Viessmann Vitocal 350-G Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 350-G
Type BW/BWS 351.A18
Brine/water heat pumps with electric drive, 1 and 2-stage
For applicability, see the last page
VITOCAL 350-G
5546 267 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 267 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 267 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Product information.............................................................................................. 6
Designations in the system examples.................................................................. 8
Primary circuit, type BW....................................................................................... 9
Primary circuit, type BW + BWS (2-stage) .......................................................... 12
Requirements regarding on-site connections....................................................... 20
Siting conditions................................................................................................... 23
Installation sequence
Siting the heat pump............................................................................................ 25
Making the hydraulic connections........................................................................ 27
Electrical connections........................................................................................... 30
Power supply........................................................................................................ 54
Make connections at terminals X3.8/X3.9............................................................ 64
Closing the heat pump......................................................................................... 65
Checking diaphragm grommets........................................................................... 66
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 68
Further details regarding the individual steps....................................................... 69
Troubleshooting
Repairs................................................................................................................. 84
Parts lists, type BW 351.A18
Overview of assemblies, type BW 351.A18......................................................... 93
Casing, type BW................................................................................................... 94
Electrical equipment, type BW............................................................................. 95
Heat pump module, type BW............................................................................... 98
Base frame, type BW........................................................................................... 101
Miscellaneous, type BW....................................................................................... 103
Parts lists, type BWS 351.A18
Assembly overview, type BWS 351.A18.............................................................. 104
Casing, type BWS................................................................................................ 105
Electrical equipment, type BWS........................................................................... 106
Heat pump module, type BWS............................................................................. 109
Base frame, type BWS......................................................................................... 112
Miscellaneous, type BWS..................................................................................... 114
Index
Index
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5
Commissioning/service reports
Hydraulic parameters report................................................................................. 115
Control parameters report.................................................................................... 116
Specification
Brine/water heat pumps....................................................................................... 127
Water/water heat pumps...................................................................................... 129
Appendix
Commissioning order........................................................................................... 131
Certificates
Declaration of conformity...................................................................................... 132
Keyword index.................................................................................................... 133
Index
Index (cont.)
5546 267 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 351.A18
■ Brine/water heat pump with
Vitotronic 200 heat pump control unit
for central heating/cooling and DHW
heating. Cooling is carried out via a
heating circuit prepared for cooling
operation or a separate cooling circuit.
■ The refrigerant circuit has an elec-
tronic expansion valve (EEV) with an
independent control circuit (refrigerant
circuit controller).
■ The primary pump, secondary pump
and circulation pump for cylinder heat-
ing are available as accessories.
■ For central heating and DHW heating,
an instantaneous heating water heater
(on site) can also be switched.
Preparing for installation
Intended use
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■ The output of type BW 351.A can be
supplemented with a stage 2 heat
pump (type BWS).
■ Using the conversion kit (accessory),
the brine/water heat pump type BW
can be converted into a water/water
heat pump. A separate well circuit pro-
vides 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.A18 (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. Correspondingly, a
separate secondary pump and circu-
lation pump for cylinder heating (both
accessories) are required for the
stage 2 heat pump.
■ 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.
■ The stage 2 heat pump must be instal-
led to the left of the stage 1 heat pump.
Preparing for installation
Product information (cont.)
5546 267 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 1
22
20
2
--KM BUS--
--X3.8;3.9--
--211.1--
--230V--
--2/X3.8;3.9--
--2/211.1--
27
---------
P1
P1
--2/X3.3;3.4--
23
--X3.3;3.4--
21
--2/X3.8;3.9--
--2/211.1--
15
-----
P
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
Preparing for installation
Primary circuit, type BW
5546 267 GB
Installation

10
Pos. Designation
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 10.
■ 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 detailed information
regarding the PCBs, see from
page 34 and the service instructions
for the "Vitotronic 200 heat pump control
unit".
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
.
Preparing for installation
Primary circuit, type BW (cont.)
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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 BW (cont.)
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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 51)
qU Primary circuit return temperature sensor (for installation, see
page 51)
qO Frost stat, primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Separating heat exchanger
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
Fit primary circuit flow and return tem-
perature sensor with the sensor well set
provided.
Electrical installation scheme
For an overview of the electrical connec-
tions and more detailed information
regarding the PCBs, see from
page 34 and the service instructions
for the "Vitotronic 200 heat pump control
unit".
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 267 GB
Installation

14
On-site well pump 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.)
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On-site well pump 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~
Sensor and limiter connection
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 267 GB
Installation

16
With water/water heat pump conversion kit, incl. one common
primary pump
Note
If the stage 1 and 2 heat pumps are
installed with different rated heating out-
puts, 2 primary pumps must be used to
accommodate the different flow rates
(see page 12).
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
Equipment required
Pos. Designation
1Heat pump stage 1
2Heat pump control unit
9Heat pump stage 2
qT Common primary pump
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
5546 267 GB
Installation

18
Pos. Designation
qZ Primary circuit flow temperature sensor (for installation, see page 51)
qU Primary circuit return temperature sensor (for installation, see
page 51)
qO Frost stat, primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Separating heat exchanger
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
Fit primary circuit flow and return tem-
perature sensor with the sensor well set
provided.
Electrical installation scheme
For an overview of the electrical connec-
tions and more detailed information
regarding the PCBs, see from
page 34 and the service instructions
for the "Vitotronic 200 heat pump control
unit".
Preparing for installation
Primary circuit, type BW + BWS (2-stage) (cont.)
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On-site well pump 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
Sensor and limiter connection
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 267 GB
Installation

20
Single stage (type BW)
86
100
270
540
780
171
301
88
1074
230
400 V
230 V < 42 V
1162
Preparing for installation
Requirements regarding on-site connections
5546 267 GB