Viessmann VD2 Series Technical Information Page 1

Commercial Vitotronic Wiring Guide Overview For use by licensed heating contractor 5346540 v1.0 09/2006 IMPORTANT Read and save these instructions f

Installation of Boiler Controls Vitotronic 100, GC1 and Vitotronic 300, GW2 on Vitorond VD2 boilers (1255-4387MBH or 368-1285KW) Refer to boiler manu

Control Overview—External Controls Connections LON Connections—General Installation of LON Communication Card Applicable for Vitotronic 100, GC1, Vit

Control Overview—Extension Output Module LON Connections—Extension Output Module (Optional) Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2

Control Overview—External Controls Connections LON Connections—System Overview Applicable for Vitotronic 100, GC1, and Vitocontrol-S, CT3/VD2 IMPORTA

1 Control Overview—External Controls Connections LON Connections—System Overview with Extension Input Module 0-10VDC Applicable for Vitotronic 100, G

5 1 Control Overview—External Controls Connections LON Connections—System Overview with Extension Output Module Applicable for Vitotronic 100, GC1, a

1 Plug connections in each KK10 control for terminating communication and boiler temperature sensor. 2 Boiler temperature sensor termination for ea

4 Control Overview—External Controls Connections LON Connections—System RJ45LON Adapter Overview Applicable for Vitotronic 100, GC1, and Vitocontrol-

2 3 1 1 The Vitocontrol-S unit for operation with KK10LON boiler controls. 2 The KK10LON boiler control is equipped with a communication board whi

2 3 1 1 The Vitocontrol-S unit for operation with KK10LON boiler controls. 2 The KK10LON boiler control is equipped with a communication board whi

Control Overview—External Controls Connections LON Connections—System Alternative RJ45LON Adaptor Overview Applicable for Vitotronic 100, GC1, and Vi

Installation of Boiler Controls Vitotronic 100, GC1 and Vitotronic 300, GW2 on Vitorond VD2 boilers (1255-4387MBH or 368-1285KW) Refer to boiler manu

Notes Section 5 5346540 v1.0 09/2006 Technical information subject to change without notice 110 This page is intentionally left blank Section 5

Control Information Section 6.0 Section 6 Basic Diagnostic Plug [41] Drawings General Overview Section 6.0 Vitotronic 100, GC1—Soft Cable and Flexi

Section 6.0 Control Overview—Burner Control Wiring Diagnosis Connection of Boiler Control Wiring to Burner General Overview A Control Unit B 2nd

Control Overview—Burner Control Wiring Diagnosis Connection of Boiler Control Wiring to Burner (plug-in connection) Applicable for Vitotronic 100, GC

Control Overview—Burner Control Wiring Diagnosis Connection of Boiler Control Wiring to Burner (hard-wired connection) Applicable for Vitotronic 100,

Control Overview—Burner Control Wiring Connection of Boiler Control Wiring to Burner (plug-in connection) Applicable for Vitotronic 300, GW2 Section

Control Overview—Burner Control Wiring Diagnosis Connection of Boiler Control Wiring to Burner (hard-wired connection) Applicable for Vitotronic 300,

Vitocontrol-C System Overview Drawings Section 7 Vitocontrol-C Drawings General Information Boiler control power from Vitocontrol-C Burner/Blo

Vitocontrol-C System Overview Drawings Vitocontrol-C Boiler control power interconnections from panel to control example Section 7 Control voltage fr

Vitocontrol-C System Overview Drawings Vitocontrol-C Burner/Blower power interconnections example Section 7 Burner blower motor power interconnection

Installation of Boiler Controls Vitotronic 100, GC1 and Vitotronic 300, GW2 on Vitocrossal CT3 boilers (CT3-17 to CT3-89 models) Refer to boiler manu

Vitocontrol-C System Overview Drawings Vitocontrol-C Pump interconnections between boiler control and panel example Section 7 Output from boiler cont

Vitocontrol-C System Overview Drawings Vitocontrol-C Extension Output Module power interconnections between module and panel example Section 7 Power

Vitocontrol-C System Overview Drawings Vitocontrol-C Extension Output Module interconnections between module outputs and panel example Section 7 Dry

Appendix Section 8.0 Section 8 Related Information General Information Code information Related manual information Section 8.0 5346540 v1.0 09

Appendix Section 8.0 Section 8 Codes and Alternate Resources Applicable for Canada and USA The installation of this unit shall be in accordance with

Appendix Section 8.0 Section 8 Related Manuals Applicable for Canada and USA Line Manual Viessmann Number Version Date 1 Vitorond 200, VD2 (sma

Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island • 02886 • USA Tel: (401) 732-0667 • Fax (401) 732-0590 www.viessmann

Installation of Vitocontrol-S, VD2/CT3-MW1 Installation Steps 500mm (19 11/16”) 273mm (10 3/4”) Boiler Room Wall or Adjacent Boiler 1 Control harnes

Installation of Vitocontrol-S, VD2/CT3-MW1 Control Installation Continued 1 3 2 1 Control mounts to tabs at top of control harness. Hang control on

Installation of Vitocontrol-S, VD2/CT3-MW1 Control Installation Continued 1 The front control housing is held in place by a support rod. The support

Installation of Vitocontrol-S, VD2/CT3-MW1 16 Control Installation Continued 1 When the control is ready to be closed, the front housing can be fast

Control Wiring Installation Section 3 Boiler Control Wiring Overview Vitotronic 100, GC1 Summary of Control Outputs Control Voltage Plug Overv

Control Wiring Installation Section 3 Installation Steps Quick Overview Section 3.0 STEP 1 Review information associated with boiler and boiler con

1 2 Control Wiring Installation Section 3 Vitorond VD2 Boiler/Control/Burner Vitocrossal CT3 Boiler/Control/Burner 3 1 2 3 1 Boiler control mounted

Table of Contents 5346540 v1.0 09/2006 Technical information subject to change without notice 2 Caution, Warning Trademark Information Section 1 Con

Control Overview Vitotronic 100, GC1—Electrical 20 Standard Control Junction Box (no modules) Field Connection Vitotronic Plug DIN Rail Terminal C

Control Overview Vitotronic 100, GC1—Boiler/Burner Plugs for control voltage for Vitotronic 100, GC1 Section 3 Section 3.1 5346540 v1.0 09/2006 Tech

Control Overview Vitotronic 100, GC1—Electrical Overview drawing for Vitotronic 100, GC1 Section 3 Section 3.1 5346540 v1.0 09/2006 Technical inform

Control Overview Vitotronic 300, GW2—Electrical Standard Control Junction Box (no modules) Field Connection Vitotronic Plug DIN Rail Terminal Cabl

Control Overview Vitotronic 300, GW2—Electrical Plugs for control voltage and sensors for Vitotronic 300, GW2 Section 3 Section 3.2 5346540 v1.0 09/

Control Overview Vitotronic 300, GW2—Electrical Section 3 Section 3.2 Plugs for control voltage and sensors for Vitotronic 300, GW2 5346540 v1.0 09

Control Overview Vitotronic 300, GW2—Electrical Section 3 Section 3.2 Plugs for control voltage and sensors for Vitotronic 300, GW2 5346540 v1.0 09

5346540 v1.0 09/2006 Technical information subject to change without notice Control Overview Vitocontrol-S, CT3/VD2—Electrical Standard Control Junct

Control Overview Vitocontrol-S, MW1 (CT3/VD2)—Electrical Plugs for control voltage and sensors for Vitocontrol-S, CT3/VD2 Section 3 Section 3.3 5346

How This Section Works Overview of control DIN rail Section 3 Section 3.4 How drawings work:  Example overview drawings showing DIN rails of contro

About these instructions → Warnings draw your attention to the presence of potential hazards or important product information. 3 Take note of all sy

1 Control Overview—Power Supply Wiring Power Control—120VAC Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and Vitocontrol-S, CT3/VD2 1 Gre

1 Control Overview—Low Water Cut Off Wiring Connection of Low Water Cut Off (LWCO) (Typical) Applicable for both Vitotronic 100, GC1 and 300, GW2 1

Control Overview—Control/Burner Interconnections Connection of Boiler Control Wiring to Burner Applicable for Vitotronic 100, GC1 and Vitotronic 300,

Control Overview—Burner Control Wiring Connection of Boiler Control Wiring to Burner (plug-in connection) Applicable for Vitotronic 100, GC1 4 2 5 1

Control Overview—Burner Control Wiring Connection of Boiler Control Wiring to Burner (hard-wired connection) Applicable for Vitotronic 100, GC1 1 B

Control Overview—Burner Control Wiring Connection of Boiler Control Wiring to Burner (plug-in connection) Applicable for Vitotronic 300, GW2 1 Boil

Control Overview—Burner Control Wiring Connection of Boiler Control Wiring to Burner (hard-wired connection) Applicable for Vitotronic 300, GW2 1 Bo

-weishaupt-Control Overview—Burner Control Wiring Weishaupt Burner Schematic G Series Burner (typical) Refer to job specific burner schematic contain

Control Overview—Burner Control Wiring Riello Burner Schematic (typical) Refer to job specific burner schematic contained in burner information packa

Control Overview—Burner Power Wiring Connection of Boiler Power Wiring to Burner Applicable for both Vitotronic 100, GC1 and 300, GW2 Flexible Condu

Important Regulatory and Installation Requirements 4 Codes The installation of this unit must be in accordance with local codes. All electrical wiri

Control Overview—Burner Power Wiring Connection of Boiler Power Wiring to Burner (hard wired connection) Applicable for both Vitotronic 100, GC1 and

Control Overview—Burner Power Wiring Connection of Boiler Power Wiring to Burner (hardwired connection) Applicable for both Vitotronic 100, GC1 and 3

Notes Section 3.4 Section 3 5346540 v1.0 09/2006 Technical information subject to change without notice 42 This page is intentionally left blank

Output [20][A1]/[M1] Switched Output [20][A1]/[M1]: Dry Contact Control Signal Section 3.5.2 Control Overview Section 3.5 Section 3.5 Control O

1 Control Overview—Pump Outputs Pump Outputs—Heating Circuit Pumps [20][M2] and [20][M3]: 120VAC Output Applicable for Vitotronic 300, GW2 and Vito

1 Control Overview—Pump Outputs Pump Outputs—Heating Circuit Pumps [20][M2] and [20][M3]: Contactor Applicable for Vitotronic 300, GW2 and Vitocontr

5 1 Control Overview—Pump Outputs Pump Outputs—Heating Circuit Pumps [20][M2] and [20][M3]: Dry Contact Control Signal Applicable for Vitotronic 300

1 Control Overview—Pump Outputs Pump Outputs—DHW Recirculation Pump [28] and DHW Production [21]: 120VAC Output Applicable for Vitotronic 100, GC1*,

1 Control Overview—Pump Outputs Pump Outputs—DHW Recirculation Pump [28] and DHW Production Pump [21]: Contactor Applicable for Vitotronic 100, GC1*,

1 Control Overview—Pump Outputs Pump Outputs—DHW Recirculation [28] and DHW Pump [21]: Dry Contact Control Signal Applicable for Vitotronic 100, GC1*

Control Installation 5 Section 2.0 Section 2 Boiler Control Installation Information General Information Boiler and control overview drawings

1 Control Overview—Pump Outputs Pump Outputs—Switched Output [20][A1]/[M1]: Dry Contact Control Signal Applicable for Vitotronic 100, GC1, Vitotroni

1 Control Overview—Pump Outputs Pump Outputs—Shunt Pump [29]: 120VAC Output Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and Vitocontrol-

1 Control Overview—Pump Outputs Pump Outputs—Shunt Pump [29]: Contactor Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and Vitocontrol-S, M

1 Control Overview—Pump Outputs Pump Outputs—Shunt Pump [29]: Dry Contact Control Signal Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and

1 Control Overview—Pump Outputs Pump Outputs—Boiler Supply Pump [29]: 120VAC Output Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and Vito

1 Control Overview—Pump Outputs Pump Outputs—Boiler Supply Pump [29]: Contactor Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and Vitocont

1 Control Overview—Pump Outputs Pump Outputs—Boiler Supply Pump [29]: Dry Contact Control Signal Applicable for Vitotronic 100, GC1, Vitotronic 300,

1 Control Overview—Alarm Output Alarm Output—Compiled Alarm [50]]: 120VAC Output Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2 and Vitocont

1 Control Overview—Alarm Output Alarm Output—Compiled Alarm [50]: Dry Contact Control Signal Applicable for Vitotronic 100, GC1, Vitotronic 300, GW2

1 Control Overview—Valve Adapter Module Valve Adapter Module—Valve Output [52][A1/M2/M3]: 24VAC or 120VAC Output Applicable for Vitotronic 100, GC1,

1 2 Boiler and Control Overview Section 2 Vitorond VD2 Boiler/Control/Burner Vitocrossal CT3 Boiler/Control/Burner 3 1 2 3 The controls are mounted

1 Control Overview—Combustion Air Control Combustion Air Device Adapter Module—Blower/Fan Single Boiler Applicable for Vitotronic 100, GC1 and Vitotr

1 Control Overview—Combustion Air Control Combustion Air Device Adaptor Module—Damper (spring close) Single Boiler Applicable for Vitotronic 100, GC1

1 Control Overview—Combustion Air Control Combustion Air Device Adaptor Module—Damper (power open/close) Single Boiler Applicable for Vitotronic 100,

1 Control Overview—Combustion Air Control Common Combustion Air Device Interface—System Overview Applicable for Vitotronic 100, GC1 1 Incoming power

3 1 Control Overview—Combustion Air Control Common Combustion Air Device Interface—System Boiler Connections Applicable for Vitotronic 100, GC1 1 Ca

Control Overview—Combustion Air Control Common Combustion Air Device Interface—Overview Applicable for Vitotronic 100, GC1 1 Common combustion air d

1 Control Overview—Combustion Air Control Common Combustion Air Device Interface—System: Blower/Damper Applicable for Vitotronic 100, GC1 1 Incoming

Control Overview—Combustion Air Control Common Combustion Air Device Interface—Damper Power Open/Close Applicable for Vitotronic 100, GC1 IMPORTANT E

Notes Section 3.4 Section 3 5346540 v1.0 09/2006 Technical information subject to change without notice 68 This page is intentionally left blank

0-10VDC Extension Input Module Module Overview Vitotronic 100, GC1 (Coded for single boiler) Vitotronic 100, GC1 (Coded for multiple boiler

Terminology Section 2 Section 2.0 Name Notes Control Harness • Mounts to the side of the boiler with respect to the Vitotronic 100/300 boiler con

5346540 v1.0 09/2006 Technical information subject to change without notice External Control Connections Section 4 Section 4.0 Control Demand Conn

5 2 Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Demand Applicable for Vitotronic 100, GC1 (without

Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Demand Applicable for Vitotronic 100, GC1 (without comm

Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Demand [146] Applicable for Vitotronic 100, GC1 (withou

2 Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Demand [150] Applicable for Vitotronic 100, GC1 (wit

Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Disable [146] Applicable for Vitotronic 100, GC1 (witho

2 Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Disable [150] Applicable for Vitotronic 100, GC1 (wit

1 Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner/Control Disable [151] Applicable for Vitotronic 100,

Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—Burner Modulation [90] Applicable for Vitotronic 100, GC1 (wit

Control Overview—External Controls Connections BMS Connections—External Changeover of Modulation to Staging [146] Applicable for Vitotronic 100, GC1

Installation of Boiler Controls Vitotronic 100, GC1 and Vitotronic 300, GW2 on Vitorond VD2 boilers (490-1096MBH or 144-321KW) Refer to boiler manual

Control Overview—External Controls Connections BMS Connections—Burner Demand [146] Applicable for Vitotronic 300, GW2 Burner Demand: Dry contact to

5 2 Control Overview—External Controls Connections BMS Connections—External Change of Heating Program/Mixing Valve Open [143] Applicable for Vitotro

5 2 Control Overview—External Controls Connections BMS Connections—External Disable/Mixing Valve Close [143] Applicable for Vitotronic 300, GW2 1 3

2 Control Overview—External Controls Connections BMS Connections—Burner Demand [150] Applicable for Vitotronic 300, GW2) Burner Demand: Dry contact

2 Control Overview—External Controls Connections BMS Connections—Burner Disable [150] Applicable for Vitotronic 300, GW2 Burner Disable: Dry contac

1 Control Overview—External Controls Connections BMS Connections—Burner/Control Disable [151] Applicable for Vitotronic 300, GW2 Burner Disable: Dr

Control Overview—External Controls Connections BMS Connections—External Changeover of Modulation to Staging [146] Applicable for Vitotronic 300, GW2

5 2 Control Overview—External Controls Connections BMS Connections—External Change of Heating Program/Mixing Valve Open [143] Applicable for Vitocon

5 2 Control Overview—External Controls Connections BMS Connections—External Disable/Mixing Valve Close [143] Applicable for Vitocontrol-S, MW1 (CT3/

Control Overview—External Controls Connections BMS Connections—External Demand [146] Applicable for Vitocontrol-S, MW1 (CT3/VD2/RS/VB2) External Dema

8 9 6 10 7 Installation of Boiler Controls Vitotronic 100, GC1 and Vitotronic 300, GW2 on Vitorond VD2 boilers (490-1096MBH or 144-321KW) Refer to bo

5 2 Control Overview—External Controls Connections BMS Connections—Boiler Disable [143] Applicable for Vitotronic 100, GC1 in conjunction with Vitoc

5 2 Control Overview—External Controls Connections BMS Connections—Switch in Boiler as Last in Sequence [143] Applicable for Vitotronic 100, GC1 in

Control Overview—External Controls Connections BMS Connections—External Changeover of Modulation to Staging [146] Applicable for Vitotronic 100, GC1

Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—0-10VDC 145 KM-BUS Applicable for Vitotronic 100, GC1 (without

Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—0-10VDC 145 KM-BUS Applicable for Vitotronic 100, GC1 (without

5 8 7 6 Control Overview—External Controls Connections BMS Connections—Single/Multiple Boilers—0-10VDC 145 KM-BUS Applicable for Vitotronic 100, GC1

Control Overview—External Controls Connections BMS Connections—Single Boiler—0-10VDC 145 KM-BUS Applicable for Vitotronic 300, GW2 (without communica

Control Overview—External Controls Connections BMS Connections—Single Boiler—0-10VDC 145 KM-BUS Applicable for Vitocontrol-S, CT3/VD2, MW1 1 Input

Notes Section 4 5346540 v1.0 09/2006 Technical information subject to change without notice 98 This page is intentionally left blank Section 4

Communications Section 5.0 Section 5 Communication Interconnection Information General Information Communication card installation overview Secti