Viessmann VITOTRONIC 300 Quick guide

Installation and Service
Instructions
for use by heating contractor
5693 979 - 05 01/2015
Read and save these instructions
for future reference.
Vitotronic 300, Type GW5B
Weather-compensated, digital boiler control unit
for boiler model CM2 - 400, 500, 620 and 620 TX
VITOTRONICr300
Please file in Service Binder
IMPORTANT
Certified as a component
part for Viessmann boilers
Product may not be exactly as shown

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Vitotronic 300, GW5B Installation and Service
Safety
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 Installation Requirements”.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
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 begins.
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 GW5B
For installation in or mounting on Viessmann boilers only.
Applicable to the following control units
Order No. 7134 555, 7143 156, 7511 362 from
Serial No. 7143 000
Order No. 7134 555, 7143 156, 7511 362 from
Serial No. 7187 101
Order No. 7134 555, 7143 156, 7511 362 from
Serial No. 7248 248
This document describes Vitotronic 300 when used:
in a single boiler system

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Safety
Preparing for Installation
Installation Sequences
Commissioning
Service Scans
Troubleshooting
Function Description
Safety, Installation and Warranty Requirements..............2
Product documentation...........................................2
Licensed professional heating contractor...................2
Advice to owner....................................................2
Warranty...............................................................2
Operating and Service Documentation......................2
Product Information.....................................................2
Overview of System Example.......................................5
Designations in the System Example..........................5
System Example....................................................6
Overview of Electrical Connections.............................11
Inserting Cables and Applying Strain Relief...................14
Inserting the Boiler Coding Card.................................14
Connect Sensors.....................................................15
120V External Connection.........................................16
Connecting the Central Fault Message Facility..............18
Connecting Actuators................................................19
Connection to Low Water Cut-Off Device....................20
Connection to Terminal 151.......................................20
External Demand via Switching Contact.......................21
External Demand via 0-10V Input................................21
External Block via Switching Contact..........................22
External “Mixer Closed”/”Mixer Open”........................22
External Heating Program Changeover”.......................23
Provisional Burner Operation.......................................24
Connecting a Burner..................................................24
Power Supply...........................................................25
Boiler Control and Junction Box.................................28
Mounting the Control Unit.........................................29
Opening the Control Unit...........................................29
Setting the Language.................................................30
Setting the Time and Date.........................................30
Testing the high limit Safety Cut-Out..........................30
Checking Actuators and Sensors.................................31
Adjusting Heating Curves...........................................32
Connecting the Control Unit to the LON......................34
Integrating a Control Unit into the LON........................35
Entering the Service PIN for LON Participants...............35
Calling up the Service Menu.......................................36
Exiting the Service Menu...........................................36
Operating Data........................................................37
Brief Scan................................................................38
Display....................................................................39
Fault Codes..............................................................40
Boiler Water Temperature Control...............................49
Heating Circuit Control Unit.......................................49
DHW tank Temperature Control..................................53
Page
Table of Contents

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Table of Contents
Coding 1
Coding 2
Designs
Components
Parts
Specification
Calling Up Coding Level 1..........................................55
“General” Group.......................................................56
“Boiler” Group..........................................................57
“DHW” Group...........................................................58
“Solar” Group...........................................................58
“Heating Circuit 1”, “Heating Circuit 2”,
“Heating Circuit 3” Group..........................................59
Calling Up Coding Level 2..........................................62
“General” Group.......................................................63
“Boiler” Group..........................................................69
“DHW” Group...........................................................69
“Solar” Group...........................................................71
“Heating Circuit 1”, “Heating Circuit 2”,
“Heating Circuit 3” Group..........................................74
Connection and Wiring Diagram..................................79
Sensors..................................................................83
Mixing Valve Motor Kit..............................................84
Extension EA1 Accessory (optional)...........................85
Parts List.................................................................86
Specifications..........................................................87
Page

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Overview of System Example
Boiler Characteristics
Vitocrossal (CM2) Several heating circuits
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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Vitotronic 300, GW5B Installation and Service
System Example
Single boiler system with two heating circuits with mixing valve
Hydraulic installation scheme
Note: This schematic diagram is a general example without shut-off valves or safety equipment.
This does not replace the need for local engineering.
Preparing for IInstallation

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Technical Data
System Example (continued)
Equipment required
Pos. Designation
1Boiler
2Vitotronic 300 GW5B
3Boiler water temperature sensor ATS
4Boiler water temperature sensor KTS (connection at burner control unit)
5Neutralizing system
rR ON/OFF switch (on site)
6DHW tank
7DHW temperature sensor (STS)
8DHW circulation pump
9DHW recirculation pump
qP Heating circuit 2
qW Heating circuit pump M2
Mixing valve extension kit:
qQ Supply temperature sensor M2 as contact temperature sensor
qE Mixing valve motor M2
qQ Contact temperature sensor (supplied with kit)
or
Immersion temperature sensor (optional accessory)
qE Mixing valve motor for mixing valve M2
qR Heating circuit 3
qZ Heating circuit pump M3
Mixing valve extension kit:
qT Supply temperature sensor M3 as contact temperature sensor
qU Mixing valve motor M3 or supply temperature sensor M3 as
qT Contact temperature sensor (supplied with kit)
or
Immersion temperature sensor (optional accessory)
qU Mixing valve motor for mixing valve M3

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Vitotronic 300, GW5B Installation and Service
Equipment required
Pos. Designation
Accessories
qI Connection to safety equipment aBÖ (see page 20)
qO Minimum pressure switch or limiter SDB
wP Maximum pressure limiter SDB
wQ Low water cutoff
wW Central fault message system
wR Vitotrol 200A or Vitotrol 300A
As an alternative to hardwired remote control units, the following wireless accessory may be used
eP Extension EA1
eQ 1 analogue input (0–10V)
Specification of set boiler water temperature
eW 3 digital inputs
External heating program changeover, separate adjustment for heating circuits 1 to 3
External demand
External blocking with fault message input
Fault message input
Brief operation of the DHW circulation pump
eE 1 switching output (floating changeover contact)
Switching a feed pump to a substation
Signalling reduced mode for a heating circuit
External hook-ups
eR External demand
eZ External blocking/mixing valve closed
eU External heating program changeover/External mixing valve open
rP KM BUS distributor, for several KM BUS participants
rQ LON communication module for communication with the following components:
rW Vitotronic 200-H for regulating additional heating circuits
rE Vitocom 100, type LAN1
rRX On-site power supply with disconnect and protection 120V 60 Hz
Technical Data
System example (continued)
Preparing for Installation

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Vitotronic 300, GW5B Installation and Service Preparing for Installation
System example (continued)
Electrical installation scheme
PCB 120V

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Vitotronic 300, GW5B Installation and Service
Preparing for Installation
System example (continued)
Required code
Category Function
00:8 “General”
group
Two heating circuits with mixing valve M2 (heating circuit 2) and M3
(heating circuit 3) with DHW heating
Low voltage and mixing valve extension PCBs

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Vitotronic 300, GW5B Installation and Service
Overview of Electrical Connections
Note: When connecting plugs 143, 146, 21, 28, 2
M2/M3 and 20 M2/M3, bundle the individual
cores of the cables closely to the terminals.
This ensures that, should there be a fault, for
example when detaching a wire, the wires cannot
drift into the adjacent voltage area.
Strip the insulation from the cables as close to
the terminals as possible, and bundle tightly to
the corresponding terminals.
Secure cables with cable ties. This ensures that,
should there be a fault, for example when
detaching a wire, the wires cannot drift into the
adjacent voltage area.
WARNING
Incorrect wiring can lead to serious injury from electrical
current and result in appliance damage.
Installation Sequence

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Overview of Electrical Connections (continued)
Legend
Extension for heating circuits 2 and 3 with mixing valve
(accessory module supplied separately)
?M2/M3 Supply temperature sensor
sÖM2/M3 Heating circuit pump
gSM2/M3 Mixing valve motor
PCB, low voltage
!Outdoor temperature sensor (ATS)
%ADHW temperature sensor
%BDHW temperature sensor 2 for primary store
system (optional accessory, not used)
)Supply temperature sensor, low loss header
(optional accessory)
aJ BTemperature sensor primary store system
(optional accessory, not used)
aVD External hook-up
aVG KM BUS participant e.g. Vitotrol Remote (accessory)
aVH External connection
PCB 120V/60Hz
sÖA1 High temperature circuit pump
sA DHW circulation pump
sK DHW recirculation pump
sL Accessories pump
fÖ Power supply, 120V/60 Hz
fA Burner (call for heat)
gÖ Central fault message
gSA1 Isolation valve
or
3-way mixing valve, primary store system (optional
accessory, not used)
aBÖ External connections, e.g. supplementary safety
equipment
aBA Safety chain, potential free
aBH Power supply for accessories
Inserting cables and applying strain relief
Control unit fitted on the side of the boiler:
Route cables from below out of the cable
trunking into the control unit.
Installation Sequence

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Overview of Electrical Connections (continued)

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Inserting Cables and Applying Strain Relief
Legend
ACables with moulded strain relief
BRestrain cables with zip tie to cable lead
Inserting the Boiler Coding Card
Insert the boiler coding card through the recess in the
cover into slot “X7”.
Installation Sequence
Coding Card # Part #
1042 7841113

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Connecting Sensors
Legend
Main PCB, low voltage
!Outside temperature sensor (ATS)
%ADHW temperature sensor 1
%BDHW temperature sensor 2 (optional accessory,
not used) for primary store system
aJBTemperature sensor T2 (optional accessory,
not used)
) Supply temperature sensor, low loss header
(accessory).
Fitting location for outside temperature sensor
North or north-westerly wall, 6-8 ft. (2 to 2.5 m)
above ground level; in multi storey buildings, in the
upper half of the second floor.
Not above windows, doors or ventilation outlets.
Not immediately below balconies or gutters.
Never render over.
Outside temperature sensor connection
Make connection using 2 wire 18 awg communication
cable to connect outdoor sensor to #1 plug [maximum
length 100 ft. (35 m)].
Installation Sequence

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120V External Connection
Pumps 120V
Rated current: 2A~
* Maximum output 6FLA shared between all
120V outputs.
** In conjunction with extension for heating circuits
2 and 3.
Legend
APumps
BTo the control unit
Available pump connections
sÖM1/A1 Heating circuit 1 pump
sÖM2 Heating circuit 2 pump
sÖM3 Heating circuit 3 pump
sA DHW pump
sK DHW recirculation pump
sL Boiler pump
Installation Sequence
**
**

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120V External Connection (continued)
120V pumps with an amperage draw of >2FLA
208/460/575V 3 phase pumps
240V pumps
Contactor specification 120VAC 1A
ADin rail
BContactor/relay (field supplied)
CPump
DPower supply w/disconnect and protection
Contactor specification 120VAC 1A
ADin rail
BContactor/relay (field supplied)
CPump
D Power supply w/disconnect and protection
Contactor specification 120VAC 1A
ADin rail
BContactor/relay (field supplied)
C Pump
DPower supply w/disconnect and protection
120V pumps with an amperage draw of <2FLA
ADin rail
BPump

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Installation Sequence
Connecting the Central Fault Message Facility
Rated voltage 120V~
Rated current max. 2A~

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Vitotronic 300, GW5B Installation and Service
Connecting Actuators
Available connections
gS A1 Motor for 3-way mixing valve, primary store system
gS M2 For heating circuit 2
gS M3 For heating circuit 3
Rated voltage: 120V~
Rated current Max.: 0.1A~
Motor runtime for
3-way mixing valve: 10 to 255 sec, adjustable via
coding addresses “6A” in
the”DHW”group, “C3” in the HC2
group and “C3” in the HC3 group.
1. Disconnect power to control.
2. Install 120V or 24V valve adaptor on DIN rail inside
connection enclosure.
3. Insert the plug gS into socket gS on the control.
4. Fasten cable with tie.
5. Connect black wire of the adaptor to terminals 8,9 or
10 on the Din rail.
6. Connect valve actuator wires to the adaptor terminals
Legend
A24V Mixing Valve Adaptor
BDIN Rail (in junction box)
C24V Valve Actuator
DValve
Legend
A120V Mixing Valve Adaptor
BDIN Rail (in junction box)
C24V Valve Actuator
DValve
120V Valve Adaptor
Rated voltage: 120 VAC
Rated current: max. 0.1 FLA
Recommended connection wire size: AWG 14
24V Valve Adaptor
Rated voltage: 24 VAC
Rated current: max. 0.15 FLA
Recommended connection wire size: AWG 14
Operating time: 5 to 199 sec. selected via coding
address “40”. Refer to the mixing valve adaptor Installation
Instructions for additional information.
Installation Sequence

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Connection of Low Water Cut-off Device
Connections to Safety Equipment
CAUTION
The diagram shown is only a simplified conceptual
drawing of a typical low water cut off (LWCO) device.
Refer to the manual specific to the device for
interconnection details.
1. Remove jumper between terminals 12 and 15.
2. Make connection as shown in diagram.
Legend
aBH Power supply for accessories.
aBÖ Connection for external equipment.
ALow water cut-off (typical)
Connections to Terminal aBA
WARNING
The terminals should be used for safety switch-off
purposes only (e.g. through a high limit thermostat).
During switch-off, there is no frost protection of the
heating system and the boiler is not kept at the minimum
boiler water temperature.
External shut-off
1. Remove jumper (not shown) between terminals 19 and 20.
2. Connect dry contact. Controlled switch-off takes place
when the contact is opened.
Legend
AExternal shut-off (dry contact)
BDIN rail
A
Installation Sequence
Note: The heating system has no frost protection while it
is blocked. The boiler is not held at the lower boiler
water temperature.
Legend
ADIN rail
BLow water cutoff
COther safety controls
1. Connect the external safety equipment in series.