Viessmann Vitotronic 300 GW6B User manual

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5513 463 - 06 03/2015
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VITOTRONIC 300, GW6B
Installation and Service
Instructions
Vitotronic 300, Type GW6B
Weather-compensated boiler and heating circuit control unit
in single boiler or multi boiler systems
IMPORTANT
Certified as a component
part for Viessmann boilers

5513 463 - 06
Vitotronic 300, GW6B Installation and Service
General
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual 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).
WARNING
Installers must follow local regulations with respect to
installation of carbon monoxide detectors. Follow the
Viessmann maintenance schedule of the boiler contained
in this manual.
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 applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
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, shutdown procedure, and
the need for professional service annually before the
heating season begin.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Operating and Service Documentation
It is recommended that all product documentation such
as parts lists, operating and service instructions be
handed over to the system user for storage.
Documentation is to be stored near boiler in a readily
accessible location for reference by service personnel.
Product Information
Vitotronic 300, Type GW6B
For installation in or mounting on Viessmann boilers only.
Applicable to the following control units
Order No. Z013557
Serial No. 7542124
2

Page
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Table of Contents
Vitotronic 300, GW6B Installation and Service
General
Safety
Preparing for Installation
Electrical Connections
Commissioning
Service Scans
Safety, Installation and Warranty Requirements..............2
Product Information....................................................2
About these Instructions.............................................5
For your Safety..........................................................6
Overview of System Example.......................................7
Designations in the Example.........................................7
SystemExamples........................................................8
Single boiler system...........................................8
Multi boiler system..........................................12
Overview of Electrical Connections.............................21
Boiler Control and Junction Box.................................26
Mounting the Control Unit.........................................26
Opening the Control Unit..........................................27
Plugging in the Boiler Coding Card..............................27
Inserting Cables and Applying Strain Relief.................28
Connecting Sensors……………................................…28
Control Power Supply……………..............................…29
Connecting the Burner..............................................30
Connecting Pumps....................................................31
Connecting a Central Fault Massage Facility................34
Connecting Actuators...............................................34
Connection of Low Water Cut-off Device.....................36
Connecting External Safety Equipment……………......…37
Connections to Terminal 151………………………….……38
Provisional Burner Operation.......................................39
Blocking the Boiler Externally/Adding to the Boiler
Sequence................................................................40
External Blocking via Switching Contact......................41
External Demand via Switching Contact......................42
External Demand via 0 – 10V Input……..……...........…43
External “Mixing Valve Closed”/”Mixing Valve Open”....43
External Operating Program Changeover......................44
Power Supply……………….....................................…45
Making the LON Connection………………………….…..…46
Commissioning the System........................................48
Adjusting Coding......................................................49
Connecting the Control Unit to the LON......................50
Setting the Boiler Sequence at the Cascade Control Unit...52
Carrying Out an Actuator Test...................................53
Checking Sensors.....................................................54
Adjusting the Heating Curve……..............................…54
Calling up the Service Menu......................................57
Leaving the Service Menu..........................................58
Change Passwords……………………………..……...........58
Resetting all Passwords to Factory Settings.................58
Scanning Operating Data...........................................59
Resetting Operating Data...........................................59
Brief Scan...............................................................60
Maintenance Display.................................................61

Table of Contents
4
Page
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Vitotronic 300, GW6B Installation and Service
Troubleshooting
Function Description
Coding Levels
Coding Level 1
Coding Level 2
Diagrams
Components
Parts
Specification
Fault Display............................................................62
Boiler System Fault Codes.........................................63
Burner Fault Codes....................................................69
Boiler Water Temperature Control...............................72
Cascade Control Unit................................................72
Heating Circuit Control Unit.......................................77
DHW Tank Temperature Control.................................81
Calling up Coding Levels............................................85
Resetting Coding to their Factory Set Condition............85
“General” Group.......................................................86
“Combustion Controller” Group..................................88
“Boiler” Group..........................................................88
“Cascade” Group......................................................89
“DHW” Group..........................................................91
“Solar” Group...........................................................91
“Heating Circuit...” Group..........................................92
“General” Group.......................................................95
“Combustion Controller” Group................................102
“Boiler” Group........................................................103
“Cascade” Group....................................................103
“DHW” Group.........................................................106
“Solar” Group.........................................................108
“Heating Circuit...” Group........................................111
Connection and Wiring Diagram................................117
EA1 Extension........................................................120
Sensors.................................................................121
Extension EA1 Accessory (optional)..........................122
Parts List – Programming Module..............................123
Parts List – Connection Module................................124
Specification Vitotronic 300, GW6B.........................125

5
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Vitotronic 300, GW6B Installation and Service Safety
About these Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.

IMPORTANT
Warnings draw your attention to the presence of
potential hazards or important product information.
Cautions draw your attention to the presence of
potential hazards or important product information.
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must
be referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious injury
or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.

Vitotronic 300, GW6B Installation and Service
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6
If you smell gas
HDon’t smoke! Don’t use naked flames or cause sparks
(e.g. by switching lights or electrical appliances on
and off)
HOpen windows and doors
HClose the gas shut-off valve
HInform your heating engineers/service contractors from
outside the building
HObserve the safety regulations of your gas supply
company (see gas meter) and those of your heating
engineers (see start-up or instruction report).
In emergencies
HImmediately switch off the power supply, e.g. at the
separate fuse or power supply disconnect switch
(unless there is a smell of gas).
HClose the shut-off valves in the oil pipes or close the
gas shut-off valve, whichever applicable.
HUse suitable extinguishers in the event of fire.
Installation of additional components
The installation of additional components which have not
been tested together with the boiler can adversely affect
the function and performance of the boiler.
Our warranty does not cover and we accept no liability
for damage attributable to the installation of such
components.
Boiler room conditions
HDo not use a room in which the air is polluted by
halogenated hydro-carbons (e.g. as contained in
aerosols, paints, solvents and cleaning agents)
HDo not use a room subject to high levels of dust
HDo not use a room subject to permanently high humidity
HThe room should be frost-protected
HMax. ambient temperature 95°F (35°C).
HProvide good ventilation and do not close or obstruct
vents (if installed).
This symbol indicates a reference to other instructions
which must be observed.
Safety
CAUTION
Follow these safety instructions closely to avoid the risk
of injury and damage to property.
For your Safety
HOperation
Before operating the boiler, make sure you fully
understand its method of operation. Your heating
contractor should always perform the initial start-up
and explain the system. Any warranty is null and void
if these instructions are not followed.
HFlue gas smell
- Deactivate heating equipment.
- Open windows and doors.
- Inform your heating contractor.
HWorking on the equipment
All personnel working on the equipment or the heating
system must have the proper qualifications and hold
all necessary licenses. Ensure main power to
equipment, heating system, and all external controls
has been deactivated. Close main gas supply valve.
Take precautions in all instances to avoid accidental
activation of power during service work.
HDangerous conditions
- Deactivate main power immediately.
- Close gas supply valve.
HMaintenance and cleaning
Regular inspection and service by a qualified heating
contractor is important to the performance of the boiler.
Neglected maintenance impacts on warranty; regular
inspection ensures clean, environmentally friendly and
efficient operation. We recommend a maintenance
contract with a qualified heating contractor.
HTechnical documentation
- Installation Instruction and Service Instructions
- Operating Instructions and User’s Information Manual
Additional applicable literature:
- Accessory manuals

7
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Vitotronic 300, GW6B Installation and Service Preparing for Installation
Overview of System Example
This system example is merely a GENERIC LAYOUT
and must therefore be checked on site for completeness
and function.
The heating circuits must be regulated by an external
control unit.
Connect three-phase consumers via additional
contactors.
Designations in the System Example

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System Examples
Preparing for Installation
ID: 4800078_1407_01
Single boiler system
Note: This schematic is a general example without shutoff
valves or safety equipment. This does not replace
the need for local engineering.

9
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Vitotronic 300, GW6B Installation and Service
Required Devices
ID: 4800078_1407_01
Position Equipment
1Boiler
2Vitotronic 300 GW6B
3Outdoor temperature sensor ATS
4Boiler temperature sensor KTS (connection to burner control)
5Neutralization system
wT Junction box
wZ Burner base
rR Power switch
6DHW
7DHW tank temperature sensor STS delivered with Vitotronic 300
8DHW pump UPSB
9DHW re-circulation pump ZP
qP Heating circuit I
qW Heating circuit M2 (heating circuit I)
qE Mixing valve M2 (heating circuit I)
qQ Strap-on temperature sensor
and
qE Mixing Valve Actuator M2 (heating circuit I)
qZ Mixing valve adapter 24V
qR Heating circuit II
qZ Heating circuit M3 (heating circuit II)
qU Mixing valve M3 (heating circuit II)
qT Strap-on temperature sensor
and
qU Mixing valve actuator M3 (heating circuit II)
uU Mixing valve adapter 24V
Accessories
wW Compiled fault output
wR Vitotrol 200A or Vitotrol 300A
eP Extension EA1:
eQ 1 analog input (0 to 10 V) - Specification of the boiler water temperature setpoint
eW 3 digital inputs - Separated External switch the operating status for heating circuits 1 to 3 switchable
(with control for weather-compensated operation)
- External blocking with collective fault
- Error messages
- Brief operation DHW re-circulation pump (for weather-compensated control units)
eE 1 switching output (floating changeover contact)- Control system pump to a substation
- Signal reduced mode for one heating circuit external hook
eR - External demand
eZ - External blocking / mixer to close
eU - External heating program changeover / mixer on site
4KM BUS distributor, with several KM BUS participants
KM BUS subscriber: - Extension EA1
- Vitotrol 200A, 300A
rQ LON communication module to communicate with the following components:
rW Vitotronic 200-H (for controlling additional heating circuits)
rE Vitocom 100, type LAN1 with communication module
rR Power switch on site / main disconnect
System Examples (continued)
Preparing for Installation

Vitotronic 300, GW6B Installation and Service
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10
System Examples (continued)
Preparing for Installation

11
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Vitotronic 300, GW6B Installation and Service
ID: 4800078_1407_01
Group Coding address Function
General 00:8 Two heating circuits with mixing valve M2 (heating circuit 2) and
M3 (circuit 3) DHW heating
System Examples (continued)
Preparing for Installation

Vitotronic 300, GW6B Installation and Service
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12
ID: 4800061_1407_01
Multi boiler system
Note: This schematic is a general example without shutoff
valves or safety equipment. This does not replace
the need for local engineering.
System Examples (continued)
Preparing for Installation

13
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Vitotronic 300, GW6B Installation and Service
Required Devices
ID: 4800061_1407_01
Position Equipment
1Boiler 1
2Flue gas damper (for boiler I)
3Isolation valve
4Boiler temperature sensor KTS (connection to burner control)
5Common supply temperature sensor
6Outdoor temperature sensor ATS
8Vitotronic 300 GW6B
9Neutralization system
rT Power switch
uW Junction box
uE Burner base
uZ Mixing valve adapter 24V
qP Boiler II
qW Isolation valve
qQ Mixing valve adapter 24V
qE Boiler temperature sensor KTS (connection to burner control)
qR Vitotronic 300 GW6B
qT Neutralization system
rT Power switch
uR Junction box
uT Burner base
uO Flue gas damper (for boiler II)
qZ DHW
qU DHW tank temperature sensor STS delivered with Vitotronic 300
qI DHW pump UPSB
qO DHW re-circulation pump ZP
wP Heating circuit I
wW Heating circuit pump M2 (heating circuit I)
wE Mixing valve M2 (heating circuit I)
wQ Strap-on temperature sensor
and
wE Mixing valve actuator M2 (heating circuit I)
uU Mixing valve adapter 24V
wR Heating circuit II
wZ Heating circuit pump M3 (heating circuit II)
wU Mixing valve M3 (heating circuit II)
wT Strap-on temperature sensor
and
wU Mixing valve actuator M3 (heating circuit II)
uI Mixing valve adapter 24V
wI Heating circuit III (low-temperature heating circuit)
eE Heating circuit pump M1 (heating circuit III)
eR Mixing valve M1 (heating circuit III)
wO Strap-on temperature sensor
and
eR Mixing valve actuator M1 (heating circuit III)
eT Vitotronic 200-H HK1B
and
LON communication module for Pos. 35
and
LON connecting cable
System Examples (continued)
Preparing for Installation

Vitotronic 300, GW6B Installation and Service
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14
Required Devices
ID: 4800061_1407_01
Position Equipment
eZ Outdoor temperature sensor ATS (ATS-value can be taken from Vitotronic 300 GW6B master and cascade
or
wI Heating circuit III (underfloor heating)
wO Supply temperature sensor M1 (circuit III) delivery Pos. 35
eR Mixing valve M1 (heating circuit III)
or
wO Strap-on temperature sensor
and
eR Mixing Valve Actuator M1 (heating circuit III)
eT Vitotronic 200-H HK1B
and
uP LON communication module for Pos. 35
and
LON connecting cable
eZ Outdoor temperature sensor ATS (ATS-value can be taken from Vitotronic 300 GW6B master and cascade
eP Temperature monitor as Maximum temperature limiter for underfloor heating
- Immersion thermostat or - Contact thermostat
eQ Heating circuit M1 (secondary)
eE Heating circuit pump M1 (primary)
rT Power switch on site / main disconnect
Accessories for boilers
eO Maximum pressure SDB
rP Minimum pressure switch or limiter SDB
rQ Water level (Low water cutoff) WB
zI External blocking / Boilers
zO Switch on boiler as the last in a row
Accessories
tP Compiled Fault Output
tW Vitotrol 200A or Vitotrol 300A
tE KM BUS subscriber: - Extension EA1, AM1
- Vitotrol 200A, 300A
zP Extension EA1:
zQ 1 switching output (floating changeover contact)
- Control system pump to a substation
- Signal reduced mode for one heating circuit
zW 1 analog input (0 to 10 V)
- Specification of the boiler water temperature setpoint
zE 3 digital inputs
- Separated External switch the operating status for heating circuits 1 to 3 switchable
(with control for weather-compensated operation)
- External blocking with collective fault
- Error messages
- Brief operation DHW re-circulation pump (for weather-compensated control units)
zE external hook-up
- Switch on boiler as the last boiler
- External blocking
zU KM BUS distributor, with several KM BUS participants
uP LON communication module to communicate with the following components:
eT Vitotronic 200-H (for controlling other heating circuits)
uQ Vitocom 100, type LAN1 with communication module
System Examples (continued)
Preparing for Installation

15
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Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Preparing for Installation

Vitotronic 300, GW6B Installation and Service
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16
System Examples (continued)
Preparing for Installation

17
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Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Preparing for Installation

Vitotronic 300, GW6B Installation and Service
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18
System Examples (continued)
Preparing for Installation

19
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Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Preparing for Installation

Vitotronic 300, GW6B Installation and Service
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ID: 4800061_1407_01
coding addresses Vitotronic 300, type GW6B; Lead boiler / Pos. 8
Group Coding address Function
General
System Layout
00:8 Two heating circuits with mixing valve M2 (heating
circuit 2) and M3 (circuit 3) DHW heating
Cascade
Number of boilers in cascade
35:2 Number of boilers connected in the heating system
Cascade
Boiler rotation
38:1 Boiler rotation - Monthly
coding addresses Vitotronic 300 Type GW6B Pos. 14
General
LON Participant Number
77:2 LON Participant Number
Boiler
Boiler number in multiboiler system
07:2 Boiler number in multiboiler system
coding addresses Vitotronic 200-H, type HK1B / Pos. 35
General 81:3 The control unit receives time
General 97:1 Control unit receives the outdoor temperature
System Examples (continued)
Preparing for Installation