Service Instructions for use by heating contractor

Transcription

1 Service Instructions for use by heating contracr Please file in Service Binder Vitronic 300 Model KW3 Weather-responsive indoor/outdoor, digital boiler control for heating systems with one or more heating circuits VITOTRONIC 300 IMPORTANT Read and save these instructions for future reference. 09/2011

2 Safety instructions Safety Instructions Safety, Installation and Warranty Requirements Please ensure that these instructions are read and undersod before commencing installation and operation. Failure comply with the instructions listed below and details printed in these instructions can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are undersod and fulfilled (including detailed information found in manual subsections). Licensed professional heating contracr The installation, adjustment, service, and maintenance of this equipment must be performed by a licensed professional heating contracr. Please see sections entitled Safety and Important Regulary and Installation Requirements. Advice owner Once the installation work is complete, the heating contracr must familiarize the system operar/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. Product documentation Read all applicable documentation before commencing installation. Sre 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 Regulary and Installation Requirements. Warranty Information contained in this and related product documentation must be read and followed. Failure do so renders warranty null and void. Safety Terminology One or more of the following terms are used throughout this manual bring attention the presence of potential hazards or important product information. Please heed the advice given! 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 Helpful hints for installation, operation or maintenance which pertain the product. 2

3 Index Page Safety Instructions... 2 General Information Overview of Boiler Coding Cards... 5 Application Example 1 System with one direct-connected heating circuit without mixing valve... 6 Application Example 2 System with one heating circuit with mixing valve... 9 Application Example 3 System with one direct-connected heating circuit without mixing valve and one with mixing valve Application Example 4 System with two heating circuits with mixing valves. 17 Application Example 5 System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves Service Information Controls and display elements Overview of Service Levels Adjusting heating curves Heating circuit control Tank temperature control Temperatures, Boiler Coding Cards and Scans Scan Relay Test Scanning Operating Status Information Scanning and Resetting Service Information Components Components from the parts list Flue gas temperature sensor Extension kit for mixing valve circuit Remote control Room temperature sensor Switching module V KM BUS expansion module Input module extension 0-10V

4 Troubleshooting Additional Information Diagnosis Fault with fault message on control unit Retrieving fault codes from error log (fault hisry) Codings Accessing coding level Coding Coding 2 information Accessing coding level Resetting codings facry default settings Coding Wiring Diagram Parts List

5 General Information Overview of Boiler Coding Cards Vitronic 300, Part No. Z , in conjunction with Required boiler coding card Vila 200, VB2 Series Vigas 100, GS1 Series MBH / kw MBH / kw Vigas 50, RS Series Virond 100, VR1 Series E1 F0 C6 C6 F1 5

6 General Information Application Example 1 System with one direct-connected heating circuit without mixing valve Boiler with Vitronic 300 Domestic hot water tank Vitrol, Switching Module-V, KM-BUS Expansion Module for the connection of several KM-BUS participants Heating circuit without mixing valve Power Pump Module Low water cut-off device Connecrs Outdoor temperature sensor Boiler temperature sensor DHW tank temperature sensor KM-BUS participants Extension for two-stage/modulating burner *1 Heating circuit pump Boiler circuit DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *1 Burner, two-stage/modulating *1 Available System Accessories Vitrol remote control Room temperature sensor Switching Module-V for expanding the range of control functions KM-BUS Expansion Module Flue gas temperature sensor *1 Included in standard boiler equipment. 6

7 General Information Application Example 1 (continued) System with one direct-connected heating circuit without mixing valve (continued) Function/Component Coding Remarks Facry default setting Setting changes System type 00: System without DHW tank 00: 1 (facry default setting) System with DHW tank 00: 2 (setting changed aumatically) Burner type 02: 0 (single-stage) Vitrol 200 (accessory) A0: 0 02: 1 (two-stage) 02: 2 (modulating) The two-stage/modulating extension is required for two-stage and modulating burners (included in standard boiler equipment) Coding A0: 0 is changed aumatically A0: 1. or Vitrol 300 (accessory) Room temperature sensor (accessory), only in conjunction with remote control Sensor/Burner fault indication module (included in standard equipment) KM-BUS Expansion Module (accessory) Switching Module-V (accessory) A0: Coding A0: 0 is changed aumatically A0: For measuring room temperature when remote control cannot be placed in a suitable location. The room temperature sensor is activated via a coding switch on the remote control. 92: For displaying and transmitting fault messages when fixed high limit is activated when additional safety equipment operates Required when more than one KM-BUS participant is connected 94: Required for external burner activation and disable. The Switching Module-V is aumatically recognized. Coding 94: 0 is changed aumatically 94: 2. 7

8 General Information Application Example 1 (continued) System with one direct-connected heating circuit without mixing valve (continued) Function/Component Coding Remarks Flue gas temperature sensor (accessory) Facry default setting Setting changes For displaying the flue gas temperature and for moniring high limit values. The flue gas temperature sensor is aumatically recognized. Coding switch settings on Vitrol 200 and Vitrol 300 (Coding switch on rear of remote control) The respective remote control must be assigned a heating circuit via the coding switches. Remote control effective for Vitrol 200 Coding switch S6 Heating circuit without mixing valve (facry default setting) Vitrol 300 Coding switch S30 If separate room temperature sensor is connected Coding switch 3 ON Coding switch 3 ON 8

9 General Information Application Example 2 System with one heating circuit with mixing valve Boiler with Vitronic 300 Domestic hot water tank KM-BUS Expansion Module (accessory) for the connection of several KM-BUS participants Heating circuit with mixing valve Mixing valve actuar accessory kit Power Pump Module Low water cut-off device Connecrs Outdoor temperature sensor Supply temperature sensor (accessory) *2 Boiler temperature sensor DHW tank temperature sensor Return water temperature sensor (accessory) *2,3 KM-BUS participant Extension for two-stage/modulating burner *4 M1 Heating circuit pump *2 Mixing valve circuit DHW production pump (accessory) DHW recirculation pump (installed on site) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/ modulating *4 Available System Accessories Vitrol remote control Room temperature sensor Return water temperature sensor Switching Module-V for expanding the range of control functions KM-BUS Expansion Module Flue gas temperature sensor *1 Supply check valve, only required if piping connection is made on one common boiler return. *2 To be connected in actuar accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard boiler equipment. 9

10 General Information Application Example 2 (continued) System with one heating circuit with mixing valve (continued) Function/Component Coding Remarks Facry default setting Setting changes System type 00: 1 System without DHW tank 00: 3 System with DHW tank 00: 4 Burner type 02: 0 (single-stage) Mixing valve actuar accessory kit (accessory) Vitrol 200 (accessory) 02: 1 (two-stage) 02: 2 (modulating) Coding is aumatically changed 00: 5 or 00: 6, must be reset manually The two-stage/modulating burner extension is required for two-stage and modulating burners (included in standard equipment) For assignment heating circuit refer page 12. A0: Coding A0: 0 is changed aumatically A0: 1. or Vitrol 300 (accessory) Room temperature sensor (accessory), only in conjunction with remote control Sensor/burner fault indication module KM-BUS Expansion Module (accessory) Switching Module-V (accessory) A0: Coding A0: 0 is changed aumatically A0: For measuring the room temperature when the remote control cannot be placed in a suitable location. The room temperature sensor is activated via a coding switch on the remote control. 92: For displaying and transmitting fault messages when fixed high limit has opened when additional safety equipment operates Required when more than one KM-BUS participant is connected 94: Required for external burner activation and disable. The Switching Module-V is aumatically recognized. Coding 94: 0 is changed aumatically 94: 2. 10

11 General Information Application Example 2 (continued) System with one heating circuit with mixing valve (continued) Function/Component Coding Remarks Return water temperature sensor (accessory) Flue gas temperature sensor (accessory) Facry default setting Setting changes For measuring the return water temperature. The return water temperature sensor is activated via a coding switch in actuar accessory kit (see following page) For displaying the flue gas temperature and moniring high limit values. The flue gas temperature sensor is aumatically recognized. 11

12 General Information Application Example 2 (continued) System with one heating circuit with mixing valve (continued) Coding switch settings for mixing valve mor, part no (old version) (Coding switches on mother board of mixing valve mor) Facry default setting Effective for heating circuit with mixing valve When connecting a return water temperature sensor (accessory), the coding switch must be reset. (Set coding switch 3 ON ). Coding switch settings on Vitrol 200 or Vitrol 300 (Coding switch on rear of remote control) The respective remote control must be assigned the heating circuit via the coding switches. Remote control effective for Vitrol 200 Coding switch S6 Heating circuit M1 (mixing valve circuit) Heating circuit is assigned heating circuit selecr butn Coding switch 1 OFF Coding switch 2 ON Vitrol 300 Coding switch S30 Coding switch 1 OFF Coding switch 2 ON If separate room temperature sensor is connected Coding switch 3 ON Coding switch 3 ON Coding switch settings for mixing valve mor, part no (new version) (the rotary sletecr is located on the motherboard of the mixing valve controller) Heating circuit that mixing valve affects Connected sensors Rotary selecr position Heating circuit with mixing valve, M2 Flow temperature sensor 2 (facry set) Heating circuit with mixing valve, M3 Flow tremperature sensor and return temperature sensor Flow temperature sensor Flow tremperature sensor and return temperature sensor 3 4 (facry set) 5 12

13 General Information Application Example 3 System with one direct-connected heating circuit without mixing valve and one heating circuit with mixing valve Boiler with Vitronic 300 Domestic hot water tank Heating circuit without mixing valve KM-BUS Expansion Module (accessory) for the connection of several KM-BUS participants Heating circuit with mixing valve Mixing valve actuar accessory kit Power Pump Module Low water cut-off device Connecrs Outdoor temperature sensor Supply temperature sensor (accessory) *2 Boiler temperature sensor DHW tank temperature sensor Return water temperature sensor (accessory) *2,3 KM-BUS participant Extension for two-stage/modulating burner *4 Boiler circuit pump M1 Mixing valve circuit pump *2 DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/modulating *4 Available System Accessories Vitrol remote control Room temperature sensor Return water temperature sensor Switching Module-V for expanding the range of control functions KM-BUS Expansion Module Flue gas temperature sensor *1 Supply check valve, only required if piping connection is made on one common header. *2 To be connected in actuar accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard equipment. 13

14 General Information Application Example 3 (continued) System with one direct-connected heating circuit without mixing valve and one heating circuit with mixing valve (continued) Function/Component Coding Remarks Facry default setting Setting changes System type 00: System without DHW tank 00: 5 (changed aumatically) System with DHW tank 00: 6 (changed aumatically) Single-/Multi-family house 7F: 1 The switching times for the DHW production pump, the DHW recirculation pump and the holiday program are identical for all heating circuits Burner type 02: 0 (single-stage) Mixing valve actuar accessory kit (accessory) Vitrol 200 (accessory) 7F: 0 The switching times for the DHW production pump, the DHW recirculation pump and the holiday program can be set separately for all heating circuits 02: 1 (two-stage) 02: 2 (modulating) The two-stage/modulating burner extension is required for two-stage and modulating burners (included in standard equipment) The mixing valve and strap-on sensor are recognized aumatically through the KM-BUS. For assignment heating circuit refer page 16. A0: Coding A0: 0 is changed aumatically A0: 1. or Vitrol 300 (accessory) Room temperature sensor (accessory) Sensor/burner fault indication module A0: Coding A0: 0 is changed aumatically A0: For measuring the room temperature when the remote control cannot be installed in a suitable location. The room temperature sensor is activated via a coding switch on the remote control. 92: For displaying and transmitting fault messages when the fixed high limit has opened when additional safety equipment operates 14

15 General Information Application Example 3 (continued) System with one direct-connected heating circuit without mixing valve and one heating circuit with mixing valve (continued) Function/Component Coding Remarks KM-BUS Expansion Module (accessory) Switching Module-V (accessory) Return water temperature sensor (accessory) Flue gas temperature sensor (accessory) Facry default setting Setting changes Required when more than one KM-BUS participant is connected 94: Required for external burner activation and disable. The Switching Module-V is aumatically recognized. Coding 94: 0 is changed aumatically 94: For measuring the return water temperature. The return water temperature sensor is activated via a coding switch in the actuar accessory kit For displaying the flue gas temperature and for moniring high limit values 15

16 General Information Application Example 3 (continued) System with one direct-connected heating circuit without mixing valve and one heating circuit with mixing valve (continued) Coding switch settings for mixing valve mor, part no (old version) (Coding switches on mother board of mixing valve mor) Facry default setting Effective for heating circuit with mixing valve (M1) When connecting a return water temperature sensor (accessory), the coding switch must be reset. (Set coding switch 3 ON ). Coding switch settings on Vitrol 200 or Vitrol 300 (Coding switch on rear of remote control) The respective remote control must be assigned a heating circuit via the coding switches. Remote control effective for Vitrol 200 Coding switch S6 Heating circuit (boiler circuit, facry default setting) Heating circuit is assigned heating circuit selecr butn Vitrol 300 Coding switch S30 Heating circuit M1 (mixing valve circuit) Heating circuit is assigned heating circuit selecr butn If separate room temperature sensor is connected Coding switch 1 OFF Coding switch 2 ON Coding switch 3 ON Coding switch 1 OFF Coding switch 2 ON Coding switch 3 ON Coding switch settings for mixing valve mor, part no (new version) (the rotary sletecr is located on the motherboard of the mixing valve controller) Heating circuit that mixing valve affects Connected sensors Rotary selecr position Heating circuit with mixing valve, M2 Flow temperature sensor 2 (facry set) Flow tremperature sensor and return temperature sensor 3 Heating circuit with mixing valve, M3 Flow temperature sensor Flow tremperature sensor and return temperature sensor 4 (facry set) 5 16

17 General Information Application Example 4 System with two heating circuits with mixing valves I Boiler with Vitronic 300 Domestic hot water tank Heating circuit with mixing valve 1 Mixing valve actuar accessory kit Heating circuit with mixing valve 2 Mixing valve actuar accessory kit KM-BUS Expansion Module (accessory) for the connection of several KM-BUS participants Power Pump Module I Low water cut-off device Available System Accessories Vitrol remote control Room temperature sensor Return water temperature sensor Connecrs Outdoor temperature sensor Supply temperature sensor (accessory) *2 Boiler temperature sensor DHW tank temperature sensor Return water temperature sensor (accessory) *2,3 KM-BUS participant Extension for two-stage/modulating burner *4 Switching Module-V for expanding the range of control functions KM-BUS Expansion Module Flue gas temperature sensor M1 Mixing valve circuit pump 1 *2 M2 Mixing valve circuit pump 2 DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/ modulating *4 *1 Supply check valve, only required if piping connection is made on one common header. *2 To be connected in the actuar kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard equipment. 17

18 General Information Application Example 4 (continued) System with two heating circuits with mixing valves (continued) Function/Component Coding Remarks Facry default setting Settings changes System type 00: 1 System without DHW tank 00: 7 System with DHW tank 00: 8 Single-/Multi-family house 7F: 1 The switching times for the DHW production pump, the DHW recirculation pump and the holiday program are identical for all heating circuits Burner type 02: 0 (single-stage) Mixing valve actuar accessory kit (accessory) Vitrol 200 (accessory) 7F: 0 The switching times for the DHW production pump, the DHW recirculation pump and the holiday program can be set separately for all heating circuits 02: 1 (two-stage) 02: 2 (modulating) Coding is aumatically changed 00: 9 or 00: 10, must be reset manually The two-stage/modulating burner extension is required for two-stage and modulating burners (included in standard equipment) The mixing valve and strap-on sensor are recognized aumatically through the KM-BUS. For assignment heating circuit see page 20. A0: Coding A0: 0 is changed aumatically A0: 1. or Vitrol 300 (accessory) Room temperature sensor (accessory), in conjunction with remote control Sensor/burner fault indication module KM-BUS Expansion Module (accessory) A0: Coding A0: 0 is changed aumatically A0: For measuring the room temperature when the remote control cannot be installed in a suitable location. The room temperature sensor is activated via a coding switch on the remote control. 92: For displaying and transmitting fault messages when the fixed high limit has opened when additional safety equipment operates Required when more than one KM-BUS participant is connected 18

19 General Information Application Example 4 (continued) System with two heating circuits with mixing valves (continued) Function/Component Coding Remarks Switching Module-V (accessory) Return water temperature sensor (accessory) Flue gas temperature sensor (accessory) Facry default setting Setting changes 94: Required for external burner activation and disable. The Switching Module-V is aumatically recognized. Coding 94: 0 is changed aumatically 94: For measuring the return water temperature. The return water temperature sensor is activated via a coding switch in the actuar accessory kit For displaying the flue gas temperature and for moniring high limit values. The flue gas temperature sensor is aumatically recognized. 19

20 General Information Application Example 4 (continued) System with two heating circuits with mixing valves (continued) Coding switch settings for mixing valve mor, part no (old version) (Coding switches on mother board of mixing valve mor) Facry default setting Effective for heating circuit with mixing valve 1, M1 Effective for heating circuit with mixing valve 2, M2 (Set coding switch 1 ON ) When connecting a return water temperature sensor (accessory), the coding switch must be reset. (Set coding switch 3 ON ). Coding switch settings on Vitrol 200 or Vitrol 300 (Coding switch on rear of remote control) The respective remote control must be assigned a heating circuit via the coding switches. Remote control effective for Vitrol 200 Coding switch S6 Heating circuit with mixing valve 1 Heating circuit is assigned heating circuit selecr butn Coding switch 1 OFF Coding switch 2 ON Vitrol 300 Coding switch S30 Coding switch 1 OFF Coding switch 2 ON Heating circuit with mixing valve 2 Heating circuit is assigned heating circuit selecr butn Coding switch 2 ON Coding switch 2 ON If separate room temperature sensor is connected Coding switch 3 ON Coding switch 3 ON Coding switch settings for mixing valve mor, part no (new version) (the rotary sletecr is located on the motherboard of the mixing valve controller) Heating circuit that mixing valve affects Connected sensors Rotary selecr position Heating circuit with mixing valve, M2 Flow temperature sensor 2 (facry set) Flow tremperature sensor and return temperature sensor 3 Heating circuit with mixing valve, M3 Flow temperature sensor Flow tremperature sensor and return temperature sensor 4 (facry set) 5 20

21 General Information Application Example 5 System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves 2 Boiler with Vitronic 300 Domestic hot water tank Heating circuit with mixing valve 1 Mixing valve actuar accessory kit Heating circuit with mixing valve 2 Mixing valve actuar accessory kit KM-BUS Expansion Module for the connection of several KM-BUS participants Heating circuit without mixing valve Power Pump Module Low water cut-off device Available System Accessories Vitrol remote control Room temperature sensor Return water temperature sensor Connecrs Outdoor temperature sensor Supply temperature sensor (accessory) *2 Boiler temperature sensor DHW tank temperature sensor Return water temperature sensor (accessory) *2,3 KM-BUS participant Extension for two-stage/modulating burner *4 Switching Module-V for expanding the range of control functions KM-BUS Expansion Module Flue gas temperature sensor M1 Mixing valve circuit pump 1 *2 M2 Mixing valve circuit pump 2 Heating circuit pump DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/ modulating *4 *1 Supply check valve only required if piping connection is made on one common boiler return. *2 Connected in actuar accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard delivery of boiler. 21

22 General Information Application Example 5 (continued) System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves (continued) Function/Component Coding Remarks Facry default setting Setting changes System type 00: System without DHW tank 00: 9 (changed aumatically) System with DHW tank 00: 10 (changed aumatically) Single-/Multi-family house 7F: 1 The switching times for the DHW production pump, the DHW recirculation pump and the holiday program are identical for all heating circuits Burner type 02: 0 (single-stage) Mixing valve actuar accessory kit (accessory) Vitrol 200 (accessory) 7F: 0 The switching times for the DHW production pump, the DHW recirculation pump and the holiday program can be set separately for all heating circuits 02: 1 (two-stage) 02: 2 (modulating) The two-stage/modulating burner extension is required for two-stage and modulating burners (included in standard equipment) The mixing valve and strap-on sensor are recognized aumatically through the KM-BUS. For assignment heating circuit see page 24. A0: Coding A0: 0 is changed aumatically A0: 1. or Vitrol 300 (accessory) Room temperature sensor (accessory), in conjunction with remote control Sensor/burner fault indication module A0: Coding A0: 0 is changed aumatically A0: For measuring the room temperature when the remote control cannot be installed in a suitable location. The room temperature sensor is activated via a coding switch on the remote control. 92: For displaying and transmitting fault messages when the fixed high limit is activated when additional safety equipment operates 22

23 General Information Application Example 5 (continued) System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves (continued) Function/Component Coding Remarks KM-BUS Expansion Module (accessory) Switching Module-V (accessory) Return water temperature sensor (accessory) Flue gas temperature sensor (accessory) Facry default setting Setting changes Required when more than one KM-BUS participant is connected 94: Required for external burner activation and disable. The Switching Module-V is aumatically recognized. Coding 94: 0 is changed aumatically 94: For measuring the return water temperature. The return water temperature sensor is activated via a coding switch in the actuar accessory kit For displaying the flue gas temperature and for moniring limit values 23

24 General Information Application Example 5 (continued) System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves (continued) Coding switch settings for mixing valve mor, part # (old version) (Coding switches on mother board of mixing valve mor) Facry default setting Effective for heating circuit with mixing valve 1, M1 Effective for heating circuit with mixing valve 2, M2 (Set coding switch 1 ON ) When connecting a return water temperature sensor (accessory), the coding switch must be reset. (Set coding switch 3 ON ). Coding switch settings on Vitrol 200 or Vitrol 300 (Coding switch on rear of remote control) The respective remote control must be assigned a heating circuit via the coding switches. Remote control effective for Vitrol 200 Coding switch S6 Heating circuit without mixing valve (boiler circuit, facry default setting) Heating circuit is assigned heating circuit selecr butn Heating circuit with mixing valve M1 Heating circuit is assigned heating circuit selecr butn Coding switch 1 OFF Coding switch 2 ON Vitrol 300 Coding switch S30 Coding switch 1 OFF Coding switch 2 ON Heating circuit with mixing valve M2 Heating circuit is assigned heating circuit selecr butn If separate room temperature sensor is connected Coding switch 2 ON Coding switch 3 ON Coding switch 1 OFF Coding switch 2 ON Coding switch 3 ON Coding switch settings for mixing valve mor, part no (new version) (the rotary sletecr is located on the motherboard of the mixing valve controller) Heating circuit that mixing valve affects Connected sensors Rotary selecr position Heating circuit with mixing valve, M2 Flow temperature sensor 2 (facry set) Heating circuit with mixing valve, M3 Flow tremperature sensor and return temperature sensor Flow temperature sensor Flow tremperature sensor and return temperature sensor 3 4 (facry set) 5 24

25 Service Information Controls and display elements ABC D EF Boiler temp. Mo U T S P N L K H G R O M A Heating circuit selection B Reduced room temperature C DHW temperature D Standard room temperature E Standby mode F DHW only G Heating and DHW H Economy mode K Party mode L Information M Standard settings N Acknowledgment/Confirmation O Adjusting values P Time programs R Holiday program S Time/date T Heating curve level U Heating curve slope Checking the heating circuit allocation Check whether the label for heating circuit allocation has been affixed the corresponding field of the programming unit. Check the corresponding key before commencing all adjustments Checking the high limit safety cut-out Hold down the TEST key during this test (position h ). The control thermostat R has now been bypassed. The burner remains switched ON until the boiler water temperature has reached the safety temperature and the high limit safety cut-out (FHL) has switched OFF. After the Burner has been shut down by the high limit safety cut-out: Release the Test key Wait until the boiler water temperature has dropped 15-20K below the selected safety temperature, then reset the high limit saftey cut-out by pressing E. Changing the display language 1.Press. This displays the outdoor temperature. 2. Select the required language with. 3. Confirm with. 25

26 Service Information Overview of Service Levels Boiler temperture Function Butn combination Access Exit Diagnosis (see section entitled Diagnosis ) and Press both butns simultaneously for approx. 2 seconds Press Coding level 1 and Press and simultaneously for approx. 1 second Coding level 2 and, then Press and simultaneously for approx. 1 second Reset codings facry default settings and, then Press the or butn select Facry default setting? Yes or Facry default setting? No and press confirm. Calling up acknowledged fault messages Press for approx. 3 seconds. Press Relay test and Press butns simultaneously for approx. Fault hisry and 2 seconds Press Press Operating status Immediately Press Fault search (see section entitled Diagnosis ) (if Fault flashing) Press Service scan (if Service flashing) Press Adjust display contrast and Display darkens and Display brightens 26

27 Service Information Adjusting heating curves Adjusting the heating curve The heating curves illustrate the relationship between the outdoor temperature and the boiler water or the supply temperature. To put it simply: The lower the outdoor temperature, the higher the boiler water or supply temperature. The room temperature again depends on the boiler water or the supply temperature. Facry default settings: Slope: =1.4 Shift: =0 Generally, the heating curve is set: in range A for underfloor heating systems, in range B for low temperature heating systems (according the Energy Savings Order), in range C for heating systems with boiler water temperatures above 75 C / 167 F. Slope 110/ / Supply tempertaure in ºC / ºF /194 80/176 70/158 60/140 50/122 40/104 30/ Setroomtemperature inºc /ºF Outdoor temperature in ºC / ºF 27

28 Service Information Adjusting heating curves (continued) Adjusting the normal room temperature (for every heating circuit separately) Normal room temperature: Select the normal day temperature with the set value adjuster. The value will be aumatically transferred after approx. 2 seconds. Examples Reduced room temperature: 1. Call up the reduced night temperature with tm. 2. Change the value with or. 3.Confirm the set value with. Temperature conversion: D E D E C F Example 1: Adjustment of the normal room temperature from C / F. A Boiler water temperature or supply temperature in C / F B Outdoor temperature in C / F C Set room temperature in C / F D Heating circuit pump OFF E Heating circuit pump ON Accordingly, the heating curve is adjusted along the set room temperature axis, which results in modified start/shutdown characteristics of the heating circuit pumps, if heating circuit pump logic is activated. Changing slope and shift (for every heating circuit separately) 1.Call up slope with, adjustable value ; call up shift with ; adjustable value C / F. 2. Change the value with or. 3.Confirm the set value with A Change slope B Change shift Supply temperature in C / F B 1.4 A / / -4 Outdoor temperature in C / F 28

29 Service Information Heating circuit control unit Brief description The control unit comprises control circuits for one heating circuit without mixing valve and two mixing valve circuits. The set supply temperature of each heating circuit results from the outdoor temperature, the set room temperature, the operating mode and the heating curve. Functions The heating circuit without mixing valve is subject the boiler water temperature and its control range limits. The heating circuit pump is the only actuar. The supply temperature sensor registers the supply temperature of the mixing valve circuits. Time program The control unit time switch changes in accordance with the times programmed in the Heating and DHW program between Central heating with standard room temperature and Central heating with reduced room temperature. Every operating mode has its own set level. Outdoor temperature A heating curve must be set up for matching the control unit the building and the heating system. The heating curve characteristics determine the set boiler water temperature subject outdoor temperature. An average outdoor temperature is used for control purposes. This comprises the actual and the adjusted outdoor temperature. The supply temperature of heating circuits without mixing valve is equal the boiler water temperature. The supply temperature of the mixing valve circuit is regulated by a stepped opening or closing of the mixing valve. The mixing valve mor control changes the actuating and pause times subject the control differential (control deviation). Domestic hot water temperature With DHW priority: The set supply temperature will be set 0 ºC/ 32 ºF while the tank is heated up. The mixing valve closes, and the heating circuit pump is switched OFF. Without DHW priority: The heating circuit control unit continues operate with the same set value. With modulating priority (only in conjunction with a mixing valve circuit): The heating circuit pump remains switched ON. The set supply temperature of the heating circuits will be reduced for as long as the set boiler water temperature has not been reached while the tank is being heated up. The set supply temperature is subject the difference between the set and the actual boiler water temperature, the outdoor temperature, the heating curve slope and coding address A2. Heating circuit pump logic (economy mode) The heating circuit pump is switched OFF (set supply temperature set 0 ºC), when the outdoor temperature exceeds the value selected via coding address A5. Coding addresses which influence the heating circuit control A0 Fb For a description, see the coding overview. Room temperature In conjunction with remote control and room temperature hook-up (observe coding address b0 ). Compared with the outdoor temperature, the room temperature has a greater influence on the set boiler water temperature. This influence may be changed via coding address b2. In conjunction with the mixing valve circuit: For a control difference (deviation from the actual value) above 2 K room temperature, the influence can be further increased (via coding address b6, quick heat-up/quick setback). Quick heat-up: Only possible for weather-compensated mode with room temperature hook-up. The set room temperature must be raised by a minimum of 2 K by pressing party key g changing from reduced mode standard mode start-up time optimisation Quick heat-up will sp when the set room temperature has been reached. Quick setback: Only possible for weather-compensated mode with room temperature hook-up. The set room temperature must be reduced by a minimum of 2 K by pressing economy key û changing from heating mode reduced mode shutdown time optimisation Quick setback will sp when the set room temperature has been reached. 29

30 Service Information Heating circuit control unit (continued) Extended economy mode The heating circuit pump is switched OFF: if the outdoor temperature exceeds the value selected via coding address A6 if the set room temperature is reduced via coding address A9 if the mixing valve has been closed for 12 min. (mixing valve economy function, coding address A7 ) if the actual room temperature exceeds the value selected via coding address b5 Slab curing function In conjunction with the mixing valve circuit Note Observe DIN 4725 part 4. Four different temperature profiles can be selected for drying the slab. These profiles are activated via coding address F1. When the slab curing function is activated, the heating circuit pump of the mixing valve circuit is switched ON, and the supply temperature will be held at the selected profile. After completion (30 days), the mixing valve circuit will again be regulated aumatically via the set parameters. Underfloor heating In conjunction with the mixing valve circuit An additional return temperature sensor can be connected achieve an optimum underfloor heating system. The control unit calculates a set return temperature. Changes are implemented, if the actual return temperature deviates from the set return temperature. The temperature differential may be changed via coding address C7. When changing from Central heating with reduced room temperature Central heating with standard temperature, the set supply temperature can be raised by 20 % for one hour via code C9:1. System dynamics mixing valve circuit You can influence the control characteristics of the mixing valve via coding address C4. Frost protection When the outdoor temperature reaches +1 ºC/ 34 ºF, a supply temperature of ºC/ ºF will be safeguarded (two-point control). For changes see coding address A3, variable frost limit. Supply temperature control Differential temperature: The differential temperature may be adjusted via coding address 05 ; delivered condition: 8 K. The differential temperature is that minimum value, by which the boiler water temperature should be higher than the currently required mixing valve circuit supply temperature. System with only one or two mixing valve circuits: The set boiler water temperature will be aumatically held 8 K above the set supply temperature. System with a heating circuit without mixing valve and with a mixing valve circuit: The set boiler water temperature operates in accordance with a special heating curve. The differential temperature of 8 K wards the set supply temperature is set up at the facry. Boiler water temperature or flow temperature in C Outside temperature in C A Max. boiler water temperature B Slope = 1.8 boiler circuit A1 C Slope = 1.2 mixing valve circuit M2 D Boiler water temperature (at a differential temperature of 8 K) E Lower boiler water temperature Temperature conversion C F

31 Service Information Heating circuit control unit (continued) Upper control limit Electronic maximum limit Setting range: ºC / ºF Changes via coding address C6. Note The maximum limit is no replacement for the underfloor heating system temperature limiter. Temperature limiter for underfloor heating: The temperature limiter switches the heating circuit pump OFF, if the set value has been exceeded. In such cases, the supply temperature reduces only slowly, i.e. it may be several hours before the system restarts again aumatically. Lower control range limit Electronic minimum limit Setting range: ºC / ºF Changes via coding address C5. Control sequence Mixing valve circuit The mixing valve mor will not be selected within the neutral zone (±1 K). Supply temperature drops (set value 1 K) The mixing valve mor receives the signal Mixing valve open. The signal duration lengthens with an increasing control differential. The duration of pauses reduces with an increasing control differential. 31

32 Service Information Tank temperature control Brief description The tank thermostat operates with a constant temperature. It is the result of starting and spping the tank primary pump. The switching differential is ±2.5K. While the tank is being heated up, a constant upper boiler water temperature is set, and the central heating is switched OFF (optional tank priority). Coding addresses which influence the tank thermostat 54, 55, 56, 58 62, 64, 66, 67, 70 75, 7F, A2. For a description, see the coding overview. Functions Time program An aumatic program or an individual time program may be selected for heating DHW and the control of the DHW circulation pump. Compared with the heating circuit heat-up phase, DHW heating starts 30 minutes earlier in aumatic mode. The individual time program enables up four switching periods per day be set via the time switch control the DHW heating and the DHW circulation pump. Any tank heating sequence will be completed, independent of the time program. In conjunction with coding address 7F 7F:1 Detached house: Aumatic mode The heating times for heating circuit 1 are applied systems with two or three heating circuits. Individual time program The switching times for DHW heating and the DHW circulation pump have the same effect on all heating circuits. 7F:0 Apartment block: Aumatic mode The heating times for the respective heating circuit will be applied systems with two or three heating circuits. Individual time program The switching times for DHW heating can be adjusted separately for each heating circuit. DHW priority With DHW priority (code A2:2 ): The set supply temperature will be set 0 ºC / 32 ºF while the tank is being heated up. The mixing valve closes, and the heating circuit pump is switched OFF. Without DHW priority: The heating circuit control unit continues operate with the same set value. With modulating priority (only in conjunction with a mixing valve circuit): The heating circuit pump remains switched ON. The set supply temperature of the heating circuits will be reduced, for as long as the set boiler water temperature has not been reached during tank heating. The set supply temperature is subject the difference between the set and the actual boiler water temperature, the outdoor temperature, the heating curve slope and coding address A2. Frost protection The DHW tank will be heated 20 ºC / 68 ºF if the DHW temperature falls below 10 ºC / 50 ºF. Auxiliary function for DHW heating This function is activated by providing a second set DHW temperature via coding address 58, and activating the 4th DHW phase for DHW heating. Set DHW temperature The set DHW temperature can be adjusted between 10 and 60 ºC / 50 and 140 ºF. The set range can be extended 95 ºC / 203 ºF via coding address 56. The set default value of the programming unit and/or the Vitrol 300 remote control can be applied via coding address 66. DHW circulation pump It delivers hot water the draw-off points at adjustable times. Up four control periods can be set at the time switch. Auxiliary circuits DHW heating can be blocked or enabled by changing over the heating program. An external contact in conjunction with switching module V can be used briefly select the DHW circulation pump. The time may be adjusted via coding address 74. Systems with Visolic A third set DHW temperature can be defaulted via coding address 67. Re-heating will be suppressed above the selected temperature. The DHW tank will only be heated by the solar heating system. 32

33 Service Information Tank temperature control (continued) Control sequence Pump run-on The tank primary pump runs on after tank heating, until the difference between the boiler water and the DHW temperature is less than 7 K or until the weather-compensated set boiler water temperature has been reached or until the actual temperature is 5 K higher than the set DHW temperature or until the maximum run-on time (adjustable via coding address 62 ) has been reached. Without the tank primary pump running on (code 62:0 ) Code 55:0 Tank heating DHW tank goes cold (set value 2.5 K, adjustable via coding address 59 ) The set boiler water temperature is adjusted 20 K higher than the set DHW (adjustable via coding address 60 ). Starting the tank primary pump subject boiler temperature (code 61:0 ): The pump starts when the boiler water temperature is 7 K higher than the DHW temperature. Immediate start of the tank primary pump (code 61:1 ). The DHW tank is hot (set value +2.5 K) The set boiler water temperature is returned the weather-compensated value. Code 55:1 Adaptive tank heating With adaptive tank heating, the speed of the temperature rise during DHW heating is taken in account. Also taken in account is the question, whether the boiler will be required supply heat after the tank has been heated up or whether residual boiler heat should be transferred the DHW tank. Accordingly, the control unit determines the burner and circulation pump shutdown points prevent the set DHW temperature being substantially exceeded after the tank has been heated up. 33

34 Service Information Temperatures, Boiler Coding Cards and Scans Select the heating circuit with the heating circuit selecr butns. Each heating circuit is scanned separately. Boiler temperature Diagnosis Press and simultaneously for approx. 2 seconds. Access diagnosis level. Outdoor temp. damped Select the required data for scanning with the or butn. Press. Exit diagnosis level. The following values can be scanned: Damped outdoor temp. Current outdoor temp. Desired supply temp. Current supply temp. The damped outdoor temperature can be reset the current outdoor temperature by pressing. Only displayed if supply temperature sensor connected. Slope A1/M2/M3. Shift A1/M2/M3. Desired boiler temp. Current boiler temp. Desired DHW temp. Current DHW temp. Desired return temp. Current return temp. Desired room temp. Current room temp. Max. flue gas temp. Current flue gas temp. Boiler coding card Scan 1 Scan 5 Only displayed if tank temperature sensor connected. Only displayed if return water temperature sensor connected. Only displayed if remote control or separate room temperature sensor connected. Only displayed if flue gas temperature sensor connected. The max. flue gas temperature can be reset the current value by pressing. See Overview of Boiler Coding Cards. See following pages for scans

35 Brief scan BRIEF SCAN 8 System design (see coding addresss 00 ) Software version control unit Operating mode boiler circuit 0 w/o remote control 1 with Vitrol with Vitrol 300 Variable speed pump boiler circuit 0 excl. 1 Wilo pump 2 Grundfos pump 8 Software version programming unit Software version remote control boiler circuit Software version variable speed pump boiler circuit 8 Burner type 0 single stage 1 two-stage 2 modulating Software version extension kit mixing valve circuit M2 Operating mode mixing valve circuit M2 0 w/o remote control 1 with Vitrol with Vitrol 300 Variable speed pump mixing valve circuit M2 0 excl. 1 Wilo pump 2 Grundfos pump 8 Number of KM BUS participants Software version expansion module Viessmann 2-wire BUS Software version remote control mixing valve circuit M2 Software version variable speed pump mixing valve circuit M2 8 8 Number of Viessmann 2-wire BUS participants Software version extension kit mixing valve circuit M3 Operating mode mixing valve circuit M3 0 w/o remote control 1 with Vitrol with Vitrol 300 Variable speed pump mixing valve circuit M3 0 excl. 1 Wilo pump 2 Grundfos pump Software version switching module V Software version remote control mixing valve circuit M3 Software version variable speed pump mixing valve circuit M3 Temperatures, Boiler Coding Cards and Scans (continued) 5 N/A Software version Solar control unit Service Information 35

36 Service Information Relay Test Relay test Press and simultaneously for approx. 2 seconds. Relay test activated. Burner ON Select relay outputs with the butn. or Relay test terminated. Press. The following relay outputs can be selected: IMPORTANT Burner ON Burner stage 1 ON The following lists may differ according system equipment and coding. Burner stages ON Burner modulation up Burner modulation hold Burner modulation down Heat pump ON LED of selecr butn ON. Heat pump M1 ON LED of selecr butn ON. Heat pump M2 ON LED of selecr butn ON. Mixing valve 1 open Mixing valve 2 open Mixing valve 1 closed Mixing valve 2 closed DHW tank pump ON DHW recirculation pump ON LED of selecr butn LED of selecr butn LED of selecr butn LED of selecr butn ON. ON. ON. ON. Compiled fault indicar ON Only displayed if Switching Module-V is connected. The relay switches with a delay of up 1 minute. 36

37 Service Information Scanning Operating Status Information Boiler temperature Select the heating circuit with the heating circuit selecr butns. Each heating circuit is scanned separately. Press. Operating status scanning mode is activated. Select the required operating status data for scanning with the or butn. Press. Exit the operating status scanning mode. The following operating status information can be scanned, subject the actual system equipment and coding: Heating circuits A1, M2 and M3 Holiday program Departure and return date Current outdoor temperature Current boiler water temperature Actual DHW tempemperature Supply temperature (actual value) (only for mixing valve circuits M2 and M3) Return temperature (actual value) (only for mixing valve circuits M2 and M3) Current flue gas temperature Current room temperature Burner operating hours Number of burner starts Fuel consumption Actual solar DHW temperature Collecr temperature Solar energy in kwh Time/ Date Operating status of burner Operating status of heating circuit pump Operating status of DHW production pump Operating status of DHW recirculation pump Mixing valve open/closed Solar circuit pump ON/OFF Hours run solar circuit pump Different languages The holiday program, departure and return date are only displayed when the holiday program is activated. For coding address C7 a value greater than 0 must be set. Only displayed if flue gas temperature sensor is connected. Only displayed if Vitrol or separate room temp. sensor is connected. Reset burner operating hours, number of burner starts and fuel consumption after maintenance has been performed. By pressing, the values can be individually reset zero. Display only, if 26 or 29 is set via the coding addresses. In conj. with solar heating system. In conj. with solar heating system. In conj. with solar heating system. In conj. with solar heating system. In conj. with solar heating system. 37

38 Service Information Scanning Operating Status Information (continued) Heating circuit with mixing valve (1 or 2) Holiday program Departure date Return date Current outdoor temperature Supply temperature Current boiler water temperature Domestic hot water temperature 1st tank temperature sensor Domestic hot water temperature 2nd tank temperature sensor Return water temperature Current flue gas temperature Current room temperature Burner operating hours Number of burner starts Fuel consumption Time Date Operating status of burner Operating status of heating circuit pump Operating status of DHW production pump Operating status of DHW recirculation pump Operating status of mixing valve Different languages The holiday program, departure and return date are only displayed when the holiday program is activated. Only displayed if flue gas temperature sensor is connected. Only displayed if Vitrol or separate room temperature sensor is connected. Reset burner operating hours, number of burner starts and fuel consumption after maintenance has been performed. By pressing, the values can be individually reset zero. 38

39 Service Information Scanning and Resetting the Service Information When the limit values selected via coding addresses 1F, 21 and 23 (see Additional Information for individual coding addresses) are reached, Service will appear on the display and the red fault indicar will flash. Service 1. Press. Service scan is activated. MFlue gas temperature 180 ºC 2. Scan the individual service information (if more than one message is sred) with the butn. or 3. Press and confirm the display Acknowledge: Yes by pressing. The word Service will disappear and the red fault indicar will continue flash. IMPORTANT An acknowledged service message can be displayed again by pressing (for approx. 4 seconds). Boiler temperature 4. Press. Service scan is terminated. 5. After performing the maintenance, reset coding 24:1 24:0. Red fault indicar is turned off. IMPORTANT If coding address 24 is not reset, the word Service will reappear at 07:00 hrs on Monday. 6. After performing the maintenance Press. Reset burner operating hours, number of burner starts and fuel consumption. Press. 7. After performing the maintenance Press and simultaneously for approx. 4 seconds. Reset Max. flue gas temp. the current value by pressing. Press. See Scanning Operating Status Information. See Temperatures, Boiler Coding Cards and Scans. 39

40 Components Components from the parts list Boiler temperature sensor and tank temperature sensor Check sensor 1.Pull plug 3 or from control. 2. Check the sensor resistance at terminals 1 and 2 of the plug. 3. Compare the measurement with the actual temperature displayed (for scanning.) Check the installation and replace sensor, if necessary, in case of severe deviation. Specification Protection: IP 32 Permiss. ambient temperature during operation boiler temperature sensor: ºC ºF tank temperature sensor: ºC ºF during srage and transport: ºC ºF Resistance in Ω ºC ºF Boiler water temperature 40

41 Components Components from the parts list (continued) Outdoor temperature sensor Checking the outdoor temperature sensor 1. Pull plug from control. 2. Check the sensor resistance at terminals 1 and 2 of the plug. 3. Disconnect wires from the sensor, if actual values deviate severely from the curve, repeat the sensor test and compare with the actual temperature. 4. Depending on the result, replace cable or outdoor temperature sensor. 5. Scan actual temperature Specification Protection: IP 43 Permiss. ambient temperature during operation, srage and transport: ºC ºF Resistance in Outdoor temperature in C / F 41

42 Components Flue gas temperature sensor Connection The sensor is plugged in socket 15 at the control unit. Checking the flue gas temperature sensor 1. Pull plug 15 from control. 2. Check the sensor resistance at terminals 1 and 2 of the plug. 3. Compare the measurement with the actual temperature displayed. Check the installation and replace sensor, if necessary, in case of severe deviation Specification Protection: IP 60 Permiss. ambient temperature during operation: ºC ºF during srage and transport: ºC ºF Resistance in Ω Flue gas temperature in C / F 42

43 Components Mixing valve circuit extension kit For mixing valve installation, incl. mixing valve mor, part no For wall mounting, separate mixing valve mor, part no Contact temperature sensor, part no For recording the supply and return temperature. Connection The sensor is plugged in socket 2 or 17 at the mixing valve extension. Check sensor 1. Pull plug or from control 2. Check the sensor resistance at terminals 1 and 2 of the plug. 3. Compare the measurement with the actual temperature displayed. Check the installation and replace sensor, if necessary, in case of severe deviation. 740 Specification Protection: IP 32 Permiss. ambient temperature during operation: ºC ºF during srage and transport: ºC ºF Resistance in Supply/Return temperature in C / F 43

44 Components Extension kit for mixing valve circuit (continued) Mixing valve extension Summary of electrical connections, part no (old version) A B CD EF G A Mixing valve extension B Mixing valve mor, part no Wall mounting base for part no C Main PCB D Heating circuit pump socket via plug 120 VAC/ 60Hz E Power supply socket via plug 120 VAC/ 60Hz F Fuse F1 G ON/OFF switch Low voltage connections Supply temperature sensor Return temperature sensor (accessories) No function KM BUS Pump 120 V~ connection M 1~ 20 A 44

45 Components Extension kit for mixing valve circuit (continued) Summary of electrical connections, part no (new version) F1 Fuse S1 Rotary selecr 120V plugs Heating circuit pump (on site) Power supply Power supply for additional controller for heating circuit with mixing valve Mixing valve mor Low voltage connections Supply temperature sensor Return temperature sensor (optional accessory for Vitronic 300, type KW3) KM BUS 45