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Troubleshooting
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VIESMANN
Installation and service instructions
for contractors
Vitotronic 100
Type KC2B, KC4B
Electronic boiler control unit
VITOTRONIC 100
Please keep safe.
5600124 GB
10/2018
Related Manuals for Viessmann Vitotronic 100
Summary of Contents for Viessmann Vitotronic 100
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Page 1
VIESMANN Installation and service instructions for contractors Vitotronic 100 Type KC2B, KC4B Electronic boiler control unit VITOTRONIC 100 Please keep safe. 5600124 GB 10/2018… -
Page 2
Danger system. Hot surfaces and fluids can lead to burns or Replace faulty components only with genuine scalding. Viessmann spare parts. Before maintenance and service work, switch ■ OFF the appliance and let it cool down. ■ Never touch hot surfaces on the boiler, burner,… -
Page 3: Safety Instructions
For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger…
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Page 4
Index Index 1. Information Disposal of packaging …………….Symbols ………………..Intended use ………………Product information …………….System examples ……………… 2. Installation sequence Opening the control unit …………….. Type KC2B ………………■ Type KC4B ………………10 ■ Inserting the coding card …………… 10 Adjusting the high limit safety cut-out (if required) ……… -
Page 5
Index Index Group 2 «Boiler» ………………37 Group 3 «DHW» ………………38 Group 4 «Solar» ………………39 Group 5 «Heating circuit 1» …………..43 8. Service checks Calling up the service level …………..44 Exiting the service level …………….. 44 Operating data ……………… -
Page 6
Index Index (cont.) 14. Connection and wiring dia- …………………… 70 gram 15. Specification …………………… 71 16. Settings and equipment …………………… 72 17. Keyword index …………………… 73… -
Page 7: Disposal Of Packaging
Please dispose of packaging waste in line with statu- DE: Use the disposal system organised by tory regulations. Viessmann. AT: Use the ARA statutory disposal system (Altstoff Recycling Austria AG, licence number 5766). CH: Packaging waste is disposed of by the HVAC contractor.
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Page 8: Product Information
Intended use also includes the adherence to mainte- nance and inspection intervals. Product information The control units Vitotronic 100, type KC2B and For room temperature-dependent operation KC4B for constant temperature operation, are designed for use in single boiler systems.
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Page 9: Opening The Control Unit
Installation sequence Opening the control unit Please note When the power supply is connected, touching electrical contacts can result in appliance dam- age. Before opening the control unit, switch off its mains power supply. Type KC2B Fig. 1…
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Page 10
Installation sequence Opening the control unit (cont.) Type KC4B Fig. 2 Inserting the coding card Only use the coding card included with the boiler prod- uct documentation (see following table). Fig. 3 Insert the boiler coding card through the opening in the cover into slot «X7». -
Page 11: Installation Sequence
Installation sequence Inserting the coding card (cont.) Boiler Coding card Display in brief scan Identification Part no. of individual part Vitola 200, type VB2A, VX2A 00e1:02 7435 808 7834 995 Vitola 222, type VE2A Vitoladens 300-T, type VW3B Vitorond 100, type VR2B, 18 to 63 kW Vitorond 111, type RO2D Vitorondens 200-T, type BR2 and BR2A 01e1:02…
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Page 12
Installation sequence Adjusting the high limit safety cut-out (if… (cont.) Type KC2B °C Fig. 4 Slotted screw for EGO products Slotted screw for JUMO products Type KC4B Fig. 5… -
Page 13
Installation sequence Adjusting the high limit safety cut-out (if… (cont.) °C Fig. 6 Slotted screw for EGO products Slotted screw for JUMO products Adjusting the temperature controller (if required) The temperature controller is set to 75 °C in the deliv- 1. -
Page 14
Installation sequence Adjusting the temperature controller (if… (cont.) Type KC2B Fig. 7 Type KC4B Fig. 8… -
Page 15: Overview Of Electrical Connections
Electrical connections Overview of electrical connections Danger Please note Incorrect wiring can lead to serious injury from Electronic assemblies can be damaged by elec- electrical current and result in appliance dam- trostatic loads. age. Before beginning work, touch an earthed object ■…
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Page 16: Inserting Cables/Leads And Applying Strain Relief
Electrical connections Overview of electrical connections (cont.) Connections on the low voltage PCB Plug Component No function § Boiler water temperature sensor Cylinder temperature sensor Buffer temperature sensor if the heating circuit is connected to a heating water buffer cylinder Flue gas temperature sensor KM-BUS subscriber (accessories), e.g.
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Page 17: Connecting The Sensors
Electrical connections Inserting cables/leads and applying strain… (cont.) Cable without cast-on cable entry Fig. 11 Connecting the sensors Connections on the low voltage PCB: See Fig. 9, page 15 Plug Component Boiler water temperature sensor § Cylinder temperature sensor Buffer temperature sensor (accessories) Flue gas temperature sensor (accessories) Connecting the pumps Available pump connections…
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Page 18
Electrical connections Connecting the pumps (cont.) 230 V~ pumps Rated current: 4(2) A~ Fig. 12 Pump To the control unit 230 V~ pumps with power consumption greater than 2 A or high efficiency circulation pumps Pumps with switching input Pumps without switching input N PE External N PE… -
Page 19: Provisional Burner Operation
Electrical connections Connecting the pumps (cont.) 400 V~ pumps Rated current for switching the contactor: 4(2) A~ L1 L2 L3 N PE Fig. 15 Pump To the control unit Contactor External burner start Please note If the contact is closed, burner stage 1 is switched on Live contacts lead to short circuits or phase fail- and the boiler water temperature is limited by the tem- ure.
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Page 20: External Demand Via 0-10 V Input
Electrical connections External demand via switching contact Connection options: ■ EA1 extension (accessories, see page 65). ■ Plug if no Vitotrol 100 is connected. Connection Please note Live contacts lead to short circuits or phase fail- ure. The external connection must be potential- free.
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Page 21: External Blocking Via Switching Contact
Electrical connections External demand via 0-10 V input (cont.) ≙ No specified set boiler water temperature – ≙ Set value 10 °C ≙ 10 V Set value 100 °C [{{] 0-10V fÖ Ö Fig. 18 External blocking via switching contact Connection options: Please note Plug…
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Page 22
Fig. 19 To the control unit To the burner Burner without plug Install the mating plug from Viessmann or from the burner manufacturer; connect the burner cable. 2-stage/modulating burner extension The function extension is supplied with the boiler. Max. power consumption 2-stage: 1 (0.5) A… -
Page 23
Electrical connections Connecting a pressure-jet oil/gas burner (cont.) Terminal codes T6, T7, T8 Control chain «Burner stage 2», via two- point controller Control chain «modulation controller», via three-point controller From the burner Modulating burner close Modulating burner open/stage 2 ON Signal flow direction: BN BU Control unit… -
Page 24
Electrical connections Connecting an atmospheric burner (cont.) Terminal designations T1, T2 Control chain Burner fault Hours run meter Fig. 21 To the control unit To the fuel valve 2-stage burner extension The function extension is supplied with the boiler. Colour coding to IEC 60757 BK Black BN Brown BU Blue… -
Page 25: Power Supply
Electrical connections Power supply Isolators for non-earthed conductors Danger ■ The mains isolator or «Emergency stop» must simul- The absence of system component earthing can taneously isolate from the power supply all non- lead to serious injury from electric current if an earthed conductors with a minimum contact separa- electrical fault occurs.
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Page 26
Electrical connections Power supply (cont.) Power supply for several accessories Power supply for all accessories via the control unit Fig. 23 Some accessories with direct power supply Fig. 24 Boiler control unit EA1 extension (internal fuse protection 2 A) Solar control module, type SM1 (internal fuse pro- ON/OFF switch tection 2 A) A Power supply… -
Page 27
Electrical connections Power supply (cont.) Power supply for the control unit 1. Check whether the power cable to the control unit has appropriate fuse protection. 2. Connect the power cable in the wiring chamber. 3. Insert plug into the control unit. fÖ… -
Page 28
Commissioning Testing the high limit safety cut-out Type KC2B 1. Hold down the «test» key (position » «) until the 3. Wait until the boiler water temperature has dropped burner switches off: approx. 15 to 20 K below the selected safety tem- The temperature controller «… -
Page 29
Commissioning Checking the outputs (actuator test) (cont.) Note The actuators listed in the table can be tested at the Before an actuator is selected, all actuators are relay outputs, subject to system equipment level and switched to zero volt. control unit configuration. Display Explanation All actuators are off. -
Page 30
Coding levels Calling up coding levels Which codes are shown depends on the heating sys- 6. Exiting coding level 1: Press ■ tem configuration. ■ The codes are divided into groups: Automatically after 30 min 1: «General» 2: «Boiler» Coding level 2 3: «DHW»… -
Page 31
Coding level 1 Group 1 «General» Coding Coding in the delivered condition Possible change System design 00:1 One heating circuit without mixer 00:2 One heating circuit without mixer (heating circuit 1), without DHW (heating circuit 1), with DHW heat- heating ing;… -
Page 32
Coding level 1 Group 2 «Boiler» (cont.) Coding in the delivered condition Possible change Service interval in months 23:0 No time set for burner service in- 23:1 Interval adjustable from 1 to terval 24 months. 23:24 Service status 24:0 Display does not show 24:1 Display shows . -
Page 33
Coding level 1 Group 4 «Solar» (cont.) Coding in the delivered condition Possible change Stagnation time reduction 0A:5 Temperature differential for stagna- 0A:0 Stagnation time reduction not active. tion time reduction (reduction in 0A:1 Temperature differential adjustable the speed of the solar circuit pump from 1 to 40 K. -
Page 34
Coding level 1 Group 5 «Heating circuit 1» (cont.) Coding in the delivered condition Possible change Pump control in «Standby mode» F7:25 «Standby mode» operating mode: F7:0 Heating circuit pump is constantly Heating circuit pump is constantly OFF. F7:1 The heating circuit pump starts 1 to 24 times per day for 10 min each F7:24 time. -
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Coding level 2 Group 1 «General» Coding Coding in the delivered condition Possible change 00:1 One heating circuit without mixer 00:2 One heating circuit without mixer (heating circuit 1), without DHW (heating circuit 1), with DHW heat- heating ing; automatic recognition 1E:0 With EA1 extension (analogue in- 1E:1… -
Page 36
Coding level 2 Group 1 «General» (cont.) Coding in the delivered condition Possible change 40:0 Function of input 40:1 External burner start-up/external de- Room temperature controller mand (only possible if no room tem- (Vitotrol 100) perature controller is connected). Observe the setting of coding ad- dress «9b». -
Page 37
Coding level 2 Group 1 «General» (cont.) Coding in the delivered condition Possible change 95:0 Never adjust 9b:70 Set minimum boiler water tempera- 9b:0 Set value for external demand ad- ture during external demand 70 °C justable from 0 to 127 °C (limited by 9b:127 boiler-specific parameters) Group 2 «Boiler»… -
Page 38
Coding level 2 Group 2 «Boiler» (cont.) Coding in the delivered condition Possible change 21:0 No service interval (hours run) se- 21:1 The number of hours the burner has lected. run before it should be serviced is 21:100 adjustable from 100 to 10,000 h. ≙… -
Page 39
Coding level 2 Group 3 «DHW» (cont.) Coding in the delivered condition Possible change 59:0 Cylinder heating: 59:1 Start point adjustable from 1 to 10 K Start point: Set value -2.5 K below set value. Stop point: Set value +2.5 K 59:10 5b:0 Never adjust… -
Page 40
Frost protection function for solar 0b:1 Frost protection function for solar cir- circuit switched off cuit switched on (not required with Viessmann heat transfer medium) 0C:1 Delta T monitoring switched on 0C:0 Delta T monitoring switched off No flow rate captured in the solar circuit, or flow rate too low. -
Page 41
Coding level 2 Group 4 «Solar» (cont.) Coding in the delivered condition Possible change ≙ 0F:255 1 step 0.1 l/min 10:0 Target temperature control switch- 10:1 Target temperature control switched ed off (see coding address «11») 11:50 Set solar DHW temperature 50 °C 11:10 The set solar DHW temperature is Target temperature control… -
Page 42
Coding level 2 Group 4 «Solar» (cont.) Coding in the delivered condition Possible change 24:40 Start temperature for thermostat 24:0 Start temperature for thermostat function: 40 °C (code «20:5» or function adjustable from 0 to 100 K «20:6» must be set). Start tempera- 24:100 ture for thermostat function stop… -
Page 43
Coding level 2 Group 4 «Solar» (cont.) Coding in the delivered condition Possible change After the set cyclical heating time 28:60 for the DHW cylinder without priori- ty has expired, the rise in collector temperature is captured during the cyclical pause time. Group 5 «Heating circuit 1″… -
Page 44: Exiting The Service Level
Service checks Calling up the service level 1. Press OK and simultaneously for approx. 4 s. 2. Select required function. flashes on the display. Exiting the service level 1. Use to select 3. Confirm with OK. 2. Confirm with OK. Note «OFF»…
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Page 45: Service Checks
Service checks Brief scan (cont.) Brief scan Display System scheme Software version Software version Control unit Programming unit Maximum flue gas temperature Set boiler water temperature Common demand temperature Set cylinder temperature Number of KM-BUS subscribers Burner type Device (value corresponds to setting of cod- ing address «02»…
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Page 46
Service checks Service display (cont.) The specified hours run and Note ■ ■ The specified interval with If a service is carried out prematurely, set code «24:1» ■ The specified max. flue gas temperature and in group 2 «Boiler» to «24:0». The selected service parameters for hours run and time intervals restart at If coding address «24»… -
Page 47: Fault Display
Troubleshooting Fault display In the event of a fault, the red fault indicator on the Example: control unit flashes. The 2-digit fault code and flash Fault code «d1» burner fault on the display. Use / to display other current faults. ã…
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Page 48
Troubleshooting Fault display (cont.) Displayed fault System characteristics Cause Measures code With DHW cylinder: Short circuit, boiler water Check boiler water temperature ■ Circulation pump for cylin- temperature sensor sensor (see page 51) der heating ON, boiler is maintained at set cylinder temperature. -
Page 49
Troubleshooting Fault display (cont.) Displayed fault System characteristics Cause Measures code No solar DHW heating Short circuit, cylinder tem- Check sensor at the solar control perature sensor, unit (see separate installation and connection of temperature service instructions). sensor at the solar control module or sensor at S2 of the Vitosolic. -
Page 50
Troubleshooting Fault display (cont.) Displayed fault System characteristics Cause Measures code Control mode Lead break, flue gas tem- Check flue gas temperature sensor perature sensor (see page 51). Without flue gas temperature sen- sor: Set code «1F:0» in group 2 «Boiler». Control mode Internal fault Acknowledge fault message, re-… -
Page 51: Checking The Sensors
Operating instructions Actual temperatures can be checked in the «i» menu. Checking the boiler water, cylinder and buffer temperature sensors 1. Pull out corresponding plug. Viessmann NTC 10 k (blue marking) Ω 2. Check the sensor resistance. Compare with the curve.
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Page 52: Checking The Fuses
Troubleshooting Checking the sensors (cont.) Check flue gas temperature sensor Viessmann NTC 20 k (orange marking) Ω Temperature in °C Fig. 30 1. Pull out plug 3. In the case of severe deviation, check sensor installation and replace the sensor if necessary.
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Page 53: Ordering Parts
Parts lists Ordering parts The following details are required when ordering parts: ■ Serial no. (see type plate ■ Assembly (from this parts list) Position number of the individual part within the ■ assembly (from this parts list)
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Page 54
Parts list type KC2B Casing assembly 0081 0082 0084 0018 0074 0013 0101 0100 0099 0042 0109 0102 0104 0065 0070 0072 0071 Fig. 31… -
Page 55
Parts list type KC2B Casing assembly (cont.) Pos. Part 0013 Casing, upper part (drawer) 0018 Programming unit 0042 Temperature sensor with plug 0065 Burner connecting cable with plug (for boilers with pressure-jet oil/gas burners) 0070 Power cable with plug fÖ 0071 5-core burner connecting cable with plug (for boilers with an intermittent ignition system) -
Page 56: Pcb Assembly
Parts list type KC2B PCB assembly 0050 0054 0092 0090 0014 0052 0098 0016 0017 0035 0051 0001 0097 0033 0031 0005 0030 0036 0004 0011 0010 Fig. 32 Type plate…
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Page 57
Parts list type KC2B PCB assembly (cont.) Pos. Part 0001 Cable clamp 0004 Stop dial for temperature controller 0005 Plug for high limit safety cut-out 0010 Front cover 0011 Front user panel, bottom right 0014 PCB covers 0016 Casing, lower section 0017 Back cover 0030… -
Page 58
Parts list type KC4B Casing assembly 0081 0082 0084 0017 0074 0010 0099 0100 0007 0101 0109 0102 0104 0042 0065 0071 0072 Fig. 33… -
Page 59
Parts list type KC4B Casing assembly (cont.) Pos. Part 0007 Front cover 0010 Casing, upper part 0017 Casing, upper part, back 0042 Temperature sensor with plug 0065 Burner connecting cable with plug (for boilers with pressure-jet oil/gas burners) 0071 5-core burner connecting cable with plug (for boilers with an intermittent ignition system) 0072 6-core burner connecting cable with plug… -
Page 60
Parts list type KC4B PCB assembly 0050 0054 0092 0090 0052 0033 0004 0014 0031 0016 0051 0011 0098 0030 0018 0036 0005 Fig. 34 Type plate… -
Page 61
Parts list type KC4B PCB assembly (cont.) Pos. Part 0004 Stop dial for temperature controller 0005 Plug for high limit safety cut-out 0011 Front user panel 0014 Temperature controller bracket 0016 Casing, lower section 0018 Programming unit 0030 High limit safety cut-out 0031 Temperature controller 0033… -
Page 62: Brief Description
Function description Boiler water temperature control Brief description The boiler water temperature is regulated by switch- If a Vitotrol 100 is connected, it is only switched on if ■ ■ ing the burner on or off. In the delivered condition, required by the Vitotrol 100.
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Page 63: Boiler Water Temperature Control
Function description Boiler water temperature control (cont.) The switching hysteresis, i.e. the burner runtime, var- ERB80 function ies subject to the current heat demand. Code «04:2» ERB50 function Depending on the heat demand, values between 6 and 20 K result. Code «04:1″…
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Page 64: Control Sequence
Function description Cylinder temperature control (cont.) The set value range can be extended to 90 °C via cod- Operating instructions ing address «56» in group 3 «DHW». Auxiliary function for DHW heating System with solar control unit Select a second set DHW temperature in coding A third set DHW temperature can be specified via cod- address «58»…
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Page 65: Function Description
Function description EA1 extension Fig. 38 Digital input 1 Power supply fÖ Digital input 2 Power supply for additional accessories fÖ Digital input 3 Switching contact (floating) 0 — 10 V 0 — 10 V input KM BUS Digital data inputs DE1 to DE3 Functions: Input function assignment ■…
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Page 66
Function description EA1 extension (cont.) Coding address «1E» in group 1 «General»: ≙ ■ «1E:0» temperature demand adjustable in the range from 0 to 100 °C ≙ 10 °C set value change ≙ 10 V 100 °C set value change ≙… -
Page 67: External Burner Blocking
Function description External H5 extension (cont.) ON ON N STB TR TR Fig. 40 Jumper «STB» «STB» Minimum pressure limiter – Jumper «TR» «ON/TR» Other external safety equipment – External burner blocking (floating contact) External burner blocking 1. Remove jumper «TR» «ON/TR».
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Page 68
Function description External H5 extension (cont.) Motorised flue gas damper EIN EIN N STB TR TR 1 2 3 Fig. 41 Plug aBÖ Flue gas damper motor Limit switch If making this connection, remove jumper «TR – ON/TR». Function check Flue gas damper closed (switch open) ■… -
Page 69: Vitoair Draught Stabiliser
Function description Vitoair draught stabiliser Fig. 42 To the burner To the control unit Colour coding to IEC 60757 Black GNYE Green/Yellow Function check Press the rotary selector on the motor and simultane- ously turn it to its central position. ⇒…
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Page 70
Connection and wiring diagram Connection and wiring diagram Fig. 44 Type KC2B: Pushbutton Type KC4B: Terminals Main PCB No function Power supply unit PCB Power supply, 230 V/50 Hz fÖ Oil/gas burner (connection according to DIN Programming unit 4791) Coding card Power supply for accessories ■… -
Page 71: Specification
Specification Specification Rated voltage 230 V~ Rated frequency 50 Hz Rated current 6 A~ Power consumption Protection class IP rating IP 20 D to EN 60 529; ensure through design/installation Function type Type 1 B to EN 60730-1 Permissible ambient temperature Operation 0 to +40 °C ■…
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Page 72: Switching Hysteresis
Settings and equipment Settings and equipment Tick the modified function. Function in the delivered condition Modified function High limit safety cut-out set to 110 °C. Adjusted to …°C Temperature controller set to 75 °C Adjusted to …°C Remote control With remote control Control without remote control Vitotrol 100, type UTA Vitotrol 100, type UTDB…
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Page 73
Keyword index Keyword index Fuel consumption…………38 2-stage burner (connection)……… 22, 24 Fuses…………….. 52 Acknowledged fault display High efficiency circulation pumps……. 18 – Calling up…………..47 High limit safety cut-out Actuator test, carrying out………. 28 – Adjusting…………..11 Adaptive cylinder heating……….. 64 –… -
Page 74
Keyword index Keyword index (cont.) Switching hysteresis – Heat demand-dependent……..62 Vitoair…………….. 69 – Permanent……………62 Vitosolic…………..64 Symbols…………… 7 Vitotrol 100, operation with………62 System equipment…………. 72 Wiring diagram…………70 Temperature controller adjustment……13… -
Page 76
Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com…
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Kc2bKc4b
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