Viessmann Vitocal 300-G Installation And Service Instructions For Contractors
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Viessmann Vitocal 300-G Installation And Service Instructions For Contractors

Compact heat pump with electric drive single and two-stage
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VIESMANN
Installation and service
instructions
for contractors
Vitocal 300-G
Type BW, 21 to 45 kW
Type BWS, 21 to 45 kW
Type WW, 21 to 45 kW
Compact heat pump with electric drive
Single and two-stage
For applicability, see the last page
VITOCAL 300-G
Please keep safe.
5728 049 GB
8/2010

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitocal 300-G Type BW, 21 to 45 kW Type BWS, 21 to 45 kW Type WW, 21 to 45 kW Compact heat pump with electric drive Single and two-stage For applicability, see the last page VITOCAL 300-G Please keep safe.
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ The Code of Practice of relevant trade associations Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, VDE and risk of injury.
  • Page 3 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...

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Product information....................General information - electrical connection............Installation......................Overview of possible system schemes..............12 Primary circuit, type BW (brine/water)..............14 Primary circuit, type WW (water/water)..............15 Primary circuit, type BW + BWS (two-stage)............19 Primary circuit, type WW + BWS (two-stage)............
  • Page 5 Index Index (cont.) Certificates Declaration of conformity..................138 Keyword index....................139...

  • Page 6: Preparing For Installation

    Vitotronic 200, type WO1A. Vitocal 300-G, Type BWS The Vitocal 300-G type BWS is used to extend the output (stage 2) of heat pumps type BW and WW (stage 1). Heat pump stage 2 (type BWS) can be used both for heating operation and DHW heating.

  • Page 7: General Information - Electrical Connection

    Preparing for installation General information - electrical connection ■ Connecting cables, heat pump These connections are made inside stage 1 – stage 2: the heat pump control unit. Observe See page 65. information from page 67. ■ Electrical connection of system ■...
  • Page 8 Preparing for installation Installation (cont.) ■ To prevent structure-borne noise, ■ Observe the required floor area and never site the appliance on ceilings minimum room volume (as per with wooden joists (e.g. in the attic). DIN EN 378). ■ Level the appliance. If the adjustable feet are used to com- pensate for an uneven floor (max.
  • Page 9 Preparing for installation Installation (cont.) Two-stage (type BW + BWS) ≥ 400 ≥ 400 = 300 A Clearance depends on on-site installation and location...
  • Page 10 Preparing for installation Installation (cont.) Requirements - on-site connections Single stage (type BW) 230 V < 42 V 400 V...
  • Page 11 Preparing for installation Installation (cont.) Two-stage (type BW + BWS) 230 V < 42 V 230 V < 42 V 400 V 400 V = 300 ■ Install hydraulic connections on site stress-free. ■ Establish hydraulic connections between the two heat pumps (type BW/BWS) on site.

  • Page 12: Overview Of Possible System Schemes

    Preparing for installation Installation (cont.) Line lengths in the heat pump plus wall clearance: Type Heat pump control unit 1.0 m A connecting cable is used power supply (230 V~) for the power supply Compressor power supply 1.0 m 1.0 m (400 V~) Additional power cables 1.5 m...
  • Page 13 Preparing for installation Overview of possible system schemes (cont.) Components System scheme (parameter 7000) Heating circuit – – – – – – – – – – – – – – – – – – DHW cylinder – – – – —...

  • Page 14: Primary Circuit, Type Bw (Brine/Water)

    Preparing for installation Primary circuit, type BW (brine/water) Hydraulic installation scheme P Primary circuit interface Required equipment Pos. Designation Heat pump Heat pump control unit Primary pump Brine accessory pack Pressure switch, primary circuit Brine distributor for geothermal probes/collectors Geothermal probes/collectors Electrical installation scheme Overview of electrical connections and details regarding the PCBs, see from...

  • Page 15: Primary Circuit, Type Ww (Water/Water)

    Preparing for installation Primary circuit, type BW (brine/water) (cont.) 200 W sYYA X2.N X3.9 230 V; 0.15 A wQ X3.8 Primary circuit, type WW (water/water) Hydraulic installation scheme P Primary circuit interface...
  • Page 16 Preparing for installation Primary circuit, type WW (water/water) (cont.) Equipment required Pos. Designation Heat pump Heat pump control unit Primary pump Frost stat, primary circuit Brine accessory pack Pressure switch, primary circuit Separating heat exchanger, primary circuit Flow limiter, well circuit (remove jumper when connecting) Dirt trap Well pump (suction pump for groundwater;...
  • Page 17 Preparing for installation Primary circuit, type WW (water/water) (cont.) With well pump connection 230 V~ 200 W sYYA X2.N L1 ? X3.3 230 V; 2mA ´ X3.4 X3.9 230 V; 0.15 A wQ X3.8 230 V; 0.15 A qO...
  • Page 18 Preparing for installation Primary circuit, type WW (water/water) (cont.) Well pump on-site connection 400 V 200 W sYYA X2.N L1 L2 L3 I>I>I>...

  • Page 19: Primary Circuit, Type Bw + Bws (Two-Stage)

    Preparing for installation Primary circuit, type BW + BWS (two-stage) With two primary pumps Hydraulic installation scheme P Primary circuit interface Equipment required Pos. Designation Heat pump stage 1 Heat pump control unit Heat pump stage 2 Primary pump, heat pump stage 1 Flow temperature sensor, primary circuit Return temperature sensor, primary circuit Brine accessory pack...
  • Page 20 Preparing for installation Primary circuit, type BW + BWS (two-stage) (cont.) Electrical installation scheme Overview of electrical connections and details regarding the PCBs, see from page 67 and the separate service instructions, Vitotronic 200 heat pump control unit. 200 W sYYA X2.N 200 W...
  • Page 21 Preparing for installation Primary circuit, type BW + BWS (two-stage) (cont.) Hydraulic installation scheme P Primary circuit interface Equipment required Pos. Designation Heat pump stage 1 Heat pump control unit Heat pump stage 2 Common primary pump Primary circuit flow temperature sensor (for installation, see page 87) Primary circuit return temperature sensor (for installation, see page 87) Brine accessory pack...
  • Page 22 Preparing for installation Primary circuit, type BW + BWS (two-stage) (cont.) Electrical installation scheme Overview of electrical connections and details regarding the PCBs, see from page 67 and the separate service instructions, Vitotronic 200 heat pump control unit. sYYA sXVS 200 W X2.N X3.9...

  • Page 23: Primary Circuit, Type Ww + Bws (Two-Stage)

    Preparing for installation Primary circuit, type WW + BWS (two-stage) With two primary pumps Hydraulic installation scheme P Primary circuit interface...
  • Page 24 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Equipment required Pos. Designation Heat pump stage 1 Heat pump control unit Heat pump stage 2 Primary pump, heat pump stage 1 Primary circuit flow temperature sensor (for installation, see page 87) Primary circuit return temperature sensor (for installation, see page 87) Frost stat, primary circuit...
  • Page 25 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Well pump on-site connection 230 V 200 W sYYA X2.N 200 W sXVS X2.N L1 ? N X3.1 X2.N...
  • Page 26 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Well pump on-site connection 400 V 200 W sYYA X2.N 200 W sXVS X2.N L1 L2 L3 X3.1 X2.N I>I>I>...
  • Page 27 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Connecting the sensors and limiters X3.3 230 V; 2 mA ´ X3.4 X3.8 230 V; 0.15 A wQ X3.9 230 V; 0.15 A qO Pt 500 Pt 500 With a common primary pump Note If heat pumps stage 1 and 2 (types WW and BWS) are installed with different...
  • Page 28 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Hydraulic installation scheme P Primary circuit interface...
  • Page 29 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Equipment required Pos. Designation Heat pump stage 1 Heat pump control unit Heat pump stage 2 Common primary pump Primary circuit flow temperature sensor (for installation, see page 87) Primary circuit return temperature sensor (for installation, see page 87) Frost stat, primary circuit...
  • Page 30 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Well pump on-site connection 400 V L1L2L3 sYYA sXVS 200 W I>I>I> X2.N X2.N...
  • Page 31 Preparing for installation Primary circuit, type WW + BWS (two-stage) (cont.) Connecting the sensors and limiters X3.3 230 V; 2 mA ´ X3.4 X3.8 230 V; 0.15 A wQ X3.9 230 V; 0.15 A qO Pt 500 Pt 500...

  • Page 32: Dhw Heating

    Preparing for installation DHW heating Hydraulic installation scheme Heat pump interface KW Cold water WW DHW Interface to the solar thermal sys- tem or the external heat source Required equipment Pos. Designation DHW cylinder Cylinder temperature sensor Cylinder primary pump (DHW side) Plate heat exchanger Flow limiter Motorised two-way valve, normally closed...
  • Page 33 Preparing for installation DHW heating (cont.) 50 W sYXD ZP eU X2.N 130 W sXVH UP eE X2.N Pt 500 Required parameter settings Set the required parameters during com- missioning; see from page 107. Parameter Setting "System definition" ■ "System scheme 7000" "0"...

  • Page 34: Integration Of The Two-Stage Version In The System Examples

    Preparing for installation Integration of the two-stage version in the system examples Note For the two-stage heat pump cascade, ■ Every partial scheme can be integra- the lead appliance and lag heat pumps ted into the system examples via the can each comprise a heat pump stage interfaces indicated.
  • Page 35 Preparing for installation Integration of the two-stage version in the… (cont.) Equipment required Pos. Designation Heat source Heat pump stage 1 Heat pump control unit (for the power supply, use a 3 x 1.5 mm cable; on- site fuse protection ≤ 16 A) Outside temperature sensor Circulation pump for cylinder heating (heating water side), heat pump stage Secondary pump, heat pump stage 1...
  • Page 36 Preparing for installation Integration of the two-stage version in the… (cont.) Heat pump cascade with two-stage heat pumps Hydraulic installation scheme...
  • Page 37 Preparing for installation Integration of the two-stage version in the… (cont.) Interface to the separate cooling Interface to the DHW cylinder circuit or heating/cooling circuit Lead appliance (two-stage) of Interface to the heating circuits the heat pump cascade or the heating water buffer cylin- II to IV Lag heat pumps 1 to 3, each two-stage Interface to the primary circuit...
  • Page 38 Preparing for installation Integration of the two-stage version in the… (cont.) Electrical installation scheme Overview of electrical connections and details regarding the PCBs, see from page 67 and the separate service instructions, Vitotronic 200 heat pump control unit. 130 W sXVG X2.N 130 W...

  • Page 39: System Example 1, Id: 4605307_1006_01

    Preparing for installation System example 1, ID: 4605307_1006_01 Setting system scheme 8 ■ Solar thermal system ■ Single stage heat pump, type BW ■ Heating water buffer cylinder ■ 1 underfloor heating circuit with mixer (M2) Note ■ 1 radiator circuit with mixer (M3) This scheme is a basic example without ■...
  • Page 40 Preparing for installation System example 1, ID: 4605307_1006_01 (cont.) Pos. Designation Heat source Heat pump Heat pump control unit Outside temperature sensor Circulation pump for cylinder heating (heating water side) Secondary pump KM BUS distributor Safety equipment block with safety assembly Expansion vessel Primary circuit Primary pump...
  • Page 41 Preparing for installation System example 1, ID: 4605307_1006_01 (cont.) Pos. Designation Heating water buffer cylinder Heating water buffer cylinder Buffer temperature sensor System flow temperature sensor Solar buffer temperature sensor (connection S4 to Vitosolic) Solar circuit pump R4 for heating up the heating water buffer cylinder High limit safety cut-out for heating water buffer cylinder to switch off the solar circuit pump R4 zZ Heating circuit with mixer (M2)
  • Page 42 Preparing for installation System example 1, ID: 4605307_1006_01 (cont.) 200 W 211.1 X2.N 130 W 211.4 X2.N 50 W 212.3 X2.N 130 W 211.2 X2.N 130 W 224.6 X2.N 225.3 OPEN X2.N CLOSED 225.2 100 W 225.1 UP M2 X2.N X3.9 230V;...
  • Page 43 Preparing for installation System example 1, ID: 4605307_1006_01 (cont.) H1;2 230 V/ 50 Hz 1 / N / PE UP M3 230 V/ 50 Hz...
  • Page 44 Preparing for installation System example 1, ID: 4605307_1006_01 (cont.) PT500 PT500 PT500 Ni500 PT500 VTS M2 Control unit power supply Compressor power supply 3 / PE X3.18 1 / N / PE 400 V, 50 Hz X2.1 230 V, 50 Hz X1.1 A Mains terminals on the cross con- nect PCB...

  • Page 45: System Example 2, Id: 4605308_1006_01

    Preparing for installation System example 1, ID: 4605307_1006_01 (cont.) Parameter Setting "System definition" ■ "System scheme 7000" "6" ■ "Common flow temperature sensor system "1" 701B" "Solar" ■ "Type solar control unit 7A00" "2" Note Vitosolic parameters must be set (see Vitosolic instal- lation and service instructions) DHW heating: "Time program DHW"...
  • Page 46 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) Hydraulic installation scheme --8/145-- --8/145-- -8/145- --2/F14-- --105/2-- -2/225.1--76- --87/X4.1;2-- --105/20-- -87/52- --105/52-- --74-- --2/225.2;3-- --2/F13-- ----114/50-- -2/224.3--14- -2/211.2--14- --2/224.5-- --2/211.4-- -2/212.3- -2/224.7- --6;10-- -2/222.4--51- 33 --2/224.6-- Pos. Designation Heat source Heat pump stage 1 Heat pump control unit...
  • Page 47 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) Pos. Designation Outside temperature sensor Circulation pump for cylinder heating (heating water side) for heat pump stage 1 Secondary pump for heat pump stage 1 KM BUS distributor Heat pump stage 2 Secondary pump for heat pump stage 2 Circulation pump for cylinder heating (heating water side) for heat pump stage 2...
  • Page 48 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) Pos. Designation DHW heating with a primary store system DHW cylinder Cylinder temperature sensor Cylinder primary pump (DHW side) Plate heat exchanger Flow limiter Motorised two-way valve, normally closed DHW circulation pump External heat source High limit safety cut-out to switch off the secondary pumps 6 and qP External heat source, e.g.
  • Page 49 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) Pos. Designation Natural cooling function (NC) Note All required components (with a suitably designed plate heat exchanger) for the cooling circuit must be provided on site. 3-way diverter valve Note When using a 3-way diverter valve without spring-loaded return, at contact gS2 (from pos iU) "L1"...
  • Page 50 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) Pos. Designation Heating circuit with mixer (M3) q¢P Radiator heating circuit with mixer, controlled via KM BUS q¢Q Vitotrol 200 remote control (accessory) q¢E Flow temperature sensor q¢T Extension kit for heating circuit with mixer q¢Z Heating circuit pump q¢U...
  • Page 51 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) 200 W 211.1 X2.N 100 W 212.2 UP A1 X2.N 130 W 211.4 X2.N 50 W 212.3 X2.N 130 W 211.2 X2.N 224.7 X2.N 130 W 224.6 X2.N 225.3 OPEN X2.N CLOSED 225.2 100 W...
  • Page 52 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) 211.5 X2.4 X2.N X2.3 X2.2 230 V/50 Hz X2.1 52 1. 52 2. 20 1. 20 2. X3.1 230V / 1A X3.2 X3.3 230V / 1A X3.4 X4.1 24V / 10mA X4.2 X4.3 24V / 10mA...
  • Page 53 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) H1;2 230 V/ 50 Hz 1 / N / PE 230 V/ 50 Hz 1 / N / PE 230 V/ 50 Hz 1 / N / PE 400 V, 50 Hz...
  • Page 54 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) PT500 PT500 PT500 PT500 Ni500 PT500 VTS M2 PT500 PT500 Control unit power supply Compressor power supply 3 / PE X3.18 1 / N / PE 400 V, 50 Hz X2.1 230 V, 50 Hz X1.1 A Mains terminals on the cross con-...
  • Page 55 Preparing for installation System example 2, ID: 4605308_1006_01 (cont.) Parameter Setting "System definition" ■ "System scheme 7000" "6" ■ "Swimming pool 7008" "1" ■ "External extension 7010" "1" ■ "Common flow temperature sensor system "1" 701B" "Compressor 2" ■ "Enable compressor 5100" "1"...

  • Page 56: Installation Sequence

    Installation sequence Installing the heat pump Levelling the heat pump Position and level the heat pump as described on page 7.
  • Page 57 Installation sequence Installing the heat pump (cont.) Removing the transport brackets Please note If transport brackets are not removed, they cause vibrations and excessive noise. Remove transport brackets and secure with lower screws on to the base carrier (see step 4).
  • Page 58 Installation sequence Installing the heat pump (cont.) Remove top panel...

  • Page 59: Hydraulic Connections

    Installation sequence Hydraulic connections Overview of connections < 4 Connecting the primary circuit Please note 1. Equip the primary circuit with an The components used must be expansion vessel and safety valve (in resistant to the heat transfer accordance with DIN 4757). medium.
  • Page 60 5. Fill the primary circuit with the heat transfer medium. Viessmann heat transfer medium ■ Blow-off and drain lines must con- and vent. verge in one container that can...
  • Page 61 Installation sequence Hydraulic connections (cont.) Please note 3. Fill and vent secondary circuit. To prevent equipment dam- age, 4. Thermally insulate pipes inside the connect on-site secondary building. lines to the heat pump so that they are free of load and tor- Note que stresses.

  • Page 62: Electrical Connections In The Heat Pump Control Unit

    Installation sequence Electrical connections in the heat pump control unit Installing the programming unit rl a u ft iz u ra tu /K ü h lu la re s s e In fo °C rg ie a ti W ä h le [XÖ...
  • Page 63 Installation sequence Electrical connections in the heat pump control… (cont.) Routing cables to the connection area Danger When routing the on-site power cables, Damaged cable insulation can observe the location of the cable entries cause injury and damage to the into the appliance via its back panel (see appliance.
  • Page 64 Installation sequence Electrical connections in the heat pump control… (cont.) <42 V 230 V 400 V 1. Route LV cables through opening "< 3. Route power cable for compressor 42 V" to the heat pump control unit through opening "400 V" to terminal connection area.
  • Page 65 Installation sequence Electrical connections in the heat pump control… (cont.) Route electrical cables from heat pump stage 2 (type BWS) to the heat pump control unit < 42 V 230 V < 42 V 230 V aJ B A Heat pump stage 2 (type BWS) ter- C 230 V~ connecting cables minal area for cables connecting to D Primary pump power cable, if instal-...
  • Page 66 Installation sequence Electrical connections in the heat pump control… (cont.) < 42 V 230 V [C-Ö B < 42 V low voltage connecting leads D Primary pump power cable, if instal- with plugs aJ and aVG led (connection to terminals 4X41.4, see next chapter) C 230 V~ connecting cables with plugs "X300"...
  • Page 67 Installation sequence Electrical connections in the heat pump control… (cont.) Overview of electrical connections Note ■ Route 230 V~ cables and LV cables separately and bundle them tightly together at the terminals. This ensures that, in case of failure, for example when detaching a wire, the wires can- not drift into the adjacent voltage area.
  • Page 68 Installation sequence Electrical connections in the heat pump control… (cont.) Type BW...
  • Page 69 Installation sequence Electrical connections in the heat pump control… (cont.) Type BWS A Transformer, EEV PCB G Main PCB B EEV PCB (electronic expansion H Main PCB extension valve) K Controller and sensor PCB C Compressor contactors, control unit L Programming unit starter, three-phase monitor M Plug for connecting cable stage 1/2 D Cable channel...
  • Page 70 Installation sequence Electrical connections in the heat pump control… (cont.) Terminal area, heat pump control unit fÖ sYD sYS F3/F4 F8/F9 F13/F14 F0/F2 F18/F20 F6/F7 F21/F23 F11/F12 F16/F17 sXD sXS sXA sYÖ sXÖ A Cross connect PCB E Controller and sensor PCB B F1 Fuse 6.3 A (slow) C Extension PCB D Main PCB...
  • Page 71 Installation sequence Electrical connections in the heat pump control… (cont.) Main PCB Information regarding the connection Set the required parameters during com- values missioning; see from page 107. ■ The output given is the recommended connected load. ■ The total output of all components con- nected directly to the heat pump con- trol unit (e.g.
  • Page 72 Installation sequence Electrical connections in the heat pump control… (cont.) Operating components 230 V~ Plug sYA Terminals Function Explanation 211.1 Primary pump (heat pump Connection values stage 1 or common primary ■ Output: 200 W pump), switching well pump ■ Voltage: 230 V~ ■...
  • Page 73 Installation sequence Electrical connections in the heat pump control… (cont.) Plug sYA Terminals Function Explanation 211.5 Cooling control Circuit on site NC function control (natural Connection values cooling) ■ Output: 10 W NC/AC ■ Voltage: 230 V~ ■ Max. switching current: 4(2) A Plug sYS Terminals Function...
  • Page 74 Installation sequence Electrical connections in the heat pump control… (cont.) Connecting a temperature limiter as maximum temperature limiter for under- floor heating system General connection Connection with temperature limiter (part no. 7151 728, 7151 729) X2.N X2.N sÖ A Connection on the main PCB (211.2 or 212.2 in accordance with the A Connection on the main PCB (211.2 table above)
  • Page 75 Installation sequence Electrical connections in the heat pump control… (cont.) Connection with temperature limiter (part no. 7151 728, 7151 729) to exten- sion kit for heating circuit with mixer sÖ sÖ A Plug sÖ for extension kit B Temperature limiter C Heating circuit pump...
  • Page 76 Installation sequence Electrical connections in the heat pump control… (cont.) Extension PCB Information regarding the connection Set the required parameters during com- values missioning; see from page 107. ■ The output given is the recommended connected load. ■ The total output of all components con- nected directly to the heat pump con- trol unit (e.g.
  • Page 77 Installation sequence Electrical connections in the heat pump control… (cont.) Plug sXS Terminals Function Explanation 222.3 Switching external heat Zero volt contact 222.4 source with two high limit safety cut-outs (max. 70 °C) Note to protect the heat pump and ■...
  • Page 78 Installation sequence Electrical connections in the heat pump control… (cont.) C Connection on the external heat High limit safety cut-out for heat pump in conjunction with an external source at terminals for external heat source demand D High limit safety cut-out (max. 70 °C) as heat pump protection X3.1 K1 Relay;...
  • Page 79 Installation sequence Electrical connections in the heat pump control… (cont.) Central fault message 223.1 230 V~, 0.5 A 223.2 A Terminals on extension PCB Plug sXF Terminals Function Explanation 224.2 Primary pump for heat pump Connection values stage 2 (if installed) ■...
  • Page 80 Installation sequence Electrical connections in the heat pump control… (cont.) Plug sXF Terminals Function Explanation 224.6 ■ Cylinder primary pump Switch cylinder primary pump and two- (DHW side) way shut-off valve in parallel ■ 2-way shut-off valve Connection values ■ Output: 130 W ■...
  • Page 81 Installation sequence Electrical connections in the heat pump control… (cont.) Plug sXG Terminals Function Explanation 225.1 Heating circuit pump of the Connect temperature limiter as maxi- heating circuit with mixer mum temperature limiter for underfloor heating circuit (if installed) in series. Connection values: ■...
  • Page 82 Installation sequence Electrical connections in the heat pump control… (cont.) Terminals Function Explanation ■ Power supply terminals Terminals for message and safety connec- of the control unit "L1" tions and auxiliary compo- nents Note ■ Switched phase L1: Switched phase can be used for on-site X3.1, X3.2, X3.3, X3.7, system components.
  • Page 83 Installation sequence Electrical connections in the heat pump control… (cont.) Terminals Function Explanation X3.6 Power-OFF Requires floating N/C contact: X3.7 ■ Closed: No blocking (safety chain has continuity) ■ Open: Blocking enabled ■ Breaking capacity 230 V~, 0.15 A With a connected power-OFF contact, no jumpers should be installed.
  • Page 84 Installation sequence Electrical connections in the heat pump control… (cont.) Terminals Function Explanation X3.10 Fault message, lag heat Floating contact required: X3.11 pump in a cascade ■ Closed: No faults ■ Open: Fault Jumper ■ Breaking capacity 230 V~, 0.15 A With a connected message contact, no jumpers should be installed.
  • Page 85 Installation sequence Electrical connections in the heat pump control… (cont.) Sensors Plug Sensor Type Outside temperature sensor, connect on site Ni 500 (PTC) Primary circuit flow temperature sensor, connect on site Pt 500 (X5.2/X5.3) with two-stage heat pump (see the following chapter) (PTC) Primary circuit return temperature sensor, connect on Pt 500...
  • Page 86 Installation sequence Electrical connections in the heat pump control… (cont.) Plug Sensor Type KM BUS On-site component connection (wires interchangeable); for several appliances, use the KM BUS distributor (accessory). ■ Extension kit for one heating circuit with mixer M3 ■ Vitotrol 200A remote control (assign the heating cir- cuits at the remote control) ■...
  • Page 87 Installation sequence Electrical connections in the heat pump control… (cont.) Connection of primary circuit flow/return temperature sensor, two-stage heat pump < 42 V aS Flow temperature sensor, primary aD Return temperature sensor, primary circuit circuit Please note Identify sensor leads. Fasten sensor leads and disman- tled leads (with plug aS/aD) together with the other LV leads...
  • Page 88 Installation sequence Electrical connections in the heat pump control… (cont.) Swimming pool water heating Note ■ At plug gÖ connect only the circulation ■ Swimming pool water heating is pump for swimming pool water heating switched via external extension H1 F in accordance with the following with KM BUS.
  • Page 89 Installation sequence Electrical connections in the heat pump control… (cont.) Cascade control via KM BUS Make connections at external extension H1 only in accordance with the following diagram. X3.10 X3.11 230V 223.1 fÖ 223.2 230V 223.1 223.2 230V sÖ 223.1 223.2 A Heat pump 1 (lead appliance) B KM BUS...
  • Page 90 Installation sequence Electrical connections in the heat pump control… (cont.) C External extension H1 H Zero volt contact "External demand " D Zero volt contact "External demand " K Lag heat pump 3 E Lag heat pump 1 L Central fault message input, lag Connection at contact for "External heat pump demand "...

  • Page 91: Power Supply

    Installation sequence Power supply Isolators for non-earthed conductors Danger ■ The main isolator (if installed) must The absence of component simultaneously isolate all non-earthed earthing in the system can lead to conductors from the mains with a min- serious injury from electrical cur- imum contact separation of 3 mm.
  • Page 92 Installation sequence Power supply (cont.) ■ The heat pump control unit/PCB Information regarding the compres- must be supplied without blocking by sor power supply the power supply utility; tariffs that are ■ subject to possible shutdown must not Please note be used here.
  • Page 93 Installation sequence Power supply (cont.) Compressor power supply (400 V~) ■ No parameters need to be set when using economy tariff with power-OFF facility. During the power-OFF period, 3 / PE the compressor is shut down. 400 V, 50 Hz ■...
  • Page 94 Installation sequence Power supply (cont.) Single stage (type BW) X3.7 X3.6 ≈ Diagram excluding fuses and RCD A Heat pump control unit (connection E Ripple control receiver (contact on cross connect PCB) open: power-OFF enabled) B Instantaneous heating water heater F Backup fuse ripple control receiver (accessory) G TNC system feed...
  • Page 95 Installation sequence Power supply (cont.) Two-stage (type BW + BWS) X3.7 X3.6 ≈ Shown excluding fuses and RCD A Heat pump control unit (connection E Ripple control receiver (contact on cross connect PCB) open: power-OFF enabled) B Instantaneous heating water heater F Backup fuse ripple control receiver (on site) G TNC system feed...
  • Page 96 Installation sequence Power supply (cont.) Power-OFF with on-site load disconnection The power-OFF signal is connected to Note the on-site contactor of the low tariff Observe the technical connection condi- power supply and in the heat pump con- tions of the relevant power supply util- trol unit (type BW).
  • Page 97 Installation sequence Power supply (cont.) G Ripple control receiver (contact H Economy tariff meter open: power-OFF enabled) with K TNC system feed backup fuse Two-stage (type BW + BWS) X3.7 X3.6 ≈ Shown excluding fuses and RCD A Heat pump control unit (connection F High tariff meter on cross connect PCB) G Ripple control receiver (contact...
  • Page 98 Installation sequence Power supply (cont.) Phase monitor The phase monitor is used to monitor the The phase monitor switches off (switch- mains power supply to the compressor. ing contact opens) if these tolerances The following different mains supplies (if are exceeded. adjustable) are permissible in the deliv- The phase monitor automatically re-ena- ered condition:...

  • Page 99: Connecting To Terminals X3.8/X3.9

    Installation sequence Power supply (cont.) Version 2 N 11 21 LEDs explained A Voltage "U": Illuminates green if voltage is L1 L2 L3 applied. B Relay "R": Illuminates yellow if the phase sequence is correct. Does not illuminate if the phase sequence is incorrect.

  • Page 100: Closing The Heat Pump

    Installation sequence Closing the heat pump Please note Danger Seal the appliance so it is sound- The absence of component proof and diffusion-proof. earthing in the system can lead to Check tightness of internal serious injury from electrical cur- hydraulic connections. rent if an electrical fault occurs.

  • Page 101: Checking Diaphragm Grommets

    Installation sequence Closing the heat pump (cont.) 4. 10x Checking diaphragm grommets Please note Seal the appliance so it is sound- proof and diffusion-proof. With hose outlets, ensure dia- phragm grommets A are seated correctly. Seal diaphragm grommets A with adhesive tape.
  • Page 102 Installation sequence Checking diaphragm grommets (cont.)

  • Page 103: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Opening the heat pump..........104 • 2. Writing reports..............104 •...

  • Page 104: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Opening the heat pump Danger 1. Remove front panel in reverse order; Contact with 'live' components see page 100. can lead to severe injury from electric current. 2. When work is complete, close the Never touch terminal areas heat pump;...

  • Page 105: Checking The Refrigerant Circuit For Leaks

    1. Check the pre-charge pressure of the expansion vessel (see page 106). 2. Fill the primary circuit with Viessmann heat transfer medium and vent. Note The system must be protected against frost down to –15 °C.

  • Page 106: Filling And Venting The Solar Circuit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note 5. Check the system pressure and top To prevent equipment dam- up with water if required. age, check the flow and return Minimum system pressure: 0.8 bar connections of the secondary Permiss.

  • Page 107: Commissioning The System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning the system Commissioning (configuration, setting Note parameters and function checks) can be Type and extent of parameters depends carried out with or without the commis- on the heat pump type, on the selected sioning assistant (see the following system scheme and the accessories chapter and the separate service instruc-...
  • Page 108 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Language Date Date / time Time Start commissioning? Programming Parameter group Parameter level 1 select Sensor values Temperature sensors display Signal inputs Signal inputs display Actuator test Actuator test carry out Subscriber check Subscriber check LON carry out...
  • Page 109 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning without the commissioning assistant Activating the service menu 3. Select parameter group: "System definition" The service menu can be enabled from 4. Select parameter: "System scheme any menu. 7000" Press OK + å...
  • Page 110 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pumps and other components Pump/component Parameter Setting Secondary pump (for "System definition" Ó "1" to "11" heating circuit A1 without "System scheme 7000" heating water buffer cyl- inder; no additional heat- ing circuit pump required) Heating circuit pump A1...
  • Page 111 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pump/component Parameter Setting Circulation pump for "External heat source" Ó "1" DHW reheating "Enable external heat source 7B00" "External heat source" Ó "1" "Enable external heat source for DHW heating 7B0D"...
  • Page 112 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Two-stage heat pump Parameter Setting Compressor 2: ■ "Enable compressor 5100" "1" ■ "Output compressor stage 2 5130" Value corresponding to the rated heating output of heat pump stage 2, see type plate External functions External functions...
  • Page 113 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) External functions Parameter Setting External blocking of the com- "System definition" Ó "0" to "8" pressor; mixer in control "Effect of external block- mode or CLOSED ing on heat pump/heating circuits 7015"...
  • Page 114 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) External heat source External heat source parameters Setting "External heat source" Ó "1" "Enable external heat source 7B00" With circulation pump for DHW reheating: "1" "External heat source" Ó "Enable booster heaters for DHW heating 6014"...
  • Page 115 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cascade via LON Parameter Setting Lead appliance Lag heat pump "System definition" Ó "0" to "10" "11" "System scheme 7000" "System definition" Ó "2" "0" "Cascade control 700A" "System definition" Ó "1"...

  • Page 116: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct him/her in the operation of the system.

  • Page 117: Troubleshooting

    Troubleshooting Repairs Overview of internal components A Primary circuit flow temperature L Electronic expansion valve (EEV) sensor (heat pump brine inlet) M Drain valve, primary side B Suction gas temperature sensor N Filter dryer C Condenser O Primary circuit return temperature D High pressure sensor EEV sensor (heat pump brine outlet) E Secondary circuit flow temperature...
  • Page 118 Troubleshooting Repairs (cont.) Draining the heat pump on the primary/secondary side 1. Close the on-site drain & fill valve. 2. Drain heat pump at drain valve on pri- mary/secondary side (see page 117). Checking sensors Sensor connections to the controller and For the position of the sensors in the heat sensor PCB.
  • Page 119 Troubleshooting Repairs (cont.) Temperature sensors type Pt 500 Capturing element "Pt 500" ■ System flow temperature sensor (F13) ■ Buffer temperature sensor (F4) ■ Cylinder temperature sensor (F6) ■ Flow/return temperature sensor, sec- ondary circuit (F8/F9) ■ All sensors inside the heat pump ■...
  • Page 120 Troubleshooting Repairs (cont.) Removing the heat pump module Please note Never put weight on the top, front Avoid device damage. or side panels of the appliance. [{{] U/V/W 5. Drain the primary and secondary sides (for drain valves, see page 117).
  • Page 121 Troubleshooting Repairs (cont.) Note on step 7 Please note Identify the plug-in and threaded con- Installing a compressor at a steep nections that belong together. angle inside the heat pump can Disconnect all electrical connections. result in equipment damage. Never tilt the heat pump module more than 45°.
  • Page 122 Troubleshooting Repairs (cont.) Note on step 9 To stabilise the heat pump module on the carrier, the transport brackets can be screwed on (see page 57). Installing the heat pump module Install in reverse order to removal. Please note To prevent the formation of con- densate and extreme noise development, tightly seal the control unit door.

  • Page 123: Parts Lists

    Parts lists Parts list Information for ordering spare parts. Obtain standard parts from your local Quote the part and serial numbers (see supplier. A Type plate type plate) and the position numbers of the required part (as per this parts list). Individual parts for type BW, BWS, WW 001 Compressor 029 Rubber cushion...
  • Page 124 Parts lists Parts list (cont.) 745 Thermal relay (only in type BW 145, 777 Compressor line BWS 145) 778 Cable kit, EEV 746 Thermal relay (only in type BW 121, 779 Cable harness 230 V~ BWS 121) 780 Cable harness, pressure switch 747 PCBs, terminal box 230 V~ with 781 Cable harness, low voltage cable harness...
  • Page 125 Parts lists Parts list (cont.) 211 206...
  • Page 126 Parts lists Parts list (cont.)
  • Page 127 Parts lists Parts list (cont.) 745/ 746/...

  • Page 128: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Hydraulic parameters report Setting and test values Set value Commission- Frost protection (brine medium) °C – 15 Testing the external heating circuit pumps Circulation pump type Circulation pump stage Overflow valve setting Primary circuit commissioning Primary circuit flow temperature °C Primary circuit return temperature °C...
  • Page 129 Commissioning/service reports Commissioning/service reports (cont.) Parameter Code Delivered condi- Commis- tion sioning System definition System scheme (see chapter "Overview 7000 of available system schemes") Temperature differential for calculating 7003 40 (≙ 4 K) the heating limit Temperature differential for calculating 7004 40 (≙...
  • Page 130 Commissioning/service reports Commissioning/service reports (cont.) Parameter Code Delivered condi- Commis- tion sioning External heat source Enable external heat source 7B00 Priority ext. heat source/instant. heating 7B01 water heater Dual mode temperature external heat 7B02 100 (≙ 10 °C) source Enable external heat source for DHW 7B0D heating Set DHW temperature...
  • Page 131 Commissioning/service reports Commissioning/service reports (cont.) Parameter Code Delivered condi- Commis- tion sioning Electr booster heater Enable instantaneous heating water 7900 heater Enable instant. heating water heater for 7902 central heating Max. output instantaneous heating water 7907 heater Output for instant. heating water heater at 790A power-OFF Dual mode temp.
  • Page 132 Commissioning/service reports Commissioning/service reports (cont.) Parameter Code Delivered condi- Commis- tion sioning Heating circuit 2 Standard room temperature 3000 200 (≙ 20 °C) Reduced room temperature 3001 200 (≙ 20 °C) Remote control 3003 Heating curve slope 3006 6 (≙ 0.6) Heating curve level 3007 0 (≙...
  • Page 133 Commissioning/service reports Commissioning/service reports (cont.) Parameter Code Delivered condi- Commis- tion sioning Time Automatic changeover summertime - 7C00 wintertime Start summertime - month 7C01 Start summertime - week 7C02 Start summertime - day 7C03 Start wintertime - month 7C04 Start wintertime - week 7C05 Start wintertime - day 7C06...

  • Page 134: Specification

    Specification Specification Type BW, BWS BW, BWS Output data to DIN EN 14511 (0/35 °C, 5 K spread) Rated output 21.2 28.8 42.8 Cooling capacity 17.0 23.3 34.2 Power consumption 4.48 5.96 9.28 Coefficient of performance ε 4.73 4.83 (COP) Output data to DIN EN 255 (0/35 °C, 10 K spread) Rated output...
  • Page 135 Specification Specification (cont.) Brine (primary circuit) Content 12.7 Minimum flow rate at approx. 4 K 5200 7200 10600 spread (always maintain) Pressure drop mbar Max. inlet temperature °C Min. inlet temperature °C Heating water (secondary circuit) Content 12.7 Minimum flow rate (always main- 1900 2550 3700...
  • Page 136 Specification Specification (cont.) BW, BWS, WW Refrigerant circuit Refrigerant R 410 A Fill volume 10.0 Compressor Type Hermetically sealed scroll com- pressor Permiss. operating pressure, high pressure side Permiss. operating pressure, low pressure side Permiss. operating pressure Primary circuit Secondary circuit Dimensions Total length 1085...

  • Page 137: Appendix

    All windows and external doors sealed Geothermal probes/well and connection lines fully installed Components for cooling mode fully installed (option) Preferred appointment: Date Time Date Time All work ordered from Viessmann will be charged to me/us in accordance with the current Viessmann pricelist. Place/date Signature...
  • Page 138 Certificates Declaration of conformity We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole respon- sible body that the product Vitocal 300-G, type BW, BWS, WW incl. Vitotronic 200, type WO1A complies with the following standards: DIN 7003 DIN EN 61 000-3-3; 2009-06 DIN 8901 DIN EN 61 000-3-11;...
  • Page 139 Keyword index Keyword index Activating, service menu....109 Declaration of conformity....138 Appliance fuse.........119 DHW heating........32 Appliance too noisy......119 Dimensions........10 Assembly.........101 Draining, secondary heat pump side..........118 Brine pressure switch......99 Electrical connection ■ General information......7 Cascade ■ heat pump control unit....70 ■ Control version......114 Electrical connections ■...
  • Page 140 Keyword index Keyword index (cont.) ID: 4605307_1006_01, type AWS..39 Parameter ID: 4605308_1006_01, type AWS..45 ■ Setting example......109 Inspection.........104 Parameters Installation........7, 10 ■ Cascade via H1......114 Installation room........7 ■ Cascade via LON......115 Instantaneous heating water heater...90 ■ Cooling function......113 Instructing the system user....116 ■...
  • Page 141 Keyword index Keyword index (cont.) Three-phase monitor......98 Sealing faces........101 Tilting angle..........7 Secondary circuit Transport brackets......57 ■ Connecting........60 Transport locking bracket....119 ■ Filling and venting......105 Sensors..........117 Sensors resistance curves....118 Underfloor heating circuit....74 Service menu Underfloor heating system....74 ■ Activating........109 Use of heat pump in a cas- ■...
  • Page 144 Applicability Herstell-Nr.: 7424066 7424067 7424068 7424072 7424073 7424074 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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