Viessmann BW 301.C090 Installation And Service Instructions For Contractors Download

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Installation and service instructions

for contractors

Viesmann

Vitocal 300-G Pro
Type BW 301.C090 to 302.C230

, 82.8 to 296.0 kW

Heat pump, single and two-stage

For applicability, see the last page

VITOCAL 300-G PRO

5787 232 GB

09/2016

Please keep safe.

Summary of Contents for BW 301.C090

Page 1: ...instructions for contractors Viesmann Vitocal 300 G Pro Type BW 301 C090 to 302 C230 82 8 to 296 0 kW Heat pump single and two stage For applicability see the last page VITOCAL 300 G PRO 5787 232 GB...

Page 2: ...olate the system from the power supply 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 severa...

Page 3: ...type BW 301 C090 to BW 302 C230 20 DHW heating type BW 301 C090 to BW 302 C230 21 4 Installation sequence Siting the heat pump 23 Levelling the heat pump 23 Removing the transport brackets 24 Fitting...

Page 4: ...ors 65 Temperature sensors type NTC 10 k 65 Temperature sensors type Pt500A 66 Checking MCBs fuses 66 8 Parts lists Ordering parts 67 Parts section 1 68 Parts section 2 70 9 Commissioning service repo...

Page 5: ...enance repair shut down X X X X X Dismantling removal col lection X X X X X Disposal X X X Electrical connections Danger Electromagnetic radiation near the wiring cham ber of the heat pump control uni...

Page 6: ...hreatening crushing or breaks Always use suitable ropes slings and lifting gear when installing dismantling compressors heat exchangers or similar Wear appropriate protective clothing e g safety boots...

Page 7: ...ehind sharp edges from the metal retaining tabs that can lead to life threatening injuries Finish and seal the edges appropriately before installation Note Damage to the surfaces of the casing can lea...

Page 8: ...nent or In conjunction with a tool Clean the sur face Dispose of component correctly Dispose of component at a suitable collec tion point Do not dispose of component in domestic waste The steps in con...

Page 9: ...ormation Vitocal 300 G Pro Heat pump Vitocal 300 G Pro type BW Medium Brine water Single stage heat pumps 301 C090 301 C120 Two stage heat pumps 302 C090 302 C110 302 C140 302 C180 302 C230 Characteri...

Page 10: ...wn any dam age on the delivery note and notify the haulage con tractor Lifting gear such as slings and cross beams must be provided on site The lifting capacity of each sling and that of the cross bea...

Page 11: ...ift truck or pallet truck Fig 2 Information regarding transport with fork lift truck Select a fork length appropriate for the total heat pump length see Specification from page 80 The heat pump s cent...

Page 12: ...301 C120 870 BW 302 C090 720 BW 302 C110 910 BW 302 C140 1180 BW 302 C180 1280 BW 302 C230 1425 To prevent the transmission of structure borne noise never site the appliance above ceilings with woode...

Page 13: ...ll clearance 80 mm B When using hydraulic connection accessories connection set and Victaulic flange adaptor set 2 or 3 1000 mm On site hydraulic connections 600 mm C Clearances for installation and m...

Page 14: ...ion screed C Top edge unfinished floor D Impact sound insulation as per regulations E Pressure tested sound insulation layer approx 10 to 20 mm F Heat pump Pressure points of the adjustable heat pump...

Page 15: ...e BW 301 C090 to BW 301 C120 BW 302 C090 and BW 302 C110 850 1343 1650 911 1241 644 436 1126 368 343 200 Fig 8 A Flow primary circuit inlet Victaulic 3 DN 80 B Flow secondary circuit outlet Victaulic...

Page 16: ...taulic 2 DN 65 E Low voltage 50 V F Power supply 230 V 50 Hz G Power supply 400 V 50 Hz Note The width of the heat pump is indicated with and with out side panels The dimensions without side panels ar...

Page 17: ...ary pump fail safe wP Brine safety assembly wQ Pressure switch primary circuit wW Brine manifold for geothermal probes collectors wU Geothermal probes Note If 2 primary pumps are used at least 75 of t...

Page 18: ...ol unit qT Primary pump 1 fail safe wP Brine safety assembly wQ Pressure switch primary circuit wW Brine manifold for geothermal probes collectors wT Optionally 2nd primary pump fail safe for stage 2...

Page 19: ...at pump fail safe Note For 2 stage Vitocal 300 G Pro a primary pump can be used for stages 1 and 2 respectively Ob serve minimum flow rate wP Brine safety assembly wQ Pressure switch primary circuit w...

Page 20: ...e to heating water buffer cylinder return C Interface to the separate cooling circuit or heat ing cooling circuit H Interface to heating water buffer cylinder flow P Interface to primary circuit flow...

Page 21: ...ctrical installation scheme For a summary of electrical connections see from page 31 and separate Connection and wiring dia gram DHW heating type BW 301 C090 to BW 302 C230 Hydraulic installation sche...

Page 22: ...rical connections see from page 31 and separate Connection and wiring dia gram Required parameter settings for DHW heating Set the required parameters during commissioning see from page 53 Parameter S...

Page 23: ...23 Levelling the heat pump Fig 15 Position and level the heat pump horizontally as described from page 10 Installation sequence Siting the heat pump 5787 232 GB Installation...

Page 24: ...sport brackets are not removed they cause vibrations and excessive noise Remove all 4 transport brackets fully from below and dispose of correctly Fig 16 A Transport locking screws Installation sequen...

Page 25: ...de panels and kicking plates Note After fitting the back panel make the hydraulic and electrical connections See following chapter 1 2 3 3 4 2x 6x 5 Fig 17 Installation sequence Siting the heat pump c...

Page 26: ...3 DN 80 B Flow secondary circuit outlet Victaulic 2 DN 65 C Return primary circuit outlet Victaulic 3 DN 80 D Return secondary circuit inlet Victaulic 2 DN 65 E Low voltage 50 V F Power supply 230 V...

Page 27: ...2 secondary circuit C Flexible connection pipe 3 primary circuit with anti vibration elements D Flexible connection pipe 2 secondary circuit with anti vibration elements E Hydraulic line fixings Note...

Page 28: ...fixings Fitting the Victaulic couplings Fig 21 1 Clean all Victaulic connections 2 Open Victaulic coupling B around 1 cm 3 Push Victaulic coupling B with inserted gasket as far as it will go onto conn...

Page 29: ...seated correctly Make line entries airtight 4 Insulate primary lines inside the building with ther mally insulating and vapour diffusion proof materi als 5 Charge the primary circuit with Viessmann he...

Page 30: ...t in the event of a fault e g if a wire becomes detached the wires cannot drift into the adjacent voltage area When routing the on site cables note the location of the cable entries into the appliance...

Page 31: ...16 2 1 K1116 1 6 STX3 6 5 STX3 5 13 LP1X3 13 12 LP1X3 12 11 LP1X3 11 10 LP1X3 10 9 LP1X3 9 8 LP1X3 8 7 LP1X3 7 6 LP1X3 6 4 LP1X3 4 3 LP1X3 3 2 LP1X3 2 1 LP1X3 1 16 LP1X3 16 16 LP1X3 16 16 LP1X3 16 16...

Page 32: ...fuse power circuit compressor 1 R Soft starter compressor 2 only type BW 302 C090 BW 302 C110 BW 302 C140 BW 302 C180 and BW 302 C230 S MCB fuse power circuit system components con sumers at terminal...

Page 33: ...component e g pump valve message facility contactor can be greater than specified However the breaking capacity of the corresponding relay must not be exceeded The stated current indicates the max sw...

Page 34: ...heat ing DHW heating Connection values Output 130 W Voltage 230 V Max control current 4 2 A Circulation pump for cylinder heating 211 5 NC Cooling control NC function natural cooling or NC signal for...

Page 35: ...nection and wiring dia gram Use contactor if required see separate Connection and wiring diagram 212 3 DHW circulation pump Connection values Output 50 W Voltage 230 V Max control current 4 2 A Connec...

Page 36: ...trol current 4 2 A Connect the high limit safety cut out on site In series with the secondary pump terminal 211 2 on main PCB see separate Connection and wiring diagram In series for switching externa...

Page 37: ...hut off valve in parallel Connection values Output 130 W Voltage 230 V Max control current 4 2 A Connection see separate Connection and wiring dia gram Use contactor if required see separate Connectio...

Page 38: ...5 2 M2 Switching of the mixer motor heating circuit M2 HC2 Signal mixer CLOSE Connection values Output 10 W Voltage 230 V Max control current 0 2 0 1 A Connection see separate Connection and wiring di...

Page 39: ...agram Signal and safety connections Clamps Function Explanation PE X1 Earth conductor Terminals for earth conductors of all associated system components LP1 X2 N Neutral conductor Terminals for the ne...

Page 40: ...ntinuous Open blocking enabled Breaking capacity 230 V 0 15 A Note No parameters need to be set No jumper should be installed if a power OFF contact is connected The compressor is forced off as soon a...

Page 41: ...atus of several system components Requires floating N O contact Closed demand Open no demand Breaking capacity 230 V 2 mA Note These and further external functions such as provision of external set va...

Page 42: ...in the Modbus distributor acces sories X20 Programming unit connection X24 Slot for LON communication module X25 Terminals for internal sensors and components Connections for connecting cable LV to th...

Page 43: ...ircuit Pt500A PTC X25 3 X25 4 Return temperature sensor primary circuit Pt500A PTC X25 9 X25 10 Flow temperature sensor secondary circuit Pt500A PTC X25 11 X25 12 Return temperature sensor secondary c...

Page 44: ...oller and sensor PCB Cascade control via LON The following communication modules accessories must be fitted in the heat pump control units LON cascade communication module in the lead heat pump LON co...

Page 45: ...erated at an econ omy tariff power OFF provide an additional cable for the power OFF signal from the meter box to the heat pump control unit The allocation of the power OFF for compressor and or insta...

Page 46: ...230 V Power circuit 400 V MCB fuse protec tion Cable cross section MCB fuse protection trunk line Cable cross section BW 301 C090 BW 302 C090 25 A 5 x 16 mm2 80 A 5 x 25 mm2 BW 301 C120 BW 302 C110 25...

Page 47: ...FF enabled TNC system feed H Economy tariff meter K Feed in TNC system Electronic soft starter type SMC Electronic soft starter functions Monitoring the compressor mains feed Reducing the compressor s...

Page 48: ...2 TEMP 3 PHASE REVERSAL 4 PHASE LOSS OPEN LOAD 5 PHASE IMBALANCE 6 SHORTED SCR 7 TEST L1 L2 L3 T1 T2 T3 Fig 30 Number of flashes 1 Overload 2 Excess temperature 3 Phase reversal 4 Phase loss motor not...

Page 49: ...lt in serious injury from electrical current and in component damage in the event of an electrical fault Restore all earth connections Please note Leaking hydraulic connections lead to appliance damag...

Page 50: ...on proof materials Have transport brackets been removed Are the back and side panels securely attached 2 3 1 Fig 32 2 Carefully position the front panel Pay particular attention to the shaft between t...

Page 51: ...5 Filling and venting on the secondary side 53 6 Checking expansion vessels and the primary circuit heating circuit pressure 53 7 Commissioning the system 53 8 Checking the electronic flow switch typ...

Page 52: ...s from page 72 onwards Checking the refrigerant circuit for leaks Check the floor area valves and all visible solder joints for traces of oil Note Traces of oil indicate a leak in the refrigerant circ...

Page 53: ...inimum system pressure 0 8 bar 80 kPa Permiss operating pressure 6 bar 0 6 MPa Checking expansion vessels and the primary circuit heating circuit pres sure Observe engineering information Heat pump te...

Page 54: ...en switching on the heat pump control unit progress bar visible When the unit is first commissioned the display is in German Sprache Dansk Cesky Bulgarski Deutsch W hlen mit DE BG CZ DK Fig 33 Manuall...

Page 55: ...for approx 4 s Deactivating the service menu The service menu remains active until it is disabled with Terminate service or if no key is pressed for 30 min Setting parameters using the System scheme...

Page 56: ...DHW heating DHW circulation pump Extended menu Time program DHW circulation Set time program Mixer extension kit for heating cir cuit M3 HC3 System definition System scheme 7000 With heating circuit M...

Page 57: ...ious system components System definition System components for external changeover 7011 0 to 127 Operating status for external changeover 7012 0 to 3 Duration of external changeover 7013 0 to 12 Exter...

Page 58: ...8 1 Parameters for solar DHW heating Parameters in conjunction with solar control module type SM1 Setting Solar Type solar control unit 7A00 3 Parameter C0xx See installation and service instruc tions...

Page 59: ...umptn for set DHW temperature 2 7E10 1 Enable own energy consumption for DHW heating 7E11 1 Enable own energy consumptn for heating water buffer cyl 7E12 1 Enable own energy consumption for heating 7E...

Page 60: ...rate reduced ventilation 7D0A Subject to sizing Ventilation unit service instruc tions Flow rate nominal ventilation 7D0B Flow rate intensive ventilation 7D0C Heat pump cascade Parameters for heat pum...

Page 61: ...35 Note The electronic flow switch is only used in the operating mode water water with intermediate circuit The flow switch monitors the minimum flow rate required for operating the heat pump 1 Check...

Page 62: ...uit at the switching output Note The current operating mode is displayed once the short cir cuit has been remedied No LED illuminates Operating voltage 85 V or power supply failure Carry out an operat...

Page 63: ...s it will go Hydraulic line is touching the heat pump casing back panel Hydraulic line not connected free of load and torque stress Anti vibration elements for hydraulic connection are missing Connect...

Page 64: ...age 31 Overview of internal components Fig 36 Example type BW 302 C140 1 Wiring chamber 2 Safety high pressure switch stage 1 3 Safety high pressure switch stage 2 only type BW 302 C090 to BW 302 C230...

Page 65: ...ry secondary side Checking sensors Sensor Test element Connection installation position Outside temperature sensor F0 Buffer temperature sensor F4 Cylinder temperature sensor F6 F7 Flow temperature se...

Page 66: ...ower circuit to zero volt For fuses in the front wiring chamber see page 32 and page 31 Power circuit MCB fuse compressor 1 and 2 see separate connection and wiring diagram Subject to heat pump compre...

Page 67: ...67 The following details are required when ordering parts Serial no see type plate Position number of the part from this parts list Parts lists Ordering parts 5787 232 GB Components...

Page 68: ...a 0017 0002 0014 0001 0028 0027 0004 0006 0009 0007 0007 0003 0010 0008 0005 0016 0012 0012 0013 0015 0001 0011 0026 0025 0024 0024 0023 0018 0019 0020 0027 Fig 39 Parts lists Parts section 1 5787 232...

Page 69: ...yer filter dryer assembly 0013 Dryer bracket 0014 Oil compensation line 0015 Sight glass for soldering 0016 EEV with stepper motor 0017 Sensor well with gasket 0018 Motor overload relay 0019 Cable fit...

Page 70: ...0031 0032 0031 0032 0029 0030 0032 0032 0033 6x 0034 0036 0035 0034 0040 0040 0038 0037 0039 0039 0043 0042 0041 4x 0045 0047 0049 0050 0048 0044 0046 Fig 40 Parts lists Parts section 2 5787 232 GB Co...

Page 71: ...rimary secondary pump 0039 Base for relay 0040 Relay 0041 EEV PCB 0042 Transformer EEV PCB 0043 EEV PCB retainer set 0044 Heat pump control unit 0045 Plug controller and sensor PCB 0046 Coding card 00...

Page 72: ...If secondary circuit flow temperature 35 C primary circuit flow temperature 10 C K 3 to 5 If secondary circuit flow temperature 35 C primary circuit flow temperature 0 C K 2 to 4 Testing the mixer hea...

Page 73: ...king on heat pump heating circuits 7015 4 Vitocom 100 7017 0 Effect of external blocking on pumps compressor 701A 0 Common flow temperature sensor sys tem 701B 0 Number of lag heat pumps in cascade 70...

Page 74: ...t heat pump dual mode 7B0F 500 50 C Enable boiler water temperature sen sor 7B11 1 DHW Parameter Code Delivered condition Commission ing Maintenance service Set DHW temperature 6000 500 50 C Min DHW t...

Page 75: ...l heating 7902 1 Max output instantaneous heating wa ter heater 7907 3 Output for instant heating water heater at power OFF 790A 0 Dual mode temp instant heating water heater 790B 500 50 C Internal hy...

Page 76: ...ced room temperature 2001 160 16 C Remote control 2003 0 Room temperature control 2005 0 Heating curve level 2006 0 0 K Heating curve slope 2007 6 0 6 Influence room temperature hook up 200A 10 Room t...

Page 77: ...or separate cooling circuit 7106 0 Cooling curve level 7110 0 0 K Cooling curve slope 7111 12 1 2 Remote control cooling circ 7116 0 Enable coolant buffer cylinder 7120 0 Enable active cooling 71FE 0...

Page 78: ...matching supply air tempera ture 7D77 0 K Sensor matching extract air tempera ture 7D79 0 K Photovoltaics Parameter Code Factory setting Commission ing Maintenance service Enable own energy consumptio...

Page 79: ...ion ing Maintenance Service Number of heat pump in cascade 7707 1 Enable LON communication module 7710 0 LON subscriber number 7777 1 LON fault manager 7779 0 LON system number 7798 1 Interval for dat...

Page 80: ...w rate kPa 6 0 6 5 7 5 7 6 9 0 9 3 10 0 Max flow temperature C 20 20 20 20 20 20 20 Min flow temperature C 5 5 5 5 5 5 5 Min flow temperature ice store at nominal flow rate C 10 10 10 10 10 10 10 Heat...

Page 81: ...7 Heating water secondary circuit Content l 18 4 23 1 18 4 23 1 28 7 35 1 50 3 Nominal flow rate m3 h 20 0 25 7 19 0 24 9 31 1 40 2 51 3 Pressure drop at nominal flow rate 5 K kPa 25 0 28 0 22 0 26 0...

Page 82: ...Protection class IP rating IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 Refrigerant circuit Refrigerant R410A R410A R410A R410A R410A R410A R410A Refrigerant charge kg 15 8 17 5 14 8 16 5 24 8 31 5 41 5...

Page 83: ...2 weighted to tal sound power level at B0 3 K W35 5 K At rated heating output dB A 63 67 57 63 66 65 69 ErP SCOP LT 5 16 5 22 5 13 5 1 5 1 5 17 5 23 etas LT 198 201 197 196 196 199 201 SCOP HT 3 63 3...

Page 84: ...nes fully installed Components for cooling mode fully installed All circulation pumps are connected and programmed for correct speed and the maintaining of the re quired flow rates has been checked in...

Page 85: ...be carried out by type The dismantling of refrigeration systems may only be carried out by qualified professio nals If permissible components marked with the Green Dot symbol can be disposed of via t...

Page 86: ...2002 12 EN 61 000 6 4 2011 09 EN 50 090 2 2 2007 11 EN 62233 2008 11 EN 55011 2011 EN ISO 12100 2011 03 EN 60 335 2 40 2014 01 EN 292 1991 11 EN 60 335 1 with A1 2012 10 EN 378 2012 08 EN 61 000 6 2 2...

Page 87: ...ed standards DIN 8901 2002 12 EN 61 000 6 4 2011 09 EN 50 090 2 2 2007 11 EN 62233 2008 11 EN 55011 2011 EN ISO 12100 2011 03 EN 60 335 2 40 2014 01 EN 292 1991 11 EN 60 335 1 with A1 2012 10 EN 378 2...

Page 88: ...on 32 66 General information 10 Heat pump control unit 31 66 Electrical connections 31 Overview 31 Electrical installation scheme Primary circuit brine water 17 18 19 21 22 Electric booster heater 57...

Page 89: ...nal extension 57 For heating circuit pump 56 For mixer extension kit 56 For Vitocom 100 57 Ice store system 59 Instantaneous heating water heater 57 On site components 56 Other components 56 Photovolt...

Page 90: ...23 Soft starter 47 Solar DHW heating 58 Specification 300 G 80 Swimming pool 43 Swimming pool water heating 58 System pressure checking 53 System pressure checking 53 System user instruction 62 T Temp...

Page 91: ...91 5787 232 GB...

Page 92: ...essmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0...

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