Viessmann VITOTRONIC 100 GC1B Service Manual

Installation andService Instructionsfor use by heating contractorVitotronic 100, Model GC1Digital boiler control unitVITOTRONIC 100, GC1Certified as a

Heating system types10Circuit Diagram 2Multi-boiler system with Therm-Control and three-way mixing valvein conjunction with Vitorond 200, VD2ALON LON

Troubleshooting100DiagnosisFaults with fault display on the programming unitThe red fault indicator 2 flashes whenever there is a fault.When a fault m

Troubleshooting101Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcode indisplayBehaviour of systemCause of fau

Troubleshooting102Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcode indisplayBehaviour of systemCause of fau

Troubleshooting103Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcode indisplayBehaviour of systemCause of fau

Troubleshooting104Diagnosis (continued)Retrieving fault codes from the fault memory (error history)All faults which have occurred are stored and can b

Functional description105Boiler Temperature ControlBrief descriptionThe boiler water temperature iscontrolled by switching the burner onand off.The se

Functional description106Heating Circuit ControlBrief descriptionThe supply temperature of the boilercircuit (A1) corresponds to the boilerwater tempe

Functional description107DHW Tank Temperature Control (continued)Control sequenceDHW tank temperature falls(Set-point value –2.5°C / - 4.5°F,selectabl

Additional information108OverviewPageTechnical Data 105System ComponentsLine voltage motherboard 105. . . . . . . . . . . . . . . . . . . . . . . . .

Additional information109Technical DataRated voltage: 120 V~Rated frequency: 60 HzRated actual: 2 x 6 A~Powerconsumption: 10 WProtectionclass: IDegree

Heating system types11Circuit Diagram 3Single-boiler system with shunt pump for elevating the return temperaturein conjunction with Vitorond 200, VD2A

Additional information110System Components (continued)Power supply unit board, 120 VAC Part No. 7823 991The power supply unit board containsthe low-vo

Additional information111System Components (continued)Programming unit, Part No. 7823 990The programming unit is inserted in thecontrol unit.For setti

Additional information112System Components (continued)Boiler coding cardVitotronic 200in conjunction withBoiler codingcardPart No.Vitocrossal 300, Typ

Additional information113System Components (continued)TUV button, Part No. 7819 314For checking the fixed high limit.See description on page 86.Fixed

Additional information114System Components (continued)Input Module 0 to 10 V, Part No. 7134 561From software version 7 of Vitocontrol-S, VD2/CT3, the

Additional information115Coding 1Call up coding level 11. Press and simultaneously forapprox. 2 seconds.Access coding level 1.The first arrow appears

Additional information116Coding 1 (continued)Codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:ValuePossible cha

Additional information117Coding 2Call up coding level 2The overview lists all possible coding addresses.However, only those coding addresses are displ

Additional information118Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:

Additional information119Coding 2 ((continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:

Heating system types12Circuit Diagram 3 (continued)Possible applicationsHeating systems with manifoldarranged close to the boiler. The boilerwater sup

Additional information120Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information121Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information122Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information123Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information124Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information125Wiring DiagramsOverviewA2 Low-voltage motherboardA3 Line voltage motherboardA6 Programming unitA7 Optolink/override switch bo

Additional information126Wiring Diagrams (continued)Low-voltage motherboard5351 338 v1.6A11A8A9A6A7A2A1034--pole

Additional information127Wiring Diagrams (continued)Low-voltage motherboard (continued)§ Boiler temperature sensor% Tank temperature sensor(accessory)

Additional information128Wiring Diagrams (continued)Line voltage motherboard5351 338 v1.6A11A3floatingONON

Additional information129Wiring Diagrams (continued)Line voltage motherboard (continued)sÖ Control outputsA DHW pumpsL Shunt pump or boiler circuit pu

Heating system types13Circuit Diagram 4Single-boiler system with shunt pump and return valve for elevating the return temperaturein conjunction with V

Additional information130Parts ListGC1 SeriesOrder No. Serial No.*17134 553, 7134 554, 7511 361 714300371870967248247Orderi

Additional information131Parts List5351 338 v1.6

Viessmann Manufacturing Company Inc.750 McMurray RoadWaterloo, Ontario • N2V 2G5 • CanadaTel. (519) 885-6300 • Fax (519) 885-0887www.viessmann.ca • in

Heating system types14Circuit Diagram 4 (continued)Possible applicationsHeating systems in which there is nofacility for making modifications oradjust

Heating system types15Circuit Diagram 5Multi-boiler system with shunt pump for elevating the return temperature for each boilerin conjunction with Vit

Heating system types16Circuit Diagram 5 (continued)Possible applicationsHeating systems with manifoldarranged close to the boiler. The boilerwater sup

Heating system types17Circuit Diagram 6Multi-boiler system with common supply pump and low-pressure manifoldin conjunction with Vitorond 200, VD2A Boi

Heating system types18Circuit Diagram 6 (continued)Possible applicationsWhere the manifold is arranged indistant substations (> 20 m). Theheat tran

Heating system types19Circuit Diagram 7Multi-boiler system with return valve for return temperature protectionin conjunction with Vitorond 200, VD2A B

General information2Safety, Installation and Warranty RequirementPlease ensure that this manual is read and understood before commencing installation.

Heating system types20Circuit Diagram 7 (continued)Possible applicationsE.g. old systems or systems in marketgardens and/or systems in which thereis n

Heating system types21Circuit Diagram 8Multi-boiler system with low-loss header and return valve for elevating the return temperaturein conjunction wi

Heating system types22Circuit Diagram 8 (continued)Possible applicationsE.g. old systems or systems in marketgardens as well as systems in whichthere

Heating system types23Circuit Diagram 9Several heating circuits and one mixing valve heating circuitSingle-boiler system with Vitocrossal 300A Boiler

Heating system types24Circuit Diagram 9 (continued)This circuit diagram represents arecommendation only. It is theresponsibility of the customer and/o

Heating system types25Circuit Diagram 10Single-boiler system with several heating circuits and one mixing valve heating circuitin conjunction with Vit

Heating system types26Circuit Diagram 10 (continued)Possible applicationsFor heating circuits with differenttemperatures.This circuit diagram represen

Heating system types27Circuit Diagram 11Multi-boiler system with several heating circuits and one mixing valve heating circuitin conjunction with Vito

Heating system types28Circuit Diagram 11 (continued)Possible applicationsThe cascade and DHW tank controlmust be activated by a buildingautomation sys

Heating system types29Circuit Diagram 12Multi-boiler system with several heating circuits, one mixing valve heating circuit and Vitorond with shunt pu

General information3Safety, Installation and Warranty Requirement (continued)Safety TerminologyTake note of all symbols and notations intended to draw

Heating system types30Circuit Diagram 12 (continued)Possible applicationsThe cascade and DHW tank controlmust be activated by a buildingautomation sys

Heating system types31Circuit Diagram 13Multi-boiler system with return valve, several heating circuits and one mixing valveheating circuitin conjunct

Heating system types32Circuit Diagram 13 (continued)Possible applicationsFor heating circuits with temperaturedifferences ≥20 K.The cascade and DHW ta

Heating system types33Circuit Diagram 14 (CM2 only)Single-boiler system with several heating circuits and one mixing valve heating circuitin conjuncti

Heating system types34Circuit Diagram 14 (CM2 only) (continued)Possible applicationsFor heating circuits with differenttemperatures.This circuit diagr

Heating system types35Circuit Diagram 15 (CM2 only)Multi-boiler system with several heating circuits and one mixing valve heating circuitin conjunctio

Heating system types36Circuit Diagram 15 (CM2 only) (continued)Possible applicationsThe cascade and DHW tank controlmust be activated by a buildingaut

Installation37Mounting the Front Part of the Control Unit (VD2/VD2A/CT3 only)1. Position the front part of the housingand clip hinges to counter-parts

Installation38Opening the Control Unit (VD2/VD2A/CT3 only)1. Remove the cover of theconnection enclosure.2. Unscrew the screws from thefront housing.3

Installation39Control and Junction Box Installation Instructions (for CM2 only)1. Route cables and capillaries fromcontrol through the opening in thec

4Vitotronic 100, GC1For installation on Viessmann Applicable to the following control units:boilers only. Part No. 7134 553/7134 554/7511361, from Ser

Installation40Mounting the Front Part of the Control Unit (CM2 only)1. Position the front part of the housingand clip hinges to counter-parts onmain h

Installation41Opening the Control Unit (CM2 only)1. Remove the control cosmeticcover .2. Unscrew the screws from thefront housing.3. Swing up the fron

Installation42Overview of Electrical ConnectionsLow voltage connections (motherboard)§ Boiler temperature sensor (KTS)% DHW tank temperature sensoraG

Installation43Overview of Electrical Connections (VD2/VD2A/CT3 only) (continued)5351 338 v1.6[29][20] A1

Installation44Overview of Electrical Connections (CM2 only) (continued)5351 338 v1.6

Installation45Routing and Strain Relief of Cables1. Run the cables from the connection enclosure into the control unit.2. Apply strain relief to cable

Installation46Inserting the Boiler Coding CardOnly use the boiler coding card included with the boiler.Boiler Coding card Part no.Vitocrossal 300, typ

Installation47Setting of the Fixed High Limit (if required)Settings on the control unitThe setting for the fixed high limit andthe other settings are

Installation48Setting of the Adjustable High Limit (if required)The adjustable high limit is suppliedwith a factory setting of 95°C / 203°FAdjustment

Installation49Sensor ConnectionATemperature sensor T2BTemperature sensor T1CBoiler temperature sensorDFlue gas temperature sensor5351 338 v1.617B 17A

Index5PageGeneral InformationSafety Instructions and Warranty Requirements 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Product Inf

Installation50Connection of the Boiler Temperature SensorElectrical connectionSee page 35.The sensor measures the boilerwater temperature of the boile

Installation51Connection of the DHW Tank Temperature SensorThe sensor measures the domestic hotwater tank temperature.Heating systems with domestic ho

Installation52Connection of the Return Temperature SensorStrap-on temperature sensor and immersion temperature sensorFor measuring the boiler returnan

Installation53Connection of the Flue Gas Temperature Sensor (VD2/VD2A/CT3 only)The sensor measures the flue gastemperature and monitors theselected li

Installation54Connection of the Pumps (VD2/VD2A/CT3 only)Available pump connections20A1/M129sÖ A1/M1Heating circuit hightemperature (without mixing va

Installation55Connection of the Pumps (CM2 only)Available pump connectionssÖ A1/M1Heating circuit hightemperature (without mixing valve)Terminals 7 -

Installation56Connection of Boiler Return Mixing Valve or Isolation/Modulating Valveactuator(VD2/VD2A/CT3 only)1 120V or 24V Valve Adaptor2 DIN rail i

Installation57Connection of Boiler Return Mixing Valve or Isolation/Modulating Valveactuator(CM2 only)1 120V or 24V Valve Adaptor2 DIN rail in connect

Installation58Making Space for Accessory Adaptors on the DIN Rail (CM2 only)1. Push up on the bottom front ofthe DIN rail clamp to remove andset aside

Installation59Vitotronic 100, GC1 with 30% LTP Package (VD2/VD2A only)5351 338 v1.6VD2/VD2A1 - 17B Sensor (strap-on)

6Start-upProcedure (overview) 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation60Connection of External ControlsOperation with two-stage burnerASwitch on 1st stage burnerConnect dry contact at terminals ”1”and ”2” of

Installation61Connection of External Controls (continued)Operation with two-stage burnerSettings on the control unitThe settings for the fixed high li

Installation62Connection of External Controls (VD2/VD2A only) (continued)Modulating boilers – operation with external modulation controller (continued

Installation63Connection of External Controls (VD2/VD2A only) (continued)Modulating boilers – operation with external modulation controllerSettings on

Installation64Connection of External Controls (CT3 only) (continued)Vitocrossal 300 – operation with external modulation controller1st stage burner fA

Installation65Connection of External Controls (CT3 only) (continued)Vitocrossal 300 – operation with external modulation controller (continued)Setting

Installation66Connection of Combustion Air Device (VD2/VD2A/CT3 only)Connection of the Combustion AirDevice Adaptor1. Disconnect power to control andb

Installation67Connection of Combustion Air Device (CM2 only)Connection of the Combustion AirDevice Adaptor1. Disconnect power to control andburners.2.

Installation68Connection of Combustion Air Device (continued)Connection of the combustion airdamperSee damper manual for correctinstallation.Ensure th

Installation69Connection of Combustion Air Device on Multiple Boiler SystemsIf a single combustion air device isrequired for a multiple boiler system,

Heating system types7OverviewCircuitdiagramSystem type Boiler Key features Page11 Single-boilersystemVitorond 200, VD2A With Therm-Control, single-boi

Installation70Connection of Single Combustion Air Device on Multiple Boiler SystemsConnection of the combustion airblowerA Common Combustion Air Devic

Installation71Connection of Combustion Air DamperConnection of the combustion airdamperA Common Combustion Air DeviceInterfaceB Combustion air device

Installation72Flue Gas Temp. Switch (optional for CM2 equipped with SS flue collector)(CM2 only)1. Disconnect power.2. Remove 150 plug from theVitotro

Installation73Connection of Low Water Cut-off Device (VD2/VD2A/CT3 only)aBH Power supply for accessories.aBÖ Connection for externalequipment.1. Remov

Installation74Connection of Low Water Cut-off Device (CM2 only)1. Remove jumper between terminals21 and 22.2. Make connection as shown indiagram.5351

Installation75Connections to Terminal aBÖ (VD2/VD2A/CT3 only)A JumperB External shut-off (dry contact)External shut-off1. Remove jumper between termin

Installation76Connection of the Compiled Failure Alarm Indicator (VD2/VD2A/CT3 only)Rated voltage: 120 VAC 60 HzRated current: max. 2 FLARecommended c

Installation77Connection of the Compiled Failure Alarm Indicator (CM2 only)Rated voltage: 120 VAC 60 HzRated current: max. 2 FLARecommended connection

Installation78Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only)For burners with plug-in connectionThe burner cables are included in thestan

Installation79Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)Write the terminal numbers ormarkings on the drawing for futurer

Heating system types8Circuit Diagram 1Single-boiler system with Therm-Control and three-way mixing valvein conjunction with Vitorond 200, VD2AA Heatin

Installation80Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)Burner motor power supply connection(continued)For burners with

Installation81Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)Burner motor power supply connection(continued)For burners with

Installation82Power Supply Connection, Boiler Control (VD2/VD2A/CT3 only)LegendL: LineN: NeutralG: GroundA Power supply 120 VAC, 1 PH .Provide disconn

Installation83Burner Connection, Burner Control Wiring (CM2 only)For burners with plug-in connectionThe burner cables are included in thestandard deli

Start-up84Procedure (overview)Page1. Controls and indicators 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up85Steps1. Controls and indicatorsOverride switchBoiler water temperature(without function on multi-boilersystems)Domestic hot water temperatur

Start-up86Steps (continued)2. Check the fixed high limitThe check is made via the ”TUV button” (see page 85).When making the check, the ”TUV”button mu

Start-up87Steps (continued)3. Integrate the control unit in the LON BUS system Single-boiler system onlyThe LON communication module(accessory) must b

Start-up88Steps (continued)4. Carry out participant check Single-boiler system onlyThe participant check is used to verify the communication of the sy

Start-up89Steps (continued)5. Match the control unit to the system typeSet the following coding addresses incoding 2:”00” System type”01” Single or mu

Heating system types9Circuit Diagram 1 (continued)sÖ A1 Close mixing valvesA Contactor relay, field suppliedB Heating circuit controlsconnected downst

Start-up90Steps (continued)7. Match the coding addressesMatch control unit to modulating burnerPlease note:The burner must be adjusted. In order to ac

Start-up91Steps (continued)7. Match the coding addresses (continued)10. Set the established values in codinglevel 1.See page 115 for coding 1.AddressS

Scanning service information92Overview of Service LevelsFunction Button combination To exit PageTemperatures, boiler codingcards and scansPress 9 and

Scanning service information93Temperatures, Boiler Coding Cards and Scans1. Press and simultaneously forapprox. 2 seconds.Access diagnosis level.2. Se

Scanning service information94Temperatures, Boiler Coding Cards and Scans (continued)Scan 0Scan 1Scan 25351 338 v1.68880 8Software versionCommunicatio

Scanning service information95Temperatures, Boiler Coding Cards and Scans (continued)Scan 4Scan b/d5351 338 v1.68884 8Software versionControl unitSyst

Scanning service information96Temperatures, Boiler Coding Cards and Scans (continued)Scan LScan oooo5351 338 v1.60 0 0or to to1 9 9L888l 8Scan LFreeOu

Scanning service information97Scanning Service Information1. Press .2. Select the required operating statusdata for scanning with the orbutton.3. Pres

Scanning service information98Scanning and Resetting the Service DisplayPlease note:If a service is carried out before the service display appears, se

Troubleshooting99Troubleshooting StepsPageDiagnosis 1. Establish fault message or ascertain behaviour of system2. Look for the corresponding cause of