Heat pump with electric drive, 1 and 2-stage. brine/water heat pump: 5.7 to 34.4 kw. with conversion kit to water/water heat pump: 7.5 to 45.2 kw (132 pages)
Summary of Contents for Viessmann Vitocal 300-G Pro Series
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Viesmann Installation and service instructions for contractors Vitocal 300-G Pro Type BW 302.D090 to 302.D230, 84.8 to 222.0 kW Brine/water heat pumps, 2-stage VITOCAL 300-G PRO Please keep safe. 5838144 GB 11/2018...
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■ OFF the appliance and let it cool down. lidate our warranty. ■ Never touch hot surfaces on the appliance, fit- For replacements, use only original spare parts tings or pipework. supplied or approved by Viessmann.
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Safety instructions Safety instructions (cont.) 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 Danger risk of scalding. If water escapes from the appliance there is a Never touch hot heating water.
Index Index 1. Safety and liability Occupational safety ................Electrical connections ................. ■ Work on the heat pump ..............■ Work on the refrigerant circuit ............. ■ Work on the casing ................■ 2. Information Disposal of packaging ................Symbols ....................Intended use ..................
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Index Index (cont.) 5. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......50 tion, maintenance 6. Troubleshooting Diagnosis ....................63 Increased noise emissions ..............63 ■ 7. Repairs Removing the front panel and top panel ..........64 Overview of electrical components ............64 Overview of internal components ............
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Safety and liability Occupational safety Responsibilities during the lifecycle phases Lifecycle System External Manufac- Refriger- Logistics Electri- Service Disposal user person- turer ation en- cian/ engineer contrac- gineer heating contrac- Manufacture Delivery, mov- ing, handling, siting Installation Commission- Operation Maintenance, repair, shut- down Dismantling,...
Safety and liability Occupational safety (cont.) Note Observe all information in the "Safety instructions". For further information regarding electrical connec- tions, see from page 30. Work on the heat pump Note Danger Before commissioning and after repair or maintenance Falling of heavy or unwieldy heat pump compo- work, check that the heat pump is in the intended con- nents can result in life threatening crushing or dition.
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Information Disposal of packaging Please dispose of packaging waste in line with statu- tory regulations. Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram:...
Information Intended use (cont.) For operation in industry, commerce, property develop- Commercial or industrial usage for a purpose other ment with enclosed boiler room than central heating/cooling or DHW heating shall be deemed inappropriate. Incorrect use and/or operation of the appliance (e.g. Note the appliance being opened by the system user) is pro- The Vitocal 300-G Pro must be operated exclusively...
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See page 48. Unloading and handling Note Note Before unloading, check the consignment for damage. Viessmann (Switzerland) AG accepts no liability for Note down any damage on the delivery note and notify any damage resulting from incorrect handling. the haulage contractor. ■...
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Preparing for installation Transport and siting requirements (cont.) Handling by crane Fig. 1 Lifting shackle attachment points Edge protection (e.g. 2 or 3 layers of corrugated Belt strap suitable for the weight (see page 12) cardboard) Cross beam to relieve the load on the frame Note Lifting with belt straps is only permitted without fitted side, front or back panels.
Preparing for installation Transport and siting requirements (cont.) Installation room requirements Please note To prevent the transmission of structure-borne noise, ■ Unfavourable ambient conditions can lead to never site the appliance above ceilings with wooden malfunctions and appliance damage. joists (e.g. in the attic). ■...
Preparing for installation Transport and siting requirements (cont.) Clearances for installation and maintenance: Note 500 mm The electronic injection valve and the compressor wir- ≥ Clearance (according to DIN 18101): ing chamber are located on the right-hand side. 944 mm ≥...
Preparing for installation Transport and siting requirements (cont.) Type BW 302.D140, BW 302.D180 and BW 302.D230 2040 Fig. 7 Pressure point, foot ê Pressure-tested sound insulation layer, approx. 10 to 20 mm Front of the heat pump Requirements for on-site connections Dimensions Vitocal 300-G Pro Dimensions, types BW 302.D090 and BW 302.D110 1380...
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Preparing for installation Requirements for on-site connections (cont.) Note The width of the heat pump is given with and without side panels. The dimensions without side panels are the transport dimensions for handling. Dimensions, types BW 302.D140 and BW 302.D180 1972 Fig.
Preparing for installation Hydraulic connection requirements (cont.) Heat pump cascade: 2-stage (type BW 302.D090 to BW 302.D230) A heat pump cascade consists of a lead heat pump Up to 4 lag heat pumps possible when connected via ■ and lag heat pumps. LON.
Preparing for installation Hydraulic connection requirements (cont.) Pos. Description Only for type BW 302.D140, BW 302.D180 and BW 302.D230 (2-stage heat pumps): Secondary pump 2 (fail-safe) Note Contactor relay required ■ Size secondary pump 1 for partial load. ■ Primary pump 1 (fail-safe) Optionally: 2nd primary pump (fail-safe) for stage 2 Note Contactor relay required...
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Preparing for installation Hydraulic connection requirements (cont.) Pos. Description Plate heat exchanger Flow limiter Motorised 2-way valve, normally closed Note Note Achievable cylinder temperatures: Size plate heat exchanger in accordance with the Top section: technical guide. Without a dirt trap the warranty for the ■...
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Installation sequence Siting the heat pump Levelling the heat pump Fig. 15 Position and level the heat pump horizontally as described from page 10.
Installation sequence Siting the heat pump (cont.) Removing the transport brackets Please note Operating the appliance without first removing the transport brackets may cause vibrations and excessive noise. Remove all 4 transport brackets fully from below and dispose of correctly. Fig.
Installation sequence Siting the heat pump (cont.) Fitting the back panel, side panels and kicking plates Note After fitting the back panel, make the hydraulic and electrical connections. See following chapter. Fig. 17...
Installation sequence Making the hydraulic connections (cont.) Connecting the Vitocal 300-G Pro Installation accessories Technical guide Using the 2½" or 3" flange adaptor set (accessories) Fig. 20 Type BW 302.D090 to BW 302.D180 Victaulic coupling 3" (primary circuit) Flange adaptor 2½" DN 65/PN 10, short (secon- Victaulic coupling 2½"...
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Installation sequence Making the hydraulic connections (cont.) Fig. 21 Type BW 302.D230 Victaulic coupling 3" (primary circuit) Flange adaptor 2½" DN 65/PN 10, short (secon- Victaulic coupling 2½" (secondary circuit) dary circuit), without anti-vibration elements Flange adaptor 3" DN 80/PN 10, short (primary cir- Anti-vibration expansion joints, on site cuit), without anti-vibration elements Hydraulic line fixings...
Installation sequence Making the hydraulic connections (cont.) Note If adaptors are used, compensators must always be installed to compensate for any vibration. For sound insulation without rubber expansion joints, an on-site solution must be provided. Fastening of pipes to the wall/floor Standard rubber pipe clamps only dampen flow noises.
2. Ensure adequate thermal and anti-vibration insula- als. tion of all pipes routed through walls. 5. Fill the primary circuit with Viessmann heat transfer medium and vent. See page 51. Connecting the secondary circuit 1. Equip the secondary circuit on site with an expan- 3.
Installation sequence Electrical connections Routing cables to the heat pump wiring chamber Danger When routing the on-site cables, note the location of Damaged cable insulation can cause injury and the cable entries into the appliance on the back panel. damage to the appliance. See page 25.
Installation sequence Electrical connections (cont.) Overview of electrical connections Note Route 230 V~ cables and extra low voltage (ELV) ■ leads separately and bundle them tightly together at the terminals. This ensures that, in the event of a fault, e.g. if a wire becomes detached, the wires can- not drift into the adjacent voltage area.
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Installation sequence Electrical connections (cont.) Wiring chamber, top Fig. 28 Power supply for power circuit (compressor) Contactors for primary and secondary pumps 3 x 400 V/50 Hz (only type BW 302.D180 and EEV PCB BW 302.D230, see also pos. in Fig. 29) X24 Slot for LON communication module Message and safety connections (safety chain) Controller and sensor PCB (Heat pump control...
Installation sequence Electrical connections (cont.) Wiring chamber, front Fig. 29 Note Soft starter, compressor 2 (only type Diagram without terminal covers (see also page 70) BW 302.D090, BW 302.D110, BW 302.D140, BW 302.D180 and BW 302.D230) ■ ON/OFF switch (all types) MCB/fuse, power circuit, system components (con- Power supply for compressor power circuit sumers at terminal strip...
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Installation sequence Electrical connections (cont.) sXG sXF sXD sXS Fig. 30 Set the required parameters during commissioning; see from page 53. Function components 230 V~ Plug Clamps Function Explanation 211.3 Switching of instantaneous heating Connection values water heater, stage 1 Output: 10 W ■...
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Installation sequence Electrical connections (cont.) Plug Clamps Function Explanation 212.1 Cooling control Connection values AC function (active cooling) Output: 10 W ■ Voltage: 230 V~ ■ Max. control current: 4(2) A ■ Connection, see separate "Connection and wiring dia- gram". 212.2 Heating circuit pump for heating circuit This pump is connected in addition to the secondary...
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Installation sequence Electrical connections (cont.) Plug Clamps Function Explanation 222.3 Control of external heat generators Floating contact 222.4 with 2 high limit safety cut-outs (max. 70 °C) for the heat pump and for Note switching off the secondary pump The switching contact is a floating N/O contact that ■...
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Installation sequence Electrical connections (cont.) Plug Clamps Function Explanation 224.4 Switching of instantaneous heating Connection values water heater, stage 2 Output: 10 W ■ Voltage: 230 V~ ■ Max. control current: 4(2) A ■ Connection, see separate "Connection and wiring dia- gram".
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Installation sequence Electrical connections (cont.) Plug Clamps Function Explanation 225.1 Heating circuit pump for heating circuit Connect a temperature limiter to restrict the maximum with mixer M2/HC2 temperature for underfloor heating circuits (if installed) in series. Connection values: Output: 100 W ■...
Installation sequence Electrical connections (cont.) Message and safety connections (safety chain) with distribution terminal Fig. 31 Set the required parameters during commissioning; see from page 53. ■ For connections, see separate "Connection and wiring diagram". ■ Signal and safety connections Clamps Function Explanation...
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Installation sequence Electrical connections (cont.) Clamps Function Explanation LP1 X3.2 Signal "External blocking" (external Requires floating N/O contact: LP1 X3.14 blocking of compressor and pumps, Closed: blocking enabled ■ or at external mixer in control operation or Open: no blocking ■...
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Installation sequence Electrical connections (cont.) Clamps Function Explanation X3.10 Fault message, lag heat pump in a Requires floating contact: X3.11 cascade Closed: no faults ■ Open: fault ■ Jumper Breaking capacity 230 V~, 0.15 A ■ No jumper should be installed if a message contact is connected.
Internal connection, KM-BUS Connection, PWM signal, cylinder loading a:DC Connection, Modbus 1: Viessmann appliances pump If other Viessmann appliances are to be con- Connection, Modbus 2 (cores interchangeable) nected, plug in the Modbus distributor (acces- sories). Connection, energy meter Programming unit connection ■...
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Installation sequence Electrical connections (cont.) Sensors to be connected on site Plug Sensor Type F0.1/F0.2 Outside temperature sensor NTC 10 kΩ F0.2/F0.3 Radio clock receiver (accessories) Buffer temperature sensor, top NTC 10 kΩ Cylinder temperature sensor, top NTC 10 kΩ Cylinder temperature sensor, bottom NTC 10 kΩ...
Installation sequence Electrical connections (cont.) [{{] 0-10V L1 N Fig. 33 EA1 extension Circulation pump for swimming pool heating Power supply 1/N/PE 230 V/50 Hz (accessories) Junction box (on site) Temperature controller for swimming pool temper- ature control (floating contact: 230 V~, 0.1 A, Fuses and contactor for circulation pump for swim- ming pool heating (accessories) accessories)
Installation sequence Power supply Isolators for non-earthed conductors The allocation of the power-OFF (for compressor ■ ■ The integral ON/OFF switch must simultaneously and/or instantaneous heating water heater) is made isolate all non-earthed conductors from the mains via the type of connection and by setting parameters with a minimum contact separation of 3 mm.
Installation sequence Power supply (cont.) Electrical connection requirements Note Note The type and cross-section of connecting cables must The control circuit power supply and the cable for the be determined by an authorised electrician in accord- power-OFF signal can be combined in a single 5-core ance with the local regulations.
Installation sequence Mains monitor Electronic soft starter, type SMC Electronic soft starter functions: LED explanation Monitoring the compressor mains feed ■ ■ Reducing the compressor starting current during the starting procedure Delivered condition: Rotating field, phase asymmetry: 20 % ■ HOLD TO TEST Max.
Installation sequence Fitting the shaft and dial for the ON/OFF switch and installing the programming unit Note The shaft and control dial for the ON/OFF switch as well as the programming unit are delivered inside the wiring chamber of the heat pump. Only fit the program- ming unit after all electrical connections have been made.
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Installation sequence Closing the heat pump (cont.) Do all hydraulic connections have airtight sealing Have transport brackets been removed? ■ ■ and insulation with thermal and vapour diffusion- ■ Are the back and side panels securely attached? proof materials? Fig. 37 2.
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Commissioning, inspection, maintenance Opening the heat pump Danger Note Contact with live components can lead to seri- Work on the refrigerant circuit may only be carried out ous injury from electric current. by qualified refrigeration engineers. Work on electrical ■ Never touch the terminal areas for the heat equipment may only be carried out by qualified electri- pump control unit or power supply;...
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Commissioning, inspection, maintenance Filling and venting on the primary side (cont.) 3. Charge the primary circuit with Viessmann heat transfer medium and vent. Note Depending on the main heat source, the following minimum frost protection must be observed: Ground (brine/water direct) = –16.1 °C (freezing ■...
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Commissioning, inspection, maintenance Commissioning the system Commissioning (configuration, parameter settings and Note function checks) can be carried out with or without the The type and extent of the parameters depend on the commissioning assistant (see following chapter and heat pump type, on the selected system scheme and "Vitotronic 200"...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Language Date/Time Time Date Start commissioning? Coding Parameter group Parameters level 1 select Temperature Sensor values sensors display Signal inputs Signal inputs display Actuator test Actuator test carry out Subscriber check (LON) Subscriber check carry out Function check Function...
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Commissioning, inspection, maintenance Commissioning the system (cont.) 6. Confirm parameter code: "7000" 7. Set system scheme: "6" Required parameters for components connected on site Detailed explanations on parameters "Vitotronic 200" service instructions Parameters for circulation pumps and other components Heating circuit pump Parameter Setting "System definition"...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Remote control for heating/cooling circuit or Vitocomfort 200 Parameter Setting "Heating circuit 1"/"Heating circuit 2"/"Heating circuit 3" Ó "Remote control 2003" "1" "Remote control 3003" Note To assign a heating circuit, set the "Remote control 4003"...
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Commissioning, inspection, maintenance Commissioning the system (cont.) External blocking of compressor and pumps Parameter Setting "System definition" Ó "Effect of external blocking on pumps/compressor 701A" "0" to "31" External blocking of the compressor; mixer in control mode or CLOSED Parameter Setting "System definition"...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Cooling function parameters Parameter Setting "Cooling" Ó "Cooling function 7100" "0" No cooling "1" Natural cooling with NC-Box with- out mixer (accessory) "2" Natural cooling with NC-Box with mixer (accessory) "3" "Active cooling" "Cooling circuit 7101"...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Enable required functions for utilisation of power generated on site Parameter Setting "Photovoltaics" Ó "Enable own energy consumption for set DHW temperature 2 "1" 7E10" "Enable own energy consumption for DHW heating 7E11" "1"...
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"Enable electric heaters for DHW heating 7901" "0" or "1" — "Enable 3-way diverter valve heating/DHW 730D" "0"/"1" "0"/"1" Note The additional parameters for the heat pump cascade are set during commissioning by a heat pump contrac- tor certified by Viessmann.
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Commissioning, inspection, maintenance Checking the electronic flow switch, type IFM Note The flow switch monitors the minimum flow rate required for operating the heat pump. 1. Check the tip of the sensor regularly for possible deposits. 2. Clean the tip of the sensor with a cloth, if required. Remove stubborn deposits (such as limescale) with commercially available vinegar-based clean- ers.
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Commissioning, inspection, maintenance Checking the electronic flow switch, type IFM (cont.) Carry out an operating display adjustment (high flow balancing, if required) The high flow balancing establishes the existing 1. Start the appliance with the existing flow rate. (higher) flow rate as the nominal flow rate. For the cor- 2.
Troubleshooting Diagnosis Increased noise emissions Possible causes: Hydraulic line not connected free of load and torque ■ Transport bracket not removed stress ■ ■ Doors at the front not properly closed (turn quadrant ■ Anti-vibration elements for hydraulic connection are key as far as it will go) missing ■...
Repairs Removing the front panel and top panel 1. Set the ON/OFF switch to OFF or 0 respectively. 4. Carefully remove top panel (see page 49). 2. Undo both screws on the underside of the front panel. Please note The cables between the programming unit and the wiring chamber can suffer damage.
Repairs Overview of internal components (cont.) Vibration absorber Immersion temperature sensor Schrader valve Ball shut-off valve with Schrader valve Draining the heat pump on the primary/secondary side Drain the heat pump at the on-site drain valve on the primary/secondary side. Checking sensors For the position of the sensors in the heat pump: See For sensor connections: See controller and sensor...
Repairs Checking sensors (cont.) Temperature sensors, type Pt500A -40 -30 -20 -10 Outside temperature in °C Fig. 43 Checking MCBs/fuses For fuses in the front wiring chamber, see page 33 and For the fuse in the upper wiring chamber, see page 39. page 32.
Parts lists Ordering parts The following details are required when ordering parts: ■ Serial no. (see type plate) ■ Position number of the part (from this parts list)
Commissioning/service reports Hydraulic parameter report Settings and test values Set value Commissioning Maintenance/ service Frost protection (brine medium) for geo- °C thermal probes for BW External heating circuit pump test Circulation pump type Circulation pump stage Overflow valve setting Commissioning, primary circuit Primary circuit flow temperature °C ("Diagnosis"...
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Commissioning/service reports Control parameter report (cont.) System definition Parameter Code Delivered condition Commission- Maintenance/ Service "System scheme" (see chapter "Overview 7000 of possible system schemes") ≙ "Temperature differential for calculating 7003 40 ( 4 K) the heating limit" ≙ "Temperature differential for calculating 7004 40 ( 4 K)
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Commissioning/service reports Control parameter report (cont.) Compressor 2 Parameter Code Delivered condition Commission- Maintenance/ Service "Enable compressor" 5100 "Enable use of compressor stage" 5112 "Primary source output" 5143 "Output compressor stage" 5130 Rated heating output according to type plate External heat generator Parameter Code Delivered condition Commission-...
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Commissioning/service reports Control parameter report (cont.) Solar Parameter Code Delivered condition Commission- Maintenance/ Service "Type solar control unit" 7A00 Parameters for solar control module, type C0xx These parameters will only be displayed if the solar control module, type SM1, is connected to the heat pump and "Type solar control unit"...
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Commissioning/service reports Control parameter report (cont.) Heating water buffer cylinder Parameter Code Factory setting Commission- Maintenance/ service "Enable buffer cylinder/low loss header" 7200 ≙ "Temp in operating status fixed value for 7202 500 ( 50 °C) buffer cyl" ≙ "Hysteresis temperature heating buffer 7203 50 ( 5 K)
Additional assurances or guarantees require a sepa- rate contractual agreement. Note Parameters need to be matched in conjunction with an ice store or the "external demand" function. Viessmann must be consulted.
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Specification Specification, Vitocal 300-G Pro (cont.) Operation: Water/water with intermediate circuit (B8/W35) Type BW 302. D090 D110 D140 D180 D230 Performance data to EN 14511 (3 K/5 K spread) Rated heating output 107.2 139.8 Cooling capacity 89.6 116.8 189.6 Power consumption 18.7 24.2 30.5...
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Specification Specification, Vitocal 300-G Pro (cont.) Type BW 302. D090 D110 D140 D180 D230 Electrical values Rated voltage 3LNPE/400 V/50 Hz Starting system Soft start Starting current per compressor 112.5 Total starting current Maximum power consumption Cos Phi compressor at max. output 0.77 0.89 0.88...
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The EC safety datasheet for the refrigerant used can description describe purely physical characteristics. be obtained from the Technical Services department of Additional assurances or guarantees require a sepa- Viessmann Werke. rate contractual agreement. Seasonal coefficient of performance LT (average climate) Seasonal coefficient of performance MT (average climate)
Date Time The work that is requested to be carried out by Viessmann will be billed in accordance with the latest Viessmann pricelist. Additional journeys and any work required to meet the requirements of the checklist above, e.g. incom- plete preparation work, are charged additionally.
Final decommissioning Dismantling / Disposal Following expiry of the appliance's service life and The heat pump is filled with refrigerant R410A. The when replacing components, observe the statutory refrigerant is a fluorocarbon and has a global warming regulations on dismantling, recovery and disposal. potential (GWP) of 2088.
Certificates Declaration of conformity We, Viessmann (Switzerland) AG CH-3076, Worb Conformity has been verified with the CE designation. SSB, declare as sole responsible body that the named Using the serial number, the full Declaration of Con- product complies with the European directives and...
Keyword index Keyword index Electrical connections, overview........ 31 Adjusting operating display........62 Electric booster heater..........57 Ambient temperatures..........12 Electronic expansion valve EEV........9 Appliance MCBs/fuses..........66 Electronic flow switch..........61 Appliance too noisy............ 63 Expansion vessel, checking........52 Extended menu............54 External extension............56 Boiler water temperature sensor External functions............56...
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Keyword index Keyword index (cont.) Photovoltaics..............58 Lead appliance............19 Power cable routing........... 30 LON communication module........19, 44 Power generated on site..........58 – Slot................42 Power-OFF..............46 LON module............19, 44 Power supply..........10, 45, 46 Low pressure sensor..........64 Premium tariff meter...........46 LV lead routing............30 Pressure, checking.............52 Primary circuit, filling and venting.......51 Primary circuit connection..........
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Keyword index Keyword index (cont.) Swimming pool............43 Swimming pool water heating........57 Ventilation..............59 System pressure, checking........52 Venting System user instruction..........62 – Primary side............51 – Secondary side............52 Vibration absorber............65 Temperature sensor, type NTC 10 kΩ......65 Vitocom 100............... 56 Temperature sensor, type Pt500A......66 Vitocomfort 200............