Viessmann VITOCAL 300-G PRO Type BW 2150 Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-G Pro SPS
Type BW 301.AS090 to 302.AS250
Vitocal 300-W Pro SPS
Type WW 301.AS125 to 302.AS300
For applicability, see the last page
VITOCAL 300-G PRO SPS
VITOCAL 300-W PRO SPS
5848 246 GB 9/2013 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.
■ 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
■ Codes of practice of the 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 result in severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Prior to removing equipment
covers, wait at least 4 min. to
allow the voltage to dissipate.
■ 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.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced 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 spare
parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5848 246 GB

4
Service instructions
Safety and liability
Heat pump application limits................................................................................ 6
Occupational safety.............................................................................................. 7
Installation instructions
Preparing for installation
Use....................................................................................................................... 10
Product information.............................................................................................. 10
General information on the electrical connection................................................. 11
Delivery and installation....................................................................................... 11
Siting.................................................................................................................... 14
Hydraulic connections.......................................................................................... 25
Installation sequence
Siting the heat pump............................................................................................ 28
Hydraulically connecting the primary/secondary circuits...................................... 32
Routing cables to the heat pump wiring chamber................................................ 38
Overview of electrical connections....................................................................... 40
Power supply........................................................................................................ 54
Installing the programming unit............................................................................ 59
Closing the heat pump......................................................................................... 60
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 62
Further details regarding the individual steps....................................................... 63
Troubleshooting
Repairs................................................................................................................. 92
Parts list
Ordering parts...................................................................................................... 98
Commissioning/service reports
Hydraulic parameter report................................................................................... 108
Specification
Specification, type BW 301.AS090 to BW 302.AS250......................................... 109
Specification, type WW 301.AS125 to WW 302.AS300....................................... 113
Index
Index
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Appendix
Heat pump commissioning order.......................................................................... 116
Certificates
Declaration of conformity...................................................................................... 117
Keyword index.................................................................................................... 120
Index
Index (cont.)
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6
Intended use ■ Generation of cooling and/or heating
■ For use in industry, commerce, housing with
separate boiler room
■ 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 batteries
and rechargeable batteries, safety
valve, filter dryer, refrigerant oil, fil-
ter, oil separator)
4 to 5 years, subject to hours run and operating
point
Risk assessment
System
users
Exter-
nal per-
sonnel
Manu-
facturer
Refrig-
eration
engi-
neer
Logis-
tics
Electri-
cian/
heating
con-
tractor
Service
engi-
neer
Disposal
contrac-
tor
Manufacture
X X
Delivery, moving, handling, installation
X X X X X
Installation
X X X
Commissioning
X X X X X
Operation
X X
Maintenance, repair, shutdown
X X X X
Dismantling, removal, collection
X X X X X
Disposal
X X X
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
Contact with 'live' components
can lead to serious injury from
electric current. 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 power cir-
cuits.
■ 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 40.
Danger
The absence of component
earthing can result in serious
injury from electrical current 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
5848 246 GB
Service

8
!Please note
Observe all "Safety instructions"
and information in the chapters
"Routing cables/leads to the heat
pump wiring chamber"
(page 38) and "Power supply"
(page 54).
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 246 GB
Service

10
The heat pumps Vitocal 300-G Pro SPS,
type BW 301.AS090 to 302.AS250 and
Vitocal 300-W Pro SPS,
type WW 301.AS125 to 302.AS300 may
be used for the following purposes:
■ Central heating and cooling via a heat-
ing system
■ DHW heating
■ Swimming pool heating
Any use that differs from or goes beyond
this is considered inappropriate.
Note
The Vitocal 300-G/W Pro SPS must be
operated exclusively by authorised and
trained personnel.
Product information
Vitocal 300-G/W Pro SPS
Heat pump Vitocal 300-G Pro
SPS, type BW
Vitocal 300-W Pro
SPS, type WW
Medium Brine/water Water/water
Single stage heat pumps 301.AS090
301.AS120
301.AS125
301.AS155
Two-stage heat pumps 302.AS090
302.AS120
302.AS150
302.AS180
302.AS250
302.AS125
302.AS155
302.AS200
302.AS250
302.AS300
Criteria:
■ Integral Vitotronic SPS, type SAIA
heat pump control unit
■ The refrigerant circuit has an elec-
tronic expansion valve (EEV) with an
independent control circuit (EEV con-
troller).
■ The heat pump control unit can switch
and regulate one cooling circuit. The
cooling circuit may be a heating circuit
prepared on site for cooling operation
or a separate cooling circuit.
■ All sensors are fitted inside sensor
wells.
■ Electric booster heaters (on-site) can
be switched (e.g. immersion heater in
the DHW cylinder).
A higher output in connection with addi-
tional Vitocal 300-G Pro SPS/
Vitocal 300-W Pro SPS (cascade) is only
possible with a higher ranking control
unit.
Preparing for installation
Use
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■Electrical connection of system
components (pumps, mixers, valves,
alarm facilities, contactors, function
extensions, sensors, etc.):
Connections are made inside the heat
pump wiring chamber. Observe infor-
mation from page 40.
■Power supply:
The number of power cables from the
meter box to the heat pump wiring
chamber depends on the system ver-
sion and tariffs used. See information
from page 54.
Delivery and installation
■ Vitocal 300-G/W Pro SPS is supplied
as a standard unit in addition to a sep-
arate pallet of side panels.
■ The programming unit of the Vitotronic
SPS is delivered loose inside the wir-
ing chamber and must be fitted and
connected on site (page 59).
■ Accessories are delivered separately.
■ The Vitocal 300-G Pro SPS/
Vitocal 300-W Pro SPS is filled with oil
and refrigerant at the factory.
Unloading and handling
Note
Before unloading, have the recipient
check the consignment for possible
damage. Note down any damage on the
delivery note and notify the haulage con-
tractor.
■ Lifting gear, such as slings and cross
beams must be provided on site.
■ The lifting capacity of each sling and
that of the cross beam must be at least
equal to the shipping weight, see
"Specification" (page 111).
■ Suitable equipment for unloading must
be available on site, see the following
chapter.
!Please note
Prevent equipment damage
when unloading and handling the
heat pump.
■Never put weight on top of the
appliance.
■ In order to protect the paint-
work, cover lifting tackle (e.g.
ropes, cross beam) and insert
padding between the
Vitocal 300-G Pro SPS/
Vitocal 300-W Pro SPS and the
lifting tackle.
Preparing for installation
General information on the electrical connection
5848 246 GB
Installation

12
■ Observe correct weight distri-
bution when lifting. The centre
of gravity of the
Vitocal 300-G Pro SPS/
Vitocal 300-W Pro SPS lies
through the heat exchanger on
the l.h. side.
■ Avoid impact and shocks to
prevent damage to the internal
pipework of the heat pump.
■ Avoid severely tipping the com-
pressor to safeguard the refrig-
erant circuit. Max. heat pump
tilting angle 30°. After tilting the
heat pump, wait at least 4
hours before switching it on.
The KWT Kälte-Wärmetechnik AG, a
member of the Viessmann Group, will
not be liable for any damage resulting
from inappropriate handling.
Handling by crane
AA
B
C
D
ALifting shackle BCross beams to remove the load on
the frame
Preparing for installation
Delivery and installation (cont.)
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CEdge protection (e.g. two or three
layers of corrugated cardboard)
DStrap approved for the shipping
weight
Note
Before transporting with a crane, always
ensure the side, front and back panels
are removed.
Handling by forklift truck or pallet truck
ASelect a fork length in line with the
heat pump length, see "Specifica-
tion" (page 115).
BThe centre of gravity of the
Vitocal 300-G Pro/
Vitocal 300-W Pro (through the heat
exchanger on the l.h. side)
CEdge protection (e.g. two or three
layers of corrugated cardboard)
Preparing for installation
Delivery and installation (cont.)
5848 246 GB
Installation

14
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 301.A090 to BW 302.A250:
BW 301.AS090 740 kg
BW 301.AS120 840 kg
BW 302.AS090 745 kg
BW 302.AS120 850 kg
BW 302.AS150 1190 kg
BW 302.AS180 1260 kg
BW 302.AS250 1375 kg
Total weight, type
WW 301.AS125 to
WW 302.AS300:
WW 301.AS125 1040 kg
WW 301.AS155 1050 kg
WW 302.AS125 1075 kg
WW 302.AS155 1085 kg
WW 302.AS200 1360 kg
WW 302.AS250 1405 kg
WW 302.AS300 1445 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.
Where uneven floors are being com-
pensated, distribute the load on the
adjustable feet evenly.
■ Observe minimum room volume (to
EN 378).
Note
Additional country-specific regulations
also apply.
Minimum room volume, type
BW 301.A090 to BW 302.A250:
BW 301.AS090 54 m3
BW 301.AS120 68 m3
BW 302.AS090 53 m3
BW 302.AS120 68 m3
BW 302.AS150 86 m3
BW 302.AS180 103 m3
BW 302.AS250 141 m3
Minimum room volume, type
WW 301.AS125 to WW 302.AS300:
WW 301.AS125 42 m3
WW 301.AS155 49 m3
WW 302.AS125 42 m3
WW 302.AS155 49 m3
WW 302.AS200 59 m3
WW 302.AS250 65 m3
WW 302.AS300 73 m3
■ Observe the required floor area and
minimum clearances (see the follow-
ing chapter).
Preparing for installation
Siting
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Minimum clearances
A
B
CD
E
700 600
E
B
A
CD
700 700 600
CD
AClearance subject to on-site instal-
lation and location
BClearance for installation and main-
tenance (e.g. for removing and
cleaning the tubular heat
exchanger)
■ Type BW:
≥ 500 mm
■ Type WW:
≥ 2000 mm
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 insulation parts
(side sections):
≥ 855 mm
Note
When siting cascades, observe the rele-
vant minimum clearances.
Preparing for installation
Siting (cont.)
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Installation

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Sound attenuating plinth
Position the heat pump on a base pre-
pared on site for the purpose of noise
attenuation and even weight distribu-
tion.
Note
In the case of installation in corners,
enlarge the base in accordance with the
minimum clearances (see previous
chapter).
150
A B
C
E D
AConcrete B25, iron
BFloor construction, screed
CTop edge unfinished floor
DImpact sound insulation as per reg-
ulations
ELoad-bearing sound insulation
layer, approx. 10 to 20 mm
Preparing for installation
Siting (cont.)
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Pressure points □ of the adjustable heat pump feet
Type BW 301.AS090, BW 301.AS120, BW 302.AS090, BW 302.AS120
1400
1000
1064
709
F
E
ELoad-bearing sound insulation
layer, approx. 10 mm
FFront of the heat pump
Preparing for installation
Siting (cont.)
5848 246 GB
Installation

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Type BW 302.AS150, WW 301.AS125, WW 301.AS155, WW 302.AS125,
WW 302.AS155
2040
1000
709
852 800
F
E
ELoad-bearing sound insulation
layer, approx. 10 mm
FFront of the heat pump
Type BW 302.AS180, BW 302.AS250, WW 302.AS200, WW 302.AS250,
WW 302.AS300
1000
709
2640
F
E
1150 1090
ELoad-bearing sound insulation
layer, approx. 10 to 20 mm
FFront of the heat pump
Preparing for installation
Siting (cont.)
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Requirements for on-site connections
Dimensions, type BW 301.AS090 to BW 302.AS250
Type BW 301.AS090, BW 301.AS120, BW 302.AS090, BW 302.AS120
163
406
500
1223
435
1130
343
1343
1650
911
A
B
C
D
G F E
APrimary circuit brine inlet:
Victaulic 3"
BSecondary circuit flow:
Victaulic 2½” HP water outlet
CPrimary circuit brine outlet:
Victaulic 3"
DSecondary circuit return:
Victaulic 2½"
EPower supply 400 V/50 Hz
FPower supply 230 V/50 Hz
GLow voltage < 42 V
Preparing for installation
Siting (cont.)
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Installation

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Type BW 302.AS150
911
1932
1650
163
406 343
500
1223
435 1130
A
B
C
D
GFE
APrimary circuit brine inlet:
Victaulic 3"
BSecondary circuit flow:
Victaulic 2½” HP water outlet
CPrimary circuit brine outlet:
Victaulic 3"
DSecondary circuit return:
Victaulic 2½"
EPower supply 400 V/50 Hz
FPower supply 230 V/50 Hz
GLow voltage < 42 V
Preparing for installation
Siting (cont.)
5848 246 GB