Viessmann VITOCAL 300-G Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitocal 300-G
Type BW/BWS 301.A21 to A45
Heat pump with electric drive, 1- and 2-stage
■Brine/water heat pump: 21.2 to 85.6 kW
■With conversion kit to water/water heat pump: 28.1 to 117.8 kW
VITOCAL 300-G
5546256 GB 9/2018 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised 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 electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply, 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 PCBs
remain live even after the power supply has
been switched off.
Prior to removing covers from the appliances,
wait at least 4 minutes until the voltage has
completely dropped out.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the appliance, fit-
tings or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5546256

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Safety instructions
Safety instructions (cont.)
5546256

4
1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
■Type BW 301.A ................................................................................... 7
■Type BWS 301.A (heat pump stage 2) ............................................... 7
■System examples ............................................................................... 8
2. Preparing for installation Requirements regarding on-site connections ........................................ 9
■1-stage: Type BW 301.A ..................................................................... 9
■2-stage: Type BW 301.A + BWS 301.A .............................................. 10
Siting and transport requirements .......................................................... 11
■Transport ............................................................................................ 11
■Installation room requirements ........................................................... 11
3. Installation sequence Positioning the heat pump ..................................................................... 13
■Levelling the heat pump ..................................................................... 13
■Removing the transport brackets ........................................................ 13
■Removing the top panel ...................................................................... 14
Making the hydraulic connections .......................................................... 15
■Connecting the primary circuit ............................................................ 15
■Connecting the secondary circuit ....................................................... 16
Electrical connection .............................................................................. 16
■Preparing the electrical connections ................................................... 16
■Installing the programming unit (type BW 301.A) ............................... 17
■Routing cables to the wiring chamber ................................................ 18
■Make the electrical connection of heat pump stage 1 (type
BW 301.A) and stage 2 (type BWS 301.A) ......................................... 20
■Overview of electrical connections in the heat pump control unit
(type BW 301.A) ................................................................................. 21
■Main PCB (function components 230 V~) .......................................... 21
■Expansion PCB on main PCB (230 V~ components) ......................... 25
■Cross connect PCB (message and safety connections) .................... 28
■Controller and sensor PCB (sensors) ................................................. 31
■Connecting the primary circuit flow/return temperature sensor, 2-
stage heat pump ................................................................................. 32
■Swimming pool heating ...................................................................... 33
Power supply ......................................................................................... 33
■Heat pump control unit power supply 230 V~ ..................................... 34
■Compressor power supply (400 V~) ................................................... 35
■Power supply with power-OFF: Without on-site load disconnect ....... 35
■Power supply with power-OFF: With on-site load disconnect ............ 37
■Mains power supply in conjunction with on-site power consumption . 40
■Smart Grid .......................................................................................... 40
■Phase monitor (if installed) ................................................................. 42
Make connections at terminals X3.8/X3.9 ............................................. 43
Closing the heat pump ........................................................................... 43
Checking the diaphragm grommets ....................................................... 46
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 47
5. Maintenance Overview of wiring chamber .................................................................. 62
■Type BW 301.A ................................................................................... 62
■Type BWS 301.A ................................................................................ 63
Opening the casing door ........................................................................ 63
Overview of internal components .......................................................... 64
Draining the heat pump on the primary/secondary side ........................ 64
Checking the sensors ............................................................................ 64
■Viessmann NTC 10 kΩ (blue marking) ............................................... 66
Index
Index
5546256

5
■Viessmann Pt500A (green marking) ................................................... 67
Checking fuses ...................................................................................... 67
Appliance too noisy ................................................................................ 68
Condensation and humidity in the heat pump module .......................... 68
Removing the heat pump module .......................................................... 69
Installing the heat pump module ............................................................ 71
6. Parts list type BW 301.A Overview of assemblies ......................................................................... 73
Casing .................................................................................................... 74
Electrical equipment .............................................................................. 76
Heat pump module ................................................................................ 78
Base frame ............................................................................................ 80
Miscellaneous ........................................................................................ 82
7. Parts list, type BWS 301.A Overview of assemblies ......................................................................... 84
Casing .................................................................................................... 88
Electrical equipment .............................................................................. 90
Heat pump module ................................................................................ 92
Base frame ............................................................................................ 94
Miscellaneous ........................................................................................ 96
8. Commissioning/service
reports
Hydraulic parameters report .................................................................. 98
Control parameter report ....................................................................... 98
9. Specification Specification for brine/water heat pumps ...............................................109
Specification for water/water heat pumps .............................................. 111
10. Appendix Commissioning order ............................................................................. 112
Final decommissioning and disposal ..................................................... 112
11. Certificates Declaration of conformity ....................................................................... 113
12. Keyword index ................................................................................................................ 114
Index
Index (cont.)
5546256

6
Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions.
Depending on the version, the appliance can only be
used for the following purposes:
■Central heating
■Central cooling
■DHW heating
Information
Disposal of packaging
5546256
Information

7
The range of functions can be extended with additional
components and accessories.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than central heating/cooling or DHW heating shall be
deemed inappropriate.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic or
semi-domestic use, i.e. even users who have not had
any instruction are able to operate the appliance
safely.
Product information
Type BW 301.A
Structure
Vitocal 300-G, type BW 301.A are brine/water heat
pumps for central heating, room cooling and DHW
heating in mono mode or mono energetic systems.
The refrigerant circuit has an electronic expansion
valve (EEV) with an independent control circuit (refrig-
erant circuit controller).
For central heating and DHW heating, an instantane-
ous heating water heater (on site) can also be control-
led.
Output extension
The output of type BW 301.A can be supplemented
with a heat pump stage 2 (type BWS 301.A).
Hydraulics
For type BW 301.A, high efficiency circulation pumps
for the primary and secondary circuits and a high effi-
ciency circulation pump for DHW heating are available
as accessories.
Conversion to water/water heat pump
The Vitocal 300-G brine/water heat pump, type BW
301.A, becomes a water/water heat pump in conjunc-
tion with the conversion kit (accessories). A separate
well circuit provides the primary circuit with heating
energy via a separating heat exchanger (accessories).
The components of the well circuit and primary circuit
are controlled by the heat pump control unit.
Central heating
The heat pump can supply up to 3 heating circuits –
1 heating circuit without and 2 heating circuits with
mixer. The mixer extension kit (accessories) is
required to control the mixer for the second heating cir-
cuit with mixer.
Room cooling
Rooms can be cooled either via 1 heating/cooling cir-
cuit or 1 separate cooling circuit. Hydraulic compo-
nents need to be provided on site for this purpose.
Heat pump control unit
The entire system is monitored and controlled by the
integral Vitotronic 200 heat pump control unit,
type WO1C.
Type BWS 301.A (heat pump stage 2)
Heat pump stage 2 is used to extend the output of type
BW 301.A (heat pump stage 1).
Note
Heat pump stage 2 must be installed to the left of heat
pump stage 1.
Information
Intended use (cont.)
5546256
Information

8
Design
Heat pump stage 2 has a separate refrigerant circuit
with refrigerant circuit controller, but no separate heat
pump control unit. Stage 2 is switched via the heat
pump control unit of stage 1.
Hydraulics
On the primary side of a 2-stage version, either use a
separate primary pump for each stage, or use a
shared primary pump. Irrespective of this, the flow and
return temperature sensors are installed in the primary
circuit on the shared flow and return.
Depending on the hydraulic connection, heat pump
stage 2 can be used both for central heating and for
DHW heating. A separate secondary pump and circu-
lation pump for cylinder heating (both accessories) are
therefore required for the heat pump stage 2.
System examples
Available system examples: See www.viessmann-
schemes.com.
Information
Product information (cont.)
5546256
Information

9
1-stage: Type BW 301.A
87
780
230
540
270
773
400 V~
230 V~
<42 V
903
988
1074
1267
100
1026
1086
400 V~
230 V~<42 V
A
BC
D
BCD A
Fig. 1
A
+
Secondary circuit return
B
+
Secondary circuit flow
CPrimary circuit flow (heat pump brine in-
let)
DPrimary circuit return (heat pump brine
outlet)
Preparing for installation
Requirements regarding on-site connections
5546256
Installation

10
2-stage: Type BW 301.A + BWS 301.A
87
780 780
230
540
270
1026
230
540
270
773
773
300
400 V~
230 V~< 42 V
400 V~
230 V~
< 42 V
903
988 1074
1086
100
400 V~
230 V~< 42 V
903
988
1074
1267
100
1026
1086
400 V~
230 V~< 42 V
A
BC
DE
FG
H
BCFG
HE D A
Fig. 2 Type BWS on the left; type BW on the right
A/E
+
Secondary circuit return
B/F
+
Secondary circuit flow
C/GPrimary circuit flow (heat pump brine
inlet)
D/HPrimary circuit return (heat pump
brine outlet)
Preparing for installation
Requirements regarding on-site connections (cont.)
5546256
Installation

11
Transport
For handling purposes, the heat pump module can be
removed: See page 69.
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never put weight on the top, front or side panels
of the appliance.
!Please note
Tilting the compressor at a steep angle inside
the heat pump can result in appliance damage.
Max. tilting angle: 45° for a very short time
Installation room requirements
!Please note
Unfavourable ambient conditions can lead to
malfunctions and appliance damage.
The installation room must be dry and free from
the risk of frost:
■Ensure ambient temperatures between 0 and
35 °C.
■Max. 70 % relative humidity (corresponds to
an absolute humidity of approx. 25 g water
vapour/kg dry air)
Danger
Dust, gases and vapours can be damaging to
health and trigger explosions.
Avoid dust, gases and vapours in the installation
room.
!Please note
Overloading the floor can result in damage to
the building structure.
Observe the permissible floor load. Take the
total weight of the appliance into account.
Total weight
Type Weight in kg
BW 301.A21 245 kg
301.A29 272 kg
301.A45 298 kg
Type Weight in kg
BWS 301.A21 240 kg
301.A29 267 kg
301.A45 293 kg
To prevent the transmission of structure-borne noise,
never site the appliance above ceilings with wooden
joists, e.g. in the attic.
Minimum room volume (to EN 378)
Type Refrigerant
charge in kg
Minimum
room volume
in m3
■BW
■BWS
301.A21 4.7 10.7
301.A29 6.2 14.1
301.A45 7.7 17.5
Minimum clearances for 1-stage (type BW 301.A)
≥ 400 ≥ 400
≥ 1500
A
Fig. 3
AClearance subject to on-site installation and site
conditions
Note
■Observe clearances for installation and mainte-
nance.
■Additional strain relief clamps are required for the
power cables if the clearance behind the heat pump
is more than 80 mm.
Preparing for installation
Siting and transport requirements
5546256
Installation

12
Minimum clearances for 2-stage (type BW 301.A +
BWS 301.A)
≥ 400
≥ 1500
A
= 300
≥ 400
Fig. 4
AClearance subject to on-site installation and site
conditions
Note
■Observe clearances for installation and mainte-
nance.
■Additional strain relief clamps are required for the
power cables if the clearance behind the heat pump
is more than 80 mm.
Preparing for installation
Siting and transport requirements (cont.)
5546256
Installation

13
Position the heat pump according to the details on
page 11.
Levelling the heat pump
4x
Fig. 5
Note
If the adjustable feet are used to compensate for an
uneven floor (max. 10 mm), the pressure load on the
feet must be distributed evenly.
Removing the transport brackets
!Please note
Operating the appliance without first removing
the transport brackets will cause vibrations and
excessive noise.
Undo the transport brackets and secure them to
the base support.
Installation sequence
Positioning the heat pump
5546256
Installation

14
3.
2.
1.
4x
4x
4.
4x
Fig. 6
Removing the top panel
1.
Fig. 7
Installation sequence
Positioning the heat pump (cont.)
5546256
Installation

15
■For arrangement of hydraulic connections: See
page 9.
■Make the hydraulic connections between the two
heat pumps above both heat pumps (on site).
■All required components (with a suitably designed
plate heat exchanger) for the cooling circuit must be
provided on site.
■An instantaneous heating water heater (on site) can
only be installed outside the heat pump. The system
flow temperature sensor must be installed in the flow
direction downstream of the instantaneous heating
water heater.
Connecting the primary circuit
!Please note
The heat transfer medium can cause corrosion
damage to on-site lines and components.
The components and lines used must be resist-
ant to the heat transfer medium. Never use zinc-
plated/galvanised pipes.
1. Equip the primary circuit with an expansion vessel
and safety valve (to DIN 4757).
Note
■The expansion vessel must be approved to
DIN 4807. The diaphragms of the expansion ves-
sel and safety valve must be suitable for the heat
transfer medium.
■The blow-down and drain pipes should terminate
in a container. This container must be able to
hold the maximum possible expansion volume of
the heat transfer medium.
2. Ensure adequate thermal and anti-vibration insula-
tion where pipes penetrate walls.
3. Connect primary pipes to heat pump.
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibration and appliance dam-
age.
Connect on-site lines so that they are free of
load and torque stress.
!Please note
Leaking hydraulic connections lead to appli-
ance damage.
Ensure the diaphragm grommets at the hose
outlets are seated correctly. Seal hose out-
lets with sealing tape if necessary.
4. Insulate pipes inside the building to prevent heat
and vapour diffusion.
5. Charge the primary circuit with Viessmann heat
transfer medium and vent.
Note
Ensure frost protection down to –19 °C.
Viessmann heat transfer medium is a ready-mixed
ethylene glycol-based medium. It contains inhibi-
tors for corrosion protection. The heat transfer
medium can be used at temperatures down to
–19 °C.
Note
For diaphragm grommets: See page 46.
Installation sequence
Making the hydraulic connections
5546256
Installation

16
Connecting the secondary circuit
1. Equip the secondary circuit on site with an expan-
sion vessel and safety assembly (in accordance
with DIN 4757).
Fit the safety assembly to the on-site line in the
heating water return.
2. Connect secondary lines to the heat pump
(7 ≥ 42 mm).
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Connect on-site lines so that they are free of
load and torque stress.
!Please note
Leaking hydraulic connections lead to appli-
ance damage.
■Check the internal and on-site hydraulic
connections for leaks.
■In the event of leaks, drain off liquid via the
drain valve. Check the seating of seal
rings. Always replace displaced seal
rings.
■Ensure the diaphragm grommets at the
hose outlets are seated correctly. Seal
hose outlets with sealing tape if necessary.
Position of diaphragm grommets for
hoses: See page 46.
3. Fill and vent secondary circuit.
Observe additional information regarding filling and
venting: See page 49.
4. Thermally insulate lines inside the building.
Note
■Ensure the minimum flow rate, e.g. by means of an
overflow valve: See "Specification" from page 109).
■In underfloor heating circuits, install a temperature
limiter on site to restrict the maximum temperature of
the underfloor heating system.
Electrical connection
Preparing the electrical connections
Cables
■For cable lengths and cable cross-sections, see the
following tables.
■For accessories:
Cables with the required number of cores for exter-
nal connections.
Prepare an on-site distribution box.
Danger
Damaged wiring insulation wiring can lead to
serious injury from electrical current and result in
appliance damage.
Route cables so that they cannot touch very hot,
vibrating or sharp-edged components.
Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
Take the following measures to prevent drifting
of wires into the adjacent voltage area:
■Route LV leads < 42 V separately from cables
> 42 V/230 V~/400 V~ and secure with cable
ties.
■Only strip the minimum of insulation from
cables as close as possible to the terminals
and bundle tightly to the corresponding termi-
nals.
■If 2 components are connected to the same
terminal, press both cores together in a single
wire ferrule.
Installation sequence
Making the hydraulic connections (cont.)
5546256
Installation

17
Required cable lengths in the heat pump plus distance to wall
Type BW 301.A BWS 301.A
Heat pump control unit power supply 230 V~ 1.0 m —
Compressor power supply 400 V~ 1.0 m 1.0 m
Additional connecting cables 1.5 m —
Recommended power cables
Power supply Cable Max. cable length
Compressor 400 V~ ■BW 301.A21
BWS 301.A21
4 x 2.5 mm250 m
■BW 301.A29
BWS 301.A29
4 x 4.0 mm250 m
■BW 301.A45
BWS 301.A45
4 x 6.0 mm240 m
Heat pump control unit
230 V~
■Without power-OFF 3 x 1.5 mm240 m
■With power-OFF 5 x 1.5 mm240 m
Installing the programming unit (type BW 301.A)
3. 2.
1.
2x
Fig. 8
Installation sequence
Electrical connection (cont.)
5546256
Installation

18
6x
4.
6.
9.
10.
5.
11.
[XÖ
X
7.
8.
Fig. 9
Routing cables to the wiring chamber
When routing the on-site power cables, observe the
location of the cable entry into the appliance through
its back panel: See page 9.
Installation sequence
Electrical connection (cont.)
5546256
Installation

19
400 V
230 V
<42 V
Fig. 10
1. Route LV leads through the "<42 V" opening to the
terminal area of the heat pump control unit. Pro-
vide strain relief using the cable ties supplied.
2. Route 230 V cables through the "230 V" opening to
the terminal area of the heat pump control unit.
Note
Route LV leads and 230 V cables as far apart as
possible.
3. Route the compressor power cable through the
"400 V" opening to the terminal area. For power
supply, see from page 33.
Installation sequence
Electrical connection (cont.)
5546256
Installation

20
Make the electrical connection of heat pump stage 1 (type BW 301.A) and stage 2 (type
BWS 301.A)
230 V~
230 V~
B C
BC
A
D
< 42 V
< 42 V
[C-Ö
X
aBH
C
aVG
B
aM]
B
s]
B
C
aVG
X
[XG
B
aM]
B
s]
B
aM]
aVG
B
s]
B
3.
2.
4.
1.
Fig. 11
AWiring chamber, heat pump stage 2 (type BWS)
BLV < 42 V connecting leads:
■With plugs ?B, aJB and aVG in the wiring
chamber of heat pump stage 1 (type BW)
■With plugs ?B, aJB and aVG in the wiring
chamber of heat pump stage 2 (type BWS)
C230 V~ connecting cables:
■With plugs without ID in the wiring chamber of
heat pump stage 2 (type BWS)
■With plugs Xd-Ö and aBH in the wiring chamber
of heat pump stage 1 (type BW)
DWiring chamber, heat pump stage 1 (type BW)
Installation sequence
Electrical connection (cont.)
5546256
Installation