Viessmann VITOCAL 300-G PRO Type BW 2150 Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-G Pro
Type BW 190, 1120, 2150, 2180, 2250
Vitocal 300-W Pro
Type WW 1125, 1155, 2200, 2250, 2300
See also the "Vitocal 300-W Pro installation and service instructions,
supplements".
For applicability, see the last page
VITOCAL 300-G PRO
VITOCAL 300-W PRO
5772 458 GB 11/2011 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
designed for qualified contractors.
■ Work on the refrigerant circuit must
only be carried out by qualified and
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 requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental 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 and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can lead to severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Before removing covers from
appliances, wait at least 4
minutes for the power to dissi-
pate.
■ Safeguard the system against unau-
thorised reconnection
Safety instructions
Safety instructions
5772 458 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
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.
Replace faulty components only
with original 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.)
5772 458 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
Installation............................................................................................................ 14
Primary circuit: brine/water, 1-stage..................................................................... 24
Primary circuit: brine/water, 2-stage..................................................................... 25
Primary circuit: brine/water, cascade................................................................... 27
Primary circuit: water/water, 1-stage/2-stage....................................................... 29
Primary circuit: water/water, cascade................................................................... 31
Heat pump cascade: 1-stage/2-stage.................................................................. 33
DHW heating........................................................................................................ 36
Installation sequence
Installing the heat pump....................................................................................... 38
Hydraulically connecting the primary/secondary circuits...................................... 42
Routing cables to the heat pump terminal area.................................................... 48
Overview of electrical connections....................................................................... 50
Power supply........................................................................................................ 67
Installing the programming unit............................................................................ 72
Closing the heat pump......................................................................................... 73
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 75
Further details regarding the individual steps....................................................... 76
Troubleshooting
Repairs................................................................................................................. 89
Parts list, type BW 190
Ordering parts...................................................................................................... 95
Refrigerant circuit, type BW 190........................................................................... 95
Casing, type BW 190............................................................................................ 95
Electrical equipment, type BW 190...................................................................... 96
Index
Index
5772 458 GB

5
Parts list, type BW 1120
Ordering parts...................................................................................................... 97
Refrigerant circuit, type BW 1120......................................................................... 97
Casing, type BW 1120.......................................................................................... 97
Electrical equipment, type BW 1120.................................................................... 98
Parts list, type BW 2150
Ordering parts...................................................................................................... 99
Refrigerant circuit, type BW 2150......................................................................... 99
Casing, type BW 2150.......................................................................................... 99
Electrical equipment, type BW 2150.................................................................... 100
Parts list, type BW 2180
Ordering parts...................................................................................................... 101
Refrigerant circuit, type BW 2180......................................................................... 101
Casing, type BW 2180.......................................................................................... 101
Electrical equipment, type BW 2180.................................................................... 102
Parts list, type BW 2250
Ordering parts...................................................................................................... 103
Refrigerant circuit, type BW 2250......................................................................... 103
Casing, type BW 2250.......................................................................................... 103
Electrical equipment, type BW 2250.................................................................... 104
Parts list, type WW 1125 to WW 2300
Parts list, type WW 1125 to WW 2300................................................................. 105
Commissioning/service reports........................................................................ 106
Specification
Specification, type BW 190 to BW 2250............................................................... 112
Specification, type WW 1125 to WW 2300........................................................... 115
Appendix
Heat pump commissioning order.......................................................................... 116
Certificates
Declaration of conformity...................................................................................... 117
Keyword index.................................................................................................... 119
Index
Index (cont.)
5772 458 GB

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 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
5772 458 GB

7
Electrical connections
Danger
Electromagnetic radiation near
the room where the heat pump
control unit is installed can par-
ticularly interfere 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 [IEE or local
regulations]
■ Technical connection require-
ments of 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 terminal areas in
the heat pump control unit and
power connections; see
page 50.
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 connected to the equipoten-
tial bonding of the building.
Safety and liability
Occupational safety
5772 458 GB
Service

8
!Please note
Observe all "Safety instructions"
and information in the chapters
"Routing electrical cables/leads
to the heat pump installation
room" (page 48) and "Power
connection" (page 67).
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.)
5772 458 GB

9
Work on the refrigerant circuit
Danger
Heat pump refrigerant circuits
feature extremely low (–25 °C)
and extremely 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 protective
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.
■ Observe and adhere to regula-
tions and guidelines about han-
dling refrigerant.
Danger
Direct contact with refrigerant
can harm skin.
■ Only work on the refrigerant cir-
cuit whilst wearing safety gog-
gles and 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.)
5772 458 GB
Service

10
The heat pumps Vitocal 300-G Pro,
type BW 190 to 2250 and
Vitocal 300-W Pro,
type WW 1125 to 2300 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 and
Vitocal 300-W Pro must be operated
exclusively by authorised and trained
personnel.
Product information
Vitocal 300-G Pro, Vitocal 300-W Pro
Heat pump Vitocal 300-G Pro Vitocal 300-W Pro
Medium Brine/water Water/water
Single stage heat pumps Type BW
190, 1120
Type WW
1125, 1155
Two-stage heat pumps Type BW
2150, 2180, 2250
Type WW
2200, 2250, 2300
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.
■ Electrical booster heaters (on-site)
can be switched (e.g. instantaneous
heating water heater, immersion
heater in heating water buffer cylin-
ders).
A higher output in connection with addi-
tional Vitocal 300-G Pro/
Vitocal 300-W Pro (cascade) is possi-
ble.
Preparing for installation
Use
5772 458 GB

11
■Electrical connection of system
components (pumps, mixers, valves,
alarm facilities, contactors, function
extensions, sensors etc.):
Connections are made inside the heat
pump terminal area. Observe informa-
tion from page 50.
■Power supply:
The number of power cables from the
meter box to the heat pump terminal
area depends on the system version
and tariffs used. See information from
page 67.
Note
If a Vitocal 300-G/350-G (< 60 kW) is
used for DHW heating only, for example,
use new wiring only.
Delivery and installation
■ The Vitocal 300-G Pro/
Vitocal 300-W Pro are delivered fully
assembled.
■ The programming unit of the Vitotronic
200 is delivered loose inside the ter-
minal area and must be fitted and con-
nected on site (page 72).
■ Accessories, such as the flow switch
and temperature sensors, for exam-
ple, are supplied separately.
■ The Vitocal 300-G Pro/
Vitocal 300-W Pro are filled with oil
and refrigerant at the factory.
Unloading and transportation
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".
■ Suitable equipment for unloading must
be available on site, see the following
chapter.
Preparing for installation
General information on the electrical connection
5772 458 GB
Installation

12
!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 safeguard the refrig-
erant circuit. Max. heat pump
tilting angle 30°.
The KWT Kälte-Wärmetechnik
AG company, which is a member of
the Viessmann Group, will not be lia-
ble for any damage resulting from
inappropriate handling.
Preparing for installation
Delivery and installation (cont.)
5772 458 GB

13
Handling by crane
B
C
A
D
ALifting shackle
BCross beams 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.)
5772 458 GB
Installation

14
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".
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)
Installation
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 the risk of explosion due to
dust, gases and vapours
in the installation room.
!Please note
Observe the permissible floor
load.
Total weight, type BW 190 to
BW 2250:
BW 190 720 kg
BW 1120 820 kg
BW 2150 1180 kg
Preparing for installation
Delivery and installation (cont.)
5772 458 GB

15
BW 2180 1240 kg
BW 2250 1360 kg
Total weight type WW 1125 to
WW 2300
"Vitocal 300-W Pro installation
and service instructions, supple-
ments".
■ 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 minimum room volume (to
DIN EN 378).
Note
Additional country-specific regulations
also apply.
Min. room volume, type BW 190 to
BW 2250:
BW 190 54 m3
BW 1120 68 m3
BW 2150 86 m3
BW 2180 103 m3
BW 2250 141 m3
Min. room volume
type WW 1125 to WW 2300
"Vitocal 300-W Pro installation
and service instructions, sup-
plements".
■ Observe the required floor area and
minimum clearances (see the follow-
ing chapter).
Minimum clearances
E
>250
>600
1500
AC
B
D
E
>250
>500
10001000
B
AC
D
D
AClearance depends on on-site
installation and location.
BObserve clearances required for
installation and maintenance.
CCable entries.
On-site strain relief clamps required
(wall clearance ≥ 80 mm).
Preparing for installation
Installation (cont.)
5772 458 GB
Installation

16
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■ With fitted door hinge on the heat
pump:
≥ 910 mm
■ Without fitted door hinge on the
heat pump (removed on site):
≥ 890 mm
1000 600
D
1000
4360
E
D
Note
When installing cascades, observe the
relevant minimum clearances.
Sound attenuating plinth
Position the heat pump on a base pre-
pared on site for the purpose of noise
attenuation and uniform weight distribu-
tion.
Note
In the case of corner installation, enlarge
the base by the minimum clearances
(see previous chapter).
Preparing for installation
Installation (cont.)
5772 458 GB

17
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 190, BW 1120
1380
980
1118
718
F
E
EPressure-tested sound insulation
layer, approx. 10 to 20 mm
FFront of the heat pump
Preparing for installation
Installation (cont.)
5772 458 GB
Installation

18
Type BW 2150
2020
980
718
965 793
F
E
EPressure-tested sound insulation
layer, approx. 10 to 20 mm
FFront of the heat pump
Type BW 2180, BW 2250, WW 1125, WW 1155, WW 2200, WW 2250, WW 2300
980
1265 1093
718
2620
F
E
EPressure-tested sound insulation
layer, approx. 10 to 20 mm
FFront of the heat pump
Preparing for installation
Installation (cont.)
5772 458 GB

19
Requirements for on-site connections
Dimensions, type BW 190 to BW 2250
Type BW 190, BW 1120
1400
1560
1650
370
328
533
1060
1256
490
1280
880
400V~
230V~
<42V
400V~
230V~
<42V
A
B
C
D
APrimary circuit brine inlet:
Victaulic 3"
BSecondary circuit flow:
Victaulic 2½"
CPrimary circuit brine outlet:
Victaulic 3"
DSecondary circuit return:
Victaulic 2½"
Preparing for installation
Installation (cont.)
5772 458 GB
Installation

20
Type BW 2150
400V~
230V~
<42V
328
1650
1560
1256
1060
533
370
1400
1920
880
490
400V~
230V~
<42V
A
B
C
D
APrimary circuit brine inlet:
Victaulic 3"
BSecondary circuit flow:
Victaulic 2½"
CPrimary circuit brine outlet:
Victaulic 3"
DSecondary circuit return:
Victaulic 2½"
Preparing for installation
Installation (cont.)
5772 458 GB