Viessmann Vitocal 350-G Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitocal 350-G
Type BW/BWS 351.A07
Heat pumps with electric drive, 1 and 2-stage
Type BWC 351.A07
Heat pumps with electric drive, 1-stage
For applicability, see the last page
VITOCAL 350-G
5546 273 GB 6/2014 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 inten-
ded for qualified 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 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 regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the 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, SWKI and
SVGW
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 the
PCBs will remain 'live' even
after the power supply has
been switched off.
Prior to removing equipment
covers, wait at least 4 min. to
allow the voltage to dissipate.
■ Safeguard the system against recon-
nection.
Safety instructions
Safety instructions
5546 273 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
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.
Defective components must be
replaced 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 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 spare
parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5546 273 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Product information.............................................................................................. 6
Designations in the system examples.................................................................. 8
Primary circuit, type BW, BWC............................................................................. 9
Primary circuit, type BW + BWS (2-stage) .......................................................... 12
Requirements regarding on-site connections....................................................... 20
Siting requirements.............................................................................................. 22
Installation sequence
Siting the heat pump............................................................................................ 26
Making the hydraulic connections........................................................................ 29
Electrical connection............................................................................................ 31
Power supply........................................................................................................ 57
Make connections at terminals X3.8/X3.9............................................................ 67
Closing the heat pump......................................................................................... 68
Checking the diaphragm grommets..................................................................... 69
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 70
Further details regarding the individual steps....................................................... 71
Troubleshooting
Repairs................................................................................................................. 86
Parts lists, Vitocal 350-G, type BW 351.A07
Overview of assemblies, type BW........................................................................ 95
Parts not shown, type BW ................................................................................... 96
Casing, type BW .................................................................................................. 96
Electrical equipment, type BW............................................................................. 98
Heat pump module, type BW............................................................................... 100
Hydraulics, type BW............................................................................................. 102
Parts lists, Vitocal 350-G, type BWS 351.A07
Overview of assemblies, type BWS..................................................................... 104
Parts not shown, type BWS.................................................................................. 105
Casing, type BWS................................................................................................ 105
Electrical equipment, type BWS........................................................................... 107
Heat pump module, type BWS............................................................................. 109
Hydraulics, type BWS........................................................................................... 111
Index
Index
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5
Parts lists, Vitocal 350-G, type BWC 351.A07
Overview of assemblies, type BWC..................................................................... 113
Parts not shown, type BWC................................................................................. 114
Casing, type BWC................................................................................................ 114
Electrical equipment, type BWC........................................................................... 116
Heat pump module, type BWC............................................................................. 118
Hydraulics, type BWC.......................................................................................... 120
Commissioning/service reports
Hydraulic parameters report................................................................................. 122
Control parameters report.................................................................................... 123
Specification....................................................................................................... 134
Appendix
Commissioning order........................................................................................... 142
Certificates
Declaration of conformity...................................................................................... 143
Keyword index.................................................................................................... 144
Index
Index (cont.)
5546 273 GB

6
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions.
Depending on the version, the appliance
can only be used for the following pur-
poses:
■ Central heating
■ Central cooling
■ DHW heating
The range of functions can be extended
with additional components and acces-
sories.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than central heating/cooling
or DHW heating shall be deemed inap-
propriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function.
Note
The appliance is intended exclusively for
domestic use, i.e. even users who have
not had any instruction are able to oper-
ate the appliance safely.
Product information
Type BW/BWC 351.A07
■ Brine/water heat pump with
Vitotronic 200 WO1C heat pump con-
trol unit for central heating/cooling and
DHW heating. Cooling is carried out
via a heating circuit prepared for cool-
ing operation or a separate cooling cir-
cuit.
■ The refrigerant circuit has an elec-
tronic expansion valve (EEV) with an
independent control circuit (refrigerant
circuit controller).
■ For central heating and DHW heating,
an instantaneous heating water heater
(accessories) can also be switched.
■ In the case of type BWC the primary
pump, secondary pump and circula-
tion pump for cylinder heating are inte-
grated.
In the case of type BW these pumps
are available as accessories.
Preparing for installation
Intended use
5546 273 GB

7
■ The output of type BW can be supple-
mented with a stage 2 heat pump
(type BWS).
■ Using the conversion kit (accessory),
the brine/water heat pump type BW/
BWC can be converted into a water/
water heat pump. A separate well cir-
cuit provides the primary circuit with
heating energy via a separating heat
exchanger (accessory). The compo-
nents of the well and primary circuit
are switched by the heat pump control
unit.
Type BWS 351.A07 (heat pump stage 2)
■ Heat pump stage 2 has a separate
refrigerant circuit with refrigerant cir-
cuit controller, but no separate heat
pump control unit. Stage 2 is switched
via the heat pump control unit of stage
1.
■ Depending on the hydraulic connec-
tion, the heat pump stage 2 can be
used both for central heating and for
DHW heating. A separate secondary
pump and circulation pump for cylinder
heating (both accessories) are
required for the heat pump stage 2.
■ With the 2-stage version, either a sep-
arate primary pump can be used for
both stages, or a common primary
pump can be used on the primary side.
Irrespective of this, the flow and return
temperature sensors are installed in
the primary circuit at the common flow
and return.
■ Heat pump stage 2 must be installed
to the left of the heat pump stage 1.
■ The hydraulic connection can be car-
ried out with hydraulic modules
(accessories).
Preparing for installation
Product information (cont.)
5546 273 GB
Installation

8
--230V-- -KM BUS-
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
2
2
[H
F
[YF
F
--2/F14--
--2/211.2--
-2/145-
A1
--2/X3.8;3.9--
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
Preparing for installation
Designations in the system examples
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9
With a water/water heat pump conversion kit
Hydraulic installation scheme
19
24
26
28
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--
11
6
15 74
P
Preparing for installation
Primary circuit, type BW, BWC
5546 273 GB
Installation

10
Note
Type BWC is illustrated. In this case, the
circulation pumps are fitted and connec-
ted at the factory (primary pump qT, sec-
ondary pump 6, circulation pump for
cylinder heating 7, instantaneous heat-
ing water heater 4 optional).
In the case of type BW, no circulation
pumps are factory-fitted. For the connec-
tion, see "Electrical installation
scheme".
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 switch, 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 11.
■ 400 V connection: See page 11.
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 36 and the separate
service instructions for the
"Vitotronic 200" heat pump control unit.
Preparing for installation
Primary circuit, type BW, BWC (cont.)
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11
With well pump connection 230 V~
M
1~
M
1~
X1.
X2.N
UP
UP
N
L200W
N
L1
X1.
X3.4
X3.3
X1.
X3.8
X3.9
230 V/50 Hz
230 V; 0.15 A
230 V; 0.15 A
230 V; 0.15 A
K1
2
qT
wZ
wE
wQ
qO
sH
sYYA
.
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 BW, BWC (cont.)
5546 273 GB
Installation

12
With water/water heat pump conversion kit, incl. 2 primary
pumps
Hydraulic installation scheme
19
24
26 28
22
20
--2/X3.8;3.9--
--2/211.1;224.2--
27
---------
P1
P1
--2/X3.3;3.4--
23
21
--2/X3.8;3.9--
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
--X3.3:3.4--
P
Preparing for installation
Primary circuit, type BW + BWS (2-stage)
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Equipment required
Pos. Designation
1Heat pump stage 1
2Heat pump control unit
9Heat pump stage 2
qT Primary pump, heat pump stage 1
qZ Primary circuit flow temperature sensor (for installation, see page 54)
qU Primary circuit return temperature sensor (for installation, see
page 54)
qO Frost stat, primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Heat exchanger, primary circuit
wE Flow switch, well circuit (remove jumper before connecting)
wR Dirt trap
wT Primary pump, heat pump stage 2
wZ Well pump (suction pump for groundwater; connect via on-site contactor
with fuse protection)
■ 230 V connection: See page 14.
■ 400 V connection: See pages 15, 19.
wU Delivery well
wI Return well
Note
Either fit primary circuit flow and return
temperature sensors in the sensor wells
of the hydraulic modules (accessories)
or use a sensor well set (accessories).
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 36 and the separate
service instructions for the "Vitotronic
200" heat pump control unit.
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 273 GB
Installation

14
Well pump on-site connection 230 V~
wZ
wT
2
M
1~
M
1~
M
1~
230 V / 50 Hz
UP
200 W
UP
200 W
UP
N
L1
K3
K2K1
qT
211.1
224.2
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 273 GB

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Well pump on-site connection 400 V~
2
230 V / 50 Hz
211.1
X1.
X2.N UP 25
200 W
224.2
X1.
X2.N UP 15
200 W
X3.1
K2K1
X2.N
UP
M
3~ 26
L1
K1
L2 L3
M
1~
M
1~
Connecting the sensors and limiters
2
qU
wE
wQ
qO
230 V/50 Hz
Low voltage
PT500
PT500
X1.
X3.4
X3.3
X1.
X3.9
X3.8
230 V; 0.15 A
230 V; 0.15 A
230 V; 0.15 A
qZ
F2
F3
aS
aD
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
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Installation

16
With water/water heat pump conversion kit, incl. one common
primary pump
Note
If the first and second stage heat pumps
(type BW and type BWS) are installed
with different rated heating outputs, 2 pri-
mary pumps are required due to the dif-
ferent flow rates.
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
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17
Hydraulic installation scheme
19
24
26 28
22
20
--2/X3.8;3.9--
--2/211.1;224.2--
27
---------
P1
P1
--2/X3.3;3.4--
23
21
--2/X3.8;3.9--
9 1
2
--KM BUS--
--X3.8;3.9--
--230V--
P1 P1
P1 P1
--F2--
16
--F3--
17
--F2--
--211.1-- --F3--
--2/211.1--
15
--224.2--
P
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 273 GB
Installation

18
Equipment required
Pos. Designation
1Heat pump stage 1
2Heat pump control unit
9Heat pump stage 2
qT Common primary pump
qZ Primary circuit flow temperature sensor (for installation, see page 54)
qU Primary circuit return temperature sensor (for installation, see
page 54)
qO Frost stat, primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Heat exchanger, primary circuit
wE Flow switch, well circuit (remove jumper before connecting)
wR Dirt trap
wZ Well pump (suction pump for groundwater; connect via on-site contactor
with fuse protection)
■ 230 V connection: See page 14.
■ 400 V connection: See pages 15, 19.
wU Delivery well
wI Return well
Note
Either fit primary circuit flow and return
temperature sensors in the sensor wells
of the hydraulic modules (accessories)
or use a sensor well set (accessories).
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 36 and the separate
service instructions for the "Vitotronic
200" heat pump control unit.
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 273 GB

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Well pump on-site connection 400 V~
2
230 V / 50 Hz
211.1
X1.
X2.N
UP
M
1~
200 W
224.2
L1 L2 L3
X2.N UP
M
3~ 26
Connecting the sensors and limiters
2
qU
wE
wQ
qO
230 V/50 Hz
Low voltage
PT500
PT500
X1.
X3.4
X3.3
X1.
X3.9
X3.8
230 V; 0.15 A
230 V; 0.15 A
230 V; 0.15 A
qZ
F2
F3
aS
aD
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 273 GB
Installation

20
Single stage (type BW/BWC 351.A07)
77
105
152
240
300
419
476
533
600
230 V
+
< 42 V
133
576
662662
727
792
888
962
Preparing for installation
Requirements regarding on-site connections
5546 273 GB