
valve for return temperature raising facility
3-port valve of DHW heating
Shunt pump, boiler circuit pump or
distributor pump with 5 minutes run-on
time
4F: 0
No pump run-on
4F: 1
to
4F: 60
Run-on time adjustable
from 1 to 60 minutes
Without solar control unit
54: 1
With Vitosolic 100;
will be recognised automatically
54: 2
With Vitosolic 200;
will be recognised automatically
5351 338 v1.6
54: 0
General
121
Additional information
Coding 2
(continued)
Overview of all codings (continued)
Coding as per Function
factory setting
Address: Value
55: 0
56: 0
DHW
DHW
New coding Possible change
Address:
Value
Tank heating,
differential +/- 2.5°C / 4.5°F
Setting range of domestic hot water temperature 10 to 60°C / 50 to 140°F
55: 1
Adaptive tank heating active
(takes into account the rate at
which the tank temperature
increases during domestic hot
water heating)
55: 2
Tank temperature control with 2
tank temperature sensors
55: 3
DHW heating circuit temperature
control (sensor 17B if used in
conjunction with mixing valve and
a plate heat exchanger)
56: 1
Setting range of domestic hot
water temperature 10 to 95°C /
50 to 203°F
IMPORTANT
Observe max. DHW temperature
Adjust adjustable high limit ”R”
58: 0
DHW
Without additional function for domestic
hot water heating
58: 1
to
58: 95
Input of a 2nd set-point DHW
temperature value; variable between
1 and 95°C / 34 and 203°F (note
coding address ”56”).
¨ CAUTION
Set the adjustable high limit ”R”
to a value which is at least 10°C/
18°F higher than the maximum
domestic hot water temperature
( the temperature which is reached
by activating the additional function)
The temperature set on the
adjustable high limit ”R” must not
exceed the maximum permissible
tank temperature
See installation
instructions for the DHW
tank concerned
59: 0
DHW
Tank heating:
Switch-on point – 2.5°C / 4.5°F
Switch-off point + 2.5°C / 4.5°F
59: 1
to
59: 10
Switch-on point variable between 1
and 10°C / 18°F below set point
value
5A: 0
DHW
Without function
5A: 1
Supply temperature request of DHW tank
60: 20
DHW
When domestic hot water is being
heated, the boiler water temperature is a
maximum of 20°C / 36°F higher than the
set-point domestic hot water temperature
60: 10
to
60: 50
Differential between boiler water
temperature and set-point DHW
temperature adjustable between 10
and 50°C / 18 and 90°F
61: 1
DHW
Circulation pump switches on
immediately
61: 0
The circulation pump is switched
on as a function of the boiler
temperature
122
5351 338 v1.6
is the maximum value of the system
Additional information
Coding 2
(continued)
Overview of all codings (continued)
Coding as per Function
factory setting
Address: Value
62: 10
5351 338 v1.6
67: 40
DHW
DHW
New coding Possible change
Address:
Value
62: 0
Circulation pump without run-on
time
62: 1
to
62: 15
Run-on time variable from 1 to 15
minutes
With Vitosolic:
3rd DHW set-point 40˚C/ 104˚F
Reloading suppression will be active
above set temperature. DHW tank is
heated only by solar heating system.
67: 0
Without 3rd DHW set-point
67: 1
to
67: 95
Input of a 3rd set DHW set-point
temperature; adjustable
from 1 to 95˚C / 34 to 203˚F
Circulation pump with run-on time of
10 minutes
63: 0
DHW
Without additional function for
domestic hot water heating
63: 15
Twice per day
63: 0
DHW
Without additional function for
domestic hot water heating
63: 1
Additional function: Once per day
63: 2
to
63: 14
Every 2 days
to
Every 14 days
68: 8
DHW
In conjunction with 2 tank
temperature sensors with the DHW
heating:
Switch-off point of tank heating at
setpoint value x 0.8
68: 2
to
68: 10
Factor adjustable from 0.2 to 1
per 1 increment = 0.1
69: 7
DHW
In conjunction with 2 tank
temperature sensors with the DHW
heating:
Switch-on point of tank heating at
setpoint value x 0.7
69: 1
to
69: 9
Factor adjustable from 0.1 to 0.9
per 1 increment = 0.1
76: 0
General
Without LON communication module
76: 1
With LON communication module;
recognized immediately
76: 2
With Viessmann 2-wire BUS
communication module; recognized
immediately
77: 1
General
LON participant number
77: 2
to
77: 99
LON participant number selectable
from 1 to 99
Please note:
Each number may be assigned
once only.
78: 1
General
LON communication released
78: 0
LON communication blocked
79: 0
General
Control unit is not error manager
79: 1
Control unit is error manager
80: 1
General
With 5 seconds time delay for fault
message
80: 0
Without time delay
80: 2
to
80:199
Time delay adjustable between
10 and 995 seconds;
1 increment = 5 seconds
123
Additional information
Coding 2
(continued)
Overview of all codings (continued)
Coding as per Function
factory setting
Address: Value
New coding Possible change
Address:
Value
88: 0
General
Temperatures displayed in Celsius
88: 1
Temperatures displayed in
Fahrenheit
8A:175
General
Display of codings which can be set
for the system type concerned
8A:176
All codings displayed regardless of
system type and equipment
installed
92:165
General
Do not Adjust! Is only displayed if
8A:176 is coded
93: 0
General
Central fault indication in emissions
test mode/service display not
effective for central fault
93: 1
Central fault indication in
emissions test mode/service
display effective for central fault
94: 0
General
Without plug-in adaptor for external
safety equipment
94: 2
With plug-in adaptor for external
safety equipment; recognized
automatically
98: 1
General
Viessmann system number
(in conjunction with monitoring of
several systems within one LON BUS
system)
98: 2
to
98: 5
System number
selectable from 1 to 5
9b: 0
General
Input aVH released
9b: 1
to
9b:127
Set-point supply temperature
selectable via plug aVH from 1 to
127°C / 261°F with external
request
9C: 20
General
Monitoring of LON participants:
If a participant does not answer
back, default values set within the
control unit are used for the first 20
minutes. Then an error message is
transmitted.
9C: 0
No monitoring
9C: 1
to
9C: 60
Time selectable
from 1 to 60 minutes
9d: 1
With Input Module 0 - 10V;
will be recognized automatically
General
Without Input Module
0 to 10V
5351 338 v1.6
9d: 0
124
Additional information
Wiring Diagrams
Overview
5351 338 v1.6
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
125
Additional information
Wiring Diagrams
(continued)
5351 338 v1.6
A10
A7
A2
A6
A9
A8
A11
34--pole
Low-voltage motherboard
126
Additional information
Wiring Diagrams
(continued)
Low-voltage motherboard (continued)
§
%
aJA Temperature sensor T1
aJB Temperature sensor T2
aVD Connection of external
equipment
aVG KM BUS participant (accessory)
aVH Connection of external
equipment
LON Connecting cable for data
transfer between the control
units
S3 Override switch ”S”
V1 Fault indicator (red)
V2 Operating status indicator (green)
5351 338 v1.6
aG
Boiler temperature sensor
Tank temperature sensor
(accessory)
Flue gas temperature sensor
(accessory)
127
Additional information
Wiring Diagrams
(continued)
5351 338 v1.6
A3
A11
ON ON
floating
Line voltage motherboard
128
Additional information
Wiring Diagrams
(continued)
Line voltage motherboard (continued)
sÖ
sA
sL
fÖ
lÖ Burner (2nd stage/modulating)
aBÖ External equipment
a External safety equipment
(remove jumper when
connecting)
b External controlled switch-off
(remove jumper when
connecting)
c External burner activation
aBA Safety circuit - emergency
shut-off
aBH Power supply connection for
accessories
F1, F2 Fuses
F6
Fixed high limit ”E”
120°C (99°C or 110°C) /
248°F (210°C or 230°F)
F7
adjustable high limit ”R”
95°C (100°C or 110°C)
203°F (212°F or 230°F)
K1-K10 Relay
S1
Heating system on/off
switch ”8”
S2
TUV button
5351 338 v1.6
Control output
DHW pump
Shunt pump or boiler circuit pump
Power supply connection,
120 VAC
fA Burner connection
gÖ Compiled failure alarm
gS Boiler isolation valve
or
Boiler return valve
129
Additional information
Parts List
GC1 Series
Order No.
Serial No. *1
7134 553, 7134 554, 7511 361
7143003
7187096
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
001
002
004
005
006
008
011
013
014
015
016
018
024
025
030
031
037
038
042
043
050
051
052
054
055
056
065
067
068
074
092
Circuit board (control software)
Diagnostics module (Optolink)
Motherboard
(control, line voltage)
Circuit board
(120V power supply)
Communication module,
2-wire BUS
LON module
Burner cable Nr. 41/90 l=3470
Sensor (immersion, NI500)
Sensor #2 for supply
Harness for programming unit
Fuse 6.3A / 250V (10 pack)
Other Parts (not illustrated)
060 Accessory pack (plugs)
080 Installation / Service Instructions
Vitotronic 100, GC1
081 Operating Instructions
Vitotronic 100, GC1
082 Parts List Vitotronic 100, GC1
Rating plate
*1
A 16-digit bar-coded serial no.
is printed on the front housing,
below the flip-down cover.
5351 338 v1.6
049
Hinges
Optic link
Adjustable high limit knob
Fixed high limit cover
Dial-stop 110°C / 230°F
Support arm
Safety module (wired)
Front housing (with Pos. 001)
Circuit board enclosure
Flip-down cover
Rear housing
Programming unit
Fuse holder cover
Fuse holder
Fixed high limit
Adjustable high limit
Switch, 1-pole (FHL test)
Switch, 2-pole (power on/off)
Sensor #3 for boiler
Sensor #5 for domestic hot
water production
Motherboard
(control, low voltage)
130
Additional information
5351 338 v1.6
Parts List
131
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island • 02886 • USA
Tel. (401) 732-0667 • Fax (401) 732-0590
www.viessmann-us.com • [email protected]
132
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-6
-5
-4
-3
-2
-1
0
+1
+2
+3
+4
+5
+6
+7
+8
+9
+10
+12
+14
+16
+18
+20
+25
+30
+35
+40
+50
+60
+70
+80
+90
+100
+110
-40
-31
-13
-4
0
+3
+7
+10
+14
+16
+18
+19
+21
+23
+25
+27
+28
+30
+32
+34
+36
+37
+39
+41
+43
+45
+46
+48
+50
+54
+57
+61
+64
+68
+77
+86
+95
+104
+122
+140
+158
+176
+194
+212
+230
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario • N2V 2G5 • Canada
Tel. (519) 885-6300 • Fax (519) 885-0887
www.viessmann.ca • [email protected]
Technical information subject to change without notice.
°C
5351 338 v1.6
Quick Reference
Printed on environmentally friendly
(recycled and recyclable) paper.
Additional information