Installation and Service Instructions. VITOTRONIC r 100 IMPORTANT. Read and save these instructions for future reference.

Transcription

1 Installation and Service Instructions for use by heating contracrs Vitronic 100 Type GC1B Digital boiler control unit For use with Boiler models VD2A, VD2 and CT3 VITOTRONIC r 100 Product may not be exactly as shown IMPORTANT Certified as a component part for Viessmann boilers Read and save these instructions for future reference. 02/2015 Please file in Service Binder

2 General Safety, Installation and Warranty Requirements Vitronic 100, GC1B Installation and Service Please ensure that these instructions are read and undersod before commencing installation. Failure 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 undersod and fulfilled (including detailed information found in manual subsections). 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 For your safety. Warranty Information contained in this and related product documentation must be read and followed. Failure do so renders the warranty null and void. WARNING Installers must follow local regulations with respect installation of carbon monoxide detecrs. Follow the Viessmann maintenance schedule of the boiler contained in this manual. Operating and Service Documentation It is recommended that all product documentation such as parts lists, operating and service instructions be handed over the system user for srage. Documentation is be sred near boiler in a readily accessible location for reference by service personnel. Licensed professional heating contracr The installation, adjustment, service and maintenance of this equipment must be performed by a licensed professional heating contracr. Please see section entitled For your safety. 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, shutdown procedure, and the need for professional service annually before the heating season begins. Product Information This document describes Vitronic 100 when used: in a single boiler system in a multi boiler system with higher third party control unit These instructions are not required for multi boiler systems with the Vitronic 300-K. 2

3 Vitronic 100, GC1B Installation and Service General Safety Installation Examples Table of Contents Page Safety, Installation and Warranty Requirements...2 Product Information...2 For your Safety...6 Overview of System Examples...7 Designations in the System Schemes...8 System Example Single Boiler System: Boiler with Therm-Control...9 Equipment Required...10 Electrical Installation Scheme...11 Wiring Diagram...12 Required Code...12 System Example Single Boiler System: Boiler with Shunt Pump and 3-Way Mixing Valve for Return Temperature Raising...13 Equipment Required...14 Electrical Installation Scheme...15 Required Code...16 System Example Single Boiler System with Vicrossal...17 Equipment Required...18 Electrical Installation Scheme...19 Required Code...20 System Example Multi Boiler System: Boiler with Therm-Control...21 Equipment Required...22 Electrical Installation Scheme...23 Required Code...24 System Example Multi Boiler System: Any Boiler with Shunt Pump for Return Temperature Raising...25 Equipment Required...26 Electrical Installation Scheme...27 Required Code...28 System Example Multi Boiler System: Any Boiler with Circuit Pump and 3-way Mixing Valve for Return Temperature Raising...29 Equipment Required...30 Electrical Installation Scheme...31 Required Code...32 System Example Multi Boiler System: Vicrossal or Virond With Therm-Control (with a low temperature heating circuit)...33 Equipment Required...34 Electrical Installation Scheme...35 Required Code

4 Table of Contents Vitronic 100, GC1B Installation and Service Page Installation Example (continued) System Example Multi Boiler System: Vicrossal and Low Temperature Boiler with Shunt Pump for Raising the Return Temperature...37 Equipment Required...38 Electrical Installation Scheme...39 Required Code...40 System Example Multi Boiler System: Vicrossal and Low Temperature Boiler with 3-way Mixing Valve and Boiler Circuit Pump...41 Equipment Required...42 Electrical Installation Scheme...43 Required Code Control Unit Installation Installation Sequence Commissioning Mounting the Control Unit...45 Fitting the Control Unit Front...46 Opening the Control Unit...47 Overview of Electrical Connections...48 Pump Connection Overview...50 Inserting Cables and Applying Strain Relief...51 Inserting the Boiler Coding Card...52 Inserting the LON Communication Module (if required)...52 Adjusting the Fixed High Limit (if required)...53 Changing the Adjustable High Limit (if required)...53 Connecting Sensors...54 Power Supply V External Connection...55 Connecting Actuars...56 Connecting the Central Fault Message Facility...57 Connection of Low Water Cut-off Device...57 Connections Safety Equipment abö...58 Connections Terminal aba...58 External Blocking - Single Boiler System...59 Vitronic 100, GC1B with 30% LTP Package (VD2 only)...60 External Changeover of Staged/Modulating Burners...61 Connection of Combustion Air Device...61 Provisional Burner Operation abö...62 Single Boiler System - Connecting an External Control Unit...62 Multi Boiler System - Connecting an External Control Unit...66 Burner Connection, Burner Control Wiring...71 Burner Connection, Mor Power Supply...73 Testing the Fixed High Limit...76 Matching the Coding Addresses the System Version...76 Checking Actuar and Sensors...78 Connecting the Control Unit the LON...79 Integrating a Control Unit in the LON...80 Making the LON Connections...81 Entering a Service PIN for LON Participants...82 Entering a PIN Code for Vicom

5 Vitronic 100, GC1B Installation and Service Table of Contents Service Scans Troubleshooting Page Calling up Service Level...83 Leaving the Service Level...83 Scanning Operating Data...83 Brief Scan...83 Scanning and Resetting Service Display...85 Fault Display...85 Function Description Boiler Water Temperature Control...91 DHW Tank Control...96 Code 1 Code 2 Designs Components Calling Up Coding Level Category 1 General...98 Category 2 Boiler...99 Category 3 DHW Category 4 Solar Calling Up Coding Level Category 1 General Category 2 Boiler Category 3 DHW Category 4 Solar Connection and Wiring Diagram Overview Main PCB Low Voltage Main PCB 120V~ Boiler Coding Card Sensors Checking Sensors Flue Gas Temperature Sensor Extension EA1 Accessory (optional) Parts Lists Specification Parts List Specification

6 Safety For your Safety CAUTION Follow these safety instructions closely avoid the risk of injury and damage property. H Operation Before operating the boiler, make sure you fully understand its method of operation. Your heating contracr should always perform the initial start-up and explain the system. Any warranty is null and void if these instructions are not followed. H Flue gas smell - Deactivate heating equipment. - Open windows and doors. - Inform your heating contracr. H Working on the equipment All personnel working on the equipment or the heating system must have the proper qualifications and hold all necessary licenses. Ensure main power equipment, heating system, and all external controls has been deactivated. Close main gas supply valve. Take precautions in all instances avoid accidental activation of power during service work. H Dangerous conditions - Deactivate main power immediately. - Close gas supply valve. H Maintenance and cleaning Regular inspection and service by a qualified heating contracr is important the performance of the boiler. Neglected maintenance impacts on warranty; regular inspection ensures clean, environmentally friendly and efficient operation. We recommend a maintenance contract with a qualified heating contracr. H Technical Data Manual - Installation Instruction and Service Instructions - Operating Instructions and User s Information Manual Additional applicable literature: - Accessory manuals Vitronic 100, GC1B Installation and Service If you smell gas H Don t smoke! Don t use naked flames or cause sparks (e.g. by switching lights or electrical appliances on and off) H Open windows and doors H Close the gas shut-off valve H Inform your heating engineer/service contracr from outside the building H Observe the safety regulations of your gas supply company (see gas meter) and those of your heating engineers (see start-up or installation report). In emergencies H Immediately switch off the power supply, e.g. at the separate fuse or power supply disconnect switch (unless there is a smell of gas). H Close the shut-off valves in the oil pipes or close the gas shut-off valve, whichever applicable. H Use suitable extinguishers in the event of fire. Installation of additional components The installation of additional components which have not been tested gether with the boiler can adversely affect the function and performance of the boiler. Our warranty does not cover and we accept no liability for damage attributable the installation of such components. Boiler room conditions H Do not use a room in which the air is polluted by halogenated hydro-carbons (e.g. as contained in aerosols, paints, solvents and cleaning agents) H Do not use a room subject high levels of dust H Do not use a room subject permanently high humidity H The room should be frost-protected H Max. ambient temperature 95 F (35 C). H Provide good ventilation and do not close or obstruct vents (if installed). This symbol indicates a reference other instructions which must be observed. This symbol indicates a reference other instructions which must be observed. 6

7 Vitronic 100, GC1B Installation and Service Overview of System Examples Installation Examples Boiler Characteristics Page Single Boiler Systems 1 Virond (VD2A) Therm-Control 10 2 Virond (VD2) Shunt pump and 3-way mixing valve for raising the return temperature 14 3 Vicrossal (CT3) Several heating circuits and one low temperature heating circuit 18 Multi Boiler Systems 4 Virond (VD2A) Therm-Control 22 5 Virond (VD2) Shunt pump for every boiler for return temperature raising 26 6 Virond (VD2) 3-way mixing valve for raising the return temperature 30 7 Virond (VD2A) Several heating circuits and one low temperature heating circuit, Therm-Control 34 8 Vicrossal (CT3), Virond (VD2/VD2A) 9 Vicrossal (CT3), Virond (VD2/VD2A) Several heating circuits and one low temperature heating circuit and low temperature boiler with shunt pump Several heating circuits and one low temperature heating circuit and low temperature boiler with 3-way mixing valve and boiler circuit pump These system examples are merely recommendations and must therefore be checked on site for completeness and function The heating circuits must be regulated by an external control unit. Connect three-phase consumers via additional contacrs. For multi boiler systems, the cascade and DHW tank temperature must be controlled by a higher third party control unit. For multi boiler systems, all the relevant coding addresses must be set on each Vitronic 100. For connecting a single boiler system a higher third party control unit, see page 62. For connecting a multi boiler system a higher third party control unit, see page 66. 7

8 Installation Examples Designations in the System Schemes Vitronic 100, GC1B Installation and Service 8

9 Vitronic 100, GC1B Installation and Service System Example 1 Installation Examples Single Boiler System: Boiler with Therm-Control 9

10 Installation Examples System Example 1 (continued) Vitronic 100, GC1B Installation and Service Equipment Required Pos. Designation 1 Boiler 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 5 Therm-Control temperature sensor tp ON/OFF switch qp qq qw DHW tank DHW tank temperature sensor STS DHW pump qe Heating Circuits Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB et Flue gas temperature sensor AGS External connections (for connection a higher third party control unit), (see page 62): rr External demand, load-dependent rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 wi wo er rp rq rw re ro tq System Accessories Contacr relay Downstream heating circuit controller, contact closed: Signal for mixing valve Close Central fault message system S Extension EA1 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control 3 digital inputs: External blocking External blocking with fault message Fault message input 1 switching output (dry contact switching relay): Switching a feed pump a substation KM BUS distribur, for several KM BUS participants LON communication module for communication with external control 10

11 Vitronic 100, GC1B Installation and Service System Example 1 (continued) Installation Examples Electrical Installation Scheme 11

12 Installation Examples System Example 1 (continued) Vitronic 100, GC1B Installation and Service Wiring Diagram Closing of system mixing valves installed downstream of the boiler via the Therm-Control temperature sensor. These 3rd party heating circuit control units are not connected the boiler control units. Required Code Category Function 0d:1 2 Boiler Therm-Control temperature sensor affects the mixing valves of downstream heating circuits. 4C:2 1 General Connection at plug sö affects the mixing valves of downstream heating circuits Legend A Contacr relay B Downstream heating circuit, switching contact closed: signal for mixing valve closed. 12

13 Vitronic 100, GC1B Installation and Service System Example 2 Installation Examples Single Boiler System: Boiler with Shunt Pump and 3-way Mixing Valve for Return Temperature Raising 13

14 Installation Examples System Example 2 (continued) Vitronic 100, GC1B Installation and Service Equipment Required Pos. Designation 1 Boiler 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 5 Shunt pump (on site) 6 3-way mixing valve 7 Temperature sensor T2 8 Temperature sensor T1 tp ON/OFF switch qp qq qw DHW tank DHW tank temperature sensor STS DHW pump qe Heating Circuits Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB et Flue gas temperature sensor AGS External connections (for connection a higher third party control unit), (see page 62): rr External demand, load-dependent rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 er rp rq rw re ro tq System Accessories Central fault message system Extension EA1 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control 3 digital inputs: External blocking External blocking with fault message Fault message input 1 switching output (dry contact switching relay): Switching a feed pump a substation KM BUS distribur, for several KM BUS participants LON communication module for communication with external control 14

15 Vitronic 100, GC1B Installation and Service System Example 2 (continued) Installation Examples Electrical Installation Scheme 15

16 Installation Examples System Example 2 (continued) Vitronic 100, GC1B Installation and Service Required Code Category Function 0C:1 2 Boiler Constant return temperature control. 16

17 Vitronic 100, GC1B Installation and Service System Example 3 Installation Examples Single Boiler System with Vicrossal 17

18 Installation Examples System Example 3 (continued) Vitronic 100, GC1B Installation and Service Equipment Required Pos. Designation 1 Boiler 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 5 Neutralizing system tp ON/OFF switch qp qq qw DHW tank DHW tank temperature sensor STS Circulation pump for DHW tank heating UPSB qe Heating Circuits Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB External connections (for connection a higher third party control unit), (see page 62): rr External demand, load-dependent rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 er rp rq rw re ro tq System Accessories Central fault message system Extension EA1 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party controls 3 digital inputs: External blocking External blocking with fault message Fault message input 1 switching output (dry contact switching relay): Switching a feed pump a substation KM BUS distribur, for several KM BUS participants LON communication module for communication with external cascade control 18

19 Vitronic 100, GC1B Installation and Service System Example 3 (continued) Installation Examples Electrical Installation Scheme 19

20 Installation Examples System Example 3 (continued) Vitronic 100, GC1B Installation and Service Required Code Category Function 0C:0 2 Boiler Without Therm-Control temperature sensor. 20

21 Vitronic 100, GC1B Installation and Service System Example 4 Installation Examples Multi Boiler System: Boiler with Therm-Control 21

22 Installation Examples Vitronic 100, GC1B Installation and Service System Example 4 (continued) Equipment Required Pos. Designation 1 Boiler 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 4 Therm-Control temperature sensor 5 Morized isolation valve 6 Supply temperature sensor (connection higher third party control unit) tp ON/OFF switch 9 Boiler II qp Vitronic 100, type GC1B qq Boiler water temperature sensor KTS qw Therm-Control temperature sensor qe Morized isolation valve tp ON/OFF switch qr qt qz DHW tank DHW tank temperature sensor (connection higher third party control unit) DHW pump (connection higher third party control unit) qi Heating Circuits Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB et Flue gas temperature sensor AGS External connections (for connection a higher third party control unit), (see page 66): rr Enable boiler, isolation valve open/closed rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 22

23 Vitronic 100, GC1B Installation and Service System Example 4 (continued) Installation Examples Equipment Required Pos. Designation System Accessories er Central fault message system S rp Extension EA1 rq 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control rw 3 digital inputs: External blocking External blocking with fault message Fault message input re 1 switching output (dry contact switching relay): Switching a feed pump a substation ro KM BUS distribur, for several KM BUS participants tq LON communication module for communication with external cascade control Electrical Installation Scheme 23

24 Installation Examples System Example 4 (continued) Vitronic 100, GC1B Installation and Service 24 Required Code Category Function 01:2 2 Boiler Multi boiler system with external cascade control via LON. 01:3 2 Boiler Multi boiler system with external cascade control via 0 10VDC input or switching relay.

25 Vitronic 100, GC1B Installation and Service System Example 5 Installation Examples Multi Boiler System: Any Boiler with Shunt Pump for Return Temperature Raising 25

26 Installation Examples Vitronic 100, GC1B Installation and Service System Example 5 (continued) Equipment Required Pos. Designation 1 Boiler I 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS tp Supply temperature sensor (connection higher third party control unit) 7 Morized isolation valve 8 Temperature sensor T2 9 Shunt pump (on site) qp Temperature sensor T1 tp ON/OFF switch qq qw qe qr qt qz qu tp Boiler II Vitronic 100, type GC1B Boiler water temperature sensor KTS Morized isolation valve Temperature sensor T2 Shunt pump (on site) Temperature sensor T1 ON/OFF switch qi qo wp DHW tank DHW tank temperature sensor (connection higher third party control unit) DHW pump (connection higher third party control unit) ww Heating Circuits Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB er Central fault message system et Flue gas temperature sensor AGS External connections (for connection a higher third party control unit), (see page 66): rr Enable boiler, isolation valve open/closed rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 26

27 Vitronic 100, GC1B Installation and Service System Example 5 (continued) Installation Examples Equipment Required Pos. Designation System Accessories er Central fault message system rp Extension EA1 rq 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control rw 3 digital inputs: External blocking External blocking with fault message Fault message input re 1 switching output (dry contact switching relay): Switching a feed pump a substation ro KM BUS distribur, for several KM BUS participants tq LON communication module for communication with external cascade control Electrical Installation Scheme 27

28 Installation Examples Vitronic 100, GC1B Installation and Service System Example 5 (continued) 28 Required Code Category Function 01:2 2 2 Boiler Multi boiler system with external cascade control via LON. 01:2 2 2 Boiler Multi boiler system with external cascade control via 0 10VDC input or switching relay.

29 Vitronic 100, GC1B Installation and Service System Example 6 Installation Examples Multi Boiler System: Any Boiler with Boiler Circuit Pump and 3-way Mixing Valve for Return Temperature Raising 29

30 Installation Examples Technical System Example Data 6 (continued) Vitronic 100, GC1B Installation and Service Equipment Required Pos. Designation 1 Boiler I 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 6 Supply temperature sensor (connection higher third party control unit) 7 3-way mixing valve 8 Temperature sensor T1 9 Boiler circuit pump (on site) tp ON/OFF switch qp qq qw qe qr qt tp Boiler II Vitronic 100, type GC1B Boiler water temperature sensor KTS 3-way mixing valve Temperature sensor T1 Boiler circuit pump (on site) ON/OFF switch qz qu qi DHW tank DHW tank temperature sensor (connection higher third party control unit) DHW pump (connection higher third party control unit) wp Heating Circuits Boiler Accessories ep Connection safety equipment abö (see page 58) eq ew ee et Minimum pressure limiter SDB Maximum pressure limiter SDB Water level limiter (low water cut-off) WB Flue gas temperature sensor AGS External connections (for connection a higher third party control unit), (see page 66): rr Dry contact for boiler enable, 3-way mixing valve operates in control mode rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 30

31 Vitronic 100, GC1B Installation and Service System Technical Example Data 6 (continued) Installation Examples Equipment Required Pos. Designation System Accessories er Central fault message system rp Extension EA1 rq 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control rw 3 digital inputs: External blocking External blocking with fault message Fault message input re 1 switching output (dry contact switching relay): Switching a feed pump a substation ro KM BUS distribur, for several KM BUS participants tq LON communication module for communication with external cascade control Electrical Installation Scheme 31

32 Installation Examples Vitronic 100, GC1B Installation and Service System Example 6 (continued) 32 Required Code Category Function 01:2 2 Boiler Multi boiler system with external cascade control via LON. 01:3 2 Boiler Multi boiler system with external cascade control via 0 10VDC input or switching relay. 0C:1 2 Boiler Constant return temperature control. 4d:2 1 General Boiler circuit pump at plug sl

33 Vitronic 100, GC1B Installation and Service System Example 7 Installation Examples Multi Boiler System: Vicrossal or Virond with Therm-Control (with a low temperature heating circuit) 33

34 Installation Examples Vitronic 100, GC1B Installation and Service System Example 7 (continued) Equipment Required Pos. Designation 1 Boiler I 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 4 Supply temperature sensor (connection higher third party control unit) 7 Neutralizing system tp ON/OFF switch 9 Boiler II qp Vitronic 100, type GC1B qq Boiler water temperature sensor KTS qw Morized isolation valve qe Therm-Control temperature sensor tp ON/OFF switch qr qt qz DHW tank DHW tank temperature sensor (connection higher third party control unit) DHW pump (connection higher third party control unit) wp Heating Circuit wq Low Temperature Heating Circuit Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB et Flue gas temperature sensor AGS (not for Vicrossal) External connections (for connection a higher third party control unit), (see page 66): rr Enable boiler, isolation valve open/closed rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 34

35 Vitronic 100, GC1B Installation and Service System Example 7 (continued) Installation Examples Equipment Required Pos. Designation System Accessories er Central fault message system rp Extension EA1 rq 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control rw 3 digital inputs: External blocking External blocking with fault message Fault message input re 1 switching output (dry contact switching relay): Switching a feed pump a substation ro KM BUS distribur, for several KM BUS participants tq LON communication module for communication with external cascade control Electrical Installation Scheme 35

36 Installation Examples Vitronic 100, GC1B Installation and Service System Example 7 (continued) Required Code Category Function 01:2 2 Boiler Multi boiler system with external cascade control via LON. 01:3 2 Boiler Multi boiler system with external cascade control via 0 10VDC input or switching relay. 0d:0 2 Boiler Only with the Vitronic 100 for Vicrossal: Without Therm-Control. 36

37 Vitronic 100, GC1B Installation and Service System Example 8 Installation Examples Multi Boiler System: Vicrossal and Low Temperature Boiler with Shunt Pump for Raising the Return Temperature (with a low temperature heating circuit) 37

38 Installation Examples Vitronic 100, GC1B Installation and Service System Example 8 (continued) Equipment Required Pos. Designation 1 Boiler I 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 4 Supply temperature sensor (connection higher third party control unit) 7 Neutralizing system tp ON/OFF switch 9 Boiler II qp Vitronic 100, type GC1B qq Boiler water temperature sensor KTS qw Temperature sensor T2 qe Temperature sensor T1 qr Morized isolation valve qt Shunt pump (on site) tp ON/OFF switch qz qu qi DHW tank DHW tank temperature sensor (connection higher third party control unit) DHW pump (connection higher third party control unit) wp Heating Circuit wq Low Temperature Heating Circuit Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB et Flue gas temperature sensor AGS (not for Vicrossal) External connections (for connection a higher third party control unit), (see page 66): rr Enable boiler, isolation valve open/closed rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 38

39 Vitronic 100, GC1B Installation and Service System Example 8 (continued) Installation Examples Equipment Required Pos. Designation System Accessories er Central fault message system rp Extension EA1 rq 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control rw 3 digital inputs: External blocking External blocking with fault message Fault message input re 1 switching output (dry contact switching relay): Switching a feed pump a substation ro KM BUS distribur, for several KM BUS participants tq LON communication module for communication with external cascade control Electrical Installation Scheme 39

40 Installation Examples Vitronic 100, GC1B Installation and Service System Example 8 (continued) 40 Required Code Category Function 01:2 2 Boiler Multi boiler system with external cascade control via LON. 01:3 2 Boiler Multi boiler system with external cascade control via 0 10VDC input or switching relay. 0d:0 2 Boiler Only with the Vitronic 100 for Vicrossal: Without Therm-Control.

41 Vitronic 100, GC1B Installation and Service System Example 9 Installation Examples Multi Boiler System: Vicrossal and Low Temperature Boiler with 3-way Mixing Valve and Boiler Circuit Pump (with a low temperature heating circuit) 41

42 Installation Examples Vitronic 100, GC1B Installation and Service System Example 9 (continued) Equipment Required Pos. Designation 1 Boiler I 2 Vitronic 100, type GC1B 3 Boiler water temperature sensor KTS 4 Supply temperature sensor (connection higher third party control unit) 7 Neutralizing system tp ON/OFF switch 9 Boiler II qp Vitronic 100, type GC1B qq Boiler water temperature sensor KTS qw Boiler circuit pump qe 3-way mixing valve qr Temperature sensor T1 tp ON/OFF switch qt qz qu DHW tank DHW tank temperature sensor (connection higher third party control unit) DHW pump (connection higher third party control unit) wp Heating Circuit wq Low Temperature Heating Circuit Boiler Accessories ep Connection safety equipment abö (see page 58) eq Minimum pressure limiter SDB ew Maximum pressure limiter SDB ee Water level limiter (low water cut-off) WB et Flue gas temperature sensor AGS (not for Vicrossal) External connections (for connection a higher third party control unit), (see page 66): rr Dry contact for boiler enable, 3-way mixing valve operates in control mode rt External changeover of staged/modulating burners rz External demand burner stage 2 ru External demand burner stage 1 42

43 Vitronic 100, GC1B Installation and Service System Example 9 (continued) Installation Examples Equipment Required Pos. Designation System Accessories er Central fault message system rp Extension EA1 rq 1 analog input (0 10VDC): Boiler water setpoint temperature via 3rd party control rw 3 digital inputs: External blocking External blocking with fault message Fault message input re 1 switching output (dry contact switching relay: Switching a feed pump a substation ro KM BUS distribur, for several KM BUS participants tq LON communication module for communication with external cascade control Electrical Installation Scheme 43

44 Installation Examples Vitronic 100, GC1B Installation and Service System Example 9 (continued) 44 Required Code Category Function 01:2 2 Boiler Multi boiler system with external cascade control via LON. 01:3 2 Boiler Multi boiler system with external cascade control via 0 10VDC input or switching relay. 0C:1 2 Boiler Only with the Vitronic 100 for low temperature boilers: Constant return temperature control. 0d:0 2 Boiler Only with the Vitronic 100 for Vicrossal: Without Therm-Control. 4d:2 1 General Only with the Vitronic 100 for low temperature boilers: Boiler circuit pump at plug sl

45 Vitronic 100, GC1B Installation and Service Mounting the Control Unit Control Unit Installation 1. Fasten the metal back plate the boiler jacket with four fasteners. Refer the installation instructions of the relevant boiler for mounting location. 2. Install the mid plate and junction box the back plate. 3. Fasten the junction box and mid plate the back plate with two fasteners. 4. Install the control rear section the junction box housing. Hook the control the back plate tabs and pivot downwards. 5. Fasten the control rear section the junction box with two fasteners. 45

46 Control Unit Installation Fitting the Control Unit Front Vitronic 100, GC1B Installation and Service 1. Snap on the control cover the control housing. 2. Snap on the interface cover the control cover. 3. Release the stay bar and lock in position. 4. Verify the coding plug installed (see page 52). Note: Route the ribbon cable through retainer A. 5. Return the stay bar the control cover and lock in position. 6. Close the control cover. 7. Secure the control cover the front housing with supplied fasteners. 8. Install the junction box cover and support with a supplied screws. 46 Legend A Cable retaining tab

47 Vitronic 100, GC1B Installation and Service Opening the Control Unit Control Unit Installation 1. Remove the junction box cover screws and remove the cover. 2. Remove the front housing screws. 3. Swing up the front part of the control housing. 4. Position the stay bar so that it supports the front housing. 47

48 Installation Sequence Overview of Electrical Connections Note: When making connection plugs avd and avh, bundle the individual wires of the cables closely the terminals. Vitronic 100, GC1B Installation and Service This prevents the wires from drifting in the adjacent voltage area. Legend Main PCB, low voltage Boiler water temperature sensor %A DHW tank temperature sensor %B DHW tank temperature sensor 2 for primary sre system (optional accessory, not used) ) Supply temperature sensor, low loss header (accessory) ag Flue gas temperature sensor (accessories) aja Therm-Control temperature sensor or Return temperature sensor T1 (supplied with VD2 and VD2A, accessory for CT3) ajb Return temperature sensor T2 (accessory) or Temperature sensor primary sre system (optional accessory, not used) avd External connection avg KM BUS participant (accessory) avh External connection Main PCB 120V~ söa1 Switching output or Primary pump for primary sre system (optional accessory, not used) sa DHW pump sl Shunt pump or boiler circuit pump (on site) fö Power supply fa Burner stage 1 gö Central fault message gsa1 Morized isolation valve or Mixing valve, return temperature raising facility or 3-way mixing valve, primary sre system (optional accessory not used) lö Burner stage 2/mod. abö External connections, e.g. supplementary safety equipment aba Safety chain, potential free abh Power supply for accessories 48

49 Vitronic 100, GC1B Installation and Service Overview of Electrical Connections (continued) Installation Sequence Legend A Vitronic 100 B Junction box C Burner mor power supply (refer page 73) fö Vitronic 100 GC1B power supply 49

50 Installation Sequence Pump Connection Overview Vitronic 100, GC1B Installation and Service Legend A 120V pump output B To the Vitronic control unit C Junction box Rated current: 2A~ * Maximum output 6FLA shared between all 120V outputs. Pumps 120V Available pump connections söa1 Switching contact/shunt pump sl Boiler pump sa DHW Pump 50

51 Vitronic 100, GC1B Installation and Service Inserting Cables and Applying Strain Relief Installation Sequence Control unit fitted the side of the boiler Route the cables from the junction box below in the control unit. Legend A Cables with moulded strain relief B On-site cables; strip up 4 in. (100 mm) insulation 51

52 Installation Sequence Inserting the Boiler Coding Card Vitronic 100, GC1B Installation and Service Only use the boiler coding card designated for the installed boiler (also see table on page 114). Insert the boiler coding card through the recess in the cover in slot X7. Boiler Coding card Identification Spare parts no. Vicrossal 300, CT Virond 200, VD2, VD2A Inserting the LON Communication Module (if required) B Connecting the control unit the LON, see page 79. A Legend A LON communication module (accessory) B Vitronic 100 GC1B 52

53 Vitronic 100, GC1B Installation and Service Adjusting the Fixed High Limit (if required) Installation Sequence When adjusting the fixed high limit, the adjustable high limit and the electronic temperature limiter must also be adjusted (see chart below). WARNING Disconnect power the 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 desired temperature. 3. Re-fi t the fuse box. Non-condensing boiler (VD2/VD2A) F ( C) Condensing boiler (CT3) F ( C) Facry set at; Adjustable ; Facry set at; Fixed high limit 230 F (110 C) Adjustable high limit 212 F (100 C) Coding address for the electronic maximum temperature limit of Vitronic 100; set coding address 06 (see boiler coding section) the temperature as shown or less 200 F (93 C) 210 F (99 C) 203 F (95 C) 188 F (87 C) 248 F (120 C) 230 F (110 C) 223 F (106 C) 210 F (99 C) 203 F (95 C) 188 F (87 C) Changing the Adjustable High Limit (if required) Note: Excessive DHW temperatures can damage the DHW tank. If the system is operated in conjunction with a DHW tank, ensure that the maximum permissible water temperature of the tank is not exceeded. If necessary, install suitable safety equipment for this purpose. 1. Remove rotary selecr A. 2. Using a pair of pointed pliers, break the restraining tab B or C out of the sp dial as shown. 3. Install rotary selecr A. Turn rotary selecr A the required temperature. The slot should line up the selected temperature. Legend A Rotary selecr B Break required tab or C Break required tab 53

54 Installation Sequence Connecting Sensors Vitronic 100, GC1B Installation and Service Main PCB, low voltage Boiler water temperature sensor %A DHW tank temperature sensor %B DHW tank temperature sensor 2 for primary sre system (optional accessory, not used) ) Supply temperature sensor, low loss header (accessory) ag Flue gas temperature sensor (accessory) aja Therm-Control temperature sensor or Return temperature sensor T1 (supplied with VD2 and VD2A - optional accessory for CT3) ajb Temperature sensor T2 (accessory) or Temperature sensor primary sre system (optional accessory, not used) Power Supply Legend L: Line N: Neutral G: Ground A Power supply 120VAC, 1PH, 60Hz, provide disconnect means and over current protection as per local codes B Terminals N, G and 11 (in junction box) C Junction box 1. Ensure that the main power supply the control contains over current protection with a minimum rating of 12A and 2-pole disconnect. WARNING The control must be grounded. Ensure that L, N and G are not interchanged. 2. Connect power supply wire the connection fö terminals 11, N and G on the DIN rail inside the junction box. 54

55 Vitronic 100, GC1B Installation and Service 120V External Connection Installation Sequence 120V pumps with an amperage draw of <2FLA Legend A DIN rail B Pump 120V pumps with an amperage draw of >2FLA Contacr specification 120VAC 1A Legend A DIN rail B Contacr/relay (field supplied) C Pump D Power supply w/disconnect and protection 240V single phase pumps Contacr specification 120VAC 1A Legend A DIN rail B Contacr/relay (field supplied) C Pump D Power supply w/disconnect and protection 208/460/575V 3 phase pumps Contacr specification 120VAC 1A Legend A DIN rail B Contacr/relay (field supplied) C Pump D Power supply w/disconnect and protection 55

56 Installation Sequence Connecting Actuars Vitronic 100, GC1B Installation and Service Legend A 24V Mixing Valve Adapr B DIN Rail (in junction box) C 24V Valve Actuar D Valve Legend A 120V Mixing Valve Adapr B DIN Rail (in junction box) C 24V Valve Actuar D Valve 120V Valve Adapr Rated voltage: Rated current: 24V Valve Adapr Rated voltage: Rated current: 120VAC max. 0.1 FLA 24VAC max FLA gs A1: for boiler protection (via 100% low temperature protection package) or morized isolation valve. Operating time: sec. selected via coding address Disconnect power control. 2. Install 120V or 24V valve adapr on DIN rail inside junction box. Refer the valve adapr Installation Instructions. 3. Insert the plug gs in socket gsa1 on the Vitronic control. 4. Fasten cable with tie. 5. Connect black wire of the adapr terminals 8,9 or 10 on the Din rail. 6. Connect valve actuar wires the adapr terminals 56

57 Vitronic 100, GC1B Installation and Service Connecting the Central Fault Message Facility Installation Sequence Rated voltage: 120V~ Rated current: max. 2A~ Connection of Low Water Cut-off Device 150 Legend abh Power supply for accessories. abö Connection for external equipment. A Low water cut-off (typical) CAUTION The diagram shown is only a simplified conceptual drawing of a typical low water cut off (LWCO) device. Refer the manual specific the device for interconnection details. 1. Remove jumper between terminals 12 and Make connection as shown in diagram. 57

58 Installation Sequence Vitronic 100, GC1B Installation and Service Connections Safety Equipment Connect the external safety equipment in series. A Legend A DIN rail B Low water cuff C Other safety controls Connections Terminal aba External shut-off 1. Remove jumper between terminals 19 and Connect dry contact. Controlled switch-off takes place when the contact is opened. WARNING B The terminals should be used for safety switch-off purposes only (e.g. through a high limit thermostat). During switch-off, there is no frost protection of the heating system and the boiler is not kept at the minimum boiler water temperature. Legend A Dry contact B DIN rail A Note: The heating system has no frost protection while it is blocked. The boiler is not held at the lower boiler water temperature. 58

59 Vitronic 100, GC1B Installation and Service External Blocking Single Boiler System Installation Sequence Connection options (dry contact) at: Plug abö Extension EA1 (accessory, see page 117) Plug abö Connection Note: Live contacts lead short circuits or phase failure. The external connection must be potential-free. Extension EA1 B Legend A Dry contact B Extension EA1 Legend A Dry contact B DIN rail Opening this contact leads a controlled burner shutdown. Note: Connect only safety shutdown equipment, e.g. temperature limiter, these terminals. Closing this contact leads a controlled burner shutdown. Any connected shunt or boiler circuit pump is spped. Note: The heating system has no frost protection during blocking. The boiler is not held at the lower boiler water temperature. Code Set 5d, 5E or 5F in category 1 General 3 or 4. 59

60 Installation Sequence Vitronic 100, GC1B with 30% LTP Package (VD2 only) Vitronic 100, GC1B Installation and Service 30% LTP Package consists of: - 1 circulation pump - 1 cast iron flange set - 2 full port ball valves - 1 flow check valve B sensor (strap -on) Each pump output: 120V single phase Max. pump current: 2 FLA IMPORTANT Pump current larger than 2 FLA will require a contacr or isolation relay (see page 55). Mandary Coding Address Changes 0C:5 - Modulating isolation valve (independant of boiler water temperature). 0d:2 - Switching contact 4A:1-17A Sensor installed 4b:1-17B Sensor installed 4C:2 - Connections at plug 20A1 Therm-control switch contact 4d:2 - Boiler circuit pump Legend A Vitronic 100 control B Junction box C Return temperature 2 ajb D Return temperature 1 aja E Shunt pump söa1 F Boiler pump sl 60

61 Vitronic 100, GC1B Installation and Service External Changeover of Staged/Modulating Burners Installation Sequence Connection at Plug avh. Note: Live contacts lead short circuits or phase failure. The external connection must be potential-free. Contact open: modulating mode Contact closed: two stage mode Legend A External changeover (dry contact) Note: When scanning the burner version, the address for modulation appears even after an external changeover. Code Set code 02:2 in group 2 Boiler. Connection of Combustion Air Device Legend A Combustion Air Device Adapr B DIN Rail in connection enclosure Connection of the Combustion Air Device Adapr 1. Disconnect power control and burners. 2. Install Combustion Air Device Adapr, on DIN Rail inside connection enclosure (refer installation manual of Combustion Air Device Adapr). 3. Remove jumper between terminals 16 and Make connection as shown in the diagram. IMPORTANT Wire BK2 must be connected terminal 16 and BK3 terminal 17 - DO NOT reverse. For more detail, refer the combustion air device Installation Instructions. 61

62 Installation Sequence Provisional Burner Operation 150 Vitronic 100, GC1B Installation and Service Remove jumper across terminals 16 and 17 (not shown) and connect terminals 16 and 18 external control via dry contact (heat demand on close). Upon heat demand the boiler will maintain low fire until modulation is externally controlled through BMS. Temperature control is limited by the adjustable high limit. For connection points refer the burner Installation Instructions. B Legend A Dry contact B DIN rail Single Boiler System Connecting an External Control Unit Settings Codes in category 2 Boiler : 02:1 for two-stage burner 02:2 for modulating burner 01:1 for single boiler system (delivered condition) The boiler water temperature must be set the lower value. The boiler is held at the required minimum temperature. The DHW tank adjustable high limit is activated when a DHW tank temperature sensor is connected. The fixed high limit settings and other settings depend on the system equipment. Non-condensing boiler (VD2/VD2A) F ( C) Condensing boiler (CT3) F ( C) Facry set at; Adjustable ; Facry set at; Fixed high limit 230 F (110 C) 210 F (99 C) 248 F (120 C) 210 F (99 C) Adjustable high limit 212 F (100 C) 203 F (95 C) 230 F (110 C) 203 F (95 C) Coding address for the electronic maximum temperature limit of Vitronic 100; set coding address 06 (see boiler coding section) the temperature as shown or less 200 F (93 C) 188 F (87 C) 223 F (106 C) 188 F (87 C) 62

63 Vitronic 100, GC1B Installation and Service Single Boiler System Connecting an External Control Unit (continued) Installation Sequence External Demand Via 0 10VDC Input Connection at 0 10VDC input at extension EA1 (see page 117). 0-1VDC No default set boiler water temperature 1VDC Set value 50 F (10 C) 10VDC Set value 212 F (100 C) Observe coding address 1E in the General category. 1E:1 temperature demand adjustable in the range from F ( C) 1V 86 F (30 C) set value 10V 248 F (120 C) set value External Demand Via Switching Contacts Connection at plug avd/avh of the control unit. The set boiler water temperature is adjusted via code 9b in category 1 General. Two-stage Burner A, B and C are dry contacts of the higher control unit. Legend A Burner stage 1 ON B Burner stage 2 ON C External load-dependent starting External Burner Start Burner Stage 1 Contact at terminals 1 and 2 of plug avd: Contact closed: Burner stage 1 is switched on. Burner stage 2 is switched ON only for maintaining the minimum temperature. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R. Contact open: Burner stage 1 is switched off. External Burner Start Burner Stage 1 and 2 Contact at terminals 2 and 3 of plug avd Contact closed: Both burner stages are switched ON. The boiler water temperature is limited by the electronic maximum temperature limiter, if it is set below that of mechanical control thermostat R. Burner stage 2 is switched OFF 2 K sooner. Contact open: Burner stages 1 and 2 are switched OFF. External Starting Subject Load The burner is started, subject load, when the zero volt contact across terminals 2 and 3 at plug-in connecr avh closes. The boiler will be constantly operated at the set temperature. The boiler water temperature is limited via the maximum set boiler water temperature or via the mechanical control thermostat. The set value is adjusted via code 9b. 63

64 Installation Sequence Single Boiler System Connecting an External Control Unit (continued) Vitronic 100, GC1B Installation and Service Legend A Control unit B Junction box C Burner control unit D Burner activation (base load) E Burner modulation up F Burner modulation down Low Temperature Boiler With Modulating Burner (on-site modulation controller) Burner Connection: Connect plug fa of Vitronic 100 the burner. Plug lö from the Vitronic 100 via modulation controller (on site) modulation terminals on the burner. Set the minimum temperature at the higher control unit with the modulation controller 5 K higher than the lower boiler water temperature. Dry contact from BMS system triggers burner activation via avd at base load. Modulation control via dry contact from BMS points F and E. Temperature limited by the adjustable high limit. 64 For connection points refer the burner Installation Instructions.

65 Vitronic 100, GC1B Installation and Service Single Boiler System Connecting an External Control Unit (continued) Installation Sequence Legend A Control unit B Junction box C Burner control unit D Burner activation (base load) E BMS - Burner modulation control Refer the burner Installation Instructions. Vicrossal With Modulating Burner (on-site modulation controller) Burner Connection: Connect plug fa of Vitronic 100 the burner. Plug lö of the Vitronic 100 remains unallocated. Connect modulation terminals of the burner the onsite modulation controller. External Burner Start Base Load Contact at terminals 1 and 2 of plug avd Contact closed: The burner is started with base load. An external modulation controller regulates the load-dependent modulation. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R. Contact open: The burner is switched OFF. 65

66 Installation Sequence Vitronic 100, GC1B Installation and Service Multi Boiler System Connecting an External Control Unit Settings Codes in category 2 Boiler : 02:1 for two-stage burner 02:2 for modulating burner 01:3 for multi boiler system with on-site cascade control (third party control unit) 01:2 with on-site cascade control (third party control unit) via LON The cascade and DHW tank control must be provided by the higher third party control unit. Note: A boiler enable contact is essential prevent boiler damage. This contact must always be closed on the lead boiler. The fixed high limit safety settings and other settings depend on the system equipment. Non-condensing boiler (VD2/VD2A) F ( C) Condensing boiler (CT3) F ( C) Facry set at; Adjustable ; Facry set at; Fixed high limit 230 F (110 C) Adjustable high limit 212 F (100 C) Coding address for the electronic maximum temperature limit of Vitronic 100; set coding address 06 (see boiler coding section) the temperature as shown or less 200 F (93 C) 210 F (99 C) 203 F (95 C) 188 F (87 C) 248 F (120 C) 230 F (110 C) 223 F (106 C) 210 F (99 C) 203 F (95 C) 188 F (87 C) External Demand Via 0 10VDC Input Connection at 0 10VDC input at extension EA1 on each Vitronic 100 (accessory, see page 115). Enable Boiler Without an Additional Enable Contact 0 1VDC Boiler blocked. Morized isolation valve closed. Boiler circuit pump or shunt pump OFF. 1 10VDC Boiler water temperature default 1VDC Set value 50 F (10 C) 10VDC Set value 212 F (100 C) Observe coding address 1E in the General category. Boiler enabled and held at its minimum temperature. Isolation valve open. Boiler circuit pump or shunt pump enabled. Note: Only for low temperature boilers: On the lead boiler, the voltage must be higher than 1VDC. 66 Enable Boiler With an Additional Enable Contact 0-1VDC No default set boiler water temperature 1VDC Set value 50 F (10 C) 10VDC Set value 212 F (100 C) Observe coding address 1E in the General category.

67 Vitronic 100, GC1B Installation and Service Multi Boiler System Connecting an External Control Unit (continued) Installation Sequence Make connection at plug avh. Note: This contact must always be closed on the lead boiler. Legend A Boiler enable (dry contact) Closed Contact Open A Boiler enabled and held at its minimum temperature. The isolation valve opens. The isolation valve is closed after approx. 5 min. External burner start not possible. External Burner Start Burner Stage 1 Contact at terminals 1 and 2 of plug avd: Contact closed: Burner stage 1 is switched on. Burner stage 2 is switched ON only for maintaining the minimum temperature. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R. Contact open: Burner stage 1 is switched off. Legend A Burner stage 1 ON B Burner stage 2 ON C Boiler enable Morized isolation valve Open or Close Enable Boiler, Isolation Valve Contact at terminals 2 and 3 of plug avh: Contact closed: Vicrossal: The isolation valve opens. Low temperature boiler: Initially, the preheat function for lag boilers is activated. After the preheat function has expired, the minimum boiler water temperature will be maintained and the burner stages can be controlled externally. The isolation valve opens. Contact open: The isolation valve is closed after approx. 5 min. Burner stages cannot be switched ON externally; a minimum temperature will not be maintained. External Burner Start Burner Stage 1 and 2 Contact at terminals 2 and 3 of plug avd: Contact closed: Both burner stages are switched ON. The boiler water temperature is limited by the electronic maximum temperature limiter, if it is set below that of mechanical control thermostat R. Burner stage 2 is switched OFF 2 K sooner. Contact open: Burner stages 1 and 2 are switched OFF. External Demand Via Switching Contacts Connection at plug avd/avh of the control unit. The set boiler water temperature is adjusted via code 9b in category 1 General. Two-Stage Burner A, B and C are dry contacts of the higher control unit. 67

68 Installation Sequence Multi Boiler System Connecting an External Control Unit (continued) Vitronic 100, GC1B Installation and Service Legend A Control unit B Junction box C Burner control unit D Burner activation (base load) E Isolation valve open F Burner Modulation up G Burner Modulation down Refer the burner Installation Instructions. 68 Enable Boiler, Isolation Valve Contact at terminals 2 and 3 of plug avh: Contact closed: Initially, the preheat function for lag boilers is activated. After the preheat function has expired, the minimum boiler water temperature is maintained and the burner is controlled by the on-site modulation controller. Contact open: The isolation valve is closed after approx. 5 min. The burner cannot be switched ON externally; a minimum temperature will not be maintained. Vicrossal With Modulating Burner (on-site modulation controller) Burner Connection: Connect plug fa of Vitronic 100 the burner. Plug lö of the Vitronic 100 remains unallocated. Via external demand avh, the on-site modulation controller starts the burner with base load. Low Temperature Boiler With Modulating Burner (on-site modulation controller) Burner Connection: Connect plug fa of Vitronic 100 the burner. Plug lö from the Vitronic 100 via modulation controller (on site) plug lö on the burner. Via external demand avd, the on-site modulation controller starts the burner with base load. External Burner Start Base Load Contact at terminals 1 and 2 of plug avd: Contact closed: The burner is started with base load. To maintain the minimum temperature, the burner is switched full load via the Vitronic 100. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R. Contact open: The burner is switched OFF.

69 Vitronic 100, GC1B Installation and Service Multi Boiler System Connecting an External Control Unit (continued) Installation Sequence Legend A Control unit B Junction box C Burner control unit D Burner activation - base load E Isolation valve open F BMS - Burner modulation control External Burner Start Base Load Contact at terminals 1 and 2 of plug avd: Contact closed: The burner is started with base load. An external modulation controller regulates the loaddependent modulation. The boiler water temperature is limited by the electronic maximum temperature limiter, if that is set below that of mechanical adjustable high limit R. Contact open: The burner is switched OFF. Enable Boiler, Isolation Valve Contact at terminals 2 and 3 of plug avh: Contact closed: The isolation valve opens. Contact open: The isolation valve is closed after approx. 5 min. The burner cannot be switched ON externally; a minimum temperature will not be maintained. 69

70 Installation Sequence Multi Boiler System Connecting an External Control Unit (continued) Vitronic 100, GC1B Installation and Service Legend A Boiler blocking B Start boiler as the last one in the boiler sequence C External changeover of stepped/ modulating burners Hooking Up On-site Control Devices Via LON Boiler Blocking Contact at terminals 1 and 2 of plug avd: Contact closed: The boiler is blocked and has been removed from the boiler sequence. The isolation valve or the 3-way mixing valve for constant return temperature raising, the shunt pump or the boiler circuit pump are switched OFF. The other boilers provide the required heating. Note: If all boilers are blocked or there is no other boiler ready for operation, then there will be no frost protection for the heating system. Contact open: The boiler is reinstated in the current boiler sequence. Start Boiler as the Last One in the Boiler Sequence Contact at terminals 2 and 3 of plug avd: Contact closed: The boiler is started as the last one in the boiler sequence. This boiler is started if the other boilers in the heating system cannot provide sufficient heat. Contact open: The boiler is reinstated in the current boiler sequence. 70

71 Vitronic 100, GC1B Installation and Service Burner Connection, Burner Control Wiring Installation Sequence For burners with plug-in connection The burner cables are included in the standard delivery of the Vitronic. Connect the burner in accordance with applicable codes. Terminal codes L Phase via fixed high limit the burner? Ground connection N Neutral connection the burner T1,T2 Control circuit S3 Connection for burner fault indicar B4 Connection for burner hours counter 1. Disconnect power burner and boiler control. 2. Connect plugs fa and plug lö respective counter plugs in boiler control unit. 3. Connect the 7-pole plug fa and the 3-pole plug lö the burner. CAUTION This is a generic connection drawing only! Follow the burner manufacturer s connection drawings for Viessmann controls. Legend A To boiler control unit 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 Color codes as applicable BK Black BN Brown BU Blue Legend A To plug-in connection in the Vitronic boiler control junction box B To burner 71

72 Installation Sequence Burner Connection, Burner Control Wiring (continued) Vitronic 100, GC1B Installation and Service CAUTION This is a generic connection drawing only! Follow the burner manufacturer s connection drawings for Viessmann controls. For burner without plug-in connection The burner cables are included in the standard delivery of the Vitronic. Connect the burner in accordance with applicable codes. Note: Write the terminal numbers or markings on the drawing for future reference. 72 Legend A Vitronic 100 control B Junction box C Burner fa Burner, 1st stage lö Burner, 2nd stage/modulation Refer burner manufacturer s instruction on detailed connections for Viessmann controls.

73 Vitronic 100, GC1B Installation and Service Burner Connection, Mor Power Supply Installation Sequence CAUTION The control must be grounded. Ensure that L, N and G are not interchanged. 1. Ensure that the main power supply the control contains over current protection with a maximum rating of 15A and 2 pole disconnect. 2. Connect power supply wire the Connection fö terminals 11, N and G on the DIN rail inside the connection enclosure. Legend A Burner mor power supply 120 VAC, 1PH B Connection terminals and plug inside connection enclosure C Cable and conduit- facry supplied D Burner E Mor starter F Burner mor G Connection enclosure on boiler control Supply power must be sufficient cover both the 12A control plus the required mor amperage. 73

74 Installation Sequence Vitronic 100, GC1B Installation and Service Burner Connection, Mor Power Supply (continued) For burners with 240VAC, 1PH power supply. See burner manual for correct fuse and wire gauge sizing, and specifi c connections for Viessmann controls. 1. Disconnect power burner and boiler control. 2. Connect 240VAC power the terminals 21, 22 and 23 on the DIN rail inside the connection enclosure. Provide fuseable disconnect means according local codes. 3. Connect supplied power cable the mor terminals on the burner. 4. Connect cable plug the socket on the DIN rail in the connection enclosure. Legend A Burner mor power supply 240VAC, 1PH B Connection terminals and plug inside connection enclosure C Cable and conduit- facry supplied D Burner E Mor starter F Burner mor G Connection enclosure on boiler control 74

75 Vitronic 100, GC1B Installation and Service Burner Connection, Mor Power Supply (continued) Installation Sequence For burners with 3PH 208, 460 or 575V power supply. See burner manual for correct fuse and wire gauge sizing, and specific connections for Viessmann controls. 1. Disconnect power burner and boiler control. 2. Connect 3PH power the terminals 21, 22, 23 and 24 on the DIN rail inside the connection enclosure. Provide fuseable disconnect means according local codes. 3. Connect supplied power cable the mor terminals on the burner. 4. Connect cable plug the socket on the DIN rail in the connection enclosure. Legend A Burner mor power supply 3PH 208, 460 or 575V B Connection terminals and plug inside connection enclosure C Cable and conduit - facry supplied D Burner E Mor starter F Overload G Burner mor H Connection enclosure 75

76 Commissioning Testing the Fixed High Limit Vitronic 100, GC1B Installation and Service The minimum circulation volume should be 10% of the circulation volume at rated load. Reduce the heat consumption as far as possible. 1. Hold down the TEST key until the burner has shut down: Thermostat is bridged. The fixed high limit must shut down the burner at the latest when the safety temperature has been reached. 2. Release the TEST key. 3. Wait until the boiler water temperature has dropped approx K below the selected safety temperature. 4. Reset the fixed high limit by pressing reset butn. Refer the Operating Instructions. Matching the Coding Addresses the System Version Check and adjust accordingly all addresses in Code 1. Check the following coding addresses and adjust accordingly in Code 2: Category Function 0C: 2 Boiler Return temperature control 0d: 2 Boiler Therm-Control 4C: 1 General Function at plug sö 4d: 1 General Function at plug sl 4E: 1 General Function at plug gs 98: 1 General Viessmann system number 9C: 1 General Moniring LON participants 76

77 Vitronic 100, GC1B Installation and Service Matching the Coding Addresses the System Version (continued) Commissioning Matching the Control Unit the Two-stage Burner Matching coding addresses according the burner used Address Meaning Setting 03: Fuel Gas operation: 0 (delivered condition) Oil operation: 1 (irreversible) 08: Units and tens of the maximum burner output Example: Max. burner output: 225 kw select: 25 Note: Values up and including 199 kw can be entered directly. 09: 0A: Hundreds of the maximum burner output Ratio of output burner stage 1 maximum burner output in percent Example: Max. burner output: 225 kw select: 2 Example: Output burner stage kw Max. burner output: 225 kw (135 kw: 225 kw) 100% = 60% Matching the Control Unit the Modulating Burner Note: The burner must be fully adjusted. To achieve a wide modulating range, set the minimum output as low as possible (take the chimney and flue system in account). Matching coding addresses according the burner used Address Meaning Setting 03: Fuel Gas operation: 0 (delivered condition) Oil operation: 1 (irreversible) 08: Units and tens of the maximum burner output Example: Max. burner output: 225 kw select: 25 Note: Values up and including 199 kw can be entered directly. 09: Hundreds of the maximum burner output Example: Max. burner output: 225 kw select: 2 15: Modulation range runtime Calculate servomor runtime(s) between base load and max. burner output 0A: Ratio of output base load maximum burner output in percent Example: Output burner stage kw Max. burner output: 225 kw (135 kw: 225 kw) 100% = 60% 05: Ratio of partial output at g of the servomor runtime maximum burner output in percent Example: Partial output 171 kw Max. burner output: 225 kw (171 kw: 225 kw) 100% = 76% 77

78 Commissioning Checking Actuars and Sensors Vitronic 100, GC1B Installation and Service The following actuars (relay outputs) can be switched subject system equipment level: Display Explanation 0 All actuars are switched off 1 Burner ON or burner stage 1 ON or modulation controller ramps up (modul. burner) 2 Burner stages 1 and 2 ON or modulation controller neutral (modul. burner) 3 Modulation controller ramps down (modul. burner). 5 Output sö On 6 Output sl On 7 Output gs Open 8 Output gs Neutral 9 Output gs Close 10 Output circulation pump for DHW tank heating sa ON 11 Output central fault message gö ON 15 Solar circuit pump output sf at solar control module SM1 enabled 16 Solar circuit pump output sf at solar control module SM1 switched minimum speed 17 Solar circuit pump output sf at solar control module SM1 switched maximum speed 18 Output ss at solar control module SM1 enabled 19 Contact P - S on plug abj for extension EA1 closed 20 Output A1 at extension AM1 enabled 21 Output A2 at extension AM1 enabled Testing Relays 1. Press OK and simultaneously for approx. 4 sec. flashes on the display. 2. With select and confirm with OK. 3. Select required actuar with (see following table). The display shows the number for the activated actuar and ON. Note: During burner operation, the connected pumps are started. Checking Sensors Actual temperatures can be scanned in the i menu. Refer the Operating Instructions. 78

79 Vitronic 100, GC1B Installation and Service Connecting the Control Unit the LON Commissioning The LON communication module (accessory) must be plugged in. Installation Instructions LON communication module Note: The data transfer via LON can take several minutes. Single boiler system with Vitronic 200-H and Vicom 100 LAN 1 (example) Set the LON participant numbers and further functions via code 2 (see the following table). Note: In the same LON system, the same participant number must not be allocated twice. Only one Vitronic may be programmed as fault manager. All coding addresses in the table are listed in the General group. Boiler control unit Vitronic 200-H Vitronic 200-H Vicom A A Legend A Terminal end resisr Participant no. 1. Code 77:1. Participant no. 10. Code 77:10. Participant no. 11. Set code 77:11. Participant no. 99. Control unit is fault manager. Code 79:1. Control unit is not fault manager. Code 79:0. Control unit is not fault manager. Code 79:0. Device is fault manager. Control unit transmits the time. Code 7B:1. Control unit receives the time. Set code 81:3. Control unit receives the time. Set code 81:3. Device receives the time. Control unit transmits outside temperature. Set code 97:2. Control unit receives outside temperature. Set code 97:1. Control unit receives outside temperature. Set code 97:1. -- Viessmann system number. Code 98:1. Viessmann system number. Code 98:1. Viessmann system number. Code 98:1. -- LON participant fault moniring Code 9C:20. LON participant fault moniring Code 9C:20. LON participant fault moniring Code 9C:

80 Commissioning Integrating a Control Unit in the LON Vitronic 100, GC1B Installation and Service Carrying out a LON participant check The participant check is used test communication with the system devices connected the fault manager. Preconditions: The control unit must be programmed as fault manager (code 79:1 in the General group). The LON participant number must be programmed in all control units. The LON participant list in the fault manager must be up date. Service menu: 1. Press OK and simultaneously for approx. 4 sec. 2. Service functions 3. Participant check 4. Select participant (e.g. participant 10). 5. Start the participant check with OK. Successfully tested participants are designated with OK. Unsuccessfully tested participants are designated with Not OK. Note: To carry out a new participant check, create a new participant list with Delete list? (participant list is updated). Note: During the participant check, the display for the relevant participant shows the participant no. and Wink for approx. 1 min. 80

81 Vitronic 100, GC1B Installation and Service Making the LON Connection Connection with Viessmann LON cable The line may be up 23 ft. (7 m) long Legend A Control unit or Vicom B LON cable, 23 ft. (7 m) long C Terminar Commissioning The Viessmann LON system is designed for the Line BUS pology with a terminar at both ends (accessories). The transfer distances for LON are subject the electrical properties of the respective cabling. For this reason, only use the stated cable types. Use only one type of cable within the LON. Observe the cabling requirements for the operation of the LON interface FTT 10-A (see All Viessmann equipment is connected via RJ45 plugs. The Viessmann LON system always requires the cores 1 and 2 and the screen. The cores are interchangeable. The installation is therefore safe from pole errors. Connection with Viessmann LON cable and coupling Connection with on-site cable and LON plug Installation spacing ft. (7 21 m) Legend A Control unit or Vicom B LON cable, 23 ft. (7 m) long Max. 3 cables between 2 appliances C Terminar D LON coupling 3000 ft. The line may be up 3000 ft. (900 m)(with LON plug) Legend A Control unit or Vicom B On-site cable C Terminar D LON plug E Up 99 participants Connection with LON cable, on-site cable and LON junction box 3000 ft. The line may be up 3000 ft. (900 m) (with LON junction boxes) Legend A Control unit or Vicom B LON cable, 23 ft. (7 m) long C Terminar D LON junction boxes E On-site cable F Up 99 participants 81

82 Commissioning Entering a Service PIN for LON Participants Vitronic 100, GC1B Installation and Service Integration of the Vitronic 100 in a higher LON system, e.g. in conjunction with a third party control unit. The LON participant is identified with the service PIN. 1. Press OK and simultaneously for approx. 4 sec. 2. Press select 6. PIN is displayed. 3. Enable PIN with OK. 4. Exiting the input function: Press. Entering a PIN Code for Vicom 100 The PIN code of a connected Vicom 100 can be entered at the Vitronic 100. Vicom 100 installation instructions 1. Press OK and simultaneously for approx. 4 sec. 2. Press select is displayed for the entry of the PIN code and the number of remaining entry attempts. 3. Select the position for the entry with. 4. Select the relevant figures with. 5. Confirm the PIN code with OK. The entered PIN code is checked (figures flashing). If the PIN code entered is correct, FrEE is displayed and the entry is aumatically left. 6. Exiting the input function: Press. 82

83 Vitronic 100, GC1B Installation and Service Calling Up the Service Level Service Scans 1. Press OK and simultaneously for approx. 4 sec. flashes on the display. 2. Select required function. See the following pages. Leaving the Service Level 1. Press select Confirm with OK. OFF flashes. 3. Confirm with OK. Note: The service level is aumatically exited after 30 min. Scanning Operating Data Operating data can be scanned in the i menu. Refer the Operating Instructions. Brief Scan 1. Press OK and simultaneously for approx. 4 sec. flashes on the display. 2. Confirm with OK. 3. Select the required scan with. For example, b for Boiler coding card (see following table) 4. Confirm selected scan with OK. For explanations of individual scans, see the following table: Brief Scan Display System scheme Software version Control unit 2 -- Maximum flue gas temperature 3 -- Set boiler water temperature 4 -- Common demand temperature 5 -- Set DHW tank temperature Software version Programming unit 83

84 Service Scans Brief Scan (continued) Vitronic 100, GC1B Installation and Service Brief Scan Display Number of KM BUS participants Number of LON participants 7 SNVT configuration 0:Au 1:Tool Software version communication coprocessor Software version LON module 8 -- Subnet address/system no. Node address 9 -- Burner type Appliance type b -- Boiler coding card L Burner: 0: OFF 1: Burner stage 1/base load 2: Burner stage 2/full load Isolation valve: 0: OFF 1: Preheating 2: Control Close 3: Control 4: Control Open 5: Open 6: Run-on Output reduction in % 0: OFF E 1 E 3 Software version solar control module, type SM Software version cascade module Software version plug-in adapr for external safety equipment Extension AM1 F 2 F 3 F 4 Software version Extension EA1 Output 157 configuration (value corresponds code 5C setting) Software version Output A1 configuration (value corresponds code 33 setting) Output 157 switching state 0: OFF 1: ON Output A1 switching state 0: OFF 1: ON Input DE1 switching state 0: open 1: closed Output A2 configuration (value corresponds code 34 setting) Input DE2 switching state 0: open 1: closed -- External hook-up 0-10V Display in % Output A2 switching state 0: OFF 1: ON Input DE3 switching state 0: open 1: closed F 5 F 6 F 7 F 8 Solar Control Module SM1 Stagnation time of the solar thermal system in hrs. Night DHW circulation, solar thermal system (number) Moniring of differential temperature, solar thermal system Reheating suppression 0: disabled 1: enabled Output 22 switching state 0: OFF 1: ON 84

85 Vitronic 100, GC1B Installation and Service Scanning and Resetting Service Display Service Scans/ Troubleshooting When the limits specified in coding addresses 21, 23 or 1F in category 2 Boiler are reached, the red fault indicar flashes and the following appears on the programming unit display (subject the setting): The specified hours run and. The defaulted interval with clock symbol u and. The defaulted max. flue gas temperature and. Acknowledging and Resetting Service Press OK acknowledge a service message. Note: An acknowledged service message that was not reset reappears after 7 days. After a Service Has Been Carried Out (resetting service) Reset code 24:1 24:0 in category 2 Boiler. Note: The selected service parameters for hours run and time interval restart at 0. Fault Display In the event of a fault, the red fault display flashes at the control unit. On the programming unit display, the 2-digit fault code and flash. Output gö (central fault message) is switched ON. Other current faults can be displayed with. For an explanation of the fault codes, see the following pages. Example: Fault code 50 Acknowledge Fault Press OK; the standard display is shown again. A fault message facility, if connected, will be switched off. If an acknowledged fault is not remedied, the fault message will be re-displayed the following day and the fault message facility restarted. Calling up Acknowledged Faults Press OK for approx. 4 sec. The 10 most recent faults (including resolved ones) can be scanned. Calling Up Fault Codes From the Fault Memory (fault hisry) The 10 most recent faults (including those remedied) are saved and can be called up. Faults are sorted by date. 1. Press OK and simultaneously for approx. 4 sec. 2. Select with and activate fault hisry with OK. 3. Select fault messages with. 85

86 Troubleshooting Vitronic 100, GC1B Installation and Service Fault Display (continued) 86 Fault Codes Displayed System Characteristics Cause Measures Fault Code 0F Control mode. Service 0F is only displayed in fault hisry. Service required Note: After servicing, set code 24:0. 30 With DHW tank: Short circuit, boiler Check the boiler water temperature Circulation pump for DHW tank water temperature sensor (see page 116). heating on; boiler is maintained at set sensor. DHW tank temperature. Without DHW tank: Boiler is regulated by the adjustable high limit. 38 With DHW tank: Circulation pump for DHW tank heating on; boiler is maintained at set DHW tank temperature. Without DHW tank: Boiler is regulated by the adjustable high limit. 50 DHW tank primary pump ON : Set DHW temperature = Set boiler water temperature Priority control is cancelled or With primary sre system: DHW tank heating is started and spped via DHW tank temperature sensor With primary sre system: DHW tank heating is started and spped via DHW tank temperature sensor 1. Lead break, boiler water temperature sensor. Short circuit, DHW tank temperature sensor 1. Short circuit, DHW tank temperature sensor Control mode. Short circuit, supply temperature sensor. 58 DHW tank primary pump ON : Set DHW temperature = Set boiler water temperature Priority control is cancelled or With primary sre system: DHW tank heating is started and spped via DHW tank temperature sensor With primary sre system: DHW tank heating is started and spped by DHW tank temperature sensor 1. Lead break, DHW tank temperature sensor 1. Lead break, DHW tank temperature sensor 2. 5A Control mode. Lead break, supply temperature sensor. 60 Boiler with maximum temperature, no output reduction, mixing valve return temperature control Open. 68 Boiler with maximum temperature, no output reduction, mixing valve return temperature control Open. Short circuit, temperature sensor aja. Lead break, temperature sensor aja. Check the boiler water temperature sensor (see page 116). Check the DHW tank temperature sensor (see page 116). Check the DHW tank temperature sensor (see page 116). Check the boiler water temperature sensor (see page 116). Check the DHW tank temperature sensor (see page 116). Check the DHW tank temperature sensor (see page 116). Check the supply temperature sensor (see page 116). Check temperature sensor (see page 116). Check temperature sensor (see page 116). Without temperature sensor: Set code 4A:0 in group 1 General.

87 Vitronic 100, GC1B Installation and Service Fault Display (continued) Troubleshooting Fault Codes Displayed System Characteristics Cause Measures Fault Code 70 Shunt pump constantly ON. With primary sre system: Mixing valve primary circuit Short circuit, temperature sensor ajb. Check temperature sensor (see page 116). Close ; no DHW heating. 78 Shunt pump constantly ON. With primary sre system: Mixing valve primary circuit Close ; no DHW heating. Lead break, temperature sensor ajb. 90 Control mode. Short circuit, temperature sensor /, Connection at the solar control module. 91 Control mode. Short circuit, temperature sensor aö, Connection at the solar control module. 92 No solar DHW heating. Short circuit, collecr temperature sensor, Connection of temperature sensor & at solar control module. 93 Control mode. Short circuit, temperature sensor, connection at S3 of the Visolic. 94 No solar DHW heating. Short circuit, DHW tank temperature sensor, connection of temperature sensor % at solar control module. 98 Control mode. Lead break, temperature sensor /, connection the solar control module. 99 Control mode. Lead break, temperature sensor aö, connection the solar control module. Check temperature sensor (see page 116). Without temperature sensor: Set code 4b:0 in group 1 General. Check temperature sensor /. Solar control module installation and service instructions Check temperature sensor aö. Solar control module installation and service instructions Check solar control unit sensor. Solar control unit installation and service instructions Check solar control unit sensor. Solar control unit installation and service instructions Check solar control unit sensor. Solar control unit installation and service instructions Check temperature sensor /. Solar control module installation and service instructions Check temperature sensor aö. Solar control module installation and service instructions 87

88 Troubleshooting Vitronic 100, GC1B Installation and Service Fault Display (continued) Fault Codes Displayed System Characteristics Cause Measures Fault Code 9A No solar DHW heating. Lead break, collecr temperature sensor, connection of temperature sensor & at solar control module. Check solar control unit sensor. Solar control unit installation and service instructions 9b No solar DHW heating. Lead break, temperature sensor, connection of sensor at S3 of the Visolic. 9C Control mode. Lead break, DHW tank temperature sensor, connection of temperature sensor % at solar control module. 9E Control mode. No flow rate in solar circuit or flow rate o low, or temperature limiter has responded. Check solar control unit sensor. Solar control unit installation and service instructions Check solar control unit sensor. Solar control unit installation and service instructions Check solar circuit pump and solar circuit. Acknowledge fault message. 9F Control mode. Solar control module or Visolic fault. Displayed if a fault occurs at these appliances that has no fault code in the Vitronic. A0 Boiler cools down. Fault, safety equipment at X7 of plug-in adapr 2 for external safety equipment. A1 Boiler cools down. Fault, safety equipment at X3 of plug-in adapr 2 for external safety equipment. A2 Boiler cools down. Fault, safety equipment at X2 of plug-in adapr 2 for external safety equipment. A3 Boiler cools down. Fault, safety equipment at X1 of plug-in adapr 2 for external safety equipment. AA Control mode. Therm-Control configuration fault: Plug aja not plugged in. Ab Control operation; DHW tank may be cold. Primary sre system configuration error: Code 55:3 has been selected, but plug ajb is not plugged in and/ or Codes 4C:1 and 4E:2 in the General category have not been set. Solar control unit installation and service instructions Check solar control unit. Solar control unit installation and service instructions Check safety equipment, and reset if required. Check safety equipment, and reset if required. Check safety equipment, and reset if required. Check safety equipment, and reset if required. Insert plug aja. For Vicrossal, code 0d: 0 in group 2 Boiler must be selected. Insert plug ajb and check codes. 88

89 Vitronic 100, GC1B Installation and Service Fault Display (continued) Troubleshooting Fault Codes Displayed System Characteristics Cause Measures Fault Code AC Control mode. Return temperature control configuration error: Code 0C:1 in group 2 Boiler has been set, but plug aja is not plugged in and/or code 4E:0 in group 1 General is not set. Ad Control mode. Isolation valve configuration error: Code 0C:2, 0C: 3 or 0C:4 in group 2 Boiler is set and code 4E:1 in group 1 General is set. Insert plug aja and check codes. With isolation valve: Set code 4E:0 in group 1 General. Without isolation valve: Set code 0C:1 in group 2 Boiler. b0 Control mode. Short circuit, flue gas temperature sensor. Check the flue gas temperature sensor (see page 116). b1 Control mode. Communication error, programming unit. Check connections and replace the programming unit if required. b5 Control mode. Internal fault. Check PCB and plug-in connection; replace PCB if required. b6 Constant mode. Invalid hardware recognized. Check coding address 92 ; 92:161 must be selected. b7 Boiler is regulated by the adjustable high limit. Boiler coding card fault. Plug in or replace boiler coding card. b8 Control mode. Lead break, flue gas temperature sensor. Check the flue gas temperature sensor (see page 116). Without flue gas temperature sensor: Set code 1F:0 in group 2 Boiler. bf Control mode. No communication via LON. Incorrect LON communication module. Replace LON communication module. C1 Boiler cools down. External safety equipment at plug abö. Check connection and external safety equipment. C2 No solar DHW heating. Lead break, KM BUS solar control module or Visolic. Check KM BUS cable and appliance. Without solar control unit: Set code 54:0 in group 1 General. C3 Control mode. Communication error, extension AM1. Check connections. Without extension AM1: Set code 32:0 in group 1 General. C8 Boiler cools down. Fault, low water indicar at X7 of plug-in adapr 1 for external safety equipment. Check the system water level; reset low water indicar. 89

90 Troubleshooting Vitronic 100, GC1B Installation and Service Fault Display (continued) Fault Codes Displayed System Characteristics Cause Measures Fault Code C9 Boiler cools down. Fault, maximum pressure limiter at X3 of plug-in adapr 1 for external safety equipment. Check system pressure; reset maximum pressure limiter. CA Boiler cools down. Fault, minimum or maximum pressure limiter 2 at X2 of plug-in adapr 1 for external safety equipment. Cb Boiler cools down. Additional fixed high limit fault or Temperature limiter at X1 of plug-in adapr 1 for external safety equipment. Check system pressure, reset minimum or maximum pressure limiter 2. Check system temperature; reset fixed high limit. Cd Control mode. Vicom 100 communication fault. Check connections and the Vicom 100. CE Control mode. Communication fault, plug-in adapr 1 for external safety equipment. CF Control mode. No communication via LON. Communication error, LON communication module of control unit. Installation and service instructions Vicom 100 Without Vicom 100: Set code 95:0 in group 1 General. Check plug-in adapr. Without plug-in adapr: Set code 30:0 in group 1 General. d1 Boiler cools down. Burner fault. Check burner. d2 Control mode. Communication fault, plug-in adapr 2 for external safety equipment. Check LON communication module and replace if required. If no LON communication module is installed, set code 76:0 in category 1 General. Check plug-in adapr). Without plug-in adapr: Set code 31:0 in group 1 General. d3 Control mode. Communication error, extension EA1. Check connections (see page 115). Without extension EA1: Set code 5b:0 in category 1 General. d4 Boiler cools down. The fixed high limit has responded or fuse F2 has blown. d6 Control mode. Input DE1 at extension EA1 reports a fault. d7 Control mode. Input DE2 at extension EA1 reports a fault. d8 Control mode. Input DE3 at extension EA1 reports a fault. Check the fixed high limit or the burner, burner loop and fuse F2. Remove fault at appliance concerned. Remove fault at appliance concerned. Remove fault at appliance concerned. 90

91 Vitronic 100, GC1B Installation and Service Boiler Water Temperature Control Function Description Brief Description The boiler water temperature is regulated by starting and spping the burner or through modulation. The set boiler water temperature is determined from the following parameters: Set supply temperature of the heating circuit A1 (system circuit) or the heating circuits connected via the LON External demand Set DHW temperature The set boiler water temperature is subject the boiler and the heating/control versions. The boiler coding card defaults a minimum boiler water temperature that must be maintained protect the boiler. In conjunction with Therm-Control: The set boiler water temperature will be increased when the actual temperature at the Therm-Control sensor falls below the set temperature. For heating the DHW tank, a set boiler water temperature is defaulted that lies 20 K above the set DHW temperature (change in coding address 60 in category 3 DHW ). Functions The boiler water temperature is captured by the following equipment: Fixed high limit STB (liquid expansion) Adjustable high limit TR (liquid expansion) Boiler water temperature sensor (change in resistance) Upper Control Range Limits Fixed high limit STB 230/210ºF (110/99ºC) Adjustable high limit TR 203/189ºF (95/87ºC) Electronic maximum temperature limit: Setting range: 68/260ºF (20 127ºC) Changed via coding address 06 in the Boiler category. Lower control range limits Boiler Protection Function Therm-Control (Start-up system) For heating systems with distribur installed close the boiler. Requirement: The boiler water flow rate in the startup phase (e.g. after a weekend shutdown) must be able be reduced by at least 50%. Also affects the heating circuits. Function Single Boiler Systems The Therm-Control sensor, installed near the return connecr, captures the return temperature. The burner is ramped up full load if the facryselected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the mixing valve. When the set temperature is exceeded, the mixing valves are opened and the flow rate gradually increased 100%. Multi Boiler Systems The Therm-Control sensor, installed near the return connecr, captures the return temperature. The burner is ramped up full load if the facryselected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the isolation valve. Where the Therm-Control sensor cannot affect the isolation valves it must, instead, regulate the downstream heating circuits. When the set temperature is exceeded, the isolation valve is opened and the flow rate gradually increased 100%. Lower Control Range Limits In standard mode and when frost protection is enabled, the boiler water temperature will be regulated subject the respective boiler 91

92 Function Description Boiler Water Temperature Control (continued) Vitronic 100, GC1B Installation and Service Connection in Heating Systems Without LON Single Boiler System Plug söa1 of the Vitronic is used as switching contact for the Therm-Control. Required code: 4C:2 in category 1 General Legend söa1 A B Closing the mixing valves Contacr relay Downstream heating circuit controller, switching contact closed: Signal for mixing valve Close Multi Boiler System Plug söa1 of the Vitronic is used as switching contact for the Therm-Control. Required code: 0d:1 in category 2 Boiler and 4C:2 in category 1 General Legend söa1 Closing the mixing valves A1 Contacr relay connection boiler #1 A2 Contacr relay connection boiler #2 B Downstream heating circuit controller, switching contact closed: Signal for mixing valve Close C Power supply, 120V/60 Hz D Junction box, on site Raising the Return Temperature Via Shunt Pump or/and 3-way Mixing Valve With shunt pump: For heating systems with distribur installed close the boiler. With 3-way mixing valve: For heating systems where downstream heating circuits cannot be controlled, e.g. older heating systems or commercial green houses. 92

93 Vitronic 100, GC1B Installation and Service Boiler Water Temperature Control (continued) Function Description Requirement: The boiler water flow rate must be able be reduced by at least 50%. With shunt pump: Size the shunt pump approx. 30% of the tal throughput. With 3-way mixing valve: Size the boiler circuit pump at each boiler approx. 110% of the tal throughput. Also affects the heating circuits. Function Single boiler systems and multi boiler systems with a common shunt pump Temperature sensors T1 and T2 capture the return temperature at different test points. The shunt pump is started via temperature sensor T2 if the facry-selected minimum return temperature (defaulted by the boiler coding card) is not being achieved. The flow rate will be reduced via the mixing valve if the minimum return temperature captured by temperature sensor T1 is not achieved despite the return temperature raising. Single boiler systems with shunt pump and 3-way mixing valve Temperature sensors T1 and T2 capture the return temperature at different test points. The shunt pump is started via temperature sensor T2 if the facry-selected minimum return temperature (defaulted by the boiler coding card) is not being achieved. The flow rate will be reduced via the 3-way mixing valve if, in spite of the return temperature raising facility, the minimum return temperature captured by temperature sensor T1 is not achieved. Multi boiler systems with boiler circuit pump and 3-way mixing valve Temperature sensor T1 records the return temperature. The flow rate is proportionally reduced via the 3-way mixing valve on the boilers if the facry-selected set temperature (defaulted by the boiler coding card) is not achieved. When the set temperature is exceeded, the 3-way mixing valve is opened and the flow rate is gradually increased 100%. Multi boiler systems with boiler circuit pump, low loss header and 3-way mixing valve Temperature sensor T1 records the return temperature. The flow rate is proportionally reduced via the 3-way mixing valve on the boilers if the facry-selected set temperature (defaulted by the boiler coding card) is not achieved. When the set temperature is exceeded, the 3-way mixing valve is opened and the flow rate is gradually increased 100%. Downstream heating circuits are hydraulically separated. The flow temperature is controlled by the temperature sensor (cascade control unit) in the low loss header. Connection in Heating Systems Without LON Single Boiler System Plug söa1 of the Vitronic is used as switching contact. Required code: 4C:2 in category 1 General Multi boiler systems with shunt pumps for every boiler Temperature sensors T1 and T2 capture the return temperature at different test points. The shunt pump is started via temperature sensor T2 if the facry-selected minimum return temperature (defaulted by the boiler coding card) is not being achieved. If the minimum return temperature captured by temperature sensor T1 is not achieved despite the return temperature raising, the flow rate will be reduced via the isolation valve. Where temperature sensor T1 cannot affect the isolation valves it must, instead, regulate the downstream heating circuits. Legend söa1 A B Closing the mixing valves Contacr relay Downstream heating circuit controller, switching contact closed: Signal for mixing valve Close 93

94 Function Description Boiler Water Temperature Control (continued) Vitronic 100, GC1B Installation and Service Multi Boiler System Plug söa1 of the Vitronic is used as switching contact. Required code: 0d:1 in category 2 Boiler and 4C:2 in category 1 General Legend söa1 Closing the mixing valves A1 Contacr relay connection boiler #1 A2 Contacr relay connection boiler #2 B Downstream heating circuit controller, switching contact closed: Signal for mixing valve Close C Power supply, 120V/60 Hz D Junction box, on site Distribution Pump For heating systems with remote substation (> 20 m). Requirement: The heat transfer must be able be reduced. Also affects the heating circuits. The distribution pump must be started by a higher third party control unit if a boiler is enabled. Size the distribution pump approx. 110% of the tal throughput. With injection control: For heating circuits that require heat immediately a heat demand is issued (e.g. air heaters). Function Multi boiler systems with distribution pump and low pressure distribur Temperature sensor T1 records the return temperature. The burner is ramped up full load if the facryselected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the mixing valve. The mixing valves are fully closed upon demand. When the set temperature is exceeded, the mixing valves are opened and the flow rate gradually increased 100%. Multi boiler systems with distribution pump and injection control Temperature sensor T1 records the return temperature. The burner is ramped up full load if the facryselected set temperature (defaulted by the boiler coding card) is not being achieved. The flow rate is reduced via the mixing valve. For this, the mixing valves are proportionally or fully closed. When the set temperature is exceeded, the mixing valves are opened and the flow rate gradually increased 100%. Connection in Heating Systems Without LON Multi Boiler System Plug söa1 of the Vitronic is used as switching contact. Required code: 0d:1 in category 2 Boiler and 4C:2 in category 1 General 94 Legend söa1 Closing the mixing valves A1 Contacr relay connection boiler #1 A2 Contacr relay connection boiler #2 B Downstream heating circuit controller, switching contact closed: Signal for mixing valve Close C Power supply, 120V/60 Hz D Junction box, on site

95 Vitronic 100, GC1B Installation and Service Boiler Water Temperature Control (continued) Function Description Switching Hysteresis, Burner Permanent Switching Hysteresis Code 04:0 Heat Demand-dependent Switching Hysteresis The heat demand-dependent switching hysteresis takes the boiler load in account. The switching hysteresis, i.e. the burner runtime varies subject actual heat demand. ERB50 Function Code 04:1 Subject heat demand, values between 6 and 12 K result. ERB80 Function Code 04:2 Subject heat demand, values between 6 and 20 K result. Control Sequence Boiler Goes Cold (set value 2 K) The burner start signal is set as the set boiler water temperature minus 2 K, and the burner starts its own moniring program. The burner start may be delayed by a few minutes subject the number of auxiliary circuits and the combustion type. Boiler Heats Up The burner spping point is determined by the shutdown differential (coding address 13 in category 2 Boiler ). 95

96 Function Description DHW Tank Control Brief Description The DHW tank adjustable high limit functions as a constant temperature controller. This is achieved by starting and spping the circulation pump for DHW tank heating. The switching differential is ±2.5 K. For heating the DHW tank, a set boiler water temperature is defaulted that lies 20 K above the set DHW temperature (change in coding address 60 in category 3 DHW ). During DHW tank heating, central heating is switched off (optional DHW tank priority control). Functions Frost Protection The DHW tank will be heated 68ºF (20ºC) if the DHW temperature falls below 41ºF (5ºC). Auxiliary Function for DHW Heating This function is activated by providing a second set DHW temperature via coding address 58 in category 3 DHW and activating the fourth DHW phase for DHW heating. Set DHW Temperature The set DHW temperature can be adjusted between 50/140ºF (10/60ºC). The set range can be extended up 203ºF (95ºC) via coding address 56 in category 3 DHW. System With Primary Sre The above functions also apply in conjunction with primary sre systems. Set the following codes: 4C:1, 4E:2 in category 1 General, 55:3 in category 3 DHW (see coding overview). Vitronic 100, GC1B Installation and Service Control Sequence Coding 55:0 in Category 3 DHW, tank Heating The DHW tank Goes Cold (set value 2.5 K; change via coding address 59 in category 3 DHW ): The set boiler water temperature is adjusted 20 K higher than the set DHW temperature (adjustable via coding address 60 ). Pump on: Starting the circulation pump for DHW tank heating subject the boiler water temperature (code 61:0 ): The circulation pump starts when the boiler water temperature is 7 K higher than the DHW temperature. Immediate start of the circulation pump for DHW tank heating (code 61:1 ). The DHW tank is Hot (set value +2.5 K): The set boiler water temperature is returned the selected set value. Pump run-on: The circulation pump runs on after DHW tank heating until one of the following criteria is met: The differential between the boiler water and the DHW temperature is less than 7 K. The weather-compensated set flow temperature has been reached. The set DHW temperature is exceeded by 5 K. The set max. run-on time has been reached (coding address 62 ). Without pump run-on (code 62:0 ) Coding 55:1 in Category 3 DHW, Adaptive DHW tank Heating With adaptive DHW tank heating, the speed of the temperature rise during DHW heating is taken in account. System With Solar DHW Heating A third set DHW temperature can be defaulted via coding address 67 in category 3 DHW. Reheating by the boiler will be suppressed above this value. The DHW tank is heated exclusively by the solar thermal system. 96

97 Vitronic 100, GC1B Installation and Service DHW Tank Control (continued) Function Description The DHW tank Goes Cold (set value 2.5 K; change via coding address 59 ): The set boiler water temperature is adjusted 20 K higher than the set DHW temperature (adjustable via coding address 60 ). Pump on: Starting the circulation pump for DHW tank heating subject the boiler water temperature (code 61:0 ): The circulation pump starts when the boiler water temperature is 7 K higher than the DHW temperature. Immediate start of the circulation pump for DHW tank heating (code 61:1 ). The DHW tank is hot: The control unit checks whether the boiler will still be required supply heating energy after the DHW 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 sp times prevent the set DHW temperature being substantially exceeded after the DHW tank has been heated up. Code 55:2 in category 3 DHW, tank temperature control with 2 DHW tank temperature sensors DHW tank temperature sensor 1 enables the circulation pump for DHW tank heating and is evaluated for sp conditions during the pump run-on time. DHW tank temperature sensor 2: DHW tank heating will start early if a lot of hot water is drawn off. DHW tank heating will terminate early if no hot water is drawn off. DHW tank goes cold: Set value 2.5 K, adjustable via coding address 59 or Actual DHW temperature at sensor 2 < set DHW temperature x facr for start time (adjustment via coding address 69 ). Coding 55:3 in category 3 DHW, tank temperature control, primary sre system The DHW tank Goes Cold (set value 2.5 K; change via coding address 59 ): The set boiler water temperature is adjusted 20 K higher than the set DHW temperature (adjustable via coding address 60 ). The primary pump in the primary sre system starts. The 3-way mixing valve opens and then regulates the defaulted set DHW temperature. The circulation pump for DHW tank heating cycles (short term ON and OFF) until the set supply temperature has been reached (set DHW temperature + 5 K). Then it runs constantly. If, during heating, the actual value falls below the required set temperature, the circulation pump for DHW tank heating will temporarily cycle again. The DHW tank is Hot: DHW tank temperature sensor 1: Actual value set value and DHW tank temperature sensor 2: Actual value > set value 1.5 K: The set boiler water temperature is returned the weather-compensated set value. The circulation pump for DHW tank heating sps immediately when the 3-way mixing valve is fully opened or The circulation pump for DHW tank heating sps after expiry of the run-on time that is selected via coding address 62. The DHW tank is hot: Set value +2.5 K and Actual DHW temperature at sensor 2>set DHW temperature x facr for sp time (adjustment via coding address 68 ). 97

98 Coding Level 1 Calling Up Coding Level 1 Vitronic 100, GC1B Installation and Service Note: Codes that have not been assigned due the heating system equipment level or the setting of other codes are not displayed. 1. Press OK and simultaneously for approx. 4 sec. flashes on the display. 2. With, select 1 for coding level 1 and confirm with OK. I flashes on the display for the coding addresses in category Select the category of the required coding address with : 1: General 2: Boiler 3: DHW 4: Solar 6: All codes std device. In this category, all coding addresses of coding level 1 are displayed in ascending order. Confirm selected category with OK. 4. Select coding address with. 5. Select value according the following tables with and confirm with OK. 6. If you want reset all codes their delivered condition: Select 7 with and confirm with OK. When D flashes, confirm with OK. Note: This also resets codes from coding level Exit coding level 1: Press. 8. Exit the service level: Press select Confirm with OK. OFF flashes. 10. Confirm with OK. Note: The service level is aumatically exited after 30 min. Category 1 General Coding in the Delivered Condition System Design 00:1 One heating circuit without mixing valve (heating circuit 1), without DHW heating. Possible Change 00:0 Set aumatically if 01:2 or 01:3 has been selected. 00:2 One heating circuit without mixing valve A1 (heating circuit 1), with DHW heating (code is adjusted aumatically). Servomor Runtime 40:... Runtime, servomor at plug gsa1 in conjunction with return temperature raising. Delivered condition specified by the boiler coding card. 40:5 40:199 Runtime adjustable from sec. Boiler Circuit Pump Function 53:1 System with low loss header: Boiler circuit pump only runs when there is demand if the burner is running (with run-on time). 53:0 System with low loss header: Boiler circuit pump always runs when there is demand User No. 77:1 LON participant number. 77:1 77:99 LON participant number, adjustable from Note: Allocate each number only once. 98 Set Supply Temperature for External Demand 9b:0 No set minimum boiler water temperature for external demand. 9b:0 9b:127 Set value for external demand adjustable from ºF (0 127 C) (limited by boiler specific parameters).

99 Vitronic 100, GC1B Installation and Service Category 2 Boiler Coding Level 1 Coding in the Delivered Condition Possible Change System Design 01:1 Single boiler system. 01:2 Multi boiler system with cascade control via LON (e.g. Vitronic 300-K, type MW1B). 01:3 Multi boiler system with on site cascade control (third party control unit) via switching contacts (input avd and avh) or 0 10VDC input. Burner Type 02:1 Two-stage burner. 02:0 Single stage burner. 02:2 Modulating burner. Gas/Oil Operation 03:0 Gas operation. 03:1 Oil operation (irreversible). Boiler/Burner. 05:... Modulating burner: Burner curve. Delivered condition specified by the boiler coding card. 05:0 Linear burner curve. 05:1 05:99 Non-linear burner curve (P T : P max ) 100 P T in kw: Partial output at g of the servomor runtime P max in kw: Maximum output. Boiler Water Temperature Maximum Limit 06:87 Set 188ºF (87ºC). 06:20 06:127 Adjustable from ºF ( C). Observe the adjustable high limit settings. Boiler 07:1 Sequential boiler number in a multi boiler system (in conjunction with coding address 01 ). 07:2 07:4 Consecutive boiler number in multi boiler system. 99

100 Coding Level 1 Category 2 Boiler (continued) Vitronic 100, GC1B Installation and Service Coding in the Delivered Condition Flue Gas Monir 1F:0 With flue gas temperature sensor: Flue gas temperature is not monired for service display. Possible Change 1F:1 1F:250 When the limit for the flue gas temperature is exceeded, is displayed. Flue temperature measured in diagram C - e.g. IF:50 is displayed when flue gas temperature reaches or exceeds 50 C (122ºF) Burner Service in 100 hours 21:0 No service interval (hours run) selected. 21:1 21:100 The number of hours run before the burner should be serviced is adjustable from h; 1 step 100 h. Service Interval in Months 23:0 No interval for service. 23:1 23:24 Interval adjustable from 1 24 months. Service Status 24:0 No display. 24:1 display (the address is aumatically set and must be manually reset after a service has been carried out). Category 3 DHW Coding in the Delivered Condition Set DHW Temperature Reheating Suppression 67:40 For solar DHW heating: Set DHW temperature 104ºF (40 C). Reheating is suppressed above the selected set temperature (DHW heating by the boiler only if solar energy is not sufficient). Possible Change 67:0 67:95 Set DHW temperature adjustable from ºF (0 95 C) (limited by boiler-specific parameters). 100

101 Vitronic 100, GC1B Installation and Service Category 4 Solar Coding Level 1 Only in conjunction with solar control module, type SM1. Coding Coding in the Delivered Condition Speed control solar circuit pump 02:0 Solar circuit pump (multi stage) without speed control by solar control module SM1. Possible Change 02:1 Solar circuit pump (multi stage) is speedcontrolled with wave pack control. 02:2 Solar circuit pump is speed-controlled with PWM control. DHW tank Maximum Temperature 08:60 The solar circuit pump sps when the actual DHW temperature reaches the maximum DHW tank temperature 140ºF (60 C). 08:10 08:90 The maximum DHW tank temperature is adjustable from ºF (10 90 C). Stagnation Time Reduction 0A:5 To protect system components and heat transfer medium: the speed of the solar circuit pump is reduced if the actual DHW temperature is 5 K below the maximum DHW tank temperature 0A:0 Stagnation time reduction is disabled. 0A:1 0A:40 Value for stagnation time reduction is adjustable from 1 40 K. Flow Rate Solar Circuit 0F:70 The solar circuit flow rate at maximum pump speed is 7 L/min. 0F:1 0F:255 Flow rate adjustable from L/min; 1 step 0.1 L/min. Extended Solar Control Functions 20:0 No extended control functions enabled. 20:1 Additional function for DHW heating. 20:2 Differential temperature control 2. 20:3 Differential temperature control 2 and auxiliary function. 20:4 Differential temperature control 2 for central heating backup. 20:5 Thermostat function. 20:6 Thermostat function and auxiliary function. 20:7 Solar heating via external heat exchanger without additional temperature sensor. 20:8 Solar heating via external heat exchanger with additional temperature sensor. 20:9 Solar heating of two DHW tanks. 101

102 Coding Level 2 Calling Up Coding Level 2 Vitronic 100, GC1B Installation and Service Note: At coding level 2, all codes are accessible, including the codes in coding level 1. Codes that have not been assigned due the heating system equipment level or the setting of other codes are not displayed. 1. Press OK and simultaneously for approx. 4 sec. flashes on the display. 2. Press OK and simultaneously for approx. 4 sec. 3. With, select 2 for coding level 2 and confirm with OK. I flashes on the display for the coding addresses in category Select the category of the required coding address with : 1: General 2: Boiler 3: DHW 4: Solar 6: All codes std device. In this category, all coding addresses of coding level 2 are displayed in ascending order. Confirm selected category with OK. 5. Select coding address with. 6. Select value according the following tables with and confirm with OK. 7. If you want reset all codes their delivered condition: Select 7 with and confirm with OK. When D flashes, confirm with OK. Note: This also resets codes from coding level Exit coding level 2: Press. 9. Exit the service level: Press select Confirm with OK. OFF flashes. 11. Confirm with OK. Note: The service level is aumatically exited after 30 min. 102

103 Vitronic 100, GC1B Installation and Service Category 1 General Coding Level 2 Coding Coding in the Delivered Condition 00:1 Heating circuit without mixing valve A1, without DHW heating. Possible Change 00:0 Set aumatically, if codes 01:2 or 01:3 are selected. 00:2 Heating circuit without mixing valve A1, and with DHW heating. 1E:0 With extension EA1 (analog input 0-10V): Temperature demand from F (0 100 C): 1V 50 F (10 C) 10V 212 F 100 C. 20:... Controller integral time for low loss header in sec. Delivered condition specified by the boiler coding card. The greater the integral action time, the more accurate but slower the controller. 22:... Controller integral time for low loss header in min. Time between burner start and controller start. Delivered condition specified by the boiler coding card. 30:0 Without plug-in adapr for external safety equipment 1. 31:0 Without plug-in adapr for external safety equipment 2. 1E:1 Temperature demand from F ( C): 1V 86 F (30 C) 10V 248 F (120 C). 20:10 20:199 22:1 22:199 Controller integral time adjustable from sec; 1 step 10 sec. Controller integral time adjustable from min. 30:1 With plug-in adapr for external safety equipment 1 (aumatic recognition). 31:1 With plug-in adapr for external safety equipment 2 (aumatic recognition). 32:0 Without extension AM1. 32:1 With extension AM1; aumatic recognition. 33:1 Function output A1 at extension AM1: 33:0 DHW recirculation pump. Heating circuit pump, heating circuit without 33:2 DHW tank primary pump. mixing valve A1 (heating circuit 1). 33:3 Circulation pump for neutralising system or flue gas/ water heat exchanger. 34:1 Function output A2 at extension AM1: 34:0 DHW recirculation pump. Heating circuit pump, heating circuit without mixing valve A1 (heating circuit 1). 40:... Runtime, servomor at plug gsa1 in conjunction with return temperature raising. Delivered condition specified by the boiler coding card. 34:2 DHW tank primary pump. 34:3 Circulation pump for neutralising system or flue gas/ water heat exchanger. 40:5 40:199 Runtime adjustable from sec. 4A:0 Sensor aja not available. 4A:1 Sensor aja available (e.g. Therm-Control temperature sensor); aumatic recognition. 4b:0 Sensor ajb not installed. 4b:1 Sensor ajb installed (e.g. temperature sensor T2) (aumatic recognition). 4C:2 Connection at plug sö: 4C:1 Primary pump, primary sre system. Switching contact, Therm-Control. 4C:3 Circulation pump flue gas/water heat exchanger. 103

104 Coding Level 2 Category 1 General (continued) Vitronic 100, GC1B Installation and Service Coding in the Delivered Condition 4d:1 Connection at plug sl: Shunt pump. 4E:0 Connection at plug gs: Mor for isolation valve. Possible Change 4d:2 Boiler circuit pump. 4d:3 Boiler circuit pump with isolation valve function. 4E:1 Mor for 3-way mixing valve for return temperature control. 4E:2 Mor for 3-way mixing valve, primary sre system. 4F:5 Run-on time shunt or boiler circuit pump 5 min. 4F:0 No pump run-on. 4F:1 Run-on time adjustable from 1 60 min. 4F:60 52:0 Without supply temperature sensor for low loss header. 52:1 With supply temperature sensor for low loss header; aumatic recognition. 53:1 System with low loss header: Boiler circuit pump only runs when there is demand if the 53:0 System with low loss header: Boiler circuit pump always runs when there is demand. burner is running (with run-on time). 54:0 Without solar thermal system. 54:1 With Visolic 100; aumatic recognition. 54:2 With Visolic 200; aumatic recognition. 54:3 With solar control module, type SM1, without auxiliary function; aumatic recognition. 54:4 With solar control module, type SM1, with auxiliary function, e.g. central heating backup (aumatic recognition). 5b:0 Without extension EA1. 5b:1 With extension EA1; aumatic recognition. 5C:0 Function output abj at extension EA1: Central fault message. 5d:0 Function input DE1 at extension EA1: Not assigned. 5E:0 Function input DE2 at extension EA1: Not assigned. 5C:1 Feed pump. 5C:2 Never adjust. 5C:3 Never adjust. 5C:4 Never adjust. 5C:5 Never adjust. 5d:1 Not assigned. 5d:2 External demand with set minimum boiler water temperature. Set value selected in coding address 9b. 5d:3 External blocking. 5d:4 External blocking with fault message input. 5d:5 Fault message input. 5d:6 Not assigned. 5E:1 Not assigned. 5E:2 External demand with set minimum boiler water temperature. Set value selected in coding address 9b. 5E:3 External blocking. 5E:4 External blocking with fault message input. 5E:5 Fault message input. 5E:6 Not assigned. 104

105 Vitronic 100, GC1B Installation and Service Category 1 General (continued) Coding Level 2 Coding in the Delivered Condition Possible Change 5F:0 Function input DE3 at extension EA1: 5F:1 Not assigned. Not assigned. 5F:2 External demand with set minimum boiler water temperature. Set value selected in coding address 9b. 5F:3 External blocking. 5F:4 External blocking with fault message input. 5F:5 Fault message input. 5F:6 Not assigned. 6C:0 Run-on time for circulation pump, 6C:1 Run-on time adjustable from sec. neutralizing system at output A1 at extension AM1: None. 6C:255 6d:0 Run-on time for circulation pump, 6d:1 Run-on time adjustable from sec. neutralizing system at output A2 at extension AM1: None. 6d:255 6E:50 Do Not Adjust :0 Without LON communication module. 76:1 With LON communication module; aumatic recognition. 77:1 LON participant number. 77:1 77:99 LON participant number, adjustable from Note: Allocate each number only once. 78:1 LON communication enabled. 78:0 LON communication disabled. 79:0 Control unit is not fault manager. 79:1 Control unit is fault manager A fault message is issued if a fault occurs for at least 30 sec. 80:0 Immediate fault message. 80:2 80:199 The minimum fault duration until a fault message is issued is adjustable from sec.; 1 step 5 sec. 88:0 Temperature displayed in C (Celsius). 88:1 Temperature displayed in F (Fahrenheit). 8A:175 Do Not Adjust b:0 Do Not Adjust F:0 Do Not Adjust :0 Fault messages during emissions test function/service display do not affect central fault messages. 94:0 System with low loss header: Primary circuit pump and DHW tank primary pump always run when there is demand. 95:0 Without Vicom 100 communication interface. 98:1 Viessmann system number (in conjunction with moniring several systems via Vicom 300). 9b:0 No set minimum boiler water temperature for external demand. 9C:20 Moniring LON participants: If there is no response from a participant, values defaulted by the control unit are used 20 min. later, and a fault message is issued. 93:1 Fault messages during emissions test function/ service display affect central fault messages. 94:1 Primary circuit pump only runs when there is demand if the burner is running (with run-on time). 94:2 DHW tank primary pump only runs when there is demand if the burner is running (with run-on time). 95:1 With Vicom 100 communication interface; aumatic recognition. 98:1 System number adjustable from :5 9b:0 Set value for external demand adjustable from F (0 127 C) (limited by boiler specific 9b:127 parameters). 9C:0 No moniring. 9C:5 9C:60 9d:0 Do Not Adjust Time adjustable from 5 60 min. 105

106 Coding Level 2 Category 2 Boiler Vitronic 100, GC1B Installation and Service Coding Coding in the Delivered Condition Possible Change 01:1 Single boiler system. 01:2 Multi boiler system with cascade control via LON (e.g. Vitronic 300-K, type MW1B). 01:3 Multi boiler system with on site cascade control (third party control unit) via switching contacts (input avd and avh) or 0 10V input. 02:1 Two-stage burner. 02:0 Single stage burner. 02:2 Modulating burner. 03:0 Gas operation. 03:1 Oil operation (irreversible). 03:2 Set aumatically if no boiler coding card or an incorrect boiler coding card is inserted. 04:... Switching hysteresis, burner: 04:0 Switching hysteresis 4 K (see page 95) Delivered condition specified by the boiler coding card. 05:... Modulating burner: Burner curve. Delivered condition specified by the boiler coding card. 06:87 Maximum limit of the boiler water temperature set 189 F (87 C). 07:1 Sequential boiler number in a multi boiler system (in conjunction with coding address 01 ). 08:... Maximum burner output in kw. Delivered condition specified by the boiler coding card. 09:... Maximum burner output in kw. Delivered condition specified by the boiler coding card. 0A:... Burner base load in kw. Delivered condition specified by the boiler coding card. 04:1 Switching hysteresis, heat demand-dependent (see page 95). ERB50 function (values from 6 12 K). 04:2 ERB80 function (values from 6 20 K). 05:0 Linear burner curve. 05:1 05:99 06:20 06:127 07:2 07:4 08:0 08:199 09:0 09:199 0A:0 0A:100 Non-linear burner curve. (P T : P max ) 100 P T in kw: Partial output at g of the servomor runtime P max in kw: Maximum output. Maximum limit adjustable from F ( C). Observe the adjustable high limit settings. Consecutive boiler number in multi boiler system. Maximum output adjustable from kw. Maximum output adjustable from 0 19,900 kw; 1 step 100 kw. Non-linear burner curve (P G :P max ) 100% P G in kw: Base output P max in kw: Maximum output. 106

107 Vitronic 100, GC1B Installation and Service Category 2 Boiler (continued) Coding Level 2 Coding in the Delivered Condition 0C:5 Modulating isolation valve, independent of the set boiler water temperature. 0d:2 With Therm-Control, affects the isolation valve (function disabled with code 0C:1 ). 13:... Shutdown differential in K. The burner is switched off when the set boiler water temperature is exceeded. Delivered condition specified by the boiler coding card. 14:... Minimum burner runtime in min. Delivered condition specified by the boiler coding card. Possible Change 0C:0 No function. 0C:1 Constant return temperature control. 0C:2 Time-controlled isolation valve. 0C:3 Isolation valve switching subject the boiler water temperature. 0C:4 Isolation valve modulating subject the set boiler water temperature. 0d:0 Without Therm-Control. 0d:1 With Therm-Control, affects the mixing valves of downstream heating circuits. 13:0 Without sp differential. 13:2 13:20 14:0 14:15 15:10 Runtime servomor modulating burner 10 sec. 15:5 15:199 16:... Burner offset with start optimization in K (temporary reduction of the set boiler water temperature after burner start). Delivered condition specified by the boiler coding card. 1A:... Start optimization in min. Delivered condition specified by the boiler coding card. 1b:60 Time from burner ignition before control starts 60 sec. 1C:120 Signal B4 at plug fa is not available: Compensation of signal delay for hours run meter. Time from burner start signal initiation at T2 in plug fa opening of the solenoid valve. At each burner start, 120 sec. will be taken off the runtime. 1F:0 With flue gas temperature sensor: Flue gas temperature is not monired for service display. 16:0 16:15 1A:0 1A:60 1b:0 1b:199 1C:1 1C:199 1F:1 1F:250 Sp differential adjustable from 2 20 K. Minimum runtime adjustable from 0 15 min. Runtime adjustable from sec. For the Vicrossal, see separate service instructions. Offset adjustable from 0 15 K. Duration of start optimization adjustable from 0 60 min. Control delay adjustable from sec. Delay adjustable from sec. This time is deducted from the operating time for every burner start. E.g. operating situations in which the burner is shut down via the mechanical adjustable high limit, but a burner demand is still present (hours run continue be counted). If required, change coding address 06. When the flue gas temperature limit is exceeded, is displayed. Flue temperature measured in diagram C - e.g. IF:50 is displayed when flue gas temperature reaches or exceeds 50 C (122ºF) 107

108 Coding Level 2 Category 2 Boiler (continued) Vitronic 100, GC1B Installation and Service Coding in the Delivered Condition Possible Change 21:0 No service interval (hours run) selected. 21:1 The number of hours run before the burner should be serviced is adjustable from :100 10,000 h; One adjusting step 100 h. 23:0 No interval for service. 23:1 23:24 Interval adjustable from 1 24 months. 24:0 No display. 24:1 display (the address is aumatically set and must be manually reset after a service has been carried out). 26:0 Burner fuel consumption (stage 1): No count if 26:0 and 27:0 are programmed. 27:0 Burner fuel consumption (stage 1): No count if 26:0 and 27:0 are programmed. 26:1 26:99 27:1 27:199 28:0 No burner interval ignition. 28:1 28:24 29:0 Burner fuel consumption (stages 1 and 2): No count if 29:0 and 2A:0 are programmed. 2A:0 Burner fuel consumption (stages 1 and 2); No count if 29:0 and 2A:0 are programmed. 2b:5 Maximum preheating time of the isolation valve 5 min. 29:1 29:99 2A:1 2A:199 Input of ; 1 step 0.1 L/h or USG/h. Note: Values of coding addresses 26 and 27 are added gether. Input of ; 1 step 10 L/h or USG/h. Interval adjustable from 1 24 h. Burner is force started for 30 sec. respectively. Input of ; 1 step 0.1 L/h or USG/h. Note: Values of coding addresses 29 and 27 are added gether. Input of ; 1 step 10 L/h or USG/h. 2b:0 No preheating time. 2b:1 Preheating adjustable from 1 60 min. 2b:60 2C:5 Maximum run-on time of the isolation valve 5 min. 2C:0 No run-on time. 2C:1 2C:60 Run-on time adjustable from 1 60 min. 2d:0 Shunt pump control function only ON if the boiler is enabled. 2d:1 Shunt pump control function permanently ON. 108

109 Vitronic 100, GC1B Installation and Service Category 3 DHW Coding Level 2 Coding Coding in the Delivered Condition Possible Change 55:0 DHW tank heating, hysteresis ± 2.5 K. 55:1 Adaptive DHW tank heating enabled (see page 96). 55:2 DHW tank temperature control with 2 DHW tank temperature sensors (see page 97). 55:3 DHW tank temperature control, primary sre system (see page 97). 56:0 Set DHW temperature adjustable from F (10 60 C). 58:0 Without auxiliary function for DHW heating. 58:1 58:95 59:0 DHW tank heating: Start point: Set value 2.5 K Shutdown point: Set value +2.5 K 5A:0 For DHW heating: The set boiler water temperature is determined by the highest system supply temperature demand. 60:20 During DHW heating, the boiler water temperature is up 20 K higher than the set DHW temperature. 61:1 The circulation pump for DHW tank heating is started immediately. 62:10 Circulation pump with a run-on time after DHW tank heating of up 10 min. 56:1 Set DHW temperature adjustable from F (10 95 C). Note: Observe the max. permissible DHW temperature. Reset the adjustable high limit R. 59:1 59:10 Input of a second set DHW temperature, adjustable from F (1 95 C). (observe coding address 56 ). Start point adjustable from 1 10 K below the set value. 5A:1 For DHW heating: The set boiler water temperature is determined by the DHW tank supply temperature demand. 60:5 60:50 The differential between the boiler water temperature and the set DHW temperature is adjustable from K. 61:0 The circulation pump for DHW tank heating is started depending on the boiler water temperature. 62:0 Circulation pump without run-on. 62:1 Run-on time adjustable from 1 15 min. 62:15 63:0 Without auxiliary function for DHW heating. 63:1 Auxiliary function: 1 x daily. 63:2 63:14 Every 2 days every 14 days. 67:40 For solar DHW heating: Set DHW temperature 104 F (40 C). Reheating is suppressed above the selected set temperature (DHW heating by the boiler only if solar energy is not sufficient). 68:8 With 2 DHW tank temperature sensors (code 55:2 ): DHW tank heating sp point at set value x :7 With 2 DHW tank temperature sensors (code 55:2 ): DHW tank heating start point at set value x A:75 Runtime, servomor, mixing valve, heat exchanger set, Vitrans 222, 80 and 120 kw: 75 sec. 63:15 2 x daily. 67:0 67:95 68:2 68:10 69:1 69:9 6A:10 6A:255 Set DHW temperature adjustable from F (0 95 C). (limited by boiler-specific parameters). Facr adjustable from 0.2 1; 1 step 0.1. Facr adjustable from ; 1 step 0.1. For heat exchanger set Vitrans 222, 240 kw: set 113 sec. Runtime adjustable from sec. 109

110 Coding Level 2 Category 4 Solar Vitronic 100, GC1B Installation and Service Only in conjunction with solar control module, type SM1. Coding Coding in the Delivered Condition 00:8 The solar circuit pump starts when the collecr temperature exceeds the actual DHW temperature by 8 K. 01:4 The solar circuit pump sps when the differential between the collecr temperature and the actual DHW temperature is less than 4 K. 02:0 Solar circuit pump (multi stage) without speed control by solar control module SM1. 03:10 The temperature differential between the collecr temperature and actual DHW temperature is regulated 10 K. 04:4 Controller amplification of the speed control 4%/K. 05:10 Minimum speed of the solar circuit pump 10% of the maximum speed. 06:75 Maximum speed of the solar circuit pump 75% of the maximum possible speed. 07:0 Interval function of the solar circuit pump switched off. 08:60 The solar circuit pump sps when the actual DHW temperature reaches the maximum DHW tank temperature 140 F (60 C). 09:130 The solar circuit pump sps if the collecr temperature reaches 266 F (130 C) (maximum collecr temperature protect the system components). 0A:5 To protect system components and heat transfer medium: The solar circuit pump speed is reduced when the actual DHW tank temperature is 5 K below the maximum DHW tank temperature. Possible Change 00:2 00:30 01:1 01:29 The differential between the actual DHW temperature and the start point for the solar circuit pump is adjustable from 2 30 K. The differential between the actual DHW temperature and the sp point of the solar circuit pump is adjustable from 1 29 K. 02:1 Solar circuit pump (multi stage) is speed-controlled with wave pack control. 02:2 Solar circuit pump is speed-controlled with PWM control. 03:5 03:20 04:1 04:10 05:2 05:100 06:1 06:100 The differential temperature control between the collecr temperature and actual DHW temperature is adjustable from 5 20 K. Controller amplification adjustable from 1 10%/K. Minimum speed of the solar circuit pump is adjustable from 2 100%. Maximum speed of the solar circuit pump is adjustable from 1 100%. 07:1 Interval function of the solar circuit pump switched on. To capture the collecr temperature more accurately, the solar circuit pump starts for short cycles. 08:10 08:90 09:20 09:200 The maximum DHW tank temperature is adjustable from F (10 90 C). The temperature is adjustable from F ( C). 0A:0 Stagnation time reduction is disabled. 0A:1 0A:40 Value for stagnation time reduction is adjustable from 1 40 K. 110

111 Vitronic 100, GC1B Installation and Service Category 4 Solar (continued) Coding Level 2 Coding in the Delivered Condition 0b:0 Frost protection function for solar circuit switched off. 0C:1 nt moniring switched on. No flow rate captured in the solar circuit, or flow rate o low. 0d:1 Night circulation moniring switched on. Unintentional flow rate is captured in the solar circuit (e.g. at night). Possible Change 0b:1 Frost protection function for solar circuit switched on (not required with Viessmann heat transfer medium). 0C:0 nt moniring switched off. 0d:0 Night circulation moniring switched off. 0E:1 Calculation of solar yield with Viessmann heat transfer medium. 0F:70 The solar circuit flow rate at maximum pump speed is 7 L/min. 10:0 Target temperature control switched off (see coding address 11 ). 11:50 Set solar DHW temperature 122 F (50 C). Target temperature control switched on (code 10:1 ): Temperature at which the solar heated water in the DHW tank is be stratified. Extended control functions set heat two DHW tanks (code 20:8 ): The second DHW tank is heated when one DHW tank reaches its set DHW temperature. 12:10 Minimum collecr temperature 50 F (10 C). The solar circuit pump will only start when the set minimum collecr temperature is exceeded. Controller amplification of the speed control 4%/K. 0E:2 Calculation of solar yield with water as heat transfer medium (never adjust, as operation is only possible with Viessmann heat transfer medium). 0E:0 Calculation of solar yield switched off. 0F:1 0F:255 Flow rate adjustable from L/min. 1 step 0.1 L/min. 10:1 Target temperature control switched on. 11:10 11:90 The set solar DHW temperature is adjustable from F (10 90 C). 12:0 Minimum collecr temperature function switched off. 12:1 12:90 The minimum collecr temperature is adjustable from F (1 90 C). 20:0 No extended control functions enabled. 20:1 Additional function for DHW heating. 20:2 Differential temperature control 2. 20:3 Differential temperature control 2 and auxiliary function. 20:4 Differential temperature control 2 for central heating backup. 20:5 Thermostat function. 20:6 Thermostat function and auxiliary function. 20:7 Solar heating via external heat exchanger without additional temperature sensor. 20:8 Solar heating via external heat exchanger with additional temperature sensor. 20:9 Solar heating of two DHW tanks. 22:8 Start temperature differential for central heating backup: 8 K. Switching output ss is switched on when the temperature at sensor / exceeds the temperature at sensor aö by the selected value. 22:2 22:30 Start temperature differential for central heating backup is adjustable from 2 30 K. 111

112 Coding Level 2 Category 4 Solar (continued) Vitronic 100, GC1B Installation and Service 112 Coding in the Delivered Condition 23:4 Sp temperature differential for central heating backup: 4 K. Switching output ss is switched off when the temperature at sensor / falls below the sp point. The sp point is the sum of the temperature at sensor aö and the value selected for the sp temperature differential. 24:40 Start temperature for thermostat function 104 F (40 C). Start temperature for thermostat function sp temperature for thermostat function: Thermostat function, e.g. for reheating. Switching output ss is switched on when the temperature at sensor / falls below the start temperature for the thermostat function. Start temperature for thermostat function > sp temperature for thermostat function: Thermostat function, e.g. for utilizing excess heat. Switching output ss is switched on when the temperature at sensor / exceeds the start temperature for the thermostat function. 25:50 Sp temperature for thermostat function 122 F (50 C). Start temperature for thermostat function sp temperature for thermostat function: Thermostat function e.g. for reheating. Switching output ss is switched off when the temperature at sensor / exceeds the start temperature for the thermostat function. Start temperature for thermostat function > sp temperature for thermostat function: Thermostat function e.g. for utilizing excess heat. Switching output ss is switched off when the temperature at sensor / falls below the start temperature for the thermostat function. 26:1 Priority for DHW tank 1 with alternate heating. Possible Change 23:2 23:30 24:0 24:100 25:0 25:100 Sp temperature differential for central heating backup is adjustable from 1 29 K. Start temperature for thermostat function is adjustable from K. Start temperature for thermostat function is adjustable from K. 26:0 Priority for DHW tank 1 without alternate heating. Only when setting code 20:8. 26:2 Priority for DHW tank 2 without alternate heating 26:3 Priority for DHW tank 2 without alternate heating 26:4 Alternate heating without priority for one of the DHW tanks. 27:15 Alternate heating time 15 min. The DHW tank without priority is heated at most for the duration of the set alternate heating time if the DHW tank with priority is heated up. 28:3 Alternate pause time 3 min. After the selected alternate heating time for the DHW tank without priority has expired, the rise in collecr temperature is captured during the alternate pause time. 27:5 27:60 28:1 28:60 The alternate heating time is adjustable from 5 60 min. The alternate pause duration is adjustable from 1 60 min.

113 Vitronic 100, GC1B Installation and Service Connection and Wiring Diagram Designs Overview Legend A2 Main PCB low voltage A3 Main PCB 120V~ A6 Programming unit A7 Oplink PCB/emissions test switch A8 PCB A9 Boiler coding card A10 LON communication module (accessory) A11 Power supply unit PCB A12 ON/OFF switch X Electrical interfaces 113

114 Designs Connection and Wiring Diagram (continued) Vitronic 100, GC1B Installation and Service Main PCB Low Voltage 114 Legend Boiler water temperature sensor %A DHW tank temperature sensor %B DHW tank temperature sensor 2 for primary sre system (optional accessory) ) Supply temperature sensor ag Flue gas temperature sensor aja Therm-Control temperature sensor or Return temperature sensor T1 ajb Return temperature sensor T2 or Temperature sensor primary sre system (optional accessory) avd External hook-up avg KM BUS participant avh External hook-up LON Cable for data exchange between control units (accessories) S3 Emissions test switch V1 Fault indicar (red) V2 ON indicar (green) X Electrical interfaces

115 Vitronic 100, GC1B Installation and Service Connection and Wiring Diagram (continued) Designs Main PCB 120V~ Legend sö sa sk sl fö fa gö gs Primary pump or primary sre system (optional accessory) or DHW pump or Switching output Circulation pump for DHW tank heating (accessory) No function Shunt pump or boiler circuit pump (on site) Power supply, 120V/60 Hz Oil/gas burners Central fault message Isolation valve or Mixing valve mor, return temperature raising facility or Mor for 3-way mixing valve, primary sre system (optional accessory not used) lö abö Burner stage 2/modulating External connections (remove jumper when connecting) a External safety equipment b External blocking aba Safety chain (potential-free) abh Power supply for accessories F1, F2 Fuse F6 Fixed high limit F7 Adjustable high limit K1-K10 Relay S1 ON/OFF switch S2 TEST key X Electrical interfaces 115

116 Components Boiler Coding Card Vitronic 100, GC1B Installation and Service Boiler Boiler Coding Card Service Menu Display Diagnosis Category General Identification Spare Part No. Vicrossal 300, type CT Virond 200, type VD2, VD2A Sensors Viessmann NTC 10 kω (blue identification) Resistance in k ohms Boiler, DHW tank, Supply (Therm-Control Sensor) and Return Temperature Sensor Checking Sensors Note: The supply temperature sensor can be used as a strap on or immersion temperature sensor. 1. Pull corresponding plug. 2. Check the sensor resistance and compare it with the curve. 3. In the case of severe deviation, check the installation and replace the sensor if required. Temperature Viessmann NTC 20 kω (orange identification) Resistance in k ohms Flue Gas Temperature Sensor A service message appears when a set limit has been reached (see coding address 1F in category 2 Boiler ). Checking the Flue Gas Temperature Sensor 1. Disconnect plug ag. 2. Check the sensor resistance and compare it with the curve. 3. In the case of severe deviation, check the installation and replace the sensor if required. Temperature 116

117 Vitronic 100, GC1B Installation and Service Extension EA1 Accessory (optional) Components Duration of the heating program changeover Contact constantly closed: The changeover is active as long as the contact is closed. Contact only closed briefly via push butn: The changeover is enabled for the time selected in coding address F2 in the Heating circuit... group. DHW recirculation pump runtime for brief operation The DHW recirculation pump can be started outside the times when it is enabled according the time program. Digital data inputs DE1 DE3 Functions: External heating program changeover, separate for heating circuits 1 3 External blocking External blocking with fault message input External demand with minimum boiler water temperature Fault message input Brief operation of the DHW recirculation pump When connecting external contacts, observe the requirements of safety category II, i.e. 8.0 mm air-gap and creep path or maintain a 2.0 mm insulation thickness against live parts. Input function assignment Select the input functions by means of the following codes in the General group at the boiler control unit: DE1: Coding address 5D DE2: Coding address 5E DE3: Coding address 5F Assigning the heating program changeover function the heating circuits The allocation of the heating program changeover the relevant heating circuit is selected via coding address D8 in the Heating circuit... group: Code D8:1 : Changeover via input DE1 Code D8:2 : Changeover via input DE2 Code D8:3 : Changeover via input DE3 The DHW recirculation pump is started by closing the contact at DE1, DE2 or DE3 by means of a push butn. The runtime is adjusted via coding address 3D in the General group. Analog input 0 10VDC The 0 10VDC hook-up provides an additional set boiler water temperature: 0 1VDC Is taken as no default for set boiler water temperature. Note: Ensure DC separation between the LV output and the earth conducr of the on site voltage source. Coding address 1E in the General group: 1E:0 temperature demand adjustable in the range from F (0 100 C) 1VDC 50 F (10 C) set value change 10VDC 212 F (100 C) set value change 1E:1 temperature demand adjustable in the range from F ( C) 1VDC 86 F (30 C) set value change 10VDC 248 F (120 C) set value change Output abj Connection of a central fault messaging facility or signalling reduced mode (reduction of the heating circuit pump speed). Select the function of output abj via coding address 5C in the General group. Refer the EA1 module Installation Instructions The effect of the heating program changeover is selected via coding address D5 in the Heating circuit... group. 117

118 Parts List Parts List Vitronic 100, GC1B Installation and Service When Ordering Spare Parts Quote the part and serial no. (see type plate A) and the item no. of the required part (as per this parts list). Standard parts are available from your local supplier. Parts 0001 Hinges 0004 Adjustable high limit rotary selecr 0006 Adjustable high limit sp dial 0008 Supporting stay 0011 Safety valve with wiring 0013 Casing front with frame (see 001) 0014 PCB cover 0015 Front flap 0016 Casing, rear panel 0018 Programming unit 0019 Fascia left 0020 Fascia right 0021 Ribbon cable, 10-PIN 0023 Connecting cable, emissions test switch 0024 Fuse holder cap for control fuse 0025 Fuse holder for control fuse 0030 Fixed high limit 0031 Adjustable high limit 0037 Emissions test switch, single-pole 0038 ON/OFF switch, 2-pole 0039 TEST key, single-pole 0042 Temperature sensor (boiler water temperature sensor or DHW tank temperature sensor) 0049 Main PCB low voltage 0050 PCB 0051 Oplink PCB and emissions test switch 0052 Main PCB 120V~ 0054 Power supply unit PCB 0056 LON communication module 0057 LON cable 0058 LON terminar 0065 Burner connecting cable with plug fa and burner connecting cable with plug lö 0066 Burner connecting cable with plug fa and burner connecting cable with plug lö for Vicrossal 0074 Connection line 0080 Installation and service instructions 0081 Operating instructions 0092 Fuse, 6.3A (slow), 250V~ 0100 Plug for LV (7 pieces) 0101 Plug for pumps (3 pieces) 0102 Plug gs (3 pieces) 0103 Plug abh (3 pieces) 0104 Power supply plug fö (3 pieces) 0105 Plug abö 0106 Plug gö (3 pieces) Pole Plug avd, avg, avh 0109 Burner plugs fa, lö, aba and a.a A Type plate 118

119 Vitronic 100, GC1B Installation and Service Specifications Specifications Rated voltage 120V~ Rated frequency 60 Hz Rated current 2 x 6 A~ Power consumption 10 W Safety category I Permiss. ambient temperature: During operation During srage and transport F (0 +40 C) Installation in living spaces or boiler rooms (standard ambient conditions) F ( C) Rated relay output breaking capacity at 120V~ söa1 Primary pump, primary sre system or Circulation pump flue gas/water heat exchanger or Switching output 2 A~ *1 sa Circulation pump for DHW tank heating 2 A~ *1 sl Shunt pump or boiler circuit pump 2 A~ *1 gö Central fault message 2 A~ *1 gsa1 Isolation valve Mixing valve mor, return temperature raising facility or Mor, 3-way mixing valve, primary sre system 0.1 A~ *1 fa Burner 3 A~ lö Burner (two-stage) 0.5 A~ lö Burner (modulating) 0.1 A~ *1 Total max. 6 A~ 119

120 Vitronic 100, GC1B Installation and Service Technical information subject change without notice. Printed on environmentally friendly (recycled and recyclable) paper.