Viessmann VITOCAL 300-G PRO Type BW 2150 Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitocal 300-G Pro SPS
Type BW 302.DS090 to 302.DS230, 84.8 to 222.0 kW
Brine/water heat pumps, 2-stage and hydraulic module defrost box HMD90 to
HMD190
VITOCAL 300-G PRO SPS
5837251 GB 10/2018 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on the refrigerant circuit may only be carried
out by authorised refrigeration engineers.
■Work on electrical equipment may only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■Relevant country-specific safety regulations
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply, 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 result in
severe injuries. Some components on PCBs
remain live even after the power supply has
been switched off.
Prior to removing covers from the appliances,
wait at least 4 minutes until the voltage has
completely dropped out.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the appliance, fit-
tings or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing 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 func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
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Safety instructions for operating the system
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Safety instructions
Safety instructions (cont.)
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1. Safety and liability Occupational safety ............................................................................... 6
■Electrical connections ......................................................................... 6
■Work on the heat pump ...................................................................... 7
■Work on the refrigerant circuit ............................................................. 7
■Work on the casing ............................................................................. 7
2. Information Disposal of packaging ............................................................................ 8
Symbols ................................................................................................. 8
Intended use .......................................................................................... 8
Product information ................................................................................ 9
■Vitocal 300-G Pro SPS, type BW 302.DS090 to BW 302.DS230 ....... 9
■Vitocal 300-G Pro AW package .......................................................... 9
3. Preparing for installation General information on electrical connection ......................................... 11
Transport and siting requirements: Heat pump ..................................... 11
■Unloading and handling ...................................................................... 11
■Installation room requirements ........................................................... 13
■Minimum clearances ........................................................................... 13
■Anti-vibration base .............................................................................. 14
Transport and siting requirements: Hydraulic module defrost box ........ 15
■Unloading and handling ...................................................................... 15
■Hydraulic module siting requirements ................................................ 17
Requirements for on-site connections ................................................... 18
■Dimensions, Vitocal 300-G Pro SPS .................................................. 18
■Dimensions, hydraulic module defrost box ......................................... 21
Hydraulic connection requirements ....................................................... 21
■Overall hydraulic diagram for ground and water heat sources ........... 22
■Overall hydraulic diagram for heat source air ..................................... 26
Hydraulic connection requirements, hydraulic module defrost box ....... 29
■Hydraulic diagram ............................................................................... 29
4. Installation procedure,
heat pump
Siting the heat pump .............................................................................. 30
■Levelling the heat pump ..................................................................... 30
■Removing the transport brackets ........................................................ 31
■Fitting the back panel, side panels and kicking plates ........................ 32
Hydraulic connections ............................................................................ 33
■Overview of hydraulic connections ..................................................... 33
■Connecting the Vitocal 300-G Pro SPS .............................................. 34
■Fitting the Victaulic couplings ............................................................. 35
■Connecting the primary circuit ............................................................ 36
■Connecting the secondary circuit ....................................................... 36
Electrical connections ............................................................................ 37
■Routing cables to the heat pump wiring chamber .............................. 37
■Overview of electrical connections ..................................................... 38
■External connections .......................................................................... 39
Power supply ......................................................................................... 51
■Control circuit power supply (230 V~) and power circuit (400 V~) ..... 52
■Power supply with power-OFF without on-site load disconnect
(delivered condition) ........................................................................... 53
Mains monitor ........................................................................................ 53
■Electronic soft starter, type SMC ........................................................ 53
Fitting the shaft and dial for the ON/OFF switch and installing the pro-
gramming unit ........................................................................................ 54
Closing the heat pump ........................................................................... 55
5. Installation procedure,
hydraulic module defrost
box
Hydraulic connections ............................................................................ 56
■Overview of hydraulic connections ..................................................... 56
Electrical connections ............................................................................ 56
■Routing cables to the hydraulic module control cabinet ..................... 56
■Overview of electrical connections ..................................................... 57
Index
Index
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■External connections .......................................................................... 58
Power supply ......................................................................................... 60
■Electrical connection requirements ..................................................... 60
6. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 61
7. Troubleshooting Diagnosis ............................................................................................... 67
■Excessive noise .................................................................................. 67
8. Repairs Removing the front panel and top panel ................................................ 68
Overview of electrical components ........................................................ 68
Overview of internal components, Vitocal 300-G Pro SPS .................... 68
Draining the heat pump on the primary/secondary side ........................ 69
Checking the sensors ............................................................................ 69
■Temperature sensors type Pt 1000 ..................................................... 69
Checking fuses ...................................................................................... 70
9. Repairs, hydraulic module
defrost box
Electrical component overview .............................................................. 71
Overview of internal components, hydraulic module defrost box .......... 71
10. Parts lists Ordering parts ........................................................................................ 73
Components, heat pump ....................................................................... 74
Components, heat pump, PCB .............................................................. 76
Components, hydraulic module defrost box .......................................... 78
Components, hydraulic module defrost box, PCB ................................. 80
11. Specification Specification, Vitocal 300-G Pro SPS .................................................... 82
Specification, Vitocal 300-G Pro with AW package ............................... 85
■Operation: Air/water (A2/W35) heat recovery ..................................... 85
■W7/A35 residual heat ......................................................................... 87
Specification, hydraulic module defrost box .......................................... 88
Specification, air/brine heat exchanger .................................................. 89
■Standard version ................................................................................ 89
■Low-noise version ............................................................................... 90
12. Appendix Heat pump commissioning request ....................................................... 91
13. Final decommissioning Dismantling/disposal .............................................................................. 92
14. Certificates Declaration of conformity ....................................................................... 93
15. Keyword index ................................................................................................................ 94
Index
Index (cont.)
5837251