Weather-compensated boiler and heating circuit control unit
in single boiler or multi boiler systems
VITOTRONIC 300, GW6B
Certified as a component
part for Viessmann boilers
5513 463 - 06 03/2015
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder
General
Vitotronic 300, GW6B Installation and Service
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).
Product documentationRead 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”.
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.
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.
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.
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
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
General
Table of Contents
Page
Safety, Installation and Warranty Requirements..............2
Blocking the Boiler Externally/Adding to the Boiler
Sequence
External Blocking via Switching Contact
External Demand via Switching Contact
External Demand via 0 – 10V Input
External “Mixing Valve Closed”/”Mixing Valve Open”
External Operating Program Changeover
Power Supply……………….....................................…45
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.
Warnings draw your attention to the presence of
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.
IMPORTANT
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.
Safety
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must
be referenced.
5513 463 - 06
5
Safety
For your Safety
CAUTION
Follow these safety instructions closely to avoid the risk
of injury and damage to property.
H Operation
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.
H Flue gas smell
- Deactivate heating equipment.
- Open windows and doors.
- Inform your heating contractor.
H Working 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.
H Dangerous conditions
- Deactivate main power immediately.
- Close gas supply valve.
H Maintenance 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.
H Technical documentation
- Installation Instruction and Service Instructions
- Operating Instructions and User’s Information Manual
Additional applicable literature:
- Accessory manuals
Vitotronic 300, GW6B Installation and Service
If you smell gas
H Don’t smoke! Don’t use naked flames or cause sparks
(e.g. by switching lights or electrical appliances on
and off)
H Open windows and doors
H Close the gas shut-off valve
H Inform your heating engineers/service contractors from
outside the building
H Observe 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
H Immediately switch off the power supply, e.g. at the
separate fuse or power supply disconnect switch
(unless there is a smell of gas).
H Close the shut-off valves in the oil pipes or close the
gas shut-off valve, whichever applicable.
H Use 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
H Do 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)
H Do not use a room subject to high levels of dust
H Do not use a room subject to permanently high humidity
H The room should be frost-protected
H Max. ambient temperature 95°F (35°C).
H Provide good ventilation and do not close or obstruct
vents (if installed).
This symbol indicates a reference to other instructions
which must be observed.
6
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
Overview of System Example
Designations in the System Example
Preparing for Installation
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.
5513 463 - 06
7
Preparing for Installation
System Examples
ID: 4800078_1407_01
Single boiler system
Vitotronic 300, GW6B Installation and Service
8
Note: This schematic is a general example without shutoff
valves or safety equipment. This does not replace
the need for local engineering.
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Required Devices
ID: 4800078_1407_01
PositionEquipment
1
2
3
4
5
wT
wZ
rR
6
7
8
9
qP
qW
qE
qQ
qE
qZ
qR
qZ
qU
qT
qU
uU
wW
wR
eP
eQ
eW
eE
eR
eZ
eU
4
rQ
rW
rE
rR
5513 463 - 06
Boiler
Vitotronic 300 GW6B
Outdoor temperature sensor ATS
Boiler temperature sensor KTS (connection to burner control)
Neutralization system
Junction box
Burner base
Power switch
DHW
DHW tank temperature sensor STS delivered with Vitotronic 300
DHW pump UPSB
DHW re-circulation pump ZP
Heating circuit I
Heating circuit M2 (heating circuit I)
Mixing valve M2 (heating circuit I)
Strap-on temperature sensor
and
Mixing Valve Actuator M2 (heating circuit I)
Mixing valve adapter 24V
Heating circuit II
Heating circuit M3 (heating circuit II)
Mixing valve M3 (heating circuit II)
Strap-on temperature sensor
and
Mixing valve actuator M3 (heating circuit II)
Mixing valve adapter 24V
Accessories
Compiled fault output
Vitotrol 200A or Vitotrol 300A
Extension EA1:
1 analog input (0 to 10 V) - Specification of the boiler water temperature setpoint
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)
1 switching output (floating changeover contact)- Control system pump to a substation
- Signal reduced mode for one heating circuit external hook
- External demand
- External blocking / mixer to close
- External heating program changeover / mixer on site
KM BUS distributor, with several KM BUS participants
KM BUS subscriber: - Extension EA1
- Vitotrol 200A, 300A
LON communication module to communicate with the following components:
General00:8Two heating circuits with mixing valve M2 (heating circuit 2) and
5513 463 - 06
M3 (circuit 3) DHW heating
11
Preparing for Installation
System Examples (continued)
ID: 4800061_1407_01
Multi boiler system
Vitotronic 300, GW6B Installation and Service
12
Note: This schematic is a general example without shutoff
valves or safety equipment. This does not replace
the need for local engineering.
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Required Devices
ID: 4800061_1407_01
PositionEquipment
1
2
3
4
5
6
8
9
rT
uW
uE
uZ
qP
qW
qQ
qE
qR
qT
rT
uR
uT
uO
qZ
qU
qI
qO
wP
wW
wE
wQ
wE
uU
wR
wZ
wU
wT
wU
uI
wI
eE
eR
wO
eR
eT
Boiler 1
Flue gas damper (for boiler I)
Isolation valve
Boiler temperature sensor KTS (connection to burner control)
Common supply temperature sensor
Outdoor temperature sensor ATS
Vitotronic 300 GW6B
Neutralization system
Power switch
Junction box
Burner base
Mixing valve adapter 24V
Boiler II
Isolation valve
Mixing valve adapter 24V
Boiler temperature sensor KTS (connection to burner control)
Vitotronic 300 GW6B
Neutralization system
Power switch
Junction box
Burner base
Flue gas damper (for boiler II)
DHW
DHW tank temperature sensor STS delivered with Vitotronic 300
DHW pump UPSB
DHW re-circulation pump ZP
Heating circuit I
Heating circuit pump M2 (heating circuit I)
Mixing valve M2 (heating circuit I)
Strap-on temperature sensor
and
Mixing valve actuator M2 (heating circuit I)
Mixing valve adapter 24V
Heating circuit II
Heating circuit pump M3 (heating circuit II)
Mixing valve M3 (heating circuit II)
Strap-on temperature sensor
and
Mixing valve actuator M3 (heating circuit II)
Mixing valve adapter 24V
Heating circuit III (low-temperature heating circuit)
Heating circuit pump M1 (heating circuit III)
Mixing valve M1 (heating circuit III)
Strap-on temperature sensor
and
Mixing valve actuator M1 (heating circuit III)
Vitotronic 200-H HK1B
and
LON communication module for Pos. 35
and
LON connecting cable
Preparing for Installation
5513 463 - 06
13
Preparing for Installation
System Examples (continued)
Required Devices
ID: 4800061_1407_01
PositionEquipment
eZ
wI
wO
eR
wO
eR
eT
uP
eZ
eP
eQ
eE
rT
eO
rP
rQ
zI
zO
tP
tW
tE
zP
zQ
zW
zE
zE
zU
uP
eT
uQ
Outdoor temperature sensor ATS (ATS-value can be taken from Vitotronic 300 GW6B master and cascade
or
Heating circuit III (underfloor heating)
Supply temperature sensor M1 (circuit III) delivery Pos. 35
Mixing valve M1 (heating circuit III)
or
Strap-on temperature sensor
and
Mixing Valve Actuator M1 (heating circuit III)
Vitotronic 200-H HK1B
and
LON communication module for Pos. 35
and
LON connecting cable
Outdoor temperature sensor ATS (ATS-value can be taken from Vitotronic 300 GW6B master and cascade
Temperature monitor as Maximum temperature limiter for underfloor heating
Heating circuit pump M1 (primary)
Power switch on site / main disconnect
Accessories for boilers
Maximum pressure SDB
Minimum pressure switch or limiter SDB
Water level (Low water cutoff) WB
External blocking / Boilers
Switch on boiler as the last in a row
Accessories
Compiled Fault Output
Vitotrol 200A or Vitotrol 300A
KM BUS subscriber: - Extension EA1, AM1
- Vitotrol 200A, 300A
Extension EA1:
1 switching output (floating changeover contact)
- Control system pump to a substation
- Signal reduced mode for one heating circuit
1 analog input (0 to 10 V)
- Specification of the boiler water temperature setpoint
3 digital inputs
- Separated External switch the operating status for heating circuits 1 to 3 switchable
(with control for weather-compensated operation)
- External blocking
KM BUS distributor, with several KM BUS participants
LON communication module to communicate with the following components:
Vitotronic 200-H (for controlling other heating circuits)
Vitocom 100, type LAN1 with communication module
Vitotronic 300, GW6B Installation and Service
14
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Preparing for Installation
5513 463 - 06
15
Preparing for Installation
System Examples (continued)
Vitotronic 300, GW6B Installation and Service
16
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Preparing for Installation
5513 463 - 06
17
Preparing for Installation
System Examples (continued)
Vitotronic 300, GW6B Installation and Service
18
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
System Examples (continued)
Preparing for Installation
5513 463 - 06
19
Preparing for Installation
Vitotronic 300, GW6B Installation and Service
System Examples (continued)
ID: 4800061_1407_01
coding addresses Vitotronic 300, type GW6B; Lead boiler / Pos. 8
Group Coding addressFunction
General
System Layout
Cascade
Number of boilers in cascade
Cascade
Boiler rotation
coding addresses Vitotronic 300 Type GW6B Pos. 14
General
LON Participant Number
Boiler
Boiler number in multiboiler system
coding addresses Vitotronic 200-H, type HK1B / Pos. 35
General81:3The control unit receives time
General97:1Control unit receives the outdoor temperature
00:8Two heating circuits with mixing valve M2 (heating
circuit 2) and M3 (circuit 3) DHW heating
35:2Number of boilers connected in the heating system
38:1Boiler rotation - Monthly
77:2LON Participant Number
07:2Boiler number in multiboiler system
20
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
Overview of Electrical Connections
Electrical Connections
WARNING
Incorrect wiring can lead to serious injury from electrical
current and result in appliance damage.
IMPORTANT
Electronic assemblies can be damaged by static loads.
Prior to commencing work, touch an grounded object
such as a heating or water pipe to discharge static load.
H Route low voltage leads and line voltage cables
separately.
H Strip the insulation from the cables as close to the
terminals as possible, and bundle tightly to the
corresponding terminals.
H Secure cables with cable ties.
Connections on the low voltage PCB
PlugComponentSingle boiler system
!
§/?
%A
%B
)
aJA
aJB
5513 463 - 06
Outdoor temperature sensorXX-Common supply temperature
sensor
DHW tank temperature sensorXX--
DHW tank temperature sensor
(bottom) in a tank loading
system
Common supply temperature
sensor, low loss header
Return temperature sensor T1XXX
Temperature sensor tank
loading system
Single boiler control unit
--X--
XX--
X----
X
Multi boiler system
Cascade control unitLag boiler control unit
X
--
21
Electrical Connections
Overview of Electrical Connections (continued)
Connections on the low voltage PCB (continued)
PlugComponentSingle boiler system
sÖA1 High temperature heating circuit pump
gSA1 Mixing valve, primary store system
gÖ Compile fault output
fÖ Main power supply
aBÖ Safety circuit connections
aBA Safety circuit connections
gD Flue gas damper
F3
5513 463 - 06
Fuse 250VAC 6.3A
Rated pump and compile fault output 2A~
Note: Maximum output 6FLA shared between all mixing
valve, pump and compile fault outputs.
Note: The 120VAC line out terminals are still live even
when the control is switched off.
23
Electrical Connections
Overview of Electrical Connections (continued)
Vitotronic 300, GW6B Installation and Service
Note: The DIN terminals can be used with solid, stranded
or stranded with ferrule termination. The ferrule
will help to prevent ‘fraying’ of the standed wires
during installation.
Specific connections are detailed throughout the manual,
refer to the appropriate section prior to making any
connections.
Top
The junction box terminals include a L, N terminal
connection orientated at the top of the junction box
which is pre-wired to the cable harness set, which is
used to connect the Vitotronic control and Burner Base to
the junction box. The L,N,G terminals orientated at the
bottom of the junction box are used to for connections
to external equipment (ie. Pumps, mixing valves, etc).
The individual terminals are a ‘push-in’ design, meaning
to install or release a wire, the orange button must be
pushed in (refer to image below for location of orange
buttons denoted by B), prior to installing or removing
any wires to the terminal.
Bottom
Legend
A DIN terminal (typical)
B Push-in button
C DIN rail (typical)
D Terminal insertion point
Note: Max. wire gauge 12AWG
Min. wire gauge 26AWG
24
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
F3
F3
Overview of Electrical Connections (continued)
Accessing the DIN rail mounted fuse F3
A DIN rail mounted fuse block provides protection to the
120V line out connections as shown on page 23.
When fuse F3 requires replacement, the fuse can be
accessed as shown.
Electrical Connections
1. Flip down the front portion of the DIN rail
fuse block.
2. Flip down the front side cover of the DIN rail
fuse block.
3. Replace fuse.
4. Return the DIN rail
original postion.
mounted fuse block back to the
.
mounted
mounted
5513 463 - 06
25
Electrical Connections
Boiler Control and Junction Box
B
C
Legend
A Junction box
B Vitotronic control
C Vitocrossal 200 CM2 boiler
Vitotronic 300, GW6B Installation and Service
1. Install the junction box to the rear panel either right or
left. Secure the junction box with four 4.8 mm metal
screws.
2. Route cables from control through the opening in the
control panel. Guide the cables to the junction box
through the opening in the rear panel and along the
top rail to the control. Secure all cables to the rail with
cable ties.
Note: Never allow cables to come in contact with hot
metal components.
3. Mount the control to the top front panel.
4. Secure the control to the top front panel with screws.
Note: Screws to secure control are included in
control’s shipping box.
Mounting the Control Unit
Legend
A Cable retaining tab
26
Note: Route the ribbon cable through retainer A.
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
Opening the Control Unit
Electrical Connections
Plugging in the Boiler Coding Card
Only use the boiler coding card supplied with the boiler
junction box.
Insert the boiler coding card into slot “X7”, through the
recess in the cover.
Coding card #Part #
10427543216
5513 463 - 06
27
Electrical Connections
Inserting Cables and Applying Strain Relief
H Control unit fitted on the boiler:
Route cables from below through the front panel of the
boiler into the wiring chamber of the control unit.
Vitotronic 300, GW6B Installation and Service
Legend
A Cables with moulded strain relief
B On-site cables; strip up to 4 in. (100 mm) insulation
Connecting Sensors
Outdoor temperature sensor connection
2 wire cable, 18 AWG for a maximum length of 120 ft
(36 m)
28
Connections on the low voltage PCB
PlugComponent
!
§/?
%A
%B
)
aJA
aJB
Outdoor temperature sensor
Fitting location for outdoor temperature sensor
H North or north-westerly wall, 6 to 8 ft (2 to 2.5 m)
above ground level; in multi storey buildings, in the
upper half of the second floor.
H Not above windows, doors or ventilation outlets.
H Not immediately below balconies or gutters.
H Never cover over.
Outdoor temperature sensor
Common supply temperature sensor
Tank temperature sensor
Tank temperature sensor (bottom)
in a tank loading system
Temperature sensor, low loss header
Return temperature sensor T1
Temperature sensor tank loading system
5513 463 - 06
Vitotronic 300, GW6B Installation and Service
Control Power Supply
Electrical Connections
Connecting the power supply to the Vitotronic control
For burner base unit, see boiler service
instructions
Legend
A To the burner base unit
B Connecting cable
C To the Vitotronic control
Insert plug
burner base.
Route beneath the top B rail in a bundle using plug-in
cable retainers.
Connect plugs fÖ and aBH to the corresponding plugs in
the Vitotronic control unit.
40/156
into the corresponding plug of the
5513 463 - 06
29
Electrical Connections
Connecting the Burner
Legend
A To the Vitotronic control
B To the burner (burner control unit)
C KM BUS cable
Vitotronic 300, GW6B Installation and Service
The burner cables are included in the standard boiler
delivery.
Max. power consumption 3A.
Terminal codes
L1 Phase via external safety equipment (if installed)
to the burner
Ground conductor to burner
N Neutral conductor to burner
T1 120V~ from burner control unit
T2 Base load demand
S3 Connection for burner fault
B4 Connection for hours run meter
Insert plug fA and aVG into the corresponding plug of
the burner control.
Route beneath the top B rail in a bundle using plug-in
cable retainers.
Connect plugs fA and aVG to the corresponding plugs in
the Vitotronic control unit.
30
5513 463 - 06
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