Viessmann KWT Vitocal 350-G Pro Series Operating instructions

Installation and service
instructions
for contractors
Compact heat pump with electric drive, two-stage and three-stage
Vitocal 350-G Pro
Type BW 352.A027 to BW 353.A198
Type BW 352.A027 SA to BW 353.A198 SA
For applicability, see the last page
VITOCAL 350-G PRO
5848 449 GB 09/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on the refrigerant circuit may
only be carried out by authorised
refrigeration engineers.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician who have corresponding
authorisation.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ National installation regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and
SVGW
Working on the system
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can lead to fatal injury due to
electric shock. Some compo-
nents on the PCBs will remain
'live' even after the power sup-
ply has been switched off.
Prior to removing equipment
covers, wait at least 30 sec-
onds to allow the voltage to dis-
sipate.
■ Safeguard the system against recon-
nection.
Safety instructions
Safety instructions
5848 449 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any work,
touch earthed objects, such as
heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components with
genuine Viessmann spare parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5848 449 GB

4
Installation instructions
Safety and liability
Heat pump application limits................................................................................ 6
Boiler application limits......................................................................................... 6
Occupational safety.............................................................................................. 7
Preparing for installation
Use....................................................................................................................... 10
Product information.............................................................................................. 10
General information on the electrical connection................................................. 11
Delivery and handling........................................................................................... 11
Siting.................................................................................................................... 13
General hydraulic diagram................................................................................... 22
Hydraulic connection, geothermal probe.............................................................. 25
Hydraulic connection, groundwater...................................................................... 26
Hydraulic connection, heating water buffer cylinder............................................. 27
Hydraulic connection, external heat generator..................................................... 27
Hydraulic connection, heating circuits.................................................................. 28
"Natural and active cooling"................................................................................. 29
Hydraulic connection, cooling water buffer cylinder............................................. 30
Hydraulic connection, residual heat heat exchanger........................................... 32
DHW heating........................................................................................................ 33
Installation sequence
Siting the heat pump............................................................................................ 35
Making the hydraulic connections........................................................................ 39
Making the electrical connections........................................................................ 45
Overview of electrical connections....................................................................... 47
Power supply........................................................................................................ 62
Closing the heat pump......................................................................................... 68
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 69
Further details regarding the individual steps....................................................... 70
Troubleshooting
Repairs................................................................................................................. 98
Parts list, type BW
Spare part for part winding start version.............................................................. 102
Spare part for soft starter version......................................................................... 110
Index
Index
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Appendix
Heat pump commissioning order.......................................................................... 127
Certificates
Declaration of conformity...................................................................................... 128
Keyword index.................................................................................................... 130
Index
Index (cont.)
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6
Intended use ■ Generation of cooling and/or heating
■ For use in industry, commerce, domestic
households
■ For power supply systems up to 1000 A and
400 V
System limit See pipework and instrumentation diagram,
connection and wiring diagram
Service life
Heat pump Between 15 and 25 years
Wearing parts (back-up battery
and rechargeable batteries, safety
valve, filter dryer, refrigerant oil,
compressor, filter, oil separator)
4 to 5 years, subject to hours run and operating
point
Boiler application limits
Life cycle stages
Life cycle stages Responsible/participating personnel
Manufacture ■ External personnel
■ Manufacturer
Delivery, moving, handling, siting ■ External personnel
■ Manufacturer
■ Logistics
■ Electrician/heating contractor
Installation ■ External personnel
■ Electrician/heating contractor
Commissioning ■ System operators
■ External personnel
■ Electrician/heating contractor
Operation ■ System operators
■ External personnel
Service, repair, shutdown ■ System operators
■ Electrician/heating contractor
■ Service engineer
Dismantling, removal, collection ■ External personnel
■ Logistics
■ Electrician/heating contractor
■ Disposal contractor
Disposal ■ External personnel
■ Disposal contractor
Safety and liability
Heat pump application limits
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Electrical connections
Danger
Electromagnetic radiation near
the wiring chamber of the heat
pump control unit can interfere
particularly with heart pacemak-
ers and defibrillators.
■ Wearers of heart pacemakers:
Avoid the immediate vicinity of
the room where the heat pump
control unit is connected; pos-
sibly consult your physician.
■ Store and use defibrillators out-
side the area at risk.
Danger
Incorrectly executed electrical
installations can result in injuries
from electrical current and in
appliance damage.
Connect the power supply and
implement all safety measures
(e.g. RCD circuit) in accordance
with the following regulations:
■ IEC 60364-4-41
■ VDE regulations
■ Technical connection require-
ments specified by the local
power supply utility
Danger
Touching 'live' components car-
ries a risk to life. Some compo-
nents on the PCBs will remain
'live' even after the power supply
has been switched off.
■ Isolate the system from its
power supply (e.g. at a sepa-
rate MCB/fuse or mains isola-
tor), check that there are no
more 'live' currents and safe-
guard against reconnection.
Note
In addition to the control circuit,
there may be several load cir-
cuits protected by separate
MCB/fuses in the domestic dis-
tribution board.
■ Prior to removing the heat
pump covers, wait at least 4
min until the voltage has com-
pletely dropped out.
■ Never touch terminals in the
heat pump control unit and
power connections; see
page 47.
Danger
The absence of component
earthing can result in life-threat-
ening injuries from electrical cur-
rent and in component damage in
the event of an electrical fault.
■ Remake all earth connections
inside the heat pump.
■ Heat pump and pipework must
be grounded to the equipoten-
tial bonding of the building.
Safety and liability
Occupational safety
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Installation

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!Please note
Observe all "Safety instructions"
and information in the chapters
"Routing cables/leads to the heat
pump wiring chamber"
(page 45) and "Power supply"
(page 62).
Working on the heat pump
!Please note
Prior to commissioning and fol-
lowing repair or maintenance
work check that
the heat pump is in the intended
condition.
Danger
Falling of heavy or unwieldy heat
pump components can result in
life threatening crushing or
breaks.
■ Use suitable ropes/slings and
lifting gear when installing/dis-
mantling compressors and
heat exchangers, for example.
■ Wear appropriate protective
clothing (e.g. safety boots) in
compliance with applicable
regulations on accident pre-
vention and in line with trade
association recommendations.
Work on the refrigerant circuit
Danger
Refrigerant circuits of heat
pumps develop extremely low
(–25 °C) and very high (+130 °C)
temperatures. Work on heat
pumps can result in life threaten-
ing frostbite and burns.
■ Switch OFF the heat pump at
least 30 min before working on
it.
■ Never touch the injection valve
and compressor with bare
hands; wear safety gloves, if
contact is necessary.
■ Wear suitable protective cloth-
ing.
Danger
R410A refrigerant is a non-poi-
sonous gas that displaces air.
Unregulated escape of R410A
refrigerant in enclosed spaces
can result in breathing difficulties
and suffocation.
■ Never breathe in refrigerant
vapours.
■ Ensure adequate ventilation in
enclosed spaces.
■ Prevent open flames.
■ Observe regulations and
guidelines on handling this
type of refrigerant.
Safety and liability
Occupational safety (cont.)
5848 449 GB

9
Danger
Direct contact with refrigerant
can be harmful to skin.
■ Only work on the refrigerant cir-
cuit whilst wearing safety gog-
gles and gloves.
Note
Only qualified refrigeration
engineers should work on the
refrigerant circuit.
■ Wear suitable protective cloth-
ing.
Safety and liability
Occupational safety (cont.)
5848 449 GB
Installation

10
The heat pump Vitocal 350-G Pro,
type BW 352.A027/SA to BW 353.A198/SA
can be used for the following purposes:
■ Central heating and cooling via a heat-
ing system
■ DHW heating
Any use that differs from or goes beyond
this is considered inappropriate.
Note
The Vitocal 350-G Pro must be operated
exclusively by authorised and trained
personnel.
Product information
Vitocal 350-G Pro
Heat pump Vitocal 350-G Pro
Medium Brine/water
Two-stage heat pumps Type BW
352.A027, 352.A034, 352.A056,
352.A076, 352.A097, 352.A114,
352.A132, 352.A156
352.A027 SA, 352.A034 SA,
352.A056 SA, 352.A076 SA,
352.A097 SA, 352.A114 SA,
352.A132 SA, 352.A156 SA
Three-stage heat pumps Type BW
353.A172, 353.A198
353.A172 SA, 353.A198 SA
Characteristics:
■ Brine/water heat pump with electronic
heat pump control unit
■ The refrigerant circuit has an elec-
tronic expansion valve (EEV).
■ The heat pump control unit can acti-
vate and control a heating circuit pro-
vided on site for cooling or a separate
cooling circuit.
■ All sensors are fitted inside sensor
wells.
Preparing for installation
Use
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■Electrical connection of system
components
(pumps, mixers, valves, alarm facili-
ties, contactor, function extensions,
sensors, etc.):
The heat pump is connected via the
wiring chamber; observe the informa-
tion under the heading "Overview of
electrical connections".
Power supply
The number of power cables from the
distribution board (meter box) to the heat
pump control unit and to the control
panel depends on the system version
and tariffs used.
The power supply is made in the heat
pump control panel; observe the infor-
mation under the heading "Power sup-
ply".
Delivery and handling
■ The heat pump is delivered as stand-
ard appliance. Casing sections are
supplied separately. The Vitocal 350-
G Pro has been charged at the factory
with oil and refrigerant. Accessories
that are not factory-fitted are supplied
separately (e.g. flow switch, tempera-
ture sensors).
■ The programming unit of the Vitotronic
SPS is delivered loose inside the wir-
ing chamber and must be fitted and
connected on site.
Unloading and handling
1. Prior to unloading, check for visible
damage and note down any on the
delivery note, as well as notifying the
haulier and KWT AG.
2. Only use lifting gear and tackle suita-
ble for lifting the machine from the
lorry; alternatively use the base frame
as support element (for unloading by
crane, see the lifting shackles, for
example).
3. Lifting gear, such as slings and cross
beams must be provided on site.
4. The lifting capacity of each sling and
that of the cross beam must be at least
equal to the shipping weight (see
specification).
5. In order to protect the paintwork from
damage, cover ropes and similar by
suitable means prior to commencing
the lifting action.
Preparing for installation
General information on the electrical connection
5848 449 GB
Installation

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6. When lifting the equipment, prevent
impact and shock at all times. Ensure
correct weight distribution during lift-
ing. The heat pump centre of gravity
is through the heat exchanger on the
l.h. side.
7. Protect the heat pump by inserting
wadding material and timbers to
spread the ropes.
8. At the end of the unloading/lifting
process, ensure the machine is not
set down suddenly, as this can dam-
age the pipework in particular.
9. Never exceed the maximum tilt angle
of 30° of the Vitocal 350-G Pro.
KWT Kälte-Wärmetechnik AG/
Viessmann will not accept liability for
any damage resulting from incorrect
handling.
Handling by crane
AA
B
C
D
ALifting shackle
BCross beam to remove the load from
the frame
CEdge protection (e.g. two or three
layers of corrugated cardboard)
DStrap approved for the shipping
weight
Preparing for installation
Delivery and handling (cont.)
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Handling by forklift truck or pallet truck
C
C B A
ASelect a fork length in line with the
heat pump length, see "Specifica-
tion" (page 119).
BAlways centre the forklift truck forks
on the centre of gravity of the
Vitocal 350-G Pro (through the heat
exchanger on the l.h. side)
CEdge protection (e.g. two or three
layers of corrugated cardboard)
Siting
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Ensure ambient temperatures of
0 to 35 °C.
!Please note
Avoid the risk of explosion due to
dust, gases and vapours
in the installation room.
!Please note
Observe the load-bearing
capacity of the floor.
Total weight type
BW 352.A027/SA to
BW 353.A198/SA
BW 352.A027/SA 555 kg
BW 352.A034/SA 672 kg
BW 352.A056/SA 723 kg
Preparing for installation
Delivery and handling (cont.)
5848 449 GB
Installation

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BW 352.A076/SA 963 kg
BW 352.A097/SA 1065 kg
BW 352.A114/SA 1113 kg
BW 352.A132/SA 1209 kg
BW 352.A156/SA 1260 kg
BW 353.A172/SA 1604 kg
BW 353.A198/SA 1678 kg
■ To prevent the transmission of struc-
ture-borne noise, never site the appli-
ance on ceilings with wooden joists
(e.g. in the attic).
■ Level the appliance.
If the adjustable feet are used to com-
pensate for an uneven floor (max.
10 mm), the pressure load on the feet
must be distributed evenly.
■ Observe the minimum room volume to
EN 378.
Note
Additional country-specific regulations
also apply.
Minimum room volume type
BW 352.A027 to BW 353.A198/type
BW 352.A027 SA to
BW 353.A198 SA:
BW 352.A027/SA 16 m3
BW 352.A034/SA 20 m3
BW 352.A056/SA 28 m3
BW 352.A076/SA 40 m3
BW 352.A097/SA 52 m3
BW 352.A114/SA 64 m3
BW 352.A132/SA 76 m3
BW 352.A156/SA 96 m3
BW 353.A172/SA 108 m3
BW 353.A198/SA 144 m3
■ Observe the required floor area and
minimum clearances (see the follow-
ing chapter).
Minimum clearances
Observe required minimum clearances.
Note
■ Additional strain relief clamps are
required for the power cables if the
clearance behind the heat pump is
greater than 80 mm.
■ Observe clearances required for
installation and service.
■ When siting cascades, observe the
relevant minimum clearances.
A
B
CD
E
700 600
AClearance on site subject to instal-
lation and siting
BClearance for installation and serv-
ice (e.g. for removing and cleaning
the tubular heat exchanger)
■ Type BW:
≥ 500 mm
■ Type WW:
≥ 2000 mm
Preparing for installation
Siting (cont.)
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CCable entries
On-site strain relief clamps required
(wall clearance ≥ 80 mm).
D■ When using hydraulic connection
accessories (connection set and
Victaulic flange adaptor set, 2½"
or 3" version):
≥ 1000 mm
■ On-site hydraulic connections:
≥ 600 mm
E■ Without sound attenuation parts
(side sections):
≥ 855 mm
Foundation
Position the heat pump on a base pre-
pared on site for the purpose of sound
attenuation and even weight distribu-
tion.
Note
In the case of installation in a corner, the
foundation areas or clearances to the
wall increase in line with the minimum
clearances.
150
A B
C
E D
AConcrete B25, iron
BFloor construction, screed
CTop edge unfinished floor
DImpact sound insulation as per
regulations
ELoad-bearing sound insulation
layer, approx. 10 to 20 mm
Preparing for installation
Siting (cont.)
5848 449 GB
Installation

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Pressure points of the adjustable heat pump feet
Type BW 352.A027/SA, BW 352.A034/SA, BW 352.A056/SA
586 586 407
625
1900
900
G
HD
F
Type BW 352.A076/SA, BW 352.A097/SA, BW 352.A114/SA, BW 352.A132/SA,
352.A156/SA
628
705
900
G
HD
F
628628
2100
Preparing for installation
Siting (cont.)
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Type BW 353.A172/SA, BW 353.A198/SA
705
900
G
HD
F
850
2800
850 850
Preparing for installation
Siting (cont.)
5848 449 GB
Installation

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Requirements for on-site connections
BW 352.A027 to BW 352.A056/BW 352.A027 SA to BW 352.A056 SA
400V~
230V~
C
1848
750
1450
811
964
504
106
A
D B
389
AFlow, primary circuit (brine inlet)
BReturn, primary circuit (brine outlet)
CReturn, heating circuit
DFlow, heating circuit
Preparing for installation
Siting (cont.)
5848 449 GB

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BW 352.A076 to BW352.A114/BW 352.A076 SA to BW352.A114 SA
400V~
230V~
A
2153
850
1650
911
969
509
311
C
B D
525
AFlow, primary circuit (brine inlet)
BReturn, primary circuit (brine outlet)
CReturn, heating circuit
DFlow, heating circuit
Preparing for installation
Siting (cont.)
5848 449 GB
Installation

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BW 352.A132 to BW 352.A156/BW 352.A132 SA to BW 352.A156 SA
2153
850
1650
911
582
487
380
526
947
1305
A
C
BD
400V~
230V~
AFlow, primary circuit (brine inlet)
BReturn, primary circuit (brine outlet)
CReturn, heating circuit
DFlow, heating circuit
Preparing for installation
Siting (cont.)
5848 449 GB