Viessmann GW2 Service Manual

1VITOTRONIC 300Installation andService InstructionsVitotronic 300, Model GW2Outdoor-reset logic digital boiler andheating circuit control unitCertifie

Heating system types10Heating system types for modulating boilers (continued)System type 2 – Single-boiler system with shunt pump and return valve for

Additional information1A100System components (continued)Outdoor temperature sensorThe outdoor temperature sensor should be mounted 2 to 2.5 metres / 6

Additional information101System components (continued)Boiler temperature sensor, Part No. 7450 632 and DHW tank temperature sensor, Part No. 7450 633E

Additional information102System components (continued)Strap-on temperature sensor and immersion temperature sensorFor measuring the supply temperature

Additional information103System components (continued)Strap-on temperature sensor and immersion temperature sensorFor measuring the return temperature

Additional information104System components (VD2/VD2A/CT3 only)(continued)Flue gas temperature sensor, Part No. 7450 630 AccessorySee page 48 for CM2 f

Additional information105System components (continued)Installation examplesIn the as delivered condition, the electrical connections ofthe mixing valv

Additional information106System components (continued)Vitotrol 200, Part No.7133 378(with integral room temperature sensor for room temperature feed-b

Additional information107System components (continued)Remote control (continued)D Printed Circuit Board DIP switches(rear of the top casing)Remote con

Additional information108System components (continued)Vitotrol 300, Part No. 7134 452(with integral room temperature sensor for room temperature feed-

Additional information109System components (continued)Remote control (continued)D Printed Circuit Board DIP switches(rear of the top casing)Remote con

Heating system types11Heating system types for modulating boilers (continued)Possible applicationsHeating systems with distributorarranged close to th

Additional information110System components (continued)Connecting several remote control unitsWhen connecting several remote controls to the control un

Additional information111System components (continued)Version 2A To control unitB Terminal box (on site)C Vitotrol 1D Vitotrol 2E Vitotrol 3F Further

Additional information145BCA3 41 2112System components (continued)Room temperature sensor, Part No. 7133 379 AccessoryA To control unitB Remote contro

Additional information113System components (continued)Input Module 0 to 10 V, Part No. 7134 561From software version 7, the Input Module can be connec

Additional information114Coding 1Call up coding level 1Only those coding addresses are displayed which correspond to the system typeand equipment conc

Additional information115Coding 1 (continued)Codings (continued)Function Coding as per factory settingAddress: ValuePossible changeBurner type 02: 1Tw

Additional information116Coding 2Call up coding level 2The overview lists all possible coding addresses.However, only those coding addresses are displ

Additional information117Coding 2 (continued)Reset codings to factory settings1. Press w and rw simultaneouslyfor approx. 2 seconds.2. Press D.Pressto

Additional information118Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress:ValueFunction New codingAddress:Va

Additional information119Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress:ValueFunction New codingAddress:Va

Heating system types12Heating system types for condensing boilersSystem type 3 – Single-boiler system with Vitocrossal 300A Boiler with Vitotronic 300

Additional information120Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction2.4 New codingAddres

Additional information121Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information122Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information123Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information124Coding 2 (continued)Overview of all codings (continued)Coding as perfactorysettingAddress: ValueFunction New codingAddress:Va

Additional information125Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information126Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information127Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information128Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information129Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Heating system types13Heating system types for condensing boilers (continued)Please note:This circuit diagram represents arecommendation only. It is t

Additional information130Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAddress:V

Additional information131Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress:ValueFunction New codingAddress:Va

Additional information132Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAdress:Va

Additional information133Coding 2 (continued)Overview of all codings (continued)Coding as perfactory settingAddress: ValueFunction New codingAdress:Va

Additional information134Coding 2 (continued)Overview of all codings (continued)Slab curing function diagramsTemperature/time curve 1 (F1:1)Supply tem

Additional information135Wiring diagramOverviewA1 Mixing valve extension circuitboardA2 Low-voltage motherboardA3 120 V~ motherboardA4 Electronics boa

Additional information136Wiring diagram (continued)Low-voltage motherboard5285 941 v.1.5A11A8A9A6A2A10A5A734-pole

Additional information137Wiring diagram (continued)Low-voltage motherboard (continued)! Outdoor temperaturesensor/radio clock receiver(accessory)§ Boi

Additional information138Wiring diagram (continued)120 V~ motherboard5285 941 v.1.5A11A3float-ingON ON

Additional information139Wiring diagram (continued)120 V~ motherboard (continued)sÖ Heating circuit pumporcontrol outputsA Circulation pump for heatin

Heating system types14Heating system types for condensing boilers (continued)System type 4 - Single-boiler system with Vitocrossal 300 with several he

Additional information140Wiring diagramMixing valve extension circuit board? Supply temperature sensorssÖ Heating circuit pumpsgS Mixing valve motorsK

Additional Information141Order No. Serial No.*17134 555, 7134 556, 71430007511 362 71871017248248Ordering Replacement Parts

Additional Information142Parts List (continued)5285 941 v.1.5Other Parts (not illustrated)060 Accessory pack (plugs)080 Installation / Service Instruc

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Viessmann Manufacturing Company Inc.750 McMurray RoadWaterloo, Ontario • N2V 2G5 • CanadaTel. (519) 885-6300 • Fax (519) 885-0887www.viessmann.ca • in

Heating system types15Heating system types for condensing boilers (continued)Possible applicationsFor heating circuits with differenttemperatures.Plea

Heating system types16Heating system types for condensing boilersSystem type 5 – Single-boiler system with Vitocrossal 200A Boiler with Vitotronic 300

Heating system types17Heating system types for condensing boilers (continued)Please note:This circuit diagram represents arecommendation only. It is t

Installation18Overview of electrical connectionsMixing valve extension circuit board? M2/M3 Supply temperature sensorsÖ M2/M3 Heating circuit pumpgS M

Installation19Overview of electrical connections(for VD2/VD2A/CT3 only)5285 941 v.1.5

General information2Safety, Installation and Warranty RequirementsPlease ensure that this manual is read and understood before commencing installation

Installation20Overview of electrical connections (for CM2 only)5285 941 v.1.5

Installation21Routing and strain relief of cables1. Run the cables from the connection enclosure into the control unit.2. Apply strain relief to cable

Installation22Inserting the boiler coding cardOnly use the boiler coding card included with the boiler.Boiler Coding card Part No.Vitocrossal 300, typ

Installation23Adjustment of the fixed high limit (if required)The fixed high limit is supplied with a factory setting of 110°C / 230°F.Adjustment to 9

Installation24Adjustment of the adjustable high limit (if required)The adjustable high limit is supplied with a factory setting of 95°C.Adjustment to

InstallationWhen extending wire, there is thepossibility of exposure toelectromagnetic interference. Avoidrunning wires beside or near highvoltage 120

Installation26Connection of the boiler temperature sensorThe sensor measures the boilerwater temperature.The boiler temperature sensor isinstalled at

Installation27Connection of the DHW tank temperature sensorThe sensor measures the domestic hotwater tank temperature.sensor and tanktemperature senso

Installation28Connection of the return temperature sensorStrap-on temperature sensor and immersion temperature sensorFor measuring the boiler returnte

Installation29Connection of the flue gas temperature sensor (VD2/VD2A/CT3 only)The sensor measures the flue gastemperature and monitors theselected li

General information3Product InformationVitotronic 300, Model GW2For installation in or mounting onViessmann boilers only.Applicable to the following c

Installation30Connection of the Pumps (VD2/VD2A/CT3 only)Available pump connectionssÖ A1/M1Heating circuit hightemperature (without mixing valve)Termi

Installation31Connection of the Pumps (CM2 only)Available pump connectionssÖ A1/M1Heating circuit hightemperature (without mixing valve)Terminals 7 -

Installation32Connection of boiler return mixing valve or modulating valve actuator(VD2/VD2A/CT3 only)1 120V or 24V valve adaptor2 DIN rail in connect

Installation33Connection of Boiler Return Mixing Valve or Isolation/Modulating Valveactuator(CM2 only)1 120V or 24V Valve Adaptor2 Junction box3 120V

Installation34Making Space for Accessory Adaptors on the DIN Rail (CM2 only)1. Push up on the bottom front ofthe DIN rail clamp to remove andset aside

Installation35Connections to terminal aBÖ (VD2/VD2A/CT3 only)A JumperB External shut-off (dry contact)External shut-off1. Remove jumper betweentermina

Installation36Connection of the compiled failure alarm indicator (VD2/VD2A/CT3 only)Rated voltage: 120 VAC 60 HzRated current: max. 2 FLARecommended c

Installation37Connection of the compiled failure alarm indicator (CM2 only)Rated voltage: 120 VAC 60 HzRated current: max. 2 FLARecommended connection

Installation38Connection of external equipment to terminal aVDExternal changeover of the heatingprogram/”Open mixing valves”Connect floating contact t

Installation39Connection of external equipment to plug aVHA External demand (floating contact)B External changeover,staged/modulating burner(floating

Index4PageGeneral informationSafety Requirements 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation40Connection of external controlsOperation with two-stage burnerSettings on the control unitThe settings for the fixed high limit andthe o

Installation41Connection of external controls (VD2/VD2A only) (continued)Modulating boilers – operation with external modulation controller1st stage

Installation42Connection of external controls (VD2/VD2A only) (continued)Modulating boilers – operation with external modulation controller (continued

Installation43Connection of external controls (CT3 only) (continued)Vitocrossal 300 – operation with external modulation controller1st stage burner f

Installation44Connection of external controls (CT3 only) (continued)Vitocrossal 300 – operation with external modulation controller (continued)Setting

Installation45Connections of combustion air device adaptor (VD2/VD2A/CT3 only)Connection of the Combustion AirDevice Adaptor1. Disconnect power to con

Installation46Connection of Combustion Air Device (CM2 only)Connection of the Combustion AirDevice Adaptor1. Disconnect power to control andburners.2.

Installation47Connection of combustion air device (continued)Connection of the combustion airdamperSee damper manual for correctinstallation.Note:Assu

Installation48Flue Gas Temp. Switch (optional for CM2 equipped with SS flue collector)(CM2 only)1. Disconnect power.2. Remove 150 plug from theVitotro

Installation49Connection of low water cut-off device (VD2/VD2A/CT3 only)aBH Power supply for accessories.aBÖ Connection for externalequipment.1.Remove

Index5PageScanning service informationOverview of service levels 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation50Connection of Low Water Cut-off Device (CM2 only)1. Remove jumper between terminals21 and 22.2. Make connection as shown indiagram.5285

Installation51Burner connection, Burner control wiring (VD2/VD2A/CT3 only)For burners with plug-in connectionThe burner cables are included in thestan

Installation52Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)Write the terminal numbers ormarkings on the drawing for futurer

Installation53Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)Burner motor power supply connection(continued)For burners with

Installation54Burner Connection, Burner Control Wiring (VD2/VD2A/CT3 only) (continued)Burner motor power supply connection(continued)For burners with

Installation55Power Supply Connection, Boiler Control (VD2/VD2A/CT3 only)LegendL: LineN: NeutralG: GroundA Power supply 120 VAC, 1 PH .Provide disconn

Installation56Burner Connection, Burner Control Wiring (CM2 only)For burners with plug-in connectionThe burner cables are included in thestandard deli

Installation57Mounting the Front Part of the Control Unit (VD2/VD2A/CT3 only)1. Position the front part of the housingand clip hinges to counter-parts

Installation58Mounting the Front Part of the Control Unit (VD2/VD2A/CT3 only)1. Position the front part of the housingand clip hinges to counter-parts

Installation59Opening the Control Unit (VD2/VD2A/CT3 only)1. Remove the cover of theconnection enclosure.2. Unscrew the screws from thefront housing.3

Heating system types6Heating system types for modulating boilersSystem type 1 – Single-boiler system with shunt pump for raising the return temperatur

Installation60Control and Junction Box Installation Instructions (for CM2 only)1. Route cables and capillaries fromcontrol through the opening in thec

Installation61Mounting the Front Part of the Control Unit (CM2 only)1. Position the front part of the housingand clip hinges to counter-parts onmain h

Installation62Opening the Control Unit (CM2 only)1. Remove the control cosmeticcover .2. Unscrew the screws from thefront housing.3. Swing up the fron

Start-up63Procedure (overview)Page11. Controls and indicators 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up64Steps1. Controls and indicatorsOverride switchHeating circuit selectionDisplay windowNormal room temperatureHeating programsAdjustable high

Start-up65Steps (continued)3. Check the fixed high limitThe check is made via the ”TÜV TEST” button (see page 64).When making the check, the ” TÜVTEST

Start-up66Steps (continued)5. Integrate the control unit in the LON BUS system in conjunction with Vitotronic 200-HThe LON communication module (acces

Start-up67Steps (continued)6. Carry out participant checkThe participant check is used to verify the communication of the system unitsconnected to the

Start-up68Steps (continued)7. Match the control unit to the system typeSet the following coding addresses inCoding 2:”00” System type”02” Burner type”

Start-up69Steps (continued)Check sensors1. Press .2. Scan actual temperatures withor .3. Press.Scanning of operating statusinformation is activated(se

Heating system types7Heating system types for modulating boilers (continued)Possible applicationsHeating systems with manifoldarranged close to the bo

Start-up70Steps (continued)9. Match the coding addresses (continued)10. Set the established values in codingLevel 1.See page 114 for coding 1.AddressS

Start-up71Steps (continued)10. Adjust the heating curvesThe heating curves represent the relationship between the outdoor temperatureand the boiler wa

Scanning service information72Overview of service levelsFunction Button combination To exit PageTemperatures, boiler coding cardsand scansPress 9 and

Scanning service information73Temperatures, boiler coding cards and scans1. Press 9 and rw simultaneouslyfor approx. 2 seconds.Access diagnosis level.

Scanning service information74Temperatures, boiler coding cards and scans (continued)Scan 15285 941 v.1.588888Scan 18Burner type CodingSingle-stage 02

Scanning service information75Temperatures, boiler coding cards and scans (continued)Scan 2Scan 35285 941 v.1.588888Scan 28Software versionPlug-in ada

Scanning service information76Temperatures, boiler coding cards and scans (continued)Scan 4Scan 4 is not assigned.Scan 5 only in conjunction with LON

Scanning service information77Scanning operating status information1. Press .2. Select the required operating statusdata for scanning with the orbutto

Scanning service information78Scanning and resetting the ”Service” displayWhen the limit values selected via coding addresses ”1F”, ”21” and ”23” (see

Troubleshooting79Troubleshooting stepsDiagnosis 1. Establish fault message or ascertain behaviour of system2. Look for the corresponding cause of the

Heating system types8Circuit Diagram 1Single-boiler system with Therm-Control and three-way mixing valvein conjunction with Vitorond 200, VD2AA Heatin

Troubleshooting80DiagnosisFaults with fault display on the programming unitTo retrieve an acknowledged faultmessagePressfor approx. 3 seconds; selectt

Troubleshooting81Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcodein displayBehaviour of systemCause of faul

Troubleshooting82Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcodein displayBehaviour of systemCause of faul

Troubleshooting83Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcodein displayBehaviour of systemCause of faul

Troubleshooting84Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcodein displayBehaviour of systemCause of faul

Troubleshooting85Diagnosis (continued)Faults with fault display on the programming unit (continued)Faultcodein displayBehaviour of systemCause of faul

Functional description86Boiler temperature controlBrief descriptionThe boiler water temperature iscontrolled by switching the burnerstages or modulati

Functional description87Heating circuit controlBrief descriptionThe control unit has control loops for asystem circuit and two mixing valvecircuits.Th

Functional description88Heating circuit control (continued)Functions (continued)Summer energy saving function(heating circuit pump logic)If the outdoo

Functional description89Heating circuit control (continued)Functions (continued)Upper limit of control rangeElectronic maximum limitSetting range:1 to

Heating system types9Circuit Diagram 1 (continued)sÖ A1 Close mixing valvesA Contactor relay, field suppliedB Heating circuit controlsconnected downst

Functional description90DHW tank temperature controlBrief descriptionThe DHW tank temperature control is aconstant value control. It operates onthe ba

Functional description91DHW tank temperature control (continued)Control sequenceDHW tank temperature falls(Set-point value –2.5 °C / 4.5 °F,selectable

Additional information92OverviewPageTechnical data 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional information93Technical dataRated voltage: 120VRated frequency: 60 HzRated current: 2 x 6APowerconsumption: 10WProtection class: IDegree of

Additional information94System componentsLine voltage motherboard, Part No. 7165 782The motherboard contains:Relays and outputs for activatingthe pum

Additional information95System components (continued)Mixing valve extension board, Part No. 7820 193The board contains the relays foractivating the mi

Additional information96System components (continued)Front panel with heating circuit selector buttons, Part No. 7818 623For displaying and selecting

Additional information97System components (continued)Boiler coding cardVitotronic 300in conjunction withBoiler coding card Part No.Vitorond 200 1020 7

Additional information98System components (continued)Fixed high limit, Part No. 7820 036The fixed high limit has a factory setting of 110°C/ 230°F.E

Additional information99System components (continued)Outdoor temperature sensor, Part No. 7820 148Outdoor temperature sensorConnectionCheck sensor1. R