Viessmann Vitoclima 200-C Operating instructions

VIESMANN
Service instructions
for contractors
Vitoclima 200-C
Chillers for external installation as 400 V version
For cooling as well as for cooling and heating operation
For applicability, see the last page
VITOCLIMA 200-C
5692 696 GB 2/2007 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on the refrigeration circuit
must only be carried out by qualified
and authorised refrigeration engi-
neers.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations.
&all current safety regulations as
defined by DIN, EN, VDE and all
locally applicable standards
Working on the system
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Danger
Contact with 'live' compo-
nents can lead to severe inju-
ries. Some components on
the PCBs will remain 'live'
even after the power supply
has been switched OFF.
&Prior to removing equipment
covers wait at least 4 min. to
allow the voltage to dissi-
pate.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electrostatic dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Safety instructions
2
Safety instructions
5692 696 GB

Repair work
!Please note
Repairing components that ful-
fil a safety function can com-
promise the safe operation of
your system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications or conversions
can compromise safety and
may invalidate our warranty.
For replacements, use only ori-
ginal spare parts supplied or
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 696 GB

Unit layouts
Unit layout type OC208 ............................................................................... 6
Unit layout type OC211 to OC215................................................................ 8
Connection and wiring diagrams ................................................................. 9
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 10
Further details regarding the individual steps .............................................. 12
Troubleshooting
Control unit diagnostics .............................................................................. 27
Diagnosis ................................................................................................... 30
Control settings
Menu structure overview ............................................................................. 33
Scanning and changing parameters ............................................................ 35
Code entry.................................................................................................. 35
Selecting the set value for heating mode (HEA) ........................................... 36
Selecting the set value for cooling mode (Coo) ............................................ 37
Scanning sensor values.............................................................................. 37
Components
Phase monitor ............................................................................................ 39
Differential pressure regulator..................................................................... 39
Refrigerant circuits
Units for cooling mode ................................................................................ 40
Units for heating or cooling operation .......................................................... 42
Parts lists
Parts list Vitoclima 200-C, type OC208........................................................ 44
Parts list Vitoclima 200-C, type OC211 to OC215 ........................................ 44
Parts list fan convectors, type V202H to V209H........................................... 45
Parts list ceiling cassette devices, type C202H to C205H ............................ 45
Parts list duct mounted devices, type DC205H to DC210H........................... 45
Commissioning/service reports
Test report .................................................................................................. 46
Specification (units for cooling and heating mode)................................. 48
Specification (units for cooling mode)..................................................... 51
Index
4
Index
5692 696 GB

Appendix
Pump curves .............................................................................................. 53
Certificates
Declaration of conformity ............................................................................ 57
Keyword index .......................................................................................... 58
Index (cont.)
5
Index
5692 696 GB

AManual air vent valve on the flow
BON/OFF switch
CProgramming unit
DCover for the circulation pump
EPhase monitor (only for 400 V ver-
sion)
FDiaphragm expansion vessel
GFill & drain valve
Unit layout type OC208
6
Unit layouts
5692 696 GB

AManual air vent valve
BService valves, low pressure side
CService valve, high pressure side
DSafety valve, hydraulic circuit
Unit layout type OC208 (cont.)
7
Unit layouts
5692 696 GB

AON/OFF switch
BProgramming unit
CPhase monitor (only for 400 V ver-
sion)
DAutomatic air vent valve
EDiaphragm expansion vessel
FFill & drain valve
GService valve, low pressure side
HService valve, high pressure side
Unit layout type OC211 to OC215
8
Unit layouts
5692 696 GB

Rear view with back panel removed
ACover for the circulation pump
BSafety valve, hydraulic circuit
Connection and wiring diagrams
The connection and wiring diagrams
are affixed to the inside of the front
panel.
Unit layout type OC211 to OC215 (cont.)
9
Unit layouts
5692 696 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 01. Switching OFF the main fuse/MCB and the system
ON/OFF switch ....................................................................... 12
••• 02. Checking the refrigerant circuit for leaks.................... 12
•03. Filling the system.................................................................. 12
••• 04. Checking the diaphragm expansion vessel and the
pressure of the hydraulic circuit..................................... 13
• • 05. Cleaning the water filter ..................................................... 14
•06. Cleaning the condensate drain........................................ 15
••• 07. Checking the free rotation of the fans........................... 15
•08. Cleaning the air heat exchanger...................................... 15
••• 09. Checking the function of the safety valve
• • 10. Checking the tightness of electrical connections . . . . 16
••• 11. Switching ON/connecting the main fuse
••• 12. Switching the system ON/OFF switch ON (if
installed)
•13. Placing the unit in standby mode ................................... 17
••• 14. Ensuring that load is drawn .............................................. 17
••• 15. Switching the unit ON.......................................................... 17
•16. Adjusting parameters HEA and H31 .............................. 18
•17. Adjusting the throughput in the hydraulic circuit . . . . 18
• • 18. Checking the set values and adjusting, if required. . 21
•19. Checking the superheating and correcting, if
required (cooling mode) ..................................................... 22
•20. Checking the evaporator parameters............................ 23
•21. Checking the high pressure switch ............................... 23
•22. Checking the low pressure switch ................................. 23
Steps - commissioning, inspection and maintenance
10
Commissioning, inspection, maintenance
5692 696 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•23. Checking the water side of the evaporator for
contamination ........................................................................ 23
•24. Checking the antifreeze concentration in the
hydraulic circuit .................................................................... 24
•25. Checking the compressor ................................................. 24
•26. Checking the oil sump heater........................................... 24
•27. Checking the compressor power consumption ........ 24
•28. Checking the fan power consumption .......................... 25
•29. Checking the contactors .................................................... 25
•30. Checking the protective motor switch .......................... 25
•31. Checking the thermostat.................................................... 25
•32. Checking the cables............................................................. 25
•33. Checking the temperature sensors................................ 25
•34. Checking the relays ............................................................. 26
•35. Instructing the system user
Steps - commissioning, inspection and . . . (cont.)
11
Commissioning, inspection, maintenance
5692 696 GB

Switching OFF the main fuse/MCB and the system ON/OFF
switch
Danger
Touching 'live' components can result in the transfer of dangerous body
currents.
Isolate the unit from the power supply, check that it is no longer 'live' and
safeguard against unauthorised reconnection.
Checking the refrigerant circuit for leaks
Danger
An escape of R 407C in sealed
rooms and in hollows can
result in suffocation due to its
air displacing characteristics.
Prevent the unregulated
escape of R 407C in sealed
rooms; ensure adequate venti-
lation.
Always observe all relevant
regulations and directives
regarding the handling of
refrigerant.
Danger
Touching components of the
refrigerant circuit can cause
burns or frostbite.
Touch these components only
with protective gloves.
Check the interior of the equipment
with a refrigerant leak detector or leak
detection spray for refrigerant leaks.
1. Remove the front panel.
2. Check the floor area, valves and all
visible solder joints for traces of oil.
3. Check the thermal insulation of the
refrigerant circuit.
4. Record the implementation of the
work in the service report from
page 46.
Further work on the refrigeration cir-
cuit must only be carried out by a qua-
lified refrigeration engineer.
Filling the system
1. Open the shut-off valves and any
installed non-return valves.
Further details regarding the individual steps
12
Commissioning, inspection, maintenance
5692 696 GB

2. Check the inlet pressure of the
internal (and, if installed, external)
diaphragm expansion vessel.
Note
For the position of the internal dia-
phragm expansion vessels, see
unit layouts from page 6.
3. Thoroughly flush the system.
4. Fill the system with process med-
ium and fully vent the system via
the fill & drain valve (for position,
see unit layouts from page 6).
Note
&Type OC208:
&The equipment is fitted with two
manual air vent valves (for posi-
tion, see Ain Fig. on page 6
and 7)
&from type OC211:
&The unit is fitted with an auto-
matic air vent valve (for position,
see Din Fig. on page 8)
Observe the details regarding the
handling of antifreeze on page 24.
5. Check the system pressure (see
page 14).
6. Return the non-return valves (if
installed) into their operating posi-
tion.
Checking the diaphragm expansion vessel and the pressure
of the hydraulic circuit
Carry out this test on a cold system.
1. Drain the system on the heating
water side and reduce the pressure
until the pressure gauge indicates
"0".
2. If the inlet pressure of the dia-
phragm expansion vessel is lower
than the static system pressure,
top up with sufficient nitrogen to
raise the inlet pressure 0.2 bar
higher than the static system pres-
sure.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 696 GB

Example:
Static head
(The distance between
the external unit and the
highest internal device)
10 m
= static pressure 1 bar
Note
Where the installation results in
the static height of all components
being on a single level (for exam-
ple in a bungalow) or where the
internal device lies lower than the
external unit, adjust the inlet pres-
sure to 0.5 bar.
3. Top up with water, until the filling
pressure exceeds the inlet pres-
sure of the diaphragm expansion
vessel.
On a cold system, the filling pres-
sure must be approx. 0.5 bar higher
than the static pressure.
Max. operating pressure: 3.0 bar.
4. During commissioning, mark this
value on the pressure gauge as
minimum filling pressure.
Cleaning the water filter
Note
Clean the water filter installed on site
for the first time after 2 hours of opera-
tion.
!Please note
Dirt inside the heat exchanger
of the hydraulic circuit (heating
or cooling circuit) can lead to
the plate-type heat exchanger
icing up, which would result in
severe equipment damage.
Only fill the hydraulic circuit
with clean water; regularly
clean the water filter.
1. Close the shut-off valves upstream
and downstream of the water filter.
2. Regularly maintain the water filter
in accordance with the manufac-
turer's instructions.
3. Open the shut-off valves upstream
and downstream of the water filter.
4. Vent the hydraulic circuit (see
page 13) and check the pressure in
the hydraulic circuit (see page 13).
5. Record the implementation of the
work in the service report from
page 46.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 696 GB

Cleaning the condensate drain
Record the implementation of the
work in the service report from
page 46.
Checking the free rotation of the fans
Danger
Unintentional starting of the
fans can lead to severe inju-
ries.
Isolate the unit from the power
supply, check that it is no
longer 'live' and safeguard
against unauthorised recon-
nection.
Record the implementation of the
work in the service report from
page 46.
Cleaning the air heat exchanger
Note
The air heat exchanger can be
cleaned either with compressed air or
with a soapy solution.
Danger
Touching 'live' components or
bringing 'live' components into
contact with water can result in
the transfer of dangerous body
currents and equipment
damage.
Before cleaning the air heat
exchanger, isolate the equip-
ment from the power supply,
check that it is no longer 'live'
and safeguard against
unauthorised reconnection.
!Please note
The edges and sharp surfaces
of the air heat exchanger can
result in injuries.
Avoid contact with the exchan-
ger.
1. Only when cleaning with water:
Spray a soapy solution over the air
heat exchanger.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 696 GB

2. Only when cleaning with water:
!Please note
The effect of heat can result
in the refrigerant reaching
higher pressure levels.
Excessive pressure of a
high pressure cleaner can
result in the deformation of
the aluminium fins of the
heat exchanger.
Never use hot water or
steam. Only point the high
pressure cleaner at the heat
exchanger from the outside
front (not from the fan side)
and from an adequate dis-
tance. Air forced at the alu-
minium fins from the side
will result in their deforma-
tion.
Flush the air heat exchanger with
water.
3. Only when cleaning with com-
pressed air:
!Please note
Excessive air pressure can
result in the deformation of
the aluminium fins of the
heat exchanger.
Only point the compressed
air gun at the heat exchan-
ger from the front of the fan
side and at an adequate dis-
tance. Air forced at the alu-
minium fins from the side
will result in their deforma-
tion.
Blow compressed air through the
air heat exchanger.
4. Check the aluminium fins of the
heat exchanger for deformation
and scratches; if required repair
with a suitable tool.
5. Record the implementation of the
work in the service report from
page 46.
Checking the tightness of electrical connections
Record the implementation of the
work in the service report from
page 46.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 696 GB

Placing the unit in standby mode
!Please note
Starting the compressor in a
cold state can result in equip-
ment damage.
Prior to commissioning, leave
the unit at least 4 hours in
standby mode.
Only commission the unit when
the lower part of the compres-
sor is at least warm to the
touch.
1. Start the unit with the ON/OFF
switch (Bin the Fig. on page 6 or
Ain the Fig. on page 8)
The return temperature is dis-
played on the programming unit.
2. The following only applies if a
dot is shown in the segmented
display:
The unit is in standby mode.
Leave the unit in this state for
approx. 4 h.
3. The following only applies if fig-
ures are shown in the segmented
display:
Press D(see page 27).
A dot appears in the programming
unit display. The unit is in standby
mode.
Leave the unit in this state for
approx. 4 h.
Ensuring that load is drawn
Prior to switching the unit ON, ensure
a load of at least 60 % of the rated
output is drawn, in the respective
operating mode (heating/cooling).
For this, fully open the valves in the
heating or cooling circuit as well as
any other control elements that may
be installed.
Switching the unit ON
!Please note
Starting the compressor in a
cold state can result in equip-
ment damage.
Prior to commissioning, the
unit must have been in standby
mode for at least 4 h.
Only commission the unit when
the oil sump of the compressor
is at least warm to the touch.
!Please note
A sudden change from heating
to cooling mode can result in
high pressure faults.
Prior to a changeover, the
return temperature must have
fallen below 25 °C.
1. Press D.
The programming unit display
shows the return temperature.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 696 GB

2. The following only applies to
commissioning in summer
(cooling mode):
Press Crepeatedly unto the LED
below symbol "b" (cooling mode)
illuminates (see page 27):
&The LED next to symbol "B"
(compressor) flashes.
&The compressor starts after a
start-up delay of 6 minutes (stan-
dard setting).
&Note
Should the unit fail to start, observe
the LED indicators on the phase
monitor (see page 39).
&The unit is operational.
3. The following only applies to
commissioning in winter
(heating mode):
Press Crepeatedly unto the LED
below symbol "c" (heating mode)
illuminates (see page 27):
&The LED next to symbol "B"
(compressor) flashes.
&The compressor starts after a
start-up delay of 6 minutes (stan-
dard setting).
&Note
Should the unit fail to start, observe
the LED indicators on the phase
monitor (see page 39).
&The unit is operational.
Adjusting parameters HEA and H31
1. Disable the heating curve; for this,
set parameter H31 to "0".
Note
For a description of the adjustment
of parameters and the code, see
from page 35.
2. Raise the return temperature; for
this, change parameter HEA (see
page 36).
As the units are reverse controlled,
select a value approx. 5 °C lower
than the required flow temperature.
Adjusting the throughput in the hydraulic circuit
The pump rate of the internal pump of
the hydraulic circuit can be adjusted
to ensure the required minimum
throughput. This is made in accor-
dance with the system pressure drop
via the three-stage speed selector of
the pump. In the delivered condition,
the pump is set to the highest stage
(3).
For the required heating and cooling
water throughput, see the specifica-
tion (from page 48).
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 696 GB

1. Note
For this test, pressure gauges must
be fitted to the flow and return of
the hydraulic circuit.
As an alternative, pressure gauge
connectors must be available.
When a load of at least 60% is
drawn, check the pressure at the
return (p2) and the flow (p1) of the
unit.
2. Calculate the available pressure
from the pressure differential
between the unit flow and return
(p1 –p2).
3. Using the pump curves from
page 53 check at what pump set-
ting, starting from the available
delivery pressure, the required
water throughput will be achieved
(see the following example).
4. If necessary, change the pump set-
ting (see section "Adjusting the
pump rate" on page 21).
5. Check the pressure again.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 696 GB

Example:
Example diagram for determining the
required pump setting for Vito-
clima 200-C, type OC212
ARange of the required flow
rate
BCD Points of intersection deliv-
ery pressure/pump curves
(1) Stage 1: lowest throughput
(2) Stage 2: average through-
put
(3) Stage 3: highest throughput
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 696 GB