Viessmann Vitocal 350-G Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 350-G
Type BW/WW 351.A07
Type BWS 351.A07
Heat pumps with electric drive, 1 and 2-stage
Type BWC/WWC 351.A07
Heat pumps with electric drive, 1-stage
For applicability, see the last page
VITOCAL 350-G
5609 667 GB 5/2013 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
5609 667 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.)
5609 667 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Product information.............................................................................................. 6
General information on the electrical connection................................................. 8
Siting.................................................................................................................... 8
Overview of possible system schemes................................................................ 13
Designations in the system examples.................................................................. 14
Primary circuit, type BW/BWC (brine/water)........................................................ 15
Primary circuit, type WW/WWC (water/water)...................................................... 17
Primary circuit, type BW + BWS (2-stage, brine/water)....................................... 20
Primary circuit, type WW + BWS (2-stage, water/water)...................................... 25
DHW heating........................................................................................................ 33
Integration of 2-stage version............................................................................... 39
Heat pump cascade integration............................................................................ 41
System example 1, ID: 4605350_1008_01.......................................................... 45
System example 2, ID: 4605351_1008_01.......................................................... 51
System example 3, ID: 4605352_1008_01.......................................................... 57
Installation sequence
Siting the heat pump............................................................................................ 67
Hydraulic connections.......................................................................................... 69
Electrical connections........................................................................................... 71
Power supply........................................................................................................ 98
Connecting to terminals X3.8/X3.9....................................................................... 106
Closing the heat pump......................................................................................... 107
Checking diaphragm grommets........................................................................... 108
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 109
Further details regarding the individual steps....................................................... 110
Troubleshooting
Maintenance......................................................................................................... 123
Parts lists
Spare parts lists, type BW/WW............................................................................ 130
Overview of assemblies, type BW/WW................................................................ 131
Parts not shown, type BW/WW ........................................................................... 132
Casing assembly, type BW/WW .......................................................................... 132
Electrical equipment, type BW/WW...................................................................... 134
Index
Index
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5
Heat pump module, type BW/WW........................................................................ 136
Hydraulics, type BW/WW .................................................................................... 138
Parts lists, type BWS............................................................................................ 140
Overview of assemblies, type BWS .................................................................... 141
Parts not shown, type BWS.................................................................................. 142
Casing assembly, type BWS................................................................................ 142
Electrical equipment, type BWS........................................................................... 144
Heat pump module, type BWS............................................................................. 146
Hydraulics, type BWS........................................................................................... 148
Parts lists, type BWC/WWC 351.A07................................................................... 150
Overview of assemblies, type BWC/WWC........................................................... 151
Parts not shown, type BWC/WWC....................................................................... 152
Casing, type BWC/WWC...................................................................................... 152
Electrical equipment, type BWC/WWC................................................................ 154
Heat pump module, type BWC/WWC ................................................................. 156
Hydraulics, type BWC/WWC................................................................................ 158
Commissioning/service reports........................................................................ 160
Specification
Specification for brine/water heat pumps............................................................. 167
Specification for water/water heat pumps............................................................ 171
Appendix
Heat pump commissioning order.......................................................................... 175
Certificates
Declaration of conformity...................................................................................... 176
Keyword index.................................................................................................... 177
Index
Index (cont.)
5609 667 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 heat pump
control unit Vitotronic 200, type WO1B
for central heating/cooling and DHW
heating. Cooling is carried out via a heat-
ing circuit prepared for cooling operation
or a separate cooling circuit.
The refrigerant circuit has an electronic
expansion valve (EEV) with an inde-
pendent control circuit (EEV controller).
For central heating and DHW heating, an
instantaneous heating water heater
(accessories) can also be switched.
For type BWC 351.A07, the primary
pump, secondary pump and circulation
pump for cylinder heating are integrated.
For type BW 351.A07, these pumps are
available as accessories.
The output of type BW 351.A07 can be
extended with a heat pump stage 2
(type BWS).
Preparing for installation
Intended use
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7
Type WW/WWC 351.A07
The brine/water heat pump type BW/
BWC 351.A07 in conjunction with the
conversion kit (accessories) becomes
water/water heat pump
type WW/WWC 351.A07. A separate
well circuit supplies the primary circuit
with heating energy via a separating heat
exchanger (accessories). 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)
The heat pump stage 2 has a separate
refrigerant circuit with EEV 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 connection,
the 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 required for the heat
pump stage 2.
With the 2-stage version, either a sepa-
rate 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 cir-
cuit 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 carried
out with hydraulic modules (accesso-
ries).
Preparing for installation
Product information (cont.)
5609 667 GB
Installation

8
■Connecting cables, heat pump
stage 1 – stage 2:
See page 75.
■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 76.
■Power supply:
The number of power cables from the
distribution board (meter box) to the
heat pump control unit depends on the
system version and tariffs used; see
information from page 98.
Siting
!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
between 0 and 35 °C.
!Please note
Dust, gases and vapours can
cause an explosion.
Never allow these substances in
the installation room.
!Please note
Observe the permissible floor
load.
■Total weight
Type Weight
BW 351.A07 136 kg
BWS 351.A07 132 kg
BWC 351.A07 146 kg
■ To prevent the transmission of struc-
ture-borne noise, never site the appli-
ance 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.
Preparing for installation
General information on the electrical connection
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■ Observe the required floor area and
minimum room volume (to EN 378).
Type Min. room
volume
BW 351.A07 9.4 m3
BWS 351.A07 9.4 m3
BWC 351.A07 9.4 m3
■ Observe required minimum clearan-
ces:
Single stage (type BW/BWC 351.A07)
≥ 400
≥ 1500
A
B
Two-stage (type BW 351.A07 + BWS 351.A07)
= 100
≥ 400
A
≥ 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
site conditions
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
Siting (cont.)
5609 667 GB
Installation

10
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 2-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
Siting (cont.)
5609 667 GB

11
Requirements for on-site connections
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
Siting (cont.)
5609 667 GB
Installation

12
Two-stage (type BW 351.A07 + BWS 351.A07)
77
105
152
240
300
419
476
533
600
230V
+
< 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
100
Install hydraulic connections on site
stress-free.
Cable lengths in the heat pump plus wall clearance:
Type BW/BWC 351.A07 BWS 351.A07
Heat pump control unit pow-
er 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
Siting (cont.)
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13
Recommended power cables for all types:
Cable cross-section Max. cable length
Heat pump control unit
(230 V~)
3 x 1.5 mm2
(5 x 1.5 mm2 with pow-
er-OFF)
–
Compressor (400 V~) 5 x 2.5 mm250 m
Instantaneous heating water
heater (400 V~, if installed)
5 x 2.5 mm250 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 45).
Overview of all available system schemes
Component "System scheme 7000"
0 1 2 3 4 5 6 7 8 9 10 11
Heating circuit
A1/HC1 – X X – – X X – – X X –
M2/HC2 – – – X X X X X X X X –
M3/HC3 – – – – – – – 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
(in conjunction with Vitosolic 200)
0–0–0–0–0–0–
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Siting (cont.)
5609 667 GB
Installation

14
Component "System scheme 7000"
0 1 2 3 4 5 6 7 8 9 10 11
Cooling
A1/HC1 – 0 0 – – 0 0 – – 0 0 –
M2/HC2 – – – 0 0 0 0 0 0 0 0 –
M3/HC3 – – – – – – – 0 0 0 0 –
Sep. cooling circuit/
SKK
0 0 0 0 0 0 0 0 0 0 0 –
X Component selected.
0Component may be added.
Designations in the system examples
--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
Overview of possible system schemes (cont.)
5609 667 GB

15
Hydraulic installation scheme
22
27
2
--KM BUS--
--X3.8;3.9--
--230V--
P1
P1
20
21
--2/X3.8;3.9--
11
6
15 74
P
Preparing for installation
Primary circuit, type BW/BWC (brine/water)
5609 667 GB
Installation

16
Note
Type BWC 351.A07 is illustrated. In this
case, the circulation pumps are fitted and
connected at the factory (primary pump
qT, secondary pump 6 incl. check
valve, circulation pump for cylinder heat-
ing 7 incl. check valve, instantaneous
heating water heater 4 optional).
In type BW 351.A07, no circulation
pumps are fitted at the factory. For the
connection of primary pump qT, see
"Primary circuit, type BW 351.A07 +
BWS 351.A07" (page 20).
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 76 and the separate
service instructions for the 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/BWC (brine/water) (cont.)
5609 667 GB

17
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 WW/WWC (water/water)
5609 667 GB
Installation

18
Note
Type WWC 351.A07 is illustrated. In this
case, the circulation pumps are fitted and
connected at the factory (primary pump
qT, secondary pump 6 incl. check
valve, circulation pump for cylinder heat-
ing 7 incl. check valve, instantaneous
heating water heater 4 optional).
In type WW 351.A07, no circulation
pumps are installed at the factory. For
the connection, see "Electrical installa-
tion scheme".
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 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 19
■ 400 V connection: See page 19
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 76 and the separate
service instructions for the Vitotronic 200
heat pump control unit.
Preparing for installation
Primary circuit, type WW/WWC (water/water) (cont.)
5609 667 GB

19
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~
On-site well pump 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/WWC (water/water) (cont.)
5609 667 GB
Installation

20
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 + BWS (2-stage, brine/water)
5609 667 GB