Viessmann Vitotronic 300 KW3 User manual

VITOTRONIC 300
Installation Instructions
Vitotronic 300
Model KW3
Weather-responsive indoor/outdoor, digital boiler control
for heating systems with one or more heating circuits
Part No. Z00 23
Certified as a component part
of Viessmann boilers only
5303 269v .3 0/20

Safety instructions
2
Safety Instructions
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation and operation Failure to comply
with the instructions listed below and details printed in these instructions 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).
Licensed 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”.
Product 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
applicableliterature, please
see section entitled
“Important Regulatory and
Installation Requirements”.
Advice 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.
Warranty
Information contained in this and
related product documentation must be
read and followed. Failure to do so
renders warranty null and void.
Safety Terminology
One or more of the following terms are used throughout this manual to bring attention to the presence of potential hazards or
important product information. Please heed the advice given!
Helpful hints for installation, operation or
maintenance which pertain to the
product
5303 269 v .3
Indicates an imminently hazardous
situation which, if not avoided, will
result in death, serious injury or
substantial product/property damage
DANGER
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

Index
3
Page
Safety Instructions Safety Instructions 2
......................................................................
Application Examples Application Example 1
System with one direct-connected heating circuit
without mixing valve 4 ..................................................................
Application Example 2
System with one heating circuit with mixing valve 5 ......
Application Example 3
System with one direct-connected heating circuit
without mixing valve and one heating circuit with
mixing valve 6 ....................................................................................
Application Example 4
System with two heating circuits with mixing valves 7 . .
Application Example 5
System with one direct-connected heating circuit
without mixing valve and two heating circuits with
mixing valves 8 .................................................................................
Electrical Connections Overview 9
..........................................................................................
Vitotronic Connections 0 ...............................................................
Application of Strain Relief 2 .......................................................
Sensors 3 .............................................................................................
Pumps (accessory) 6 ......................................................................
Burner 7 ................................................................................................
Compiled Fault Indicator Alarm 8
External Switching of the Heating Program 9 .....................
Settings Fixed High Limit 20
............................................................................
Adjustable High Limit 2 .................................................................
Installation Boiler Coding Card 22
.......................................................................
Top of Control Unit 23 .....................................................................
Opening the Control Unit 23 ..........................................................
Appendix Post-Installation Testing 24
............................................................
Technical Data 24 ...............................................................................
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4
Application Example 1
System with one direct-connected heating circuit without mixing valve
Boiler with Vitotronic 300
Domestic hot water tank
Vitotrol, Switching Module-V,
KM-BUS Expansion Module for the
connection of several KM-BUS
participants
Heating circuit without mixing valve
Power Pump Module
Low water cut-off device
Connectors
Outdoor temperature sensor
Boiler temperature sensor
DHW tank temperature sensor
KM-BUS participants
Extension for
two-stage/modulating burner
*
Heating circuit pump
Boiler circuit
DHW production pump
(accessory)
DHW recirculation pump
(field supplied where required)
Power supply
( 20 VAC, 60 Hz)
Burner, single-stage
*
Burner, two-stage/modulating
*
Required Equipment
Description Qty Part No.
Vitotronic 300 Z00 23
Available System Accessories
Vitotrol remote control
Room temperature sensor
Switching Module-V for expanding
the range of control functions
KM-BUS Expansion Module
Flue gas temperature sensor
* Included in standard equipment
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5
Application Example 2
System with one heating circuit with mixing valve
Boiler with Vitotronic 300
Domestic hot water tank
KM-BUS Expansion Module
(accessory) for the connection of
several KM-BUS participants
Heating circuit with mixing valve
Power Pump Module
Low water cut-off device
Mixing valve actuator accessory kit
Connectors
Outdoor temperature sensor
Supply temperature sensor
(accessory)
*2
Boiler temperature sensor
DHW tank temperature sensor
Return water temperature sensor
(accessory)
*2,3
KM-BUS participant
Extension for
two-stage/modulating burner
*4
M Heating circuit pump
*2
Mixing valve circuit
DHW production pump
(accessory)
DHW recirculation pump
(installed on site)
Power supply
( 20 VAC, 60 Hz)
Burner, single-stage
*4
Burner, two-stage/
modulating
*4
Required Equipment
Description Qty Part No.
Vitotronic 300 Z00 23
Mixing valve actuator accessory kit (with mixing valve motor and supply temperature
sensor) for Viessmann mixing valve
7 33 392 (old version)
or
7837 524 (new version)
Available System Accessories
Vitotrol remote control
Room temperature sensor
Return water temperature sensor
Switching Module-V for expanding
the range of control functions
KM-BUS Expansion Module
Flue gas temperature sensor
* Supply check valve, only required if piping connection is made on one common boiler return.
*2To be connected in accessory kit.
*3In connection with underfloor heating when control measures supply and return water temperature.
*4Included in standard equipment.
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6
Application Example 3
System with one direct-connected heating circuit without mixing valve and one heating circuit with mixing valve
Boiler with Vitotronic 300
Domestic hot water tank
Heating circuit without mixing
valve
KM-BUS Expansion Module
(accessory) for the connection of
several KM-BUS participants
Heating circuit with mixing valve
Mixing valve actuator accessory kit
Power Pump Module
Low water cut-off device
Connectors
Outdoor temperature sensor
Supply temperature sensor
(accessory)
*2
Boiler temperature sensor
DHW tank temperature sensor
Return water temperature sensor
(accessory)
*2,3
KM-BUS participant
Extension for
two-stage/modulating burner
*4
Boiler circuit pump
M Mixing valve circuit pump
*2
DHW production pump
(accessory)
DHW recirculation pump
(field supplied where required)
Power supply
( 20 VAC, 60 Hz)
Burner, single-stage
*4
Burner, two-stage/modulating
*4
Required Equipment
Description Qty Part No.
Vitotronic 300 Z00 23
Mixing valve actuator accessory kit (with mixing valve motor and supply temperature
sensor) for Viessmann mixing valve
7 33 392 (old version)
or
7837 524 (new version)
Available System Accessories
Vitotrol remote control
Room temperature sensor
Return water temperature sensor
Switching Module-V for expanding
the range of control functions
KM-BUS Expansion Module
Flue gas temperature sensor
* Supply check valve, only required if piping connection is made on one common boiler return.
*2To be connected in accessory kit.
*3In connection with underfloor heating when control measures supply and return water temperature.
*4Included in standard equipment.
5303 269 v .3

Heating system types
7
Application Example 4
System with two heating circuits with mixing valves
Boiler with Vitotronic 300
Domestic hot water tank
Heating circuit with mixing valve
Mixing valve actuator accessory kit
Heating circuit with mixing valve 2
Mixing valve actuator accessory kit
KM-BUS Expansion Module
(accessory) for the connection of
several KM-BUS participants
Power Pump Module
ILow water cut-off device
Connectors
Outdoor temperature sensor
Supply temperature sensor
(accessory)
*2
Boiler temperature sensor
DHW tank temperature sensor
Return water temperature sensor
(accessory)
*2,3
KM-BUS participant
Extension for
two-stage/modulating burner
*4
M Mixing valve circuit pump
*2
M2 Mixing valve circuit pump 2
DHW production pump
(accessory)
DHW recirculation pump
(field supplied where required)
Power supply
( 20 VAC, 60 Hz)
Burner, single-stage
*4
Burner, two-stage/
modulating
*4
Required Equipment
Description Qty Part No.
Vitotronic 300 Z00 23
Mixing valve actuator accessory kit (with mixing valve motor and supply temperature
sensor) for Viessmann mixing valve 2
7 33 392 (old version)
or
7837 524 (new version)
KM-BUS Expansion Module 7 33 393
Available System Accessories
Vitotrol remote control
Room temperature sensor
Return water temperature sensor
Switching Module-V for expanding
the range of control functions
Flue gas temperature sensor
* Supply check valve, only required if piping connection is made on one common boiler return.
*2To be connected in accessory kit.
*3In connection with underfloor heating when control measures supply and return water temperature.
*4Included in standard equipment.
5303 269 v .3

8
Application Example 5
System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves
Boiler with Vitotronic 300
Domestic hot water tank
Heating circuit with mixing valve
Mixing valve actuator accessory kit
Heating circuit with mixing valve 2
Mixing valve actuator accessory kit
KM-BUS Expansion Module
for the connection of several
KM-BUS participants
Heating circuit without mixing valve
Power Pump Module
Low water cut-off device
Connectors
Outdoor temperature sensor
Supply temperature sensor
(accessory)
*2
Boiler temperature sensor
DHW tank temperature sensor
Return water temperature sensor
(accessory)
*2,3
KM-BUS participant
Extension for
two-stage/modulating burner
*4
M Mixing valve circuit pump
*2
M2 Mixing valve circuit pump 2
Heating circuit pump
DHW production pump
(accessory)
DHW recirculation pump
(field supplied where required)
Power supply
( 20 VAC, 60 Hz)
Burner, single-stage
*4
Burner staging taken from other
devices
Required Equipment
Description Qty Part No.
Vitotronic 300 Z00 23
Mixing valve actuator accessory kit (with mixing valve motor and supply temperature
sensor) for Viessmann mixing valve 2
7 33 392 (old version)
or
7837 524 (new version)
KM-BUS Expansion Module 7 33 393
Available System Accessories
Vitotrol remote control
Room temperature sensor
Return water temperature sensor
Switching Module-V for expanding
the range of control functions
Flue gas temperature sensor
* Supply check valve, only required if piping connection is made on one common boiler return.
*2To be connected in accessory kit.
*3In connection with underfloor heating when control measures supply and return water temperature.
*4Included in standard equipment.
5303 269 v .3
2

Electrical connections
9
Overview
The illustration shows the bottom part of the control unit as viewed from rear.
120 VAC connectors
Interconnections Power Pump Module
Boiler circuit pump
DHW pump (accessory)
DHW recirculation pump
(to be field supplied where
required)
Power supply
Compiled fault indication
External equipment,
e.g. additional safety equipment
Burner connections
Burner connection
The 120 VAC connections are interface
connections to the power pump
module Do not connect any external
equipment directly
Low voltage connectors
Outdoor temperature sensor
Boiler temperature sensor
DHW tank temperature sensor
BDHW tank temperature sensor 2
Flue gas temperature sensor
(accessory)
Telephone connection (external
switching of the heating program)
KM-BUS (accessory)
e.g. for connection of Vitotrol
remote control
or
mixing valve actuator accessory
kit
or
Vitocom 00 communication unit
Extension for two-stage or
modulating burner (included in
standard equipment)
Take notice of shape and orientation of
low voltage connectors when inserting
into sockets at rear of control!
5303 269 v .3
IMPORTANT
IMPORTANT

Electrical connections
0
Vitotronic Connections
5303 269 v .3
Vitotronic boiler control (view from rear)
Power Pump Module (wall-mounted)
Connections for plug-in equipment
Connections for “hard-wired” equipment
1 Ensure that main power supply to the
Power Pump Module contains overcurrent
protection with a maximum rating of 5 A.
“L” and “N”
L: LINE
N: Neutral
G: Ground
This equipment must be grounded.
Ensure that the following wires are not
interchanged:
WARNING
20 VAC, 60 Hz, Ph
Power supply
Provide 5 A overcurrent
protection and disconnect
means
Circulating pump for
domestic hot water tank
20 VAC, Ph, 3 A max.
Circulating pump for
domestic hot water
recirculation
20 VAC, Ph, 3 A max.
Alarm indicator
5
Circulating pump
Heating circuit without
mixing valve
20 VAC, Ph, 3 A max.
5
50
56 50
Pump
Space Htg.
Alarm
Output
20 VAC