Viessmann VITOCAL 300-G Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-G
Type BW/BWS 301.A06 to A17, 5.9 to 17.0 kW
Type WW 301.A06 to A17, 7.9 to 23.0 kW
Heat pump, single and two-stage
Type BWC 301.A06 to A17, 5.9 to 17 kW
Type WWC 301.A06 to A17, 7.9 to 23 kW
Heat pump, single stage
For applicability, see the last page
VITOCAL 300-G
5600 161 GB 12/2010 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
5600 161 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.)
5600 161 GB

4
Installation instructions
Preparing for installation
General information - electrical connection.......................................................... 6
Installation............................................................................................................ 6
Overview of possible system schemes................................................................ 12
Primary circuit, type BW 301.A, BWC 301.A (brine/water)................................... 14
Primary circuit, type WW 301.A, WWC 301.A (water/water)................................ 16
Primary circuit, type BW 301.A + BWS 301.A (two-stage, brine/water)............... 19
Primary circuit, type WW 301.A + BWS 301.A (two-stage, water/water)............. 24
DHW heating........................................................................................................ 32
Integration of the two-stage version in the system examples............................... 36
Integrating a heat pump cascade into the system examples............................... 38
System example 1, ID: 4605350_1008_01.......................................................... 42
System example 2, ID: 4605351_1008_01.......................................................... 48
System example 3, ID: 4605352_1008_01.......................................................... 54
Installation sequence
Siting the heat pump............................................................................................ 64
Hydraulic connections.......................................................................................... 66
Electrical connections........................................................................................... 68
Power supply........................................................................................................ 94
Connecting to terminals X3.8/X3.9....................................................................... 102
Closing the heat pump......................................................................................... 103
Checking diaphragm grommets........................................................................... 104
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 105
Further details regarding the individual steps....................................................... 106
Troubleshooting
Repairs................................................................................................................. 119
Parts lists
Parts lists.............................................................................................................. 126
Overview of the assemblies................................................................................. 127
Parts not shown.................................................................................................... 128
Assembly, casing................................................................................................. 128
Assembly, hydraulics............................................................................................ 132
Assembly, heat pump module.............................................................................. 136
Assembly, electrical equipment............................................................................ 138
Index
Index
5600 161 GB

5
Commissioning/service reports........................................................................ 146
Specification....................................................................................................... 152
Appendix
Heat pump commissioning order.......................................................................... 161
Certificates
Declaration of conformity...................................................................................... 162
Keyword index.................................................................................................... 163
Index
Index (cont.)
5600 161 GB

6
■Connecting cables, heat pump
stage 1 – stage 2:
See page 71.
■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 72.
■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 94.
Installation
!Please note
Avoid damaging the appliance
during transportation.
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 301.A06 113 kg
BWS 301.A06 109 kg
BWC 301.A06 123 kg
BW 301.A08 117 kg
BWS 301.A08 113 kg
BWC 301.A08 127 kg
BW 301.A10 129 kg
BWS 301.A10 125 kg
BWC 301.A10 139 kg
BW 301.A13 135 kg
BWS 301.A13 131 kg
BWC 301.A13 145 kg
Preparing for installation
General information - electrical connection
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7
BW 301.A17 148 kg
BWS 301.A17 144 kg
BWC 301.A17 158 kg
■ To prevent structure-borne noise,
never site the appliance on ceilings
with wooden joists (e.g. in the attic).
■ Level the appliance horizontally.
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 (to
DIN EN 378).
Type Min. space
requirement
BW 301.A06
BWS 301.A06
BWC 301.A06
3.5 m3
BW 301.A08
BWS 301.A08
BWC 301.A08
4.3 m3
BW 301.A10
BWS 301.A10
BWC 301.A10
5.5 m3
BW 301.A13
BWS 301.A13
BWC 301.A13
5.9 m3
BW 301.A17
BWS 301.A17
BWC 301.A17
8.0 m3
■ Observe required minimum clearan-
ces:
Single stage (type BW 301.A, BWC
301.A)
≥ 400
≥ 1500
A
B
Preparing for installation
Installation (cont.)
5600 161 GB
Installation

8
Two-stage (type BW 301.A + BWS 301.A)
≥ 400
A
= 100
≥ 1500
B
A■ With hydraulic module (acces-
sory, for installation above the
heat pump):
340 mm
■ Without hydraulic module:
subject to on-site installation and
location
B■ With AC-Box (accessory, for
installation to the left of the heat
pump):
≥ 400 mm (+ width of the AC-Box)
■ Without AC-Box:
≥ 100 mm
Preparing for installation
Installation (cont.)
5600 161 GB

9
Information on the use of accessories
for a heating/cooling circuit or sepa-
rate cooling circuit
AC-Box for active cooling function
■ The AC-Box can only be used up to a
rated heating output of
≤
17.6 kW. For
higher rated heating outputs, install all
the components required on site (with
correspondingly sized plate heat
exchanger) for the heating/cooling cir-
cuit or the separate cooling circuit.
NC-Box for natural cooling function
■ The NC-Box can only be used up to a
rated heating output of
≤
16 kW. For
higher rated heating outputs, install all
the components required on site (with
correspondingly sized plate heat
exchanger) for the heating/cooling cir-
cuit or the separate cooling circuit.
■ In two-stage heat pumps, the NC-Box
cannot be installed immediately
above the heat pump. The hydraulic
connection lines between heat pump
stage 1 and heat pump stage 2 are
installed above the heat pumps.
Preparing for installation
Installation (cont.)
5600 161 GB
Installation

10
Requirements for on-site connections
Single stage (type BW 301.A, BWC 301.A)
77
105
152
240
300
419
476
533
600
230 V
+
< 42 V
133
576
662662
727
792
888
962
Preparing for installation
Installation (cont.)
5600 161 GB

11
Two-stage (type BW 301.A + BWS 301.A)
77
105
152
240
300
419
476
533
600
230 V
+
< 42 V
77
105
152
240
300
419
476
533
600
+
< 42 V
105
152
240
300
419
476
533
600
105
152
240
300
419
476
533
600
77
230 V
< 42 V
230 V
+
133
576
662662
727
792
888
962
Install hydraulic connections on site
stress-free.
Line lengths in the heat pump plus wall clearance:
Type BW 301.A and BWC
301.A
BWS 301.A
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 1.0 m Connecting cable
Preparing for installation
Installation (cont.)
5600 161 GB
Installation

12
Recommended power cables for all
types:
■ Heat pump control unit (230 V~):
3 x 1.5 mm2 (5 x 1.5 mm2 with power-
OFF)
■ Compressor (400 V~):
5 x 2.5 mm2
Max. lead length:
50 m
■ Instantaneous heating water heater
(400 V~, if installed):
5 x 2.5 mm2
Max. lead length:
50 m
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 42).
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 –
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Installation (cont.)
5600 161 GB

13
X Components selected.
0Components can be added.
Preparing for installation
Overview of possible system schemes (cont.)
5600 161 GB
Installation

14
Hydraulic installation scheme
22
27
1
15 64
2
--KM BUS--
--X3.8;3.9--
--230V--
P1
P1
7
20
21
--2/X3.8;3.9--
P
Note
Type BWC 301.A is shown. The circulation pumps are installed and connected at the
factory (primary pump qT, secondary pump 6, circulation pump for cylinder heating
7, instantaneous heating water heater 4 optional).
In type BW 301.A, no circulation pumps are installed at the factory. For the connection
of primary pump qT, see "Primary circuit, type BW 301.A + BWS 301" (page 19).
Preparing for installation
Primary circuit, type BW 301.A, BWC 301.A (brine/water)
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15
Required equipment
Pos. Description
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
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 72 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
X1.
X3.8
X3.9
230 V / 50 Hz
230 V; 0.15 A 21
2
Preparing for installation
Primary circuit, type BW 301.A, BWC 301.A… (cont.)
5600 161 GB
Installation

16
Hydraulic installation scheme
19
24
26
28 1
22
20
2
--KM BUS--
--X3.8;3.9--
--211.1--
--230V--
--2/X3.8;3.9--
--2/211.1--
27
---------
P1
P1
--2/X3.3;3.4--
23
--X3.3;3.4--
21
--2/X3.8;3.9--
15 64
7
P
Note
Type WWC 301.A is shown. The circulation pumps are installed and connected at
the factory (primary pump qT, secondary pump 6, circulation pump for cylinder
heating 7, instantaneous heating water heater 4 optional).
In type WW 301.A, no circulation pumps are installed at the factory. For the connec-
tion, see "Electrical installation scheme".
Preparing for installation
Primary circuit, type WW 301.A, WWC 301.A (water/water)
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Equipment required
Pos. Description
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 18
■ 400 V connection: See page 18
wU Delivery well
wI Return well
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 72 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
Preparing for installation
Primary circuit, type WW 301.A, WWC 301.A… (cont.)
5600 161 GB
Installation

18
With well pump connection 230 V~
X1.
X2.N
UP
UP
26
2
N
L
15
200 W
26
N
L1
X1.
X3.4
X3.3
X1.
X3.8
X3.9
230 V / 50 Hz
230 V; 2 mA 23
230 V; 0.15 A 21
230 v; 0.15 A 19
K1
211.1
M
1~
M
1~
Well pump on-site connection 400 V~
X1.
X2.N
UP
UP
M
3~ 26
2
N
L
15
200 W
26
L1
230 V / 50 Hz
K1
211.1
L2 L3
M
1~
Preparing for installation
Primary circuit, type WW 301.A, WWC 301.A… (cont.)
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With two primary pumps
Hydraulic installation scheme
22
27
9
20
21
--2/X3.8;3.9--
1
2
--KM BUS--
--X3.8;3.9--
--230V--
P1 P1
P1 P1
--F2--
16
--2/224.2-- --2/211.1--
--F3--
17
--F2--
--211.1-- --F3--
--224.2--
25 15
P
Preparing for installation
Primary circuit, type BW 301.A + BWS 301.A (two-stage, brine/water)
5600 161 GB
Installation

20
Equipment required
Pos. Description
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
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 72 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
X1.
X2.N UP
2
15
200 W
X1.
X3.8
X3.9
230 V / 50 Hz
230 V; 0.15 A 21
211.1
X1.
X2.N UP 25
200 W
224.2
F2
Low voltage
16
PT500
F3
17
12
PT500
13
M
1~
M
1~
Preparing for installation
Primary circuit, type BW 301.A + BWS 301.A… (cont.)
5600 161 GB