Installation Instructions 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. Z001 231 VITOTRONIC 300 Certified as a component part of Viessmann boilers only 5303 269v1.3 10/2011

Safety instructions 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. 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. 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. 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! DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial product/property damage. WARNING Indicates an imminently hazardous situation which, if not avoided, could result in death, 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. IMPORTANT Helpful hints for installation, operation or maintenance which pertain to the product. 2

Index Safety Instructions Safety Instructions... 2 Application Examples Application Example 1 System with one direct-connected heating circuit without mixing valve... 4 Page 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... 10 Application of Strain Relief... 12 Sensors... 13 Pumps (accessory)... 16 Burner... 17 Compiled Fault Indicator Alarm... 18 External Switching of the Heating Program... 19 Settings Fixed High Limit... 20 Adjustable High Limit... 21 Installation Boiler Coding Card... 22 Top of Control Unit... 23 Opening the Control Unit... 23 Appendix Post-Installation Testing... 24 Technical Data... 24 3

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 *1 Heating circuit pump Boiler circuit DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *1 Burner, two-stage/modulating *1 Required Equipment Description Qty Part No. Vitotronic 300 1 Z001 231 Available System Accessories Vitotrol remote control Room temperature sensor Switching Module-V for expanding the range of control functions *1 Included in standard equipment KM-BUS Expansion Module Flue gas temperature sensor 4

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 M1 Heating circuit pump *2 Mixing valve circuit DHW production pump (accessory) DHW recirculation pump (installed on site) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/ modulating *4 Required Equipment Description Qty Part No. Vitotronic 300 1 Z001 231 Mixing valve actuator accessory kit (with mixing valve motor and supply temperature sensor) for Viessmann mixing valve 1 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 *1 Supply check valve, only required if piping connection is made on one common boiler return. *2 To be connected in accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard equipment. 7133 392 (old version) or 7837 524 (new version) 5

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 M1 Mixing valve circuit pump *2 DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/modulating *4 Required Equipment Description Qty Part No. Vitotronic 300 1 Z001 231 Mixing valve actuator accessory kit (with mixing valve motor and supply temperature sensor) for Viessmann mixing valve 1 7133 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 *1 Supply check valve, only required if piping connection is made on one common boiler return. *2 To be connected in accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard equipment. 6

Heating system types Application Example 4 System with two heating circuits with mixing valves Boiler with Vitotronic 300 Domestic hot water tank Heating circuit with mixing valve 1 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 I Low water cut-off device Required Equipment 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 Description Qty Part No. Vitotronic 300 1 Z001 231 Mixing valve actuator accessory kit (with mixing valve motor and supply temperature sensor) for Viessmann mixing valve 2 KM-BUS Expansion Module 1 7133 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 *1 Supply check valve, only required if piping connection is made on one common boiler return. *2 To be connected in accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard equipment. M1 Mixing valve circuit pump 1 *2 M2 Mixing valve circuit pump 2 DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner, two-stage/ modulating *4 7133 392 (old version) or 7837 524 (new version) 7

Application Example 5 System with one direct-connected heating circuit without mixing valve and two heating circuits with mixing valves 2 Boiler with Vitotronic 300 Domestic hot water tank Heating circuit with mixing valve 1 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 Required Equipment 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 Description Qty Part No. M1 Mixing valve circuit pump 1 *2 M2 Mixing valve circuit pump 2 Heating circuit pump DHW production pump (accessory) DHW recirculation pump (field supplied where required) Power supply (120 VAC, 60 Hz) Burner, single-stage *4 Burner staging taken from other devices Vitotronic 300 1 Z001 231 Mixing valve actuator accessory kit (with mixing valve motor and supply temperature sensor) for Viessmann mixing valve 2 KM-BUS Expansion Module 1 7133 393 7133 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 Flue gas temperature sensor *1 Supply check valve, only required if piping connection is made on one common boiler return. *2 To be connected in accessory kit. *3 In connection with underfloor heating when control measures supply and return water temperature. *4 Included in standard equipment. 8

Electrical connections 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 IMPORTANT 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 1 B DHW 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 100 communication unit Extension for two-stage or modulating burner (included in standard equipment) IMPORTANT Take notice of shape and orientation of low voltage connectors when inserting into sockets at rear of control! 9

Electrical connections Vitotronic Connections 1.Ensure that main power supply to the Power Pump Module contains overcurrent protection with a maximum rating of 15 A. 50 WARNING This equipment must be grounded. Ensure that the following wires are not interchanged: L and N L: LINE N: Neutral G: Ground 156 50 Vitotronic boiler control (view from rear) Connections for plug-in equipment Connections for hard-wired equipment 120 VAC, 60 Hz, 1 Ph Power supply Provide 15 A overcurrent protection and disconnect means Pump Space Htg. Output 120 VAC Circulating pump Heating circuit without mixing valve 120VAC,1Ph,3Amax. Circulating pump for domestic hot water tank 120VAC,1Ph,3Amax. Alarm Circulating pump for domestic hot water recirculation 120VAC,1Ph,3Amax. Power Pump Module (wall-mounted) 5 5 Alarm indicator 10

Electrical connections 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. Remove jumper between terminals L/P1 and P2 on Power Pump Module board when LWCO device is installed. Contact closes on water Low water cut-off device (typical) 11

Application of Strain Relief IMPORTANT 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. IMPORTANT No additional strain relief as described above is required for cables which incorporate a molded strain relief clamp. 12

Electrical connections Sensors Outdoor temperature sensor IMPORTANT 1. 4. 5. 3. 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. 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. IMPORTANT Do not run cable next to line voltage cables. 4. Connect cable wires to terminal. Cable: max. 115 ft./35 m long, AWG copper. 5. Mount outdoor temperature sensor housing. 6.Connect the cable wires from the outdoor temperature sensor to terminals 1 and 2 on plug (the wires are interchangeable). Outdoor temperature sensor 7. Insert plug into socket 1 and apply strain relief to the cable. 13

Electrical connections 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. IMPORTANT When installing the DHW tank temperature sensor in tanks from other manufacturers, ensure that sensor firmly contacts the sensor well wall. IMPORTANT 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. 14

Electrical connections Sensors (continued) Sensor connections 145 15 3 5 191 1 143 5b 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 A B C D E A Flue gas temperature sensor (accessories) B Boiler temperature sensor C Tank temperature sensor D Outdoor 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/ 115 ft and a cross-section of 1.5 mm 2 (copper) E Tank temperature sensor 2 15

Electrical connections 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 1 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 WARNING 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. 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. 16

Electrical connections Burner The burner cable is included in the standard boiler equipment. Terminal codes L1 Line via safety high limit PE Ground conductor to the burner N Neutral conductor to the burner T1, 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. WARNING 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. To control (RAST-5 plug-in connector) To burner or vent system ( plug-in connector) See technical instructions of the vent system. 17

Electrical connections Burner (continued) Electrical connection of two-stage or modulating burners 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) q Signal direction: Control unit burner p Signal 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 191 in the corresponding terminal and apply strain relief to the cable (see Application of Strain Relief ). To control unit To burner 2-stage or modulating module with potential-free burner control output Compiled Fault Indicator Alarm Rated voltage: Rated current: 120 VAC, 60 Hz 3 FLA 18 L G N 120 VAC Alarm Connection on Power Pump Module 1.A visual and / or audible alarm indicator can be connected. 2. Connect wires to respective terminals on the Power Pump Module.

External Switching of the Heating Program Coding address 91 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 1 and 2 in connector. 2. Insert connector in terminal 143 and apply strain relief to the cable (see Application of Strain Relief ). IMPORTANT External switching of the heating program (potential-free contact) 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) 9 or w or Central heating OFF/DHW OFF Central heating OFF/DHW ON rw Central heating ON/DHW ON Code 2 d5 : 0 (factory default) d5 : 1 Changed heating program (with contact closed) < > Permanent operation with reduced room temperature/dhw OFF < > Permanent operation with standard room temperature/dhw in accordance with coding address 64 19

Adjustments Fixed High Limit The fixed high limit is factory preset to 230 ºF / 110 ºC. Adjustment to 212 ºF / 100 ºC 1. Remove fuse. 2.Unclip the cover at the four snap-in clips and remove. Make: Etheco Make: EGO 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 212 ºF / 100 ºC (once adjusted, the fixed high limit cannot be reset to 230 ºF / 110 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. CAUTION If adjusted to 212 ºF / 100 ºC do not set the adjustable high limit above 167 ºF / 75 ºC. Slotted screw 20

Adjustments Fixed High Limit (contd.) Adjustment to 100 ºC (JUMO) The fixed high limit is factory preset to 230 ºF / 110 ºC. 2. 1. 5. 6. 4. 3. CAUTION If adjusted to 212 ºF / 100 ºC do not set the adjustable high limit above 167 ºF / 75 ºC. 21

Adjustments/Installation Adjustable High Limit The adjustable high limit is factory preset to 165 ºF / 75 ºC. Do not set the adjustable high limit above 165 ºF / 75 ºC if the fixed high limit has been set to 212 ºF / 100 ºC. Adjustment to 189 ºF / 87 ºC 1. Using a suitable screwdriver, lever out selector knob behind the hinged cover. 2.Using a pair of pointed pliers, break off the respective cams on the dial. 3.Install the selector knob, so that the marking is between 75 and 90. Turn the selector knob fully clockwise. 4.Check the box in the Vitotronic 300 Service Instructions to confirm that the adjustment was made. IMPORTANT If the system is operated in conjunction with a domestic hot water tank, ensure that the maximum permissible domestic hot water temperature is not exceeded. If necessary, install an approved safety device for this purpose. Boiler Coding Card IMPORTANT Only the boiler coding card which is supplied with the standard boiler equipment may be used. The coding card is enclosed in the accessory pack of the boiler. 1.Push the boiler coding card through the recess in the cover and insert it in plug-in location X7. 22

Installation Top of Control Unit 1.Install the rear control housing. 2.Position top of control unit on the bottom and snap together. 3. Cut through sticker, pull out hinged support bar and pull down until the lower section snaps into place. 4.Snap the end of the hinged support bar in the holding clip at the bottom of the control. 5. Insert the flat cable connector in plug-in location X10 and lay cable under holding clip. 6. Unlock hinged support bar by applying pressure to linkage point and bring top of control unit down, snapping into bottom of control unit. Opening the Control Unit 1. Open the flip-down cover. 2.Using a suitable tool, e.g. a Viessmann hexagon socket screw key, unlock the top of the control and raise until hinged support bar snaps into place. 23

Post-Installation Testing Check list Please check the following conditions and correct any deficiencies: Limit capillaries and sensors correctly inserted into the sensor wells? Electrical connections performed correctly? All connections properly connected? Boiler coding card inserted? Fuse F2 plugged in? Outdoor temperature sensor mounted correctly and cable connected properly to outdoor temperature sensor and connector? Fixed high limit and adjustable high limit adjusted properly (if required)? Labelled appropriate fields on programming unit according to heat circuit allocation? Start-up and adjustments See Service Instructions regarding start-up and settings. Service document ring binder 1. File Installation, Operating and Service Instructions in service binder. 2. Service box (optional equipment) now available for service binder. Technical Data Rated voltage: 120 VAC Rated frequency:60 Hz Rated current: 6 FLA Power consumption: Certification: 5 W CSA certified (in conjunction with a Viessmann boiler only) Max. ambient temperature during 32 to 104 ºF / operation: 0 to 40 ºC For use in living area and boiler rooms (normal ambient conditions) during storage and transport: 4 to 149 ºF / 20 to 65 ºC Relay outputs of Power Pump Module 120 VAC for: heating circuit pump : 3 FLA *1 DHW production pump : 3 FLA *1 DHW recirculation pump : 3 FLA *1 burner connector : 2 FLA Compiled fault indicator : 3 FLA *1 connector : two-stage 0.5 FLA modulating 0.05 FLA *1 Total: max. 9 FLA 24

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Technical information subject to change without notice. Printed on environmentally friendly (recycled and recyclable) paper. 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 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 28