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
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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.)
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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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5
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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7
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

8
!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.)
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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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