Viessmann Vitocal 350-G Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 350-G
Type BW/WW 351.A18
Type BWS 351.A18
Heat pumps with electric drive, 1 and 2-stage
For applicability, see the last page
VITOCAL 350-G
5609 670 GB 4/2011 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
designed for qualified contractors.
■ Work on the refrigerant circuit must
only be carried out by qualified and
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 requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of 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 and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can lead to severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Before removing covers from
appliances, wait at least 4
minutes for the power to dissi-
pate.
■ Safeguard the system against unau-
thorised reconnection
Safety instructions
Safety instructions
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3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
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.
Replace faulty components only
with original 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 orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5609 670 GB

4
Installation instructions
Preparing for installation
Use....................................................................................................................... 6
Product information.............................................................................................. 6
General information on the electrical connection................................................. 7
Installation............................................................................................................ 7
Overview of possible system schemes................................................................ 12
Designations in the system examples.................................................................. 14
Primary circuit, type BW 351.A18 (brine/water)................................................... 15
Primary circuit, type WW 351.A18 (water/water).................................................. 17
Primary circuit type BW 351.A18 + type BWS 351.A18 (2-stage)........................ 20
Primary circuit type WW 351.A18 + type BWS 351.A18 (2-stage)....................... 26
DHW heating........................................................................................................ 34
Integrating the 2-stage version in the system examples...................................... 36
Integrating a heat pump cascade into the system examples............................... 38
System example 1, ID: 4605307_1006_01.......................................................... 42
System example 2, ID: 4605308_1006_01.......................................................... 49
Installation sequence
Siting the heat pump............................................................................................ 59
Hydraulic connections.......................................................................................... 62
Electrical connections in the heat pump control unit............................................ 65
Power supply........................................................................................................ 91
Connecting to terminals X3.8/X3.9....................................................................... 99
Closing the heat pump......................................................................................... 100
Checking diaphragm grommets........................................................................... 101
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 103
Further details regarding the individual steps....................................................... 104
Troubleshooting
Repairs................................................................................................................. 117
Parts lists
Parts lists, type BW/WW 351.A18........................................................................ 125
Overview of assemblies, type BW/WW 351.A18.................................................. 126
Parts not shown, type BW/WW 351.A18.............................................................. 127
Assembly, casing, type BW/WW 351.A18............................................................ 127
Assembly, electrical equipment, type BW/WW 351.A18...................................... 129
Assembly, heat pump module, type BW/WW 351.A18........................................ 131
Index
Index
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Assembly, base frame, type BW/WW 351.A18.................................................... 133
Parts lists, type BWS 351.A18............................................................................. 135
Overview of assemblies, type BWS 351.A18....................................................... 136
Parts not shown, type BWS 351.A18................................................................... 137
Assembly, casing, type BWS 351.A18................................................................. 137
Assembly, electrical equipment, type BWS 351.A18........................................... 139
Assembly, heat pump module, type BWS 351.A18.............................................. 141
Assembly, base frame, type BWS 351.A18......................................................... 143
Commissioning/service reports........................................................................ 145
Specification....................................................................................................... 151
Appendix
Heat pump commissioning order.......................................................................... 154
Certificates
Declaration of conformity...................................................................................... 155
Keyword index.................................................................................................... 156
Index
Index (cont.)
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6
The heat pumps Vitocal 350-G,
type BW/WW 351.A18 and
type BWS 351.A18 can be used for the
following purposes:
■ Central heating and cooling via a heat-
ing system
■ DHW heating
■ Swimming pool heating
Any use that differs from or goes beyond
this is considered inappropriate.
Note
The Vitocal 350-G is exclusively inten-
ded for domestic use, i.e. even individu-
als that have not been instructed in its
use may safely operate this appliance.
Product information
Type BW 351.A18
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 (on
site) can also be switched.
The output of the heat pump can be
extended with a heat pump stage 2
(type BWS).
Type WW 351.A18
The brine/water heat pump type BW
351.A18 in conjunction with the conver-
sion kit (accessory) becomes water/
water heat pump type WW 351.A18. A
separate well circuit supplies the primary
circuit via a separating heat exchanger
(accessory) with heating energy. The
components of the well and primary cir-
cuit are switched by the heat pump con-
trol unit.
Preparing for installation
Use
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7
Type BWS 351.A18 (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 is made on-
site.
General information on the electrical connection
■Connecting cables, heat pump
stage 1 – stage 2:
See page 68.
■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 69.
■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 91.
Installation
For handling purposes, the heat pump
module can be removed (see
page 122). !Please note
Prevent damage to the appliance
during handling.
Preparing for installation
Product information (cont.)
5609 670 GB
Installation

8
Never put weight on top of the
appliance. !Please note If the compressor inside the heat
pump is at a steep angle, oil 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.
Safeguard ambient temperatures
of 0 to 35 °C.
!Please note
Avoid the risk of explosion due to
dust, gases and vapours
in the installation room.
!Please note
Observe the permissible floor
load.
Total weight
Type Weight
BW/WW 351.A18 322 kg
BWS 351.A18 317 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.
■ Observe minimum room volume (to
DIN EN 378):
Type Minimum
space
requirement
BW/WW 351.A18 24 m3
BWS 351.A18 24 m3
■ Observe required minimum clearan-
ces:
Single stage (type BW 351.A18)
≥ 400 ≥ 400
≥ 1500
A
AClearance depends on on-site
installation and location
Preparing for installation
Installation (cont.)
5609 670 GB

9
2-stage (type BW 351.A18 + type BWS 351.A18)
≥ 400
≥ 1500
A
= 300
≥ 400
AClearance subject to installation and
site conditions
Preparing for installation
Installation (cont.)
5609 670 GB
Installation

10
Requirements for on-site connections
Single stage (type BW 351.A18)
86
100
270
540
780
171
301
88
1074
230
400 V
230 V < 42 V
1162
Preparing for installation
Installation (cont.)
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11
2-stage (type BW 351.A18 + type BWS 351.A18)
= 300
88
1074
100
270
540
780
86 171
301
230
100
270
540
780
230
400 V
230 V < 42 V
400 V
230 V < 42 V
■ Install hydraulic connections on site
stress-free.
■ Establish hydraulic connections
between the two heat pumps (type
BW/BWS 351.A18) on site.
■ All required components (with a suita-
bly designed plate heat exchanger) for
the cooling circuit must be provided on
site.
Preparing for installation
Installation (cont.)
5609 670 GB
Installation

12
Line lengths in the heat pump plus wall clearance:
Type BW 351.A18 BWS 351.A18
Heat pump control unit
power 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 1.5 m Connecting cable
Recommended power cables:
Type Heat pump con-
trol unit (230 V~)
Compressor (400 V~)
Cable cross-sec-
tion
Cable cross-sec-
tion
Max. cable length
BW 351.A18 3 x 1.5 mm2
(5 x 1.5 mm2 with
power-OFF)
4 x 4.0 mm250 m
BWS 351.A18 — 4 x 4.0 mm250 m
Note
An instantaneous heating water heater
(on site) can only be installed outside
the heat pump. The flow temperature
sensor system must be installed in the
direction of flow downstream of the
instantaneous heating water heater.
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 42).
Preparing for installation
Installation (cont.)
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13
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 generator
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–
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 Selected components.
0Components can be added.
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5609 670 GB
Installation

14
--A/137--
--2/212.3--
--230V-- -KM BUS-
KW
WW
--2/F6--
--2/F14--
--2/211.2--
--2/F0--
-2/211.4-
--94/20--
--
--2/F8--
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
-2/145-
A1
--2/X3.8;3.9--
2
1
qE
qW
6
4
3
7
5
eU
eQ
eP
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
2
[H
F
[YF
F
Preparing for installation
Designations in the system examples
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Hydraulic installation scheme
22
27
1
20
21
--2/X3.8;3.9--
2
--KM-BUS--
--X3.8;3.9--
--211.1--
--230 V--
P1
P1
--2/211.1--
-----
15
P
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
Preparing for installation
Primary circuit, type BW 351.A18 (brine/water)
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Installation

16
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 69 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
X1.
X3.8
X3.9
230 V / 50 Hz
230 V; 0.15 A 21
2
X1.
X2.N UP 15
200 W
211.1
M
1~
Preparing for installation
Primary circuit, type BW 351.A18 (brine/water) (cont.)
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17
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
Preparing for installation
Primary circuit, type WW 351.A18 (water/water)
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Installation

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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 limiter, well circuit (remove jumper when connecting)
wR Dirt trap
wZ Well pump (suction pump for groundwater; connect via on-site contactor
with fuse/MCB 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 69 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
Preparing for installation
Primary circuit, type WW 351.A18 (water/water) (cont.)
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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 351.A18 (water/water) (cont.)
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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 351.A18 + type BWS 351.A18 (2-stage)
5609 670 GB