Operating Instructions and User s Information Manual for use by engineers and heating contractors VITOTRONIC 100 IMPORTANT

Transcription

1 Operating Instructions and User s Information Manual for use by engineers and heating contractors Vitotronic 100 Model KW10B Boiler control unit for modulating temperature heating systems Part No VITOTRONIC 100 IMPORTANT Certified as a component part for Viessmann boilers Read and save these instructions for future reference. 06/2011 Please file in Service Binder

2 Safety Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions 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). 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 Safety Requirements. 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 Safety and Important Regulatory and Installation Requirements. Warranty Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void. Safety requirements For safety information on carbon monoxide and frozen water pipe hazards, please refer to page 9 in these instructions. 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, shutdown procedure, and the need for professional service annually before the heating season begins. 2

3 About these Instructions Safety Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include WARNING, CAUTION, and IMPORTANT. WARNING Warnings draw your attention to the presence of potential hazards or important product information. Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage. CAUTION Cautions draw your attention to the presence of potential hazards or important product information. Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product / property damage. IMPORTANT Helpful hints for installation, operation or maintenance which pertain to the product. This symbol indicates to note additional information This symbol indicates that other instructions must be referenced. 3

4 Table of Contents Page Safety Safety, Installation and Warranty Requirements...2 Product documentation...2 Licensed professional heating contractor...2 Advice to owner...2 Warranty...2 About these Instructions...3 Overview...5 Front panel...5 Summer mode switch...5 Override switch...5 Power switch...5 Location of Controls...5 Starting Up the Heating System...6 Shutting Down the Heating System...6 Altering the maximum Boiler Water Temperature...7 Diagnostics...8 Failure, Cause, Correction...8 Service Notice for your Heating System...9 Boiler...9 System...9 Additional Safety Requirements...9 Carbon monoxide...9 Frozen water pipe hazard...9 Saving Energy...10 with a modern heating system...10 with proper heating...10 with regular servicing...10 with good insulation

5 Overview Front panel Front view of the control Summer mode switch The front mounted summer mode switch F when in the up (summer/winter) position a will allow the thermostat terminal to call for heat, DHW functionality and outdoor reset when programmed. Outdoor reset operation is based on the Warm weather shut down setting. When the summer mode switch F is in the down (summer/dhw) position w, the thermostat terminal to call for heat will be disabled. Units equipped with an outdoor temperature sensor and programmed for either internal outdoor reset or OpenTherm enabled thermostat will start calculating a boiler water temperature at an outdoor temperature of 37 o F (3 o C) and below. The boiler pump will be turned on and run continuously. Override switch The front mounted override switch H when in the up position h, turns the boiler pump on and enables stage 1 and 2 call for heat. The boiler operates on the adjustable high limit temperature. When the override switch H is in the down position a, the system is in normal operation. Power switch The front mounted power switch G when in the up position I, the control system is on. When the power switch G in the down position 0, the control system is off. 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. 5

6 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 8 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 8 The green power indicator deactivates. 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). CAUTION 6 In this circumstance, the control is completely deactivated and the system will not respond in the event of cold weather conditions.

7 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 F and 167 F (40 C and 75 C). An elevated setting between 104 F and 212 F (40 C and 100 C) is possible if an adjustment has been made by the heating contractor. Turn selector to the right Boiler water temperature limit (clockwise) increases. or Turn selector to the left Boiler water temperature limit (counter-clockwise) decreases. 7

8 Diagnostics Failure, cause, correction Are all controls operating properly (i.e. thermostats, low water cut-off, etc.)? Are all wire connections tight and secure? Symptom/Condition Cause Correction Boiler control is not active (GREEN power LED is not illuminated) Burner does not activate, or activates intermittently (RED fault LED flashes) Power switch 8 is in 0 position Main power to boiler control and heating system has not been activated Fuse on Vitotronic boiler control has deactivated heating system Burner is not electrically connected Fixed high limit (FHL) tripped No fuel * 1 Pumps on continuously F1 fuse blown Replace fuse Burner does not activate Control calls for heat but burner does not respond *1 Control calls for heat but burner does not respond Other accessory defect F1 fuse blown Ensure power switch 8 is in I position. Activate main power; ensure 120 VAC is supplied to control (receptacle). Replace fuse in control with same type and rating (F1: T 6.3 A / 250 V, slow blow). Ensure 7-pole fa plug-in connection to burner and/or power venter is/are made. Reset FHL by pushing in the pin, labelled with a E (using a ballpoint pen). If a click can be heard, the limit was tripped. 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). Service burner if necessary. Refer to troubleshooting section in burner manual. Power venter has to have separate 120 VAC power supply to motor (see power venter instructions). Refer to troubleshooting section in power venter manual. Air proving switch, blower wheel or timer/relay inside power vent may be defective. Ensure proper operation of all accessories; replace if necessary. Refer to technical literature supplied with accessories. Replace fuse Continuous burner call F3 Fuse blown Replace fuse Override switch on Turn off override *1 Red LED does not flash when Honeywell S8600 ignition control module is used with boiler. 8

9 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! Additional 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 , CSA ) 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. 9

10 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 68º F (20º C) since every 2º F (1º 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. 10

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12 Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario N2V 2G5 Canada Fax (519) Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island USA Fax (401) Technical information subject to change without notice. Printed on environmentally friendly (recycled and recyclable) paper.