Viessmann VITOCAL 300-G PRO Type BW 2150 Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-G Pro
Type BW 301.A090 to 302.A250
Vitocal 300-W Pro
Type WW 301.A125 to 302.A300
For applicability, see the last page
VITOCAL 300-G PRO
VITOCAL 300-W PRO
5848 164 GB 5/2013 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
5848 164 GB

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 164 GB

4
Service instructions
Safety and liability
Heat pump application limits................................................................................ 8
Occupational safety.............................................................................................. 9
Installation instructions
Preparing for installation
Use....................................................................................................................... 12
Product information.............................................................................................. 12
General information on electrical connection....................................................... 13
Delivery and installation....................................................................................... 13
Siting.................................................................................................................... 16
Primary circuit: brine/water, 1-stage..................................................................... 28
Primary circuit: brine/water, 2-stage..................................................................... 29
Primary circuit: brine/water, cascade................................................................... 31
Primary circuit: water/water, 1-stage/2-stage....................................................... 33
Water/water cascade, 1-stage/2-stage................................................................. 34
Electrical installation scheme............................................................................... 35
Heat pump cascade: 1-stage/2-stage.................................................................. 35
DHW heating........................................................................................................ 39
Installation sequence
Siting the heat pump............................................................................................ 41
Hydraulically connecting the primary/secondary circuits...................................... 45
Routing cables to the heat pump wiring chamber................................................ 51
Overview of electrical connections....................................................................... 53
Power supply........................................................................................................ 71
Installing the programming unit............................................................................ 76
Closing the heat pump......................................................................................... 77
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 79
Further details regarding the individual steps....................................................... 80
Troubleshooting
Repairs................................................................................................................. 98
Parts list type BW 301.A090
Ordering parts...................................................................................................... 107
Refrigerant circuit type BW 301.A090.................................................................. 107
Casing type BW 301.A090................................................................................... 107
Index
Index
5848 164 GB

5
Electrical equipment type BW 301.A090.............................................................. 107
Parts list type BW 301.A120
Ordering parts...................................................................................................... 109
Refrigerant circuit type BW 301.A120.................................................................. 109
Casing type BW 301.A120................................................................................... 109
Electrical equipment type BW 301.A120.............................................................. 109
Parts list type BW 302.A090
Ordering parts...................................................................................................... 111
Refrigerant circuit type BW 302.A090.................................................................. 111
Casing type BW 302.A090................................................................................... 111
Electrical equipment type BW 302.A090.............................................................. 111
Parts list type BW 302.A120
Ordering parts...................................................................................................... 113
Refrigerant circuit type BW 302.A120.................................................................. 113
Casing type BW 302.A120................................................................................... 113
Electrical equipment type BW 302.A120.............................................................. 113
Parts list type BW 302.A150
Ordering parts...................................................................................................... 115
Refrigerant circuit type BW 302.A150.................................................................. 115
Casing type BW 302.A150................................................................................... 115
Electrical equipment type BW 302.A150.............................................................. 115
Parts list type BW 302.A180
Ordering parts...................................................................................................... 117
Refrigerant circuit type BW 302.A180.................................................................. 117
Casing type BW 302.A180................................................................................... 117
Electrical equipment type BW 302.A180.............................................................. 117
Parts list type BW 302.A250
Ordering parts...................................................................................................... 119
Refrigerant circuit type BW 302.A250.................................................................. 119
Casing type BW 302.A250................................................................................... 119
Electrical equipment type BW 302.A250.............................................................. 119
Parts list type WW 301.A125 to WW 302.A300
Ordering parts...................................................................................................... 121
Refrigerant circuit type WW 301.A125................................................................. 121
Casing type WW 301.A125.................................................................................. 121
Electrical equipment type WW 301.A125............................................................. 121
Index
Index
5848 164 GB

6
Parts list type WW 301.A155
Ordering parts...................................................................................................... 123
Refrigerant circuit type WW 301.A155................................................................. 123
Casing type WW 301.A155.................................................................................. 123
Electrical equipment type WW 301.A155............................................................. 123
Parts list type WW 302.A125
Ordering parts...................................................................................................... 125
Refrigerant circuit type WW 302.A125................................................................. 125
Casing type WW 302.A125.................................................................................. 125
Electrical equipment type WW 302.A125............................................................. 125
Parts list type WW 302.A155
Ordering parts...................................................................................................... 127
Refrigerant circuit type WW 302.A155................................................................. 127
Casing type WW 302.A155.................................................................................. 127
Electrical equipment type WW 302.A155............................................................. 127
Parts list type WW 302.A200
Ordering parts...................................................................................................... 129
Refrigerant circuit type WW 302.A200................................................................. 129
Casing type WW 302.A200.................................................................................. 129
Electrical equipment type WW 302.A200............................................................. 129
Parts list type WW 302.A250
Ordering parts...................................................................................................... 131
Refrigerant circuit type WW 302.A250................................................................. 131
Casing type WW 302.A250.................................................................................. 131
Electrical equipment type WW 302.A250............................................................. 131
Parts list type WW 302.A300
Ordering parts...................................................................................................... 133
Refrigerant circuit type WW 302.A300................................................................. 133
Casing type WW 302.A300.................................................................................. 133
Electrical equipment type WW 302.A300............................................................. 133
Commissioning/service reports........................................................................ 135
Specification
Specification type BW 301.A090 to BW 302.A250............................................... 142
Specification type WW 301.A125 to WW 302.A300............................................. 146
Index
Index
5848 164 GB

7
Appendix
Heat pump commissioning request...................................................................... 149
Certificates
Declaration of conformity...................................................................................... 150
Keyword index.................................................................................................... 153
Index
Index (cont.)
5848 164 GB

8
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 piping and instrumentation diagram, con-
nection 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
Life cycle stages
System
operator
Exter-
nal per-
son
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
Operation
X X
Maintenance, repair, decommissioning
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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9
Electrical connections
Danger
Electromagnetic radiation near
the room where the heat pump
control unit is installed can inter-
fere particularly with heart pace-
makers 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 wiring chambers
in the heat pump control unit
and power connections; see
page 53.
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.
■ Always reinstate all earth con-
nections 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 164 GB
Service

10
!Please note
Observe all "Safety instructions"
and information in the chapters
"Routing electrical cables/leads
to the heat pump wiring cham-
ber" (page 51) and "Power con-
nection" (page 71).
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.
■ Always use suitable ropes/
slings and lifting gear when
installing/dismantling com-
pressors 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.
Safety and liability
Occupational safety (cont.)
5848 164 GB

11
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 frost bite and burns.
■ Switch off the heat pump at
least 30 min before working on
it.
■ If at all possible, avoid touching
the injection valve and com-
pressor; wear safety gloves, if
contact is necessary.
■ Wear suitable protective cloth-
ing.
Danger
R410A is a non-poisonous gas
that displaces air. Unregulated
escape of refrigerant R410A in
enclosed spaces can result in dif-
ficulties in breathing and suffoca-
tion.
■ Never breathe in refrigerant
vapours.
■ Ensure adequate ventilation in
enclosed spaces.
■ Prevent open flames.
■ Always observe regulations
and guidelines on handling this
type of refrigerant.
Danger
Direct contact with refrigerant
can be harmful to skin.
■ Only work on the refrigerant cir-
cuit whilst wearing safety gog-
gles and safety gloves.
Note
Work on the refrigerant cir-
cuit must only be carried out by
a qualified refrigeration engi-
neer.
■ Wear suitable protective cloth-
ing.
Safety and liability
Occupational safety (cont.)
5848 164 GB
Service

12
The heat pumps
Vitocal 300-G Pro Release,
type BW 301.A090 to 302.A250 and
Vitocal 300-W Pro Release,
type WW 301.A125 to 302-A300 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 Pro Release must be
operated exclusively by authorised and
trained personnel.
Product information
Vitocal 300-G/W Pro
Heat pump Vitocal 300-G Pro,
type BW
Vitocal 300-W Pro type
WW
Medium Brine/water Water/water
Single stage heat pumps 301.A090
301.A120
301.A125
301.A155
Two-stage heat pumps 302.A090
302.A120
302.A150
302.A180
302.A250
302.A125
302.A155
302.A200
302.A250
302.A300
Criteria:
■ Integral heat pump control unit
Vitotronic 200, type WO1B.
■ 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. instantaneous heat-
ing water heater, immersion heater in
heating water buffer cylinders).
A higher output in connection with addi-
tional Vitocal 300-G Pro/
Vitocal 300-W Pro (cascade) is possi-
ble.
Preparing for installation
Use
5848 164 GB

13
■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 53.
■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 71.
Note
If a Vitocal 300-G/W and
350-G(< 60 kW) is used for DHW heating
only, for example, use new wiring only.
Delivery and installation
■ The Vitocal 300-G/W Pro is delivered
as standard appliance with a separate
palette of side parts.
■ The programming unit of the Vitotronic
200 is delivered loose inside the wiring
chamber and must be fitted and con-
nected on site (page 76).
■ Accessories are delivered separately.
■ The Vitocal 300-G Pro/
Vitocal 300-W Pro are 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 144).
■ Suitable equipment for unloading the
lorry must be available on site, see the
following chapter.
Preparing for installation
General information on electrical connection
5848 164 GB
Installation

14
!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/
Vitocal 300-W Pro and the lift-
ing tackle.
■ Observe correct weight distri-
bution when lifting. The centre
of gravity of the
Vitocal 300-G Pro/
Vitocal 300-W Pro lies through
the heat exchanger on the l.h.
side.
■Always avoid impact and
shocks to prevent damage to
the internal pipework of the
heat pump.
■ Avoid severely tipping the com-
pressor to protect the refriger-
ant circuit. Max. heat pump tilt-
ing angle 30°.
The KWT Kälte-Wärmetechnik AG, a
member of the Viessmann Group, will
not accept any liability for damage
resulting from inappropriate han-
dling.
Preparing for installation
Delivery and installation (cont.)
5848 164 GB

15
Handling by crane
AA
B
C
D
ALifting shackle
BCross beam to remove the load on
the frame
CEdge protection (e.g. two or three
layers of corrugated cardboard)
DStrap approved for the shipping
weight
Preparing for installation
Delivery and installation (cont.)
5848 164 GB
Installation

16
Handling by forklift truck or pallet truck
ASelect a fork length in line with the
heat pump length, see "Specifica-
tion" (page 148).
BCentre 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)
Siting
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Safeguard ambient temperatures
of 0 to 35 °C.
!Please note
Avoid risks of explosion due to
dust, gases and vapours
in the installation room.
Preparing for installation
Delivery and installation (cont.)
5848 164 GB

17
!Please note
Observe the permissible floor
load.
Total weight type
BW 301.A090 to BW 302.A250:
BW 301.A090 740 kg
BW 301.A120 840 kg
BW 302.A090 745 kg
BW 302.A120 850 kg
BW 302.A150 1190 kg
BW 302.A180 1260 kg
BW 302.A250 1375 kg
Total weight type
WW 301.A125 to
WW 302.A300:
WW 301.A125 1040 kg
WW 301.A155 1050 kg
WW 302.A125 1075 kg
WW 302.A155 1085 kg
WW 302.A200 1360 kg
WW 302.A250 1405 kg
WW 302.A300 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 compensa-
ted, distribute the load on the adjusta-
ble 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.A090 54 m3
BW 301.A120 68 m3
BW 302.A090 53 m3
BW 302.A120 68 m3
BW 302.A150 86 m3
BW 302.A180 103 m3
BW 302.A250 141 m3
Minimum room volume type
WW 301.A125 to WW 302.A300:
WW 301.A125 42 m3
WW 301.A155 49 m3
WW 302.A125 42 m3
WW 302.A155 49 m3
WW 302.A200 59 m3
WW 302.A250 65 m3
WW 302.A300 73 m3
■ Observe the required floor area and
minimum clearances (see the follow-
ing chapter).
Preparing for installation
Siting (cont.)
5848 164 GB
Installation

18
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 installing cascades, observe the
relevant minimum clearances.
Preparing for installation
Siting (cont.)
5848 164 GB

19
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 by the minimum clear-
ances (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
EPressure-tested sound insulation
layer, approx. 10 to 20 mm
Pressure points □ of the adjustable heat pump feet
Type BW 301.A090, BW 301.A120, BW 302.A090, BW 302.A120
1400
1000
1064
709
F
E
EPressure-tested sound insulation
layer, approx. 10 mm
FFront of the heat pump
Preparing for installation
Siting (cont.)
5848 164 GB
Installation

20
Type BW 302.A150, WW 301.A125, WW 301.A155, WW 302.A125,
WW 302.A155
2040
1000
709
852 800
F
E
EPressure-tested sound insulation
layer, approx. 10 mm
FFront of the heat pump
Type BW 302.A180, BW 302.A250, WW 302.A200, WW 302.A250,
WW 302.A300
1000
709
2640
F
E
1150 1090
EPressure-tested sound insulation
layer, approx. 10 to 20 mm
FFront of the heat pump
Preparing for installation
Siting (cont.)
5848 164 GB