Viessmann KK10 Abmessungen und Installationsanleitung

VITOTRONIC 100

Installation, Start-up

and Service Instructions

Vitotronic 100

Model KK10

Boiler control unit

for high temperature heating systems

Part No. 7133 374

ertified as a component part

of Viessmann boilers only

Read and save these instructions

for future reference.

IMPORTANT

5167 481 v1.2 08/2010

Please file in Service Binder

Safety, Installation and Warranty Requirements

Safety Installation and Warranty Requirements

Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed

below and details printed in this manual can cause product/property damage,severe personal injury, and/or loss of life. Ensure all

requirements below are understood and fulfilled (including detailed information found in manual subsections).

HLicensed professional heating

contractor

The installation, adjustment, service,

and maintenance of this equipment

must be performed by a licensed

professional heating contractor.

Please see sections

entitled “Safety” and

“Important Regulatory and

Installation Requirements”.

HProduct documentation

Read all applicable documentation

before commencing installation. Store

documentation near boiler in a readily

accessible location for reference in the

future by service personnel.

For a listing of applicable

literature, please see

section entitled “Important

Regulatory and Installation

Requirements”.

HAdvice to owner

Once the installation work is complete,

the heating contractor must familiarize

the system operator/ultimate owner

with all equipment, as well as safety

precautions/requirements, shut-down

procedure, and the need for

professional service annually before the

heating season begins.

HWarranty

Information contained in this and

related product documentation must be

read and followed. Failure to do so

renders warranty null and void.

5167 481 v1.2

ontents

Page

Important Precautions Safety 4

................................................................................................

Important Regulatory and Installation Requirements 5

....

General Information About these Installation Instructions 5

...................................

Valid for ... 5

......................................................................................

Heating System System Configuration

One direct-connected heating circuit

without mixing valve 6

..................................................................

Electrical Connections Opening the Control 7

....................................................................

Overview 8

..........................................................................................

Routing Cabling 9

.............................................................................

Power Supply 9

.................................................................................

Burner Connection 10

.......................................................................

Room Thermostat Connection 11

................................................

Pump Connection 11

.........................................................................

Altering Settings Fixed High Limit 12

............................................................................

Testing the FHL 12

............................................................................

Adjustable High Limit 13

.................................................................

Dip Switch Settings 14

....................................................................

Appendix After Installation ...

hecklist 15

..........................................................................................

Service Binder 15

................................................................................

Start-up Start-up Instructions

heck all connections 15

................................................................

Set fixed high limit and adjustable high limit 15

...................

Ensure correct operational settings on control are set 15

Troubleshooting Diagnostics

(for qualified service personnel only)

Failure, ause, orrection 17

........................................................

Electrical connections and sequence of operation 18

.........

Additional Information Replacement Components

(for qualified service personnel only) 20

...................................

Boiler Protection 22

.............................................................................

Parts List 24

...........................................................................................

Wiring Diagram 25

...............................................................................

Technical Data 26

................................................................................

Protocol 26

.............................................................................................

5167 481 v1.2

Important Precautions

Safety

Take note of all symbols and notations intended to draw attention to potential hazards or important product information.

These include ”WARNING ” ”CAUTION ” and ”IMPORTANT”. See page 5 for details.

Approvals

Viessmann boilers, burners and

controls are approved for sale in North

America by SA International.

Codes

The installation of this unit shall be in

accordance with local codes. In the

absence of local codes, use:

HSA 22.1 Part 1 and/or local codes

in anada

HNational Electrical ode ANSI/NFPA

70 in the U.S.

Always use latest editions of codes.

Please carefully read this manual prior

to attempting installation. ny

warranty is null and void if these

instructions are not followed.

For information regarding other

Viessmann System Technology

componentry, please reference

documentation of the respective

product.

We offer frequent installation and

service seminars to familiarize our

partners with our products. Please

inquire.

Working on the equipment

The installation, adjustment, service,

and maintenance of this product must

be done by a licensed professional

heating contractor who is qualified and

experienced in the installation, service,

and maintenance of hot water boilers.

There are no user serviceable parts on

the boiler, burner, or control.

Ensure main power supply to

equipment, the heating system, and all

external controls has been deactivated.

Close main oil or gas supply valve.

Take precautions in both instances to

avoid accidental activation of power

during service work.

The completeness and functionality of

field supplied electrical controls and

components must be verified by the

heating contractor. These include low

water cut-offs, flow switches (if used),

staging controls, pumps, motorized

valves, air vents, thermostats, etc.

Technical literature

Literature applicable to all aspects of

the Vitotronic 100:

- Technical Data Manual

- Installation, Start-up

and Service Instructions

- Operating Instructions

and User’s Information Manual

- Instructions of other Viessmann

products utilized and installed

- Installation codes mentioned

in this manual

Leave all literature at the installation

site and advise the system

operator/ultimate owner where the

literature can be found. Contact

Viessmann for additional copies.

5167 481 v1.2

Turn off electric power

supply before

servicing. Contact with

live electric

components can cause

shock or loss of life.

WARNING

Important Precautions / General Information

Important Regulatory and Installation Requirements

Power supply

Install power supply in accordance with

the regulations of the authorities

having jurisdiction or, in the absence of

such requirements, in accordance with

National odes. Viessmann

recommends the installation of a

disconnect switch to the 120 VA

power supply outside of the boiler

room. The installer must provide

maximum 15 A overcurrent protection

for the 120 VA power supply (fuse or

circuit breaker).

Note on connecting external

“potential-free” contacts to the

Vitotronic 100 control’s 24 VAC

thermostat connections

Ensure that all contacts have sufficient

insulation clearance to live parts and

are certified for these applications.

A room thermostat or other

potential-free contact (i.e. end switch

of a zone valve) must be connected to

the Vitotronic 100 thermostat

connections.

Working with an open control

No static discharge to the internal

componentry must ever occur when

working with opened control

equipment.

About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information.

These include ”WARNING” ”CAUTION” and ”IMPORTANT”. See below.

Warnings draw your attention to the

presence of potential hazards or

important product information.

Cautions draw your attention to the

presence of potential hazards or

important product information.

Helpful hints for installation,

operation or maintenance which

pertain to the product.

This symbol indicates that additional,

pertinent information is to be found in

column three.

This symbol indicates that other

instructions must be referenced.

Valid for ...

Applies to Vitotronic 100, Model KK10:

Order No. 7133 374, starting with serial no. V00101

This control shall only be installed with the Vitola 200, Vitorond 200,

Vitogas 050, RS Series, or with a Vitogas 100 hot water heating boiler.

5167 481 v1.25167 481 v1.2

Indicates an imminently hazardous

situation which if not avoided could

result in death serious injury or

substantial product/property damage.

WARNING

Indicates an imminently hazardous

situation which if not avoided may

result in minor injury or

product/property damage.

CAUTION

IMPORTANT

Heating System

System Configuration

One direct-connected heating circuit without mixing valve

Boiler with

Vitotronic 100, Model KK10

Heating circuit

System pump

Room thermostat

120 VAC connections

Power supply cord,

120 VA , 60 Hz

Burner connection

Pump connection

(used with:

Vitorond 200,

Vitogas 050, RS Series, and

Vitogas 100 boilers only)

Required equipment

Description Quantity Order No.

Vitotronic 100, Model KK10 1 7133 374

Optional equipment

Description Quantity Order No.

DHW Pump Module for domestic hot water production using a

Viessmann Vitocell indirect-fired domestic hot water storage tank

1 9543 431

5167 481 v1.2

Electrical onnections

Opening the Control

1. Open front cover.

2. arefully unlock control top cover

using a screw driver and flip open

top cover.

5167 481 v1.2

Electrical onnections

Overview

The control is pictured from the rear.

120 VAC connections

for power supply cord

120 VA , 60 Hz

for burner connection

Pump connection

FHL test connection

A B Test

24 VAC connections

Room thermostat connection or

DHW pump module connection

Dip switches

2nd stage adaptor connection,

191 plug

5167 481 v1.2

Electrical onnections

Routing Cabling

Strain relief clamps are located in the

fittings package supplied with the

control.

1. Remove breakouts as necessary.

2. Mount lower portion of strain relief

clamp.

3. ut rubber grommet (if applicable).

4. Insert rubber grommet in strain

relief and mount strain relief.

5. Fasten top portion of strain relief.

6. lose off openings in the control

which are not being used.

Rubber grommets may already be

mounted on cabling.

Power Supply

Follow instructions under Important

Regulatory and Installation

Requirements.

1. Feed the power supply cord with

3-prong molded plug through rear

top panel wiring gate of the boiler.

2. Slide cable into the strain relief and

secure with strain relief set screw.

3. Plug power supply cord into

receptacle. Ensure receptacle is

designated for the heating system

only.

5167 481 v1.2

IMPORTANT

Electrical onnections

Burner Connection

to control

(RAST-5 plug)

to burner or wall vent system

(plug)

The Vitotronic 100 is prewired with the

Viessmann quick-connect plug-in

system.

1. onnect the RAST-5 plug to the

main circuit board of the control

(see page 8).

2. onnect 7-pole plug to the

counter plug of the burner

if installing a wall vent system

(accessory), connect 7-pole plug to

counter plug of wall vent system.

Refer to technical instructions

of the burner and/or wall vent

system

5167 481 v1.2

Do not connect the 41-plug from the

boiler control directly to the burner if

installing a wall vent system.

See technical instructions of the wall

vent system.

WARNING

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