Viessmann Vitotronic 200 300 Technical Manual 5167 888 V1.1

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Certified as a component part

of Viessmann boilers only

VITOTRONIC 200

Weather-responsive indoor/outdoor, digital boiler control

for heating systems with one or more heating circuits

Vitotronic 200

Model KW2, Part No. Z001 230

For operation with modulating boiler water temperatures,

and single-stage, two-stage or modulating burners

With DHW tank temperature sensor and integrated

diagnostic system

Operating module with clear text LCD display

Remote control interface with room temperature sensor

(optional)

Viessmann quick-connect plug-in system

Technical Data Manual

5167 888 v1.1 11/2002

Product Information/Standard Equipment/

Application

2

Product Information

The benefits at a glance:

HEasy and uniform operation:

–Different programming levels for

system user and heating contractor.

–Large, clear text LCD display format

facilitates legibility of all data.

–Illuminated operating mode and

heating circuit keys.

–Easy-to-program switching times.

–Digital tracking of day and week.

Programmed times for domestic hot

water production and recirculation

pump are adjusted automatically

when heating program is altered.

–Plug & Work quick-connect system for

automatic sensor and system

recognition and adaptation.

–Automatic resetting to daylight

savings time.

–Service interval display for

demand-related maintenance.

–Fuel consumption display.

HProgram selection for controlled drying

of concrete floor in radiant floor heating

application.

HShort installation time,start-upand

maintenance due to Rast-5 connector

system, plug-in function modules and

integrated diagnostic system.

Vitotronic 200, Model KW2

HWeather-responsive indoor/outdoor,

digital boiler and heating system

control:

–for heating systems with one boiler

–for heating circuits without and

heating circuits with a mixing valve

–for single-stage, 2-stage and

modulating burners

–with DHW tank temperature sensor

–with digital tracking of day and week

–with separate switching times for

room heating, domestic hot water

heating and recirculation pump

–with integrated diagnostic system

Standard Equipment

Vitotronic 200, Model KW2

(Part No. Z001 230)

with

Hoperating module with clear text LCD

display

Houtdoor temperature sensor

Hboiler water temperature sensor

HDHW tank temperature sensor

HPower/Pump Module

For the heating circuit with a mixing

valve, a mixing valve actuator accessory

kit is required. Due to the low return

water temperature of condensing boilers

only 3-way mixing valves should be

installed. The circulation pump with a

flow check valve for DHW tank

temperature control must be ordered

separately.

Heating system with underfloor heating

The underfloor heating circuit requires an

accessory kit for operation with a mixing

valve.

A temperature control with high limit

must be installed in the heating supply of

the radiant floor heating application.

The underfloor heating circuit must not

be controlled by a remote control with

room temperature sensor.

Application

In conjunction with the following Viessmann boilers

Boiler Model and Series

Fuel Minimum boiler water

temperature

without low

limit

with low limit

(average temp.)

Oil-fired hot water

heating boiler with

power burner

Vitorond 200 Oil 104 ºF/40 ºC

Oil-/gas-fired hot water

heating boiler with

power burner

Vitola 200 Oil/Gas x

Atmospheric

gas-/propane-fired hot

water heating boiler

Vitogas 050, RS Series Gas 120 ºF/49 ºC

Atmospheric gas-fired

hot water heating boiler

Vitogas 100, GS1 up to 240 MBH / 70 kW

Vitogas 100, GS10 up to 380 MBH / 111 kW

Gas

Gas

104 ºF/40 ºC

120 ºF/49 ºC

5167 888 v1.1

OTS

STS

Structure and Operation

3

Structure and Operation

Modular structure

The complete control consists of a

control base, control unit

(electronic/operating modules) and a

Power/Pump Module.

The control unit comprises:

Power on/off switch, an electronic high

limit, a temperature gage and a low

temperature control

–adjustable high limit

–fixed high limit

TUV test switch, override switch,

buttons for:

–holiday program

–party and economy modes

–reduced operating mode temperature

–domestic hot water temperature

–programming of heating curves for

boiler water temperature and/or mixing

valve circuit temperature

–heating circuit selection,

a selector knob for normal operating

temperatures and a digital timer.

Heat-demand-controlled circuit pump and

burner activation, adjusting of a variable

temperature limit, pump cycling,

integrated diagnostic system and flue gas

monitoring in connection with flue gas

temperature sensor (optional) and

maintenance display.

Boiler-specific functions

The Vitotronic control modulates the

boiler water temperature.

It gradually regulates the boiler water

temperature (= the supply temperature

of the direct-connected heating circuit) as

well as the supply water temperature of a

mixing valve circuit. The control contains

an adaptive tank temperature control

logic with priority switching (heat pump

off, mixing valve closed).

An additional function for domestic hot

water heating (short-term heating to an

increased temperature) can be selected.

The Vitotronic 200 is an ideal control

option for your heating system with

mixing valve circuit. It is the perfect

solution for your underfloor heating

circuit with supply and return water

temperature sensor or for controlled

drying of a concrete floor.

Control characteristics

–Boiler circuit control unit (high

temperature)

–Heating circuit control with mixing

valve

Dead zone: ±1.80 ºF/1ºC

–Adjustable high limit factory default

setting: 167 ºF/75 ºC

–Adjustment of the fixed high limit:

230 ºF/110 ºC

adjustable to

212 ºF/100 ºC

–Adjustment range of heating curve:

Slope: 0.2 to 3.5

Shift: –23 ºF to +72 ºF/

–13 ºC to +40 ºC

High limit: 68 to 266 ºF/

20 to 130 ºC

Low limit: 34 to 261 ºF/

1 to 127 ºC

Differential temperature for heating

circuit with mixing valve: 0 to 72 ºF/

0to40ºC

–Adjustment range for domestic hot

water setpoint temperature:

50 to 140 ºF/

10 to 60 ºC

adjustable to

50 to 203 ºF/

10 to95 ºC

Technical data

Rated voltage: 120 VAC

Rated frequency: 60 Hz

Rated current: 6 A

Power consumption: 5 W

Maximum ambient

temperature

–at operation: 32 to 104 ºF/

0to 40 ºC

(in rooms and

installation sites

with normal

ambient

conditions)

–when storing or transporting:

–4 to +149 ºF/

–20 to +65 ºC

Relay output rating in conjunction with a

Power/Pump Module:

–Heating circuit

pumps: 3 FLA/120 VAC*1

–DHW tank heating

circulation pump: 3 FLA/120 VAC*1

–Domestic hot water

recirculation pump:3 FLA/120 VAC*1

–Mixing valve

actuator: 0.1 FLA/120 VAC*1

Operating time approx. 2 minutes

–Burner plug : 2 FLA/120 VAC

–2-stage burner

plug *2: 0.5 FLA/120 VAC

–Total: max. 12 A/120 VAC

*1Total 12 A/120 VAC

*2Available only with extension module

for 2-stage burner (included in boiler

package).

Boiler coding card

Adapts the control to the specific boiler

model being used (included in boiler

package).

Connections

–Sensors, burner and Power/Pump

Module are connected to the back of

the control unit via system plugs.

–Pumps, power supply and mixing valve

are connected to the Power/Pump

Module via screw terminals or system

plugs.

Operating unit

–With digital timer

–Clear text LCD display

–Temperature and fault display

–Coding via display of operating unit

–All adjustments and basic coding

information in clear text format.

5167 888 v1.1

Structure and Operation

4

Structure and Operation (continued)

Digital timer of operating unit

A digital timer with day and week

feature, calendar, automatic resetting to

daylight savings time and automatic

functions for domestic hot water heating

and recirculation pump.

Time, day and standard switching times

for room heating, domestic hot water

heating and domestic hot water

recirculation pump are factory preset

(individually programmable), max. four

time switch intervals programmmable per

day.

Shortest interval: 10 minutes

Power reserve: 5 years

Adjusting the operating system

All operating programs feature freeze-up

protection*1 for the heating system.

With the program selector buttons the

following can be selected:

–heating and domestic hot water

–domestic hot water only

–standby operation

*1 See Freeze-up Protection Function

below.

Freeze-up protection function

The freeze-up protection function is

–activated when the outside temperature

drops to +34 ºF/1ºC.

The freeze-up protection function

activates the circulation pumps and

keeps the boiler water temperature at

the reduced operation setpoint level, at

a minimum temperature of approx.

68 ºF/20 ºC (for heating boilers with

low limit the respective temperature

will be maintained).

–deactivated when the outside

temperature exceeds +37 ºF/3ºC.

When the freeze-up protection function

is deactivated, heating boiler and

circulation pumps are turned off.

Summer economy mode

(Domestic hot water heating only,

program selector switch ” ”)

The burner only activates if domestic hot

water needs to be produced (as required

by DHW setpoint).

Heating curve adjustment

The weather-responsive Vitotronic 200

regulates the boiler water temperature

(= supply water temperature of the

heating circuit without mixing valve) and

the supply temperature of the heating

circuit with a mixing valve.

The required supply temperature for a

certain room temperature depends on the

heating system and the insulation of the

building in question.

The adjustment of both heating curves

individually allows for the boiler water

temperature and the supply temperature

of the mixing valve circuit to be adjusted

to the respective conditions.

Heating curves:

Low temperature heating system,

e.g. radiant floor heating

Medium temperature heating system,

e.g. cast iron radiation, staple-up

radiant floor heating

High temperature heating system,

e.g. fintube radiation, fan coils

The maximum boiler water temperature is

restricted by both the adjustable high

limit and the electronic maximum

temperature limit.

The supply water temperature cannot

exceed the boiler water temperature.

Boiler water temperature sensor

Cable length 5.2 ft./1.6 m, ready to plug

in.

Maximum ambient temperature

– at operation: 32 to 266 ºF/

0 to 130 ºC

– when storing or transporting:

–4 to +158 ºF/

–20 to +70 ºC

Outdoor temperature sensor

Installation site:

–North or northwest side of building

–6.6 to 8.2 ft./2 to 2.5 m above ground,

for multi-storey buildings mount sensor

on upper half of second storey.

Connection:

–2-wire cable, cable length 115 ft./

35 m with a wire size of min. AWG 16

copper.

–the cable to the outdoor sensor must

not be laid near line voltage wiring

(120/240 V).

Maximum ambient temperature at

operation,

when storing or

transporting: – 40 to +158 ºF/

–40to +70ºC

Domestic hot water tank temperature

sensor

Cable length 19 ft./5.8 m, ready to plug

in.

Maximum ambient temperature

– at operation: 32 to 194 ºF/

0to 90ºC

– when storing or transporting:

–4 to +158 ºF/

–20 to +70 ºC

5167 888 v1.1

Accessories

5

Accessories

Note on the room temperature sensing

function (RS function)*1 when using a

remote control

Due to the slow response of the

underfloor heating, the RS function must

not influence the underfloor heating

circuit.

For heating boilers with a low limit, the

RS function must not influence the

heating circuit without a mixing valve.

*1RS function = remote control with

room sensor function

*2WS function = remote control only, no

room sensor function

Vitotrol 200,

Part No. 7133 378

The Vitotrol 200 remote control takes

care of the room temperature setpoint

adjustment at normal operation and

determines the heating program from any

given room.

The Vitotrol 200 features illuminated

heating program selector buttons as well

as a party and an economy button.

Fault messages are displayed on the

boiler control.

A remote control can be connected for

each heating circuit.

WS function*2: Allows for installation at

any given place in the building.

RS function*1: The remote control is to

be installed on an inside wall of the main

living area, across from radiators, but not

on shelves, in niches, in the close vicinity

of doors or heat sources of any kind (e.g.

direct sunlight, fireplace, TV, etc.).

The installed sensor measures room

temperature and, if necessary, takes

corrective action and initiates fast

heat-up at the outset of the heating

operation (if coded).

Connection:

–2-wire cable, cable length

max. 164 ft./50 m (also for the

connection of several remote controls).

–The cable must not be placed together

with line voltage wiring.

–Low voltage plug is included.

Rated voltage: 33 VAC

Rated current: 10 mA

Power consumption: 3.3 W

Maximum ambient

temperature

– at operation: 32 to 104 ºF/

0to 40ºC

–when storing

or transporting: –4 to+149 ºF/

–20 to +65 ºC

Adjustment range of

room temperature

setpoint: 50 to 86 ºF/

10 to 30 ºC

adjustable to

37 to 73 ºF/

3to23ºC

or

63 to 99 ºF/

17 to 37 ºC

Adjustment of the room temperature

setpoint at reduced operation takes place

at the Vitotronic 200.

Vitotrol 300,

Part No. 7133 382

The Vitotrol 300 remote control takes

care of the room temperature setpoint

adjustment at normal and reduced

operation for the heating program,

switching times for room heating,

domestic hot water heating and the

domestic hot water recirculation pump.

The Vitotrol 300 features illuminated

heating program selector buttons, a party

and an economy button, an automatic

reset function to daylight savings time,

buttons for the holiday program, day of

the week and time.

WS function*2: Allows for installation at

any given place in the building.

RS function*1: The remote control is to

be installed on an inside wall of the main

living area, across from radiators, but not

on shelves, in niches, in the close vicinity

of doors or heat sources of any kind (e.g.

direct sunlight, fireplace, TV, etc.).

The installed sensor measures room

temperature and, if necessary, takes

corrective action and initiates fast

heat-up at the outset of the heating

operation (if coded).

Connection:

–2-wire cable, cable length

max. 164 ft./50 m (also for the

connection of several remote controls).

–The cable must not be placed together

with line voltage wiring.

–Low voltage plug is included.

Rated voltage: 33 VAC

Rated current: 10 mA

Power consumption: 3.3 W

Maximum ambient

temperature

– at operation: 32 to 104 ºF/

0to 40ºC

–when storing

or transporting: –4 to +149 ºF/

–20 to +65 ºC

Adjustment range of

room temp. setpoint:

– at normal operation: 50 to 86 ºF/

10 to 30 ºC

adjustable to

37 to 73 ºF/

3to23ºC

or

63 to 99 ºF/

17 to 37 ºC

– at reduced operation: 37 to 99 ºF/

3to37ºC

5167 888 v1.1

Accessories

6

Accessories (continued)

Room temperature sensor,

Part No. 7133 379

A separate room temperature sensor as

an addition to the Vitotrol 200 or 300; to

be used when the Vitotrol 200 or 300

remote controls cannot be placed in the

main living area or in a position suitable

for monitoring the room temperature.

The room temperature sensor must be

installed on an inside wall of the main

living area, across from radiators, but not

on shelves, in niches or in the close

vicinity of doors or heat sources of any

kind (e.g. direct sunlight, fireplace, TV,

etc.).

The room temperature sensor is to be

connected with the Vitotrol 200 or 300.

Connection:

–2-wire cable with a wire diameter of

AWG 16 copper.

–Cable length between control unit,

remote control and room temperature

sensor must not exceed 115 ft./35 m.

–Cable must not be placed together with

line voltage wiring.

Maximum ambient

temperature

–at operation: 32 to 104 ºF/

0to 40ºC

–when storing

or transporting:

–4 to +149 ºF/

–20 to +65 ºC

KM-BUS Expansion Module,

Part No. 7133 393

With cable (10 ft./3 m long) and low

voltage plug.

To connect up to 6 devices to the single

KM-BUS connection of the boiler control

(Vitotrol, Switching Module-V etc.).

Switching Module-V,

Part No. 7133 387

With cable (10 ft./3 m long) and low

voltage plug.

With the Switching Module-V the

following additional functions are

feasible:

–external burner activation upon heat

demand (influences burner, possible

pumps and mixing valves), e.g. pool

heating, ventilation equipment etc.

–external disabling of burner

–remote switching of heating/operating

program, separate for each heating

circuit

–external error message input

–output of error message (SPDT contact)

–connection for short-term operation of

domestic hot water recirculation pump

(e.g. by external button)

5167 888 v1.1

Accessories

7

Accessories (continued)

Mixing valve actuator accessory kit,

Part No. 7133 390

consisting of a mixing valve actuator and

supply temperature sensor (strap-on

sensor)

Mixing valve actuator

The mixing valve actuator is to be

installed directly onto the Viessmann ¾

to 2½“ mixing valve.

The mixing valve actuator is a

bi-directional, single-phase, synchronous

motor with gear system and two limit

switches.

Rated voltage: 120 VAC

Rated frequency: 60 Hz

Power consumption: 4 W

Maximum ambient

temperature

– at operation: 32 to 104 ºF/

0to 40ºC

– when storing

or transporting: –4 to +149 ºF/

0to 65ºC

Torque: 3 Nm

Operating time

for 90º∢: 2 minutes

Strap-on sensor (included with mixing

valve actuator accessory kit),

Part No. 7133 895

To determine the supply temperature of

the mixing valve circuit.

Installed with a strapping band.

Cablelength19ft./5m,readytoplugin.

Maximum ambient

temperature

– at operation: 32 to 212 ºF/

0 to 100 ºC

–when storing

or transporting: –4 to +158 ºF/

–20 to +70 ºC

5167 888 v1.1

Viessmann Manufacturing Company Inc.

750 McMurray Road

Waterloo, Ontario •N2V 2G5 •Canada

Tel. (519) 885-6300 •Fax (519) 885-0887

www.viessmann.ca •mail@viessmann.ca

Viessmann Manufacturing Company (U.S.) Inc.

45 Access Road

Warwick, Rhode Island •02886 •USA

Tel. (401) 732-0667 •Fax (401) 732-0590

www.viessmann-us.com •mail@viessmann-us.com

8

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