Viessmann Vitocal 300-G Pro BW 302.D090 Installation And Service Instructions For Contractors Download

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Installation and service instructions

for contractors

Viesmann

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

5838144 GB

11/2018

Please keep safe.

Summary of Contents for Vitocal 300-G Pro BW 302.D090

Page 1: ...lation and service instructions for contractors Viesmann 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 5838144 GB 11 2018 Please keep...

Page 2: ...may be several power circuits Danger Contact with live components can result in severe injuries Some components on PCBs remain live even after the power supply has been switched off Prior to removing...

Page 3: ...escapes from the appliance there is a risk of electrocution Switch OFF the heating system at the external isolator e g fuse box domestic distribution board Danger If water escapes from the appliance t...

Page 4: ...302 D090 to BW 302 D230 20 4 Installation sequence Siting the heat pump 22 Levelling the heat pump 22 Removing the transport brackets 23 Fitting the back panel side panels and kicking plates 24 Making...

Page 5: ...65 Checking sensors 65 Temperature sensors type NTC 10 k 65 Temperature sensors type Pt500A 66 Checking MCBs fuses 66 8 Parts lists Ordering parts 67 Components heat pump 68 Components heat pump PCB 7...

Page 6: ...y and implement all safety measures e g RCD circuit in accord ance with the following regulations IEC 60364 4 41 VDE regulations Technical connection requirements specified by the local power supply u...

Page 7: ...r Wear suitable protective clothing Danger Refrigerant circuits of heat pumps develop extremely low 25 C and very high 130 C temperatures Work on heat pumps can result in life threatening frostbite an...

Page 8: ...aintenance are found in the Commission ing inspection and maintenance section and identified as follows Symbol Meaning Steps required during commissioning Not required during commissioning Steps requi...

Page 9: ...refrigerant circuit has an electronic expansion valve EEV with an independent control circuit refrigerant circuit controller The heat pump control unit can regulate one cooling circuit The cooling ci...

Page 10: ...damage on the delivery note and notify the haulage contractor Lifting gear such as slings and cross beams must be provided on site The lifting capacity of each sling and that of the cross beam must b...

Page 11: ...klift 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 ce...

Page 12: ...site the appliance above ceilings with wooden joists e g in the attic Level the appliance horizontally Where floors are uneven distribute the load evenly across the feet Observe minimum room volume to...

Page 13: ...arge the base by the minimum clearances see chapter Minimum clear ances on page 12 150 Fig 5 A Concrete B25 iron B Floor construction screed C Top edge unfinished floor D Impact sound insulation as pe...

Page 14: ...ro Dimensions types BW 302 D090 and BW 302 D110 850 1380 1650 911 1139 609 639 1169 271 300 340 Fig 8 A Primary circuit flow inlet Victaulic 3 DN 80 B Secondary circuit flow outlet Victaulic 2 DN 65 C...

Page 15: ...Victaulic 3 DN 80 B Secondary circuit flow outlet Victaulic 2 DN 65 C Primary circuit return outlet Victaulic 3 DN 80 D Secondary circuit return inlet Victaulic 2 DN 65 E Low voltage 50 V F Power supp...

Page 16: ...ly 400 V 50 Hz 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 Hydraulic connection requirements Make...

Page 17: ...trol 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...

Page 18: ...heat 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...

Page 19: ...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 Q...

Page 20: ...lectrical installation scheme For a summary of electrical connections see from page 31 and separate Connection and wiring dia gram DHW heating type BW 302 D090 to BW 302 D230 Hydraulic installation sc...

Page 21: ...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 Setting System definition System...

Page 22: ...22 Levelling the heat pump Fig 15 Position and level the heat pump horizontally as described from page 10 Installation sequence Siting the heat pump 5838144 Installation...

Page 23: ...nce 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 16 A Transport locking screws I...

Page 24: ...side 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...

Page 25: ...0 A Primary circuit flow inlet Victaulic 3 DN 80 B Secondary circuit flow outlet Victaulic 2 DN 65 C Primary circuit return outlet Victaulic 3 DN 80 D Secondary circuit return inlet Victaulic 2 DN 65...

Page 26: ...coupling 3 primary circuit B Victaulic coupling 2 secondary circuit C Flange adaptor 3 DN 80 PN 10 short primary cir cuit without anti vibration elements D Flange adaptor 2 DN 65 PN 10 short secon da...

Page 27: ...reduce the transfer of vibrations to the floor The anti vibration bases described in chapter Requirements for heat pump siting are another structural measure for chal lenging applications The transfer...

Page 28: ...es reduce the transfer of low frequency vibrations and structure borne noise to a minimum Note Do not secure the lines between the expansion joints and the heat pump Fig 25 Incorrect Fitting the Victa...

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

Page 30: ...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 on the back pa...

Page 31: ...es that in the event of a fault e g if a wire becomes detached the wires can not drift into the adjacent voltage area Strip as little of the insulation as possible close to the terminals If 2 componen...

Page 32: ...N N X1 N L3 X1 L3 L2 X1 L2 L1 X1 L1 PE PE F3 Fig 28 A Power supply for power circuit compressor 3 x 400 V 50 Hz only type BW 302 D180 and BW 302 D230 see also pos M in Fig 29 B Message and safety con...

Page 33: ...PCB termi nals 211 1 224 2 see separate Connection and wiring diagram Secondary pump s On site connection see separate Connection and wiring diagram Factory wiring on main and expansion PCB termi nal...

Page 34: ...iring dia gram 211 4 M r 3 way diverter valve Central 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...

Page 35: ...onnection 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 Conn...

Page 36: ...ontrol 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 exter...

Page 37: ...shut 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 Connect...

Page 38: ...225 2 M2 Switching of the mixer motor heating circuit M2 HC2 Mixer CLOSE signal Connection values Output 10 W Voltage 230 V Max control current 0 2 0 1 A Connection see separate Connection and wiring...

Page 39: ...diagram 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...

Page 40: ...continuous 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...

Page 41: ...status 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...

Page 42: ...lug 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 t...

Page 43: ...ry circuit 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 seconda...

Page 44: ...e controller 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...

Page 45: ...supply utility If the compressor and or instantaneous heating water heater if installed are operated at an econ omy tariff power OFF provide an additional cable for the power OFF signal from the mete...

Page 46: ...ndition The power OFF signal is connected directly to the heat pump control unit via floating contact The compres sors are shut down when power OFF is enabled Parameter Output for instant heating wate...

Page 47: ...e DIP switches behind the transparent protective flap of the electronic soft starter At the factory the DIP switches are set to suit the respective heat pump type Prior to commissioning compare the DI...

Page 48: ...t and in component damage in the event of an electrical fault Restore all earth connections Please note Leaking hydraulic connections lead to appliance damage Check the internal hydraulic connections...

Page 49: ...s been removed Are the back and side panels securely attached 2 3 1 Fig 37 2 Carefully position the front panel Pay particular attention to the shaft between the dial and the ON OFF switch 4 Hand over...

Page 50: ...the secondary side 52 6 Checking expansion vessels and primary circuit secondary circuit pressure 52 7 Checking the electrical connections for firm seating 8 Commissioning the system 53 9 Checking th...

Page 51: ...t may only be carried out by qualified electri cians 1 Remove top panel see page 49 2 When work is complete close the heat pump see page 48 Regarding commissioning this appliance see also the operatin...

Page 52: ...VDI 2035 part 1 1 Check the Victaulic connections in the heat pump for tightness The Victaulic couplings must be form locked and fitted together seamlessly 2 Open any on site non return valves if inst...

Page 53: ...e to the appliance and the heat ing system Observe the information in the Vitotronic 200 service instructions otherwise the appliance warranty will be void Turn on the ON OFF switch of the heat pump c...

Page 54: ...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 example To set...

Page 55: ...cylinder heating Parameter Setting System definition System scheme 7000 With DHW heating DHW circulation pump Parameter Setting Extended menu Time program DHW circulation Set a time program Circulatio...

Page 56: ...he following table Parameters for external functions External demand Parameter Setting If applicable Internal hydraulics Flow temperature for external demand 730C Set flow temperature for external de...

Page 57: ...antaneous heating water heater for DHW heating Parameter Setting DHW Enable electric heaters for DHW heating 6015 1 Parameters for external heat generators Parameter Setting External heat source Enabl...

Page 58: ...it M2 HC2 3 Heating circuit M3 HC3 4 Do not adjust Parameters for ice store system Parameter Setting System definition Select primary source 7030 1 External extension 7010 2 Parameter Setting Solar Ty...

Page 59: ...PV 7E23 0 to 100 0 to 10 K Reduce set room temperature PV 7E25 0 to 100 0 to 10 K Reduce set coolant buffer cylinder temperature PV 7E26 0 to 100 0 to 10 K Parameters for ventilation with Vitovent 300...

Page 60: ...fault manager 7779 Only one control unit per system may be configured as the fault manager 0 or 1 0 or 1 Source time 77FE 0 1 Send time 77FF 1 0 Source outside temperature 77FC 0 1 Send outside temper...

Page 61: ...d carry out an operating display adjustment high flow balancing see below for example if circulation pumps had to be sized for higher flow rates LED 0 flashes green Flow rate below minimum flow rate N...

Page 62: ...with the existing flow rate 2 Press and hold for around 5 s until LED 9 flashes 3 Release Fitting the top panel and front panel closing the heat pump See page 49 Instructing the system user The syste...

Page 63: ...front not properly closed turn quadrant key as far as 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 e...

Page 64: ...om page 31 Overview of internal components Fig 41 1 Wiring chamber 2 Safety high pressure switch stage 1 3 Safety high pressure switch stage 2 4 High pressure sensor 5 Low pressure sensor 6 Electronic...

Page 65: ...sensor F4 Cylinder temperature sensor F6 F7 Flow temperature sensor heating circuit M2 HC2 F12 System flow temperature sensor F13 Flow temperature sensor cooling circuit heating circuit without mixer...

Page 66: ...parate connection and wiring diagram For the fuse in the upper wiring chamber see page 39 1 Switch OFF the power supply 2 Opening the wiring chamber 3 Check fuses Replace if necessary Danger Incorrect...

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 5838144 Components...

Page 68: ...2 0004 0001 0005 0001 0053 0072 0072 0071 0003 0008 0006 0013 0015 0013 0011 0017 0012 0016 0024 0007 0009 0010 0017 0073 0014 0014 0014 0014 0057 0056 0070 Fig 44 Parts lists Components heat pump 583...

Page 69: ...f valve 0011 Low pressure sensor 0012 High pressure sensor 0013 Pressure switch 0014 Temperature sensor 0015 Sensor well 0016 Sensor clip 0017 Schrader set 0018 Programming unit 0024 Motor overload re...

Page 70: ...70 0025 0042 0025 0020 6x 0022 0044 0021 0022 0059 0059 0060 0061 0045 0045 0068 0069 0058 4x 0067 0063 0064 0066 0065 0062 Fig 45 Parts lists Components heat pump PCB 5838144 Components...

Page 71: ...rt relay 0060 Contactor 0061 Terminal strip 0062 Controller PCB 0063 Main board 0064 Relay PCB 0065 Mating plug MB 0066 Mating plug SA 0067 Mating plug CU 0068 EEV PCB retainer pack 0069 Transformer E...

Page 72: ...T 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 h...

Page 73: ...ocking 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...

Page 74: ...mit 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...

Page 75: ...ral 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...

Page 76: ...duced 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...

Page 77: ...nsor 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...

Page 78: ...r 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 consumpt...

Page 79: ...ssion 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 d...

Page 80: ...11 0 14 6 17 9 24 3 28 8 Pressure drop at nominal flow rate total pressure drop evaporator plus connections kPa 6 7 8 10 10 Pressure drop at minimum flow rate kPa 3 4 4 5 6 Max flow temperature at pr...

Page 81: ...4 5 18 2 23 6 29 4 Pressure drop at nominal flow rate total pressure drop condenser plus connections kPa 8 7 10 2 12 1 15 9 16 7 Pressure drop at minimum flow rate kPa 3 4 4 6 6 Max flow temperature a...

Page 82: ...ressure 1 Primary circuit bar MPa 10 0 1 10 0 1 10 0 1 10 0 1 10 0 1 Secondary circuit bar MPa 10 0 1 10 0 1 10 0 1 10 0 1 10 0 1 Dimensions Total length mm 1383 1383 1972 1972 1972 Total width mm 911...

Page 83: ...ower consumption stages 1 and 2 W 45 Protection class IP rating IP 20 Note The specifications in the datasheets and the product description describe purely physical characteristics Additional assuranc...

Page 84: ...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 line wit...

Page 85: ...osal of components must 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 c...

Page 86: ...ified with the CE designation Using the serial number the full Declaration of Con formity can be found on the following website www viessmann co uk eu conformity The product characteristics determined...

Page 87: ...6 Electrical components 64 Electrical connection 33 General information 10 Heat pump control unit 32 Electrical connections 30 Electrical connections overview 31 Electric booster heater 57 Electronic...

Page 88: ...ermiss operating pressure 52 Photovoltaics 58 Power cable routing 30 Power generated on site 58 Power OFF 46 Power supply 10 45 46 Premium tariff meter 46 Pressure checking 52 Primary circuit filling...

Page 89: ...t500A 66 Temperature sensor connection 42 Terminating the service 54 Tightness test 48 52 Tilting angle 10 TNC system 46 Transport bracket 63 Transport bracket removal 23 V Ventilation 59 Venting Prim...

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Page 91: ...91 5838144...

Page 92: ...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 Fax 49 6452 70 2780 www viessmann com...

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