Operating Instructions and User’s Information Manual
Vitotronic 100
Model KW10
Boiler control unit for modulating temperature heating systems
Part No. 7133 375
VITOTRONIC 100
Certified as a component part of Viessmann boilers only
5167 484 v1.1 09/2007
IMPORTANT
Read and save these instructions for future reference.
Safety, Installation and Warranty Requirements
Safety, Installation and Warranty Requirements
Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed below and details printed in this manual can cause product/property damage , severe personal injury , and/or loss of life . Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
H Licensed professional heating contractor
The installation, adjustment, service, and maintenance of this equipment must be performed by a licensed professional heating contractor.
"
Please see sections entitled “Safety” and
“Important Regulatory and
Installation Requirements” in the Installation,
Start-up and Service Instructions.
H 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.
H Safety requirements
For safety information on carbon monoxide and frozen water pipe hazards, please refer to page 11 in these instructions.
H 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.
"
For a listing of applicable literature, please see section entitled “Important
Regulatory and Installation
Requirements” in the
Installation, Start-up and Service
Instructions.
H
Warranty
Information contained in this and related product documentation must be read and followed.
Failure to do so renders warranty null and void.
2
About these Instructions
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.
WARNING
Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.
Warnings draw your attention to the presence of potential hazards or important product information.
CAUTION
Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.
Cautions draw your attention to the presence of potential hazards or important product information.
IMPORTANT
Helpful hints for installation, operation or maintenance which pertain to the product.
This symbol indicates that additional, pertinent information is to be found in column three.
This symbol indicates that other instructions must be referenced.
Overview of Display Elements
Operation
Slope adjustment (page 6)
Warm weather shut-down adjustment
(page 7)
Boiler temperature gage
Adjustable high limit (Page 5)
Power switch (Page 4)
Space heating switch (Page 5)
Fuse F1 T 6.3 A / 250 V
Fixed high limit
LED: Burner status indicator*
LED: Power indicator
LED: Burner fault indicator*
*Not available on the following boiler models:
Vitogas 100, GS1; Vitogas 100, GS10 and Vitogas 050, RS (natural gas only)
Location of Controls
The control is located behind the flip-down cover.
Open the flip-down cover by carefully pulling it forward from the top.
Close the flip-down cover when finished all operations.
3
Operation
Starting-Up the Heating System
The initial start-up and set-up of the control must be done by a licensed professional heating contractor.
We strongly recommend a service visit if reactivating the heating system after an extended shut-down.
1.
Check the pressure of the heating system on the pressure gage . An operating pressure of 15 psi is typical - consult your heating contractor. Take corrective actions if necessary.
2.
Ensure proper/adequate fuel supply exists; open oil or gas shut-off valve.
3.
Activate power to heating system
(from, for example, a switch located external to the mechanical room).
4.
Activate power on boiler control “ .“
The green power indicator illuminates.
5.
Set room thermostat (or other heat demand control) to desired temperature.
A call for heat causes the red burner status indicator to illuminate.
Your heating system is now ready for operation.
Shutting-Down the Heating System
If it is likely that the heating system will not be used for an extended period of time, we recommend a full shut-down.
We strongly recommend a service visit if deactivating the heating system after an extended operating period. This ensures preventative service measures such as heat exchanger cleaning and burner calibration are undertaken.
1.
Deactivate power on boiler control “ .“
The green power indicator deactivates.
CAUTION
In this circumstance, the control is completely deactivated and the system will not respond in the event of cold weather conditions.
2.
Close oil or gas shut-off valve on the tank (if applicable) and near the burner.
3.
Deactivate power to heating system
(from, for example, a switch located external to the mechanical room).
4
Operation
Altering the Maximum Boiler Water Temperature
The adjustable high limit (AHL) limits the maximum boiler water temperature when a call for heat is made. The call for heat is typically made by a room thermostat.
Select an appropriate boiler water temperature (based upon advice from your heating contractor).
The factory default setting is between 104 and 167°F / 40 and 75°C.
An elevated setting between 104 and 212°F / 40 and 100°C is possible if an adjustment has been made by the heating contractor.
Boiler water temperature limit increases.
Turn selector to the right
(clockwise) or
Turn selector to the left
(counter-clockwise)
Boiler water temperature limit decreases.
Space Heating Circuit Switch
The space heating circuit switch is only operational if a Viessmann
DHW Pump Module (Accessory) is installed and connected to the control.
For heating systems with domestic hot water production:
H
Winter operation: for space heating and DHW production, set space heating circuit switch “ ” to “ .”
H
Summer operation: for DHW production only , set space heating circuit switch “ ” to “ .”
CAUTION
Space heating pump is fully disabled; it will not reactivate during cold weather conditions.
5
Operation
Altering the Indoor/Outdoor Control Settings
The adjustable high limit determines the maximum available boiler (supply) temperature. Therefore, it functions as a high limit.
The room thermostat (if used) enables and disables the outdoor reset processor in order to add indoor control (fine tuning) to the outdoor reset function.
The curve for the outdoor reset function can be adjusted by opening the front flip-down cover.
Factory settings
Heating curve slope
“ “ selection = 1.2
IMPORTANT
If there is no call for heat from the room thermostat, the burner will not be activated, even if the heating curve setting calls for a higher temperature.
Warm weather shut-down (WWSD)
“ “ selection = 70 °F / 21 °C
Slope adjustment
As outdoor temperatures drop, heat losses from a space become greater and the heating system supply water temperature must be raised to maintain a constant room temperature. The heating curve value describes how many degrees the supply water temperature is raised for a one degree drop in outdoor temperature. The supply temperature starts to increase when the outdoor temperature falls below the warm weather shut-down (WWSD) setting.
To calculate the correct setting for the heating curve, use the following formula: heating curve slope = design supply temp. - WWSD temp.
WWSD temp. - design outdoor temp.
Example: design outdoor temp.:
WWSD temperature:
5 ˚ F / -15 ˚ C
70 ˚ F / 21 ˚ C design supply temp.: 160 ˚ F / 71 ˚ C heating curve slope =
160 ˚ F - 70 ˚ F
70 ˚ F - 5 ˚ F
=
90 ˚ F
65 ˚ F
= 1.4
For further assistance, please see section entitled “Helpful hints.”
6
Additional Safety Requirements
Altering the Indoor/Outdoor Control Settings (Continued)
Warm weather shut-down adjustment
The reset function starts at the warm weather shut-down (WWSD) point and supplies increasingly more heat to a building to make up for the greater heat loss as outdoor temperatures get colder.
When the outdoor temperature rises above the setting of the WWSD dial, no more heat is required by the control, and the boiler will be shut down. The WWSD dial setting shifts the heating curve up or down in parallel, increasing or decreasing the system supply water temperature
(and consequently, the indoor air temperature) at all outdoor temperatures.
If the indoor air temperature is too hot or too cold at all outdoor temperatures, the
WWSD setting is probably incorrect and should be checked and adjusted to suit your requirements.
For further assistance, please see section entitled “Helpful hints.”
7
Operation
Altering the Indoor/Outdoor Control Settings (Continued)
Helpful hints
Alter your heating curve, if ...
...heat output is insufficient when outdoor temperatures are cold, but adequate during spring and fall
Type of alteration
Increase the value of the “slope” to the next level.
...heat output is too high when outdoor temperatures are cold, but adequate during spring and fall
...heat output during spring and fall is inadequate, but sufficient when outdoor temperatures are cold
...heat output during spring and fall is too high, but sufficient when outdoor temperatures are cold
Decrease the value of the “slope” one level.
In Figure heating curve is raised one level, in
Figure 2
1 the “WWSD” of the the “slope” is lowered one level.
In Figure 1 the “WWSD” of the heating curve is lowered one level, in
Figure level.
2 the “slope” is raised one
8
Operation
Diagnostics
Failure, Cause, Correction
Failure
Heating system does not activate
(only GREEN power LED is illuminated)
Heating system does not activate
(GREEN power LED is not illuminated)
Cause
Thermostat is not set to a sufficiently high temperature
Power switch “ “ is in “ “ position
Main power to boiler control and heating system has not been activated
Fuse on Vitotronic boiler control has deactivated heating system
Fixed high limit (FHL) tripped Burner does not activate, or activates intermittently
(RED fault LED flashes)
No fuel *1
Control calls for heat but burner does not respond *1
Correction
Adjust thermostat.
Ensure power switch “ “ is in “ “ position.
Activate main power; ensure 120 VAC is supplied to control (receptacle).
Replace fuse with same type and rating
(F1: T 6.3 A / 250 V, slow blow).
Reset FHL by pushing in the pin, labelled with a
“ “ (using a ballpoint pen).
If a “click” can be heard, the limit was tripped.
If the limit requires multiple resets, please contact your heating contractor immediately.
with oil: Ensure sufficient supply of oil with gas: Open main gas supply valve or contact your local gas utility
Attempt to reset burner using reset button on the burner (underneath burner hood).
If still unsuccessful, please contact your heating contractor.
Burner does not start Power venter (if installed) will not activate or is defective
Contact your heating contractor.
*1 Red LED does not flash when Honeywell S8600 ignition control module is used with boiler.
9
Operation
Service Notice for your Heating System
We strongly recommend that you have your heating system checked and serviced by a qualified heating contractor on an annual basis to ensure a safe and energy efficient operation.
A service contract is advisable.
Boiler
Every boiler must be cleaned within certain time frames. A lack of cleaning causes soot build-up in the combustion chamber which raises the flue gas temperature and reduces the efficiency of your heating system.
System
Ensure that a qualified heating contractor checks all system components such as the expansion tank, the pressure relief valve, the pump(s), the zone valves, the low water cut-off and all other system componentry regularly.
CAUTION
Ensure the mechanical room and the hot water heating boiler itself, is kept clean.
WARNING
The are no user-serviceable components on the boiler, burner, control or on the heating system.
Contact a qualified heating contractor for service!
10
Additional Safety Requirements
Safety Requirements
Carbon monoxide
The U.S. Consumer Product Safety
Commission strongly recommends the installation of carbon monoxide detectors in buildings in which gas-burning equipment is installed. Carbon monoxide
(CO) is a colorless, odorless gas, which may be produced during incomplete combustion of fuel and/or when the flame does not receive an adequate supply of combustion air.
Carbon monoxide can cause severe personal injury or loss of life.
Therefore, carbon monoxide detectors that are in compliance with a nationally recognized standard (e.g. ANSI/UL
2034-2002, CSA 6.19-01) should be installed and maintained in buildings that contain gas-burning equipment.
Note:
Viessmann does not test any detectors and makes no representation regarding any brand or type of detector.
Frozen water pipe hazard
Your heating boiler is designed to provide a warm and comfortable living environment. It is NOT designed to ensure against freezing of water pipes.
The boiler is equipped with several safety devices that are designed to shut down the boiler and to prevent it from restarting in the event of various unsafe conditions.
If your boiler remains off for an extended period of time during cold weather, water pipes may freeze and burst, resulting in extensive water damage and conditions in which mold could grow. Certain molds are known to cause respiratory problems, as well as to pose other serious health risks. In case of water damage, immediate measures should be taken to dry out affected areas as quickly as possible to prevent mold from developing.
If your home will be unattended for an extended period of time during cold weather, you should...
Shut off the water supply to the building, drain the water pipes and add an antifreeze for potable water to drain traps and toilet tanks. Open faucets where appropriate.
Or..
Have someone check the building frequently during cold weather and call a qualified service agency if required.
Or...
Install a reliable remote temperature sensor that will notify somebody of freezing conditions within the home.
WARNING
Failure to protect against frozen pipes could result in burst water pipes, serious property damage and/or personal injury. Boiler may shut down.
Do not leave your home unattended for long periods of time during freezing weather conditions without turning off the water supply and draining water pipes or otherwise protecting against the risk of frozen pipes.
11
Saving Energy
Saving Energy
... with a modern heating system
By purchasing a “modern” heating system, you have taken a decisive step towards saving energy.
Viessmann boilers operate optimally to ensure minimum fuel consumption for maximum heating value - efficient, environmentally friendly and comfortable.
Your new heating system provides the following alternatives to save energy:
- a well insulated hot water heating boiler and domestic hot water tank
- clean combustion and high energy extraction
...with proper heating
Additional energy can be saved by considering the following measures in addition to the above technical improvements:
- proper ventilation: briefly open the windows 1 while turning off thermostats or radiator valves 2
- avoid excess space heating; strive for a room temperature of 68 º F / 20 º C since every 2 º F / 1 º C of lower room temperature can save up to 5% in heating costs.
- proper control settings 5 .
- properly set the temperature for the
DHW tank
4
- set thermostatic zone valves properly
2
- do not block heat transfer surfaces or thermostatic zone valves 3
- control use of warm water: a shower generally requires less water than a bath
- close window shutters (if applicable) during night time hours.
...with regular servicing
Regular servicing of your heating system 6 by a qualified heating contractor ensures energy-efficient and environmentally friendly operation.
...with good insulation
If still searching for additional possibilities to save energy, review the insulation installed
- on the heating system pipes and
DHW supply pipes,
- on the outside walls and on the roof
7 ,
- between heated (shaded grey) and unheated (white fill) rooms 8 ,
- around windows 9 .
WARNING
Ensure properly sized fresh combustion air supply to all fuel burning appliances, including the hot water heating boiler.
Tightly insulated homes require a duct or opening in the boiler room to allow outside air in for combustion.
Refer to codes and instructions.
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]
12
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]
