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 ...............................................................................
5303 269 v .3

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
5303 269 v .3

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.
5303 269 v .3

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

Electrical connections
Remove jumper between
terminals L/P and P2 on
Power Pump Module board
when LWCO device is
installed.
Contact closes on water
Low water cut-off device (typical)
Vitotronic Connections (continued)
Low water cut-off connections
1 Run 3-conductor cable between low
water cut-off device and Power Pump
Module.
2 Remove jumper on Power Pump
Module board (LWCO connection).
3 Connect wiring as shown in drawing
on the left.
3 Check for LWCO function after
installation is completed.
5303 269 v .3

2
Application of Strain Relief
The strain relief clamps are supplied in
the accessories pack
1 Remove breakouts as necessary.
2 Mount lower portion of strain relief
clamp.
3 Insert the cable in the bushing and
secure the wires to the plug-in
connector. Insert bushing in clamp and
connector in socket.
4 Fasten top portion of strain relief
clamp.
No additional strain relief as described
above is required for cables which
incorporate a molded strain relief clamp
5303 269 v .3
IMPORTANT
IMPORTANT

Electrical connections
3
Sensors
Outdoor temperature sensor
The outdoor temperature sensor should
be mounted 6 6 to 8 2 ft /2 to 2 5 m
above ground on the north or
northwest wall of the building and for
buildings with multiple floors, in the
upper part of the second floor
The sensor must not be placed above
windows, doors, air vents or
immediately underneath a balcony or
drainage pipes
The outdoor temperature sensor must
not be plastered or painted over If
mounting on an unplastered wall, allow
room for plaster or remove sensor
before plastering wall
1 Remove sensor housing.
2 Secure wall-mount base to wall (cable
inlet opening to the bottom).
3 Pass cabling through openings in the
electrical connection section and the
supplied cable bushing.
Do not run cable next to line voltage
cables
4 Connect cable wires to terminal.
Cable: max. 5 ft./35 m long, AWG
copper.
5 Mount outdoor temperature sensor
housing.
6 Connect the cable wires from the
outdoor temperature sensor to
terminals ” ” and ”2” on plug (the
wires are interchangeable).
7 Insert plug into socket ” ” and
apply strain relief to the cable.
Outdoor temperature sensor
5303 269 v .3
2.
5.
.
4.
3.
IMPORTANT
IMPORTANT

Electrical connections
4
Sensors (continued)
Boiler temperature sensor
The boiler temperature sensor is installed at the same time as the boiler insulation.
Insert connector in socket ”3” (see
Vitotronic connections) and insert the
molded strain relief clamp.
Tank temperature sensor
Heating systems without domestic hot
water heating
Do not connect the DHW tank
temperature sensor to the control unit.
Heating systems with domestic hot water
heating
1 Install the DHW tank temperature
sensor.
Installation Instructions for
domestic hot water tank.
When installing the DHW tank
temperature sensor in tanks from other
manufacturers, ensure that sensor firmly
contacts the sensor well wall
Ensure that the maximum permissible
domestic hot water temperature is not
exceeded If necessary, an extra safety
high limit can be installed or an approved
type of tempering valve must be
installed
2. Insert connector in socket ”5”.
Insert molded strain relief clamp.
5303 269 v .3
IMPORTANT
IMPORTANT

Electrical connections
5
Sensors (continued)
Sensor connections
AFlue gas temperature sensor
(accessories)
BBoiler temperature sensor
CTank temperature sensor
DOutdoor temperature sensor
(cores may be interchanged)
Installation point for outdoor
temperature sensor
North or north-western wall, 2 to
2.5 m / 6.5 to 8 ft above ground
level; in case of multi-storey
buildings in the upper half of the
second floor
Not above windows, doors or
ventilation outlets
Not immediately below balconies
or gutters
Do not render over
Connection
2-core cable with a maximum
length of 35 m/ 5 ft and a
cross-section of .5 mm
2
(copper)
ETank temperature sensor 2
5303 269 v .3
5
2 3
43
2 3
5b
2 3
45
2 3
9
2 32 3
3
2 3 2 3
5
B DC EA

Electrical connections
6
Pumps (accessory)
All circulation pumps can be
“hard-wired” to the terminal strip of
the Power Pump Module. Pre-wired
Viessmann circulation pumps can be
plugged into the respective Rast-5
terminals in the Power Pump Module.
Available pump connections
Boiler circuit pump
(heating circuit pumps for mixing
valve circuits and 2 are
connected to the corresponding
actuator kit)
DHW production pump
DHW recirculation pump
For underfloor heating system only
An adjustable high limit must be
provided additionally. Install the fixed
high limit in the heating supply pipe
downstream from the mixing valve and
the heating circuit pump.
See installation instructions for
the limit thermostat
120 VAC pumps
1 Insert supplied strain relief through
Power Pump Module knock-out and
fasten with nut.
2 Connect the Rast-5 connector to the
respective plug-in terminal on the
Power Pump Module.
5303 269 v .3
ONLY Viessmann pre-wired (plug-in)
circulating pumps must be used If
pre-wired pumps are used do not
connect an additional pump to the
respective “hard-wired” terminals
WARNING

Electrical connections
7
Burner
The burner cable is included in the standard boiler equipment.
To control
(RAST-5 plug-in connector)
To burner or vent system
( plug-in connector)
Terminal codes
L Line via safety high limit
PE Ground conductor to the
burner
N Neutral conductor to the burner
T , T2 Control circuit
S3 Connection for burner fault
B4 Connection for operating
hours counter
The Vitotronic 300 is prewired with the
Viessmann quick-connect plug-in
system.
1 Connect the RAST-5 plug-in
connector to the main circuit
board of the control.
2 Connect 7-pole plug to the
counter plug of the burner.
Or
if installing a vent system
(accessory), connect 7-pole plug to
counter plug of vent system.
Refer to technical instructions
of the burner and/or wall vent
system
5303 269 v .3
Do not connect the 41-plug from the
boiler control directly to the burner if
a wall vent or flue damper / vent
damper is installed
See technical instructions of the vent
s
y
s
t
e
m
WARNING

Electrical connections
8
Burner (continued)
Electrical connection of two-stage or modulating burners
To control unit
To burner
2-stage or modulating module with
potential-free burner control output
Terminal codes
T6, T7, Control circuit ”two-stage
T8 burner” or ”modulation
controller” (via two-point
controller with two-stage
operation; via three-point
controller with
modulating operation)
qSignal direction:
Control unit →burner
pSignal direction:
Burner →control unit
The connection is made via the
extension for 2-stage/modulating
burner.
See Installation Instructions for
boiler and extension for
2-stage/modulating burner.
4 Insert the connector
9
in the
corresponding terminal and apply
strain relief to the cable (see
“Application of Strain Relief”).
Compiled Fault Indicator Alarm
Rated voltage: 20 VAC, 60 Hz
Rated current: 3 FLA
1 A visual and / or audible alarm
indicator can be connected.
2. Connect wires to respective
terminals on the Power Pump
Module.
5303 269 v .3
L G N
20 VAC Alarm Connection on
Power Pump Module

9
External Switching of the Heating Program
External switching of the heating
program (potential-free contact)
Coding address ”9 ” enables the
external heating program changeover
to be applied to individual heating
circuits.
Use switching module V for separate
heating program changeovers for 3
heating circuits .
1 Connect the potential-free contact to
terminals ” ” and ”2” in connector
.
2 Insert connector in terminal
” 43” and apply strain relief to the
cable (see “Application of Strain
Relief”).
When the contact is closed, the
manually preselected program can be
changed for all heating circuits at the
same time
See Vitotronic 300
Service Instructions
Manually pre-selected
heating program
(with contact open)
Code 2 Changed heating program (with contact closed)
9
or
Central heating
OFF/DHW OFF
d5 : 0
(factory
default)
<–> Permanent operation with reduced room temperature/DHW OFF
w
or
Central heating
OFF/DHW ON
d5 : <–> Permanent operation with standard room temperature/DHW in
accordance with coding address ”64”
rw Central heating
ON/DHW ON
5303 269 v .3
IMPORTANT

Adjustments
20
Fixed High Limit
The fixed high limit is factory preset to 230 ºF / 0 ºC.
Adjustment to 212 ºF / 100 ºC
1 Remove fuse.
2 Unclip the cover at the four snap-in
clips and remove.
3 Pull the front panel behind cover
upwards and swing open to the rear.
4 Turn slotted screw on the rear of the
fixed high limit and set to 2 2 ºF /
00 ºC (once adjusted, the fixed
high limit cannot be reset to 230 ºF /
0 ºC).
5 Put front panel, cover and fuse back
in place.
6 Check box in the Vitotronic Service
Instructions to confirm that the
adjustment has been made.
Slotted screw
5303 269 v .3
Make: Etheco Make: EGO
If adjusted to 212 ºF / 100 ºC do not
set the adjustable high limit above
1
6
7
º
F
/
7
5
º
C
CAUTION