Viessmann Vitocal 350-G Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitocal 350-G
Type BW/BWS 351.B20 to B42
Heat pump with electric drive, 1 and 2-stage
■Brine/water heat pump: 20.5 to 84.6 kW
■With conversion kit to water/water heat pump: 25.4 to 104.6 kW
VITOCAL 350-G
5855006 GB 8/2019 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for authorised contractors.
■Work on the refrigerant circuit may only
be carried out by authorised refrigera-
tion 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 to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions
Safety instructions
5855006

3
Safety instructions for working on the system
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 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 recon-
nection.
■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, fittings or pipework.
Danger
Risk of fire: Electrostatic discharge
can cause sparks which may be
ignited by escaping, flammable
refrigerant (R32).
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Work on the refrigerant circuit
Refrigerants are air displacing, colour-
less, odourless gases.
■R32 forms flammable mixtures with air.
■R410A is not flammable.
Danger
Direct contact with liquid and gas-
eous refrigerant can cause serious
damage to health.
■Avoid direct contact with liquid and
gaseous refrigerant.
■Wear personal protective equip-
ment when handling liquid and
gaseous refrigerant.
Danger
Unregulated escape of refrigerant in
enclosed spaces can lead to
breathing difficulties and suffoca-
tion.
■Never breathe in refrigerant
vapours.
■Ensure adequate ventilation in
enclosed spaces.
Perform the following measures before
beginning work on the refrigerant circuit:
■Check the refrigerant circuit for leaks.
■Ensure very good ventilation especially
in the floor area and sustain this for the
duration of the work.
■Inform all persons in the vicinity of the
system about the type of work to be
carried out.
■Secure the area surrounding the work
area.
Safety instructions
Safety instructions (cont.)
5855006

4
Further measures before starting work
on the refrigerant circuit with flammable
refrigerants (R32):
■Remove all flammable materials and
ignition sources from the immediate
vicinity of the heat pump.
■Before, during and after the work,
check the surrounding area for escap-
ing refrigerant using a suitable refriger-
ant detector.
This refrigerant detector must not gen-
erate any sparks and must be suitably
sealed.
■A CO2 or powder extinguisher must be
to hand in the following cases:
–Refrigerant is being topped up.
–When soldering or welding work is
being carried out.
■Display signs prohibiting smoking.
Danger
Damage to the refrigerant circuit
can cause refrigerant to enter the
hydraulic system. This can cause
serious damage to health.
After completion of the work, pro-
fessionally vent the hydraulic sys-
tem on the primary and secondary
sides.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
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 func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate 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.)
5855006

5
1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■Type BW 351.B ................................................................................... 8
■Type BWS 351.B (heat pump stage 2) ............................................... 8
■System examples ............................................................................... 9
■Spare parts lists .................................................................................. 9
2. Preparing for installation Requirements regarding on-site connections ........................................ 10
■1-stage: Type BW 351.B ..................................................................... 10
■2-stage: Type BW 351.B + BWS 351.B .............................................. 11
Siting and transport requirements .......................................................... 11
■Transport ............................................................................................ 11
■Installation room requirements ........................................................... 12
3. Installation sequence Positioning the heat pump ..................................................................... 14
■Levelling the heat pump ..................................................................... 14
■Removing the transport brackets ........................................................ 15
■Removing the top panel ...................................................................... 16
Making the hydraulic connections .......................................................... 16
■Connecting the primary circuit ............................................................ 17
■Connecting the secondary circuit ....................................................... 17
Electrical connection .............................................................................. 18
■Preparing the electrical connections ................................................... 18
■Installing the programming unit (type BW 351.B) ............................... 19
■Routing cables to the wiring chamber ................................................ 20
■Making the electrical connection of heat pump stage 1 (type
BW 351.B) and stage 2 (type BWS 351.B) ......................................... 22
■Overview of electrical connections in the heat pump control unit
(type BW 351.B) ................................................................................. 23
■Main PCB (function components 230 V~) .......................................... 23
■Expansion PCB on main PCB (230 V~ components) ......................... 27
■Cross connect PCB (message and safety connections) .................... 31
■Controller and sensor PCB (sensors) ................................................. 33
■Connecting the primary circuit flow/return temperature sensor, 2-
stage heat pump ................................................................................. 34
■Swimming pool heating ...................................................................... 35
Power supply ......................................................................................... 35
■Heat pump control unit power supply 230 V~ ..................................... 36
■Compressor power supply 400 V~ ..................................................... 37
■Power supply with power-OFF: Without on-site load disconnect ....... 37
■Power supply with power-OFF: With on-site load disconnect ............ 39
■Mains power supply in conjunction with on-site power consumption . 42
■Smart Grid .......................................................................................... 42
■Phase monitor (if installed) ................................................................. 44
Make connections at terminals X3.8/X3.9 ............................................. 45
Closing the heat pump ........................................................................... 45
Checking the diaphragm grommets ....................................................... 48
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 49
5. Maintenance Overview of wiring chamber .................................................................. 64
Opening the casing door ........................................................................ 64
Overview of internal components .......................................................... 65
Draining the heat pump on the primary/secondary side ........................ 66
Checking the sensors ............................................................................ 66
■Viessmann NTC 10 kΩ (blue marking) ............................................... 67
■Viessmann Pt500A (green marking) ................................................... 68
Index
Index
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6
Checking MCBs/fuses ........................................................................... 68
The appliance is too noisy ..................................................................... 69
Condensation and moisture in the heat pump module .......................... 69
Removing the heat pump module .......................................................... 70
Installing the heat pump module ............................................................ 72
6. Commissioning/service
reports
Hydraulic parameter report .................................................................... 73
Control parameter report ....................................................................... 73
7. Specification Specification for brine/water heat pumps ............................................... 84
Specification for water/water heat pumps .............................................. 86
8. Appendix Commissioning order ............................................................................. 87
Final decommissioning and disposal ..................................................... 87
9. Certificates Declaration of conformity ....................................................................... 88
10. Keyword index ................................................................................................................ 89
Index
Index (cont.)
5855006

7
Please dispose of packaging waste in line with statu-
tory regulations.
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
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.
Information
Disposal of packaging
5855006
Information

8
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 351.B
Design
Vitocal 350-G, type BW 351.B 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 351.B can be supplemented
with a heat pump stage 2 (type BWS 351.B).
Hydraulics
For type BW 351.B, 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 a water/water heat pump
The Vitocal 350-G brine/water heat pump, type
BW 351.B, becomes a water/water heat pump in con-
junction with the conversion kit (accessories). A sepa-
rate well circuit provides the primary circuit with heat-
ing energy via a separating heat exchanger (accesso-
ries). 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 351.B (heat pump stage 2)
Heat pump stage 2 is used to extend the output of type
BW 301.B (heat pump stage 1).
Note
Heat pump stage 2 must be installed to the left of heat
pump stage 1.
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.
Information
Intended use (cont.)
5855006
Information

9
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.
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Product information (cont.)
5855006
Information

10
1-stage: Type BW 351.B
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
B
C
D
BCD A
+
Fig. 1
ASecondary circuit return
BSecondary circuit flow
CPrimary circuit flow (heat pump brine inlet)
DPrimary circuit return (heat pump brine outlet)
Preparing for installation
Requirements regarding on-site connections
5855006
Installation

11
2-stage: Type BW 351.B + BWS 351.B
A
B
C
D
+
E
F
G
H
+
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
BCFG
HE D A
Fig. 2 Type BWS on the left; type BW on the right
A/ESecondary circuit return
B/FSecondary circuit flow
C/GPrimary circuit flow (heat pump brine inlet)
D/HPrimary circuit return (heat pump brine outlet)
Siting and transport requirements
Transport
For handling purposes, the heat pump module can be
removed: See page 70.
Preparing for installation
Requirements regarding on-site connections (cont.)
5855006
Installation

12
!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 351.B20 270
351.B27 285
351.B33 310
351.B42 315
Type Weight in kg
BWS 351.B20 265
351.B27 280
351.B33 305
351.B42 310
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
351.B20 5.3 12.1
351.B27 7.0 15.9
351.B33 8.6 19.6
351.B42 8.7 19.8
Minimum clearances for 1-stage (type BW 351.B)
≥ 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 (cont.)
5855006
Installation

13
Minimum clearances for 2-stage (type BW 351.B +
BWS 351.B)
≥ 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.)
5855006
Installation

14
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.
Installation sequence
Positioning the heat pump
5855006
Installation

15
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.
3.
4x
4x
4x
1.
2.
4.
Fig. 6
Installation sequence
Positioning the heat pump (cont.)
5855006
Installation

16
Removing the top panel
1.
Fig. 7
Making the hydraulic connections
■For arrangement of hydraulic connections: See
page 10.
■Make the hydraulic connections between the two
heat pumps above the 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.
Installation sequence
Positioning the heat pump (cont.)
5855006
Installation

17
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 48.
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.
Installation sequence
Making the hydraulic connections (cont.)
5855006
Installation

18
2. Connect secondary lines to the heat pump
(7 ≥ 54 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 48.
3. Fill and vent secondary circuit.
Observe additional information regarding filling and
venting: See page 51.
4. Thermally insulate lines inside the building.
Note
■Ensure the minimum flow rate, e.g. by means of an
overflow valve: See "Specification" on page 84
onwards.
■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.
Required cable lengths in the heat pump plus wall clearance
Type BW 351.B BWS 351.B
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 —
Installation sequence
Making the hydraulic connections (cont.)
5855006
Installation

19
Recommended power cables
Power supply Cable Max. cable length
Compressor 400 V~ Type BW/BWS 351.B20 5 x 2.5 mm250 m
Type BW/BWS 351.B27 5 x 4.0 mm250 m
Type BW/BWS 351.B33 5 x 4.0 mm250 m
Type BW/BWS 351.B42 5 x 6.0 mm250 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 351.B)
3. 2.
1.
2x
Fig. 8
Installation sequence
Electrical connection (cont.)
5855006
Installation

20
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 entries into the appliance through
its back panel: See page 10.
Installation sequence
Electrical connection (cont.)
5855006
Installation