Viessmann VITOCAL 300-G Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-G
Type BW, 21 to 45 kW
Type BWS, 21 to 45 kW
Type WW, 21 to 45 kW
Compact heat pump with electric drive
Single and two-stage
For applicability, see the last page
VITOCAL 300-G
5728 049 GB 8/2010 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 personnel.
■ 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
■ All legal instructions regarding the pre-
vention of accidents,
■ All legal instructions 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 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.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions
5728 049 GB

3
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.)
5728 049 GB

4
Installation instructions
Preparing for installation
Product information.............................................................................................. 6
General information - electrical connection.......................................................... 7
Installation............................................................................................................ 7
Overview of possible system schemes................................................................ 12
Primary circuit, type BW (brine/water).................................................................. 14
Primary circuit, type WW (water/water)................................................................ 15
Primary circuit, type BW + BWS (two-stage)........................................................ 19
Primary circuit, type WW + BWS (two-stage)....................................................... 23
DHW heating........................................................................................................ 32
Integration of the two-stage version in the system examples............................... 34
System example 1, ID: 4605307_1006_01.......................................................... 39
System example 2, ID: 4605308_1006_01.......................................................... 45
Installation sequence
Installing the heat pump....................................................................................... 56
Hydraulic connections.......................................................................................... 59
Electrical connections in the heat pump control unit............................................ 62
Power supply........................................................................................................ 91
Connecting to terminals X3.8/X3.9....................................................................... 99
Closing the heat pump......................................................................................... 100
Checking diaphragm grommets........................................................................... 101
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 103
Further details regarding the individual steps....................................................... 104
Troubleshooting
Repairs................................................................................................................. 117
Parts lists
Parts list................................................................................................................ 123
Commissioning/service reports........................................................................ 128
Specification....................................................................................................... 134
Appendix
Heat pump commissioning order.......................................................................... 137
Index
Index
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Certificates
Declaration of conformity...................................................................................... 138
Keyword index.................................................................................................... 139
Index
Index (cont.)
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Vitocal 300-G, Type BW
Brine/water heat pump with electronic heat pump control unit Vitotronic 200,
type WO1A
The refrigerant circuit has an electronic expansion valve (EEV) with an independent
control circuit.
The heat pump control unit can activate and control a heating circuit provided on site
for cooling or a separate cooling circuit.
All sensors are fitted inside sensor wells.
For central and DHW heating, an instantaneous heating water heater (on site) can
also be controlled.
The output can be extended in conjunction with heat pump stage 2 (Vitocal 300-G,
type BWS).
Vitocal 300-G, Type WW
The brine/water heat pump type BW with a conversion kit for the primary side
becomes water/water heat pump type WW. For type WW, a separate well circuit
provides the primary circuit with heating energy via a separating heat exchanger
(accessory). The well circuit is also controlled by heat pump control unit
Vitotronic 200, type WO1A.
Vitocal 300-G, Type BWS
The Vitocal 300-G type BWS is used to extend the output (stage 2) of heat pumps
type BW and WW (stage 1).
Heat pump stage 2 (type BWS) can be used both for heating operation and DHW
heating. Accordingly, a second secondary pump or circulation pump for cylinder
heating (on the heating water side) is required.
Heat pump stage 2 (type BWS) does not have its own heat pump control unit and is
controlled by the heat pump control unit Vitotronic 200, type WO1A of the heat pump
stage 1 (type BW, WW).
Heat pump stage 2 (type BWS) has its own refrigerant circuit. This means a separate
power supply is required for every compressor.
With the two-stage version, either a primary pump can be used for every heat pump,
or a common primary pump can be used. Independently, a collective flow and return
temperature sensor is used on the primary side at the common flow and return.
Heat pump stage 2 (type BWS) must be installed to the left of the heat pump stage
1 (type BW, WW).
The hydraulic connection between the two heat pumps is carried out on site.
An instantaneous heating water heater (on site) can only be controlled by heat pump
stage 1 (type BW, WW).
Preparing for installation
Product information
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■Connecting cables, heat pump
stage 1 – stage 2:
See page 65.
■Electrical connection of system
components (pumps, mixers, valves,
alarm facilities, contactors, function
extensions, sensors, etc.):
These connections are made inside
the heat pump control unit. Observe
information from page 67.
■Power supply:
The number of power cables from the
distribution board (meter box) to the
heat pump control unit and to the con-
trol panel depends on the system ver-
sion and tariffs used.
These connections are made inside
the heat pump control panel. Observe
information from page 91.
Installation
For handling purposes, the heat pump
module can be removed (see
page 120).
!Please note
Avoid damaging the appliance
during handling.
Never put weight on top of the
appliance.
!Please note
If the compressor is at a steep
angle in the heat pump, lubricant
will enter the refrigerant circuit
and damage the appliance.
Max. tilting angle 45°.
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 ºC.
!Please note
Avoid risk of explosion due to
dust, gases and vapours
in the installation room.
!Please note
Observe the permissible floor
load.
■Total weight
BW 121 282 kg
BWS 121 277 kg
BW 129 305 kg
BWS 129 300 kg
BW 145 345 kg
BWS 145 340 kg
Preparing for installation
General information - electrical connection
5728 049 GB
Installation

8
■ To prevent structure-borne noise,
never site the appliance 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 the required floor area and
minimum room volume (as per
DIN EN 378).
Type Floor area Min. space requirement
BW 121
BWS 121
5 m214 m3
BW 129
BWS 129
7 m217 m3
BW 145
BWS 145
9 m2123 m3
■ Observe required minimum clearan-
ces:
Single stage (type BW)
≥ 400 ≥ 400
≥ 1500
A
AClearance depends on on-site
installation and location
Preparing for installation
Installation (cont.)
5728 049 GB

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Two-stage (type BW + BWS)
≥ 400
≥ 1500
A
= 300
≥ 400
AClearance depends on on-site
installation and location
Preparing for installation
Installation (cont.)
5728 049 GB
Installation

10
Requirements - on-site connections
Single stage (type BW)
86
100
270
540
780
171
301
88
1315
230
400 V
230 V < 42 V
Preparing for installation
Installation (cont.)
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Two-stage (type BW + BWS)
= 300
88
1315
100
270
540
780
86 171
301
230
100
270
540
780
230
400 V
230 V < 42 V
400 V
230 V < 42 V
■ Install hydraulic connections on site
stress-free.
■ Establish hydraulic connections
between the two heat pumps (type
BW/BWS) on site.
■ All required components (with a suita-
bly designed plate heat exchanger) for
the cooling circuit must be provided on
site.
Preparing for installation
Installation (cont.)
5728 049 GB
Installation

12
Line lengths in the heat pump plus wall clearance:
Type BW BWS
Heat pump control unit
power supply (230 V~)
1.0 m A connecting cable is used
for the power supply
Compressor power supply
(400 V~)
1.0 m 1.0 m
Additional power cables 1.5 m Connecting cable
Recommended power cables:
Type Heat pump con-
trol unit (230 V~)
Compressor (400 V~)
Max. cable length
BW121 3 x 1.5 mm 2 4 x 2.5 mm 2 50 m
BWS 121 — 4 x 2.5 mm 2 50 m
BW 129 3 x 1.5 mm 2 4 x 4.0 mm 2 50 m
BWS 129 — 4 x 4.0 mm 2 50 m
BW 145 3 x 1.5 mm 2 4 x 6.0 mm 2 40 m
BWS 145 — 4 x 6.0 mm 2 40 m
Note
An instantaneous heating water heater
(on site) can only be installed outside
the heat pump. The flow temperature
sensor system must be installed in the
direction of flow downstream of the
instantaneous heating water heater.
Overview of possible system schemes
The following table provides an overview
of all possible system schemes.
Selected system schemes are explained
using system examples (see from
page 39).
Preparing for installation
Installation (cont.)
5728 049 GB

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Components System scheme (parameter 7000)
0 1 2 3 4 5 6 7 8 9 10 11
Heating circuit
A1 – X X – – X X – – X X –
M2 – – – X X X X X X X X –
M3 – – – – – – – X X X X –
DHW cylinder
X – X – X – X – X — X –
Heating water buffer cylinder
– 0 0 X X X X X X X X –
External heat source
00*1 0*1 0 0 0 0 0 0 0 0 –
Instantaneous heating water heater
0 0 0 0 0 0 0 0 0 0 0 –
Swimming pool
– 0 0 0 0 0 0 0 0 0 0 –
Solar thermal system
(with integral solar control module of the Vitotronic or with the Vitosolic 200)
0–0–0–0–0–0–
Cooling
A1 – 0 0 – – 0 0 – – 0 0 –
M2 – – – 0 0 0 0 0 0 0 0 –
M3 – – – – – – – 0 0 0 0 –
Sep. cooling circuit 0 0 0 0 0 0 0 0 0 0 0 –
X Components selected.
0Components can be added.
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5728 049 GB
Installation

14
Hydraulic installation scheme
wP P
wW
wQ
P
wU
qT
1
2
P
PPrimary circuit interface
Required equipment
Pos. Designation
1Heat pump
2Heat pump control unit
qT Primary pump
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Brine distributor for geothermal probes/collectors
wU Geothermal probes/collectors
Electrical installation scheme
Overview of electrical connections and
details regarding the PCBs, see from
page 67 and the separate service
instructions, Vitotronic 200 heat pump
control unit.
Preparing for installation
Primary circuit, type BW (brine/water)
5728 049 GB

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P230 V; 0.15 A wQ
2
M
1~ qT
UP
X3.9
?
X1.
X3.8
230 V / 50 Hz
?
X1.
X2.N
200 W
sYYA
.
Primary circuit, type WW (water/water)
Hydraulic installation scheme
wU wI
wZ
wW
wE
wR
wP
qT
qO
1
2
P
wQ
P
P
PPrimary circuit interface
Preparing for installation
Primary circuit, type BW (brine/water) (cont.)
5728 049 GB
Installation

16
Equipment required
Pos. Designation
1Heat pump
2Heat pump control unit
qT Primary pump
qO Frost stat, primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Separating heat exchanger, primary circuit
wE Flow limiter, well circuit (remove jumper when connecting)
wR Dirt trap
wZ Well pump (suction pump for groundwater; connect via on-site contactor
with fuse protection)
■ 230 V connection: See page 17
■ 400 V connection: See page 18
wU Delivery well
wI Return well
Electrical installation scheme
Overview of electrical connections and
details regarding the PCBs, see from
page 67 and the separate service
instructions, Vitotronic 200 heat pump
control unit.
Preparing for installation
Primary circuit, type WW (water/water) (cont.)
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With well pump connection 230 V~
X3.3
230 V; 2mA
?
X1.
X3.4
´
X3.9
?
X1.
X3.8
P
wE
230 V; 0.15 A wQ
230 V; 0.15 A qO
M
1~ qT
2
UP
K1
L1?
M
1~ wZ
UP
N
230 V / 50 Hz
X2.N
?
X1.
200 W
sYYA
.
Preparing for installation
Primary circuit, type WW (water/water) (cont.)
5728 049 GB
Installation

18
Well pump on-site connection 400 V
M
1~
2
UP
200 W
L1 L2 L3
M
3~
?
UP
I>I>I>
wZ
qT
K1
X2.N
?
X1.
sYYA
.
Preparing for installation
Primary circuit, type WW (water/water) (cont.)
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With two primary pumps
Hydraulic installation scheme
wW
9
wU
1
2
wP P
wQ
PP
wQ
P
qZ
qU
P
wT qT
PPrimary circuit interface
Equipment required
Pos. Designation
1Heat pump stage 1
2Heat pump control unit
9Heat pump stage 2
qT Primary pump, heat pump stage 1
qZ Flow temperature sensor, primary circuit
qU Return temperature sensor, primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Brine distributor, geothermal probes/collectors
wT Primary pump, heat pump stage 2
wU Geothermal probes/collectors
Preparing for installation
Primary circuit, type BW + BWS (two-stage)
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Installation

20
Electrical installation scheme
Overview of electrical connections and
details regarding the PCBs, see from
page 67 and the separate service
instructions, Vitotronic 200 heat pump
control unit.
P230 V; 0.15 A wQ
qZ
Pt 500
12
qU
Pt 500
13
2
M
1~ wT
UP
M
1~ qT
UP
X3.9
?
X1.
X3.8
Low voltage 230 V / 50 Hz
?
X1.
X2.N
?
X1.
X2.N
200 W
200 W
[G
X
[G
X
sYYA
.
sXVS
.
With a common primary pump
Note
If heat pumps stage 1 and 2 (types BW
and BWS) are installed with different
rated outputs, the different flow rates
mean that two primary pumps must be
used (see page 19).
Preparing for installation
Primary circuit, type BW + BWS (two-stage) (cont.)
5728 049 GB