Viessmann VITOCAL 060-A Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitocal 060-A
Type WWK 060-A
DHW heat pump with dry well heater
Type WWKS 060-A
DHW heat pump with connection for external heat generator or solar collectors
For applicability, see the last page
VITOCAL 060-A
5788 057 GB 5/2016 Please keep safe.

2
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 intended for author-
ised contractors.
■Work on the refrigerant circuit may only be carried
out by authorised refrigeration engineers.
■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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
Working on the system
■Isolate 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 several
load 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.
Wait at least 4 minutes before removing equip-
ment covers, to allow the voltage to dissipate.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Replace faulty components with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacement, use only spare parts supplied
or approved by Viessmann.
Safety instructions
Safety instructions
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3
1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
■Vitocal 060-A, type WWK ................................................................... 6
■Vitocal 060-A, type WWKS ................................................................. 6
■Operating modes ................................................................................ 6
2. Preparing for installation ................................................................................................................ 7
3. Installation sequence Siting the DHW heat pump .................................................................... 11
Conversion to outdoor air mode ............................................................ 12
■Converting the top panel .................................................................... 12
■Fitting the air intake/air discharge ductwork ....................................... 15
■System diagram .................................................................................. 16
Connecting the condensate drain .......................................................... 17
Connections on the DHW side ............................................................... 18
Type WWKS: solar thermal system ....................................................... 19
■Maximum collector area and sizing information ................................. 19
■Connecting solar collectors ................................................................ 19
Type WWKS: external heat generator ................................................... 20
■Fitting the temperature sensor ............................................................ 20
Adjusting the draw-off rate ..................................................................... 20
Electrical connections ............................................................................ 21
■Type WWKS with external heat generator .......................................... 21
Connecting to the power supply ............................................................ 23
■Power cable ........................................................................................ 23
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 24
5. Diagnosis and service
scans
Installation menu .................................................................................... 30
■Programming unit ............................................................................... 30
■Calling up installation menu "INST" ................................................... 30
■Overview of parameters ..................................................................... 30
■Checking the actuators ....................................................................... 31
■Actual temperatures ........................................................................... 31
6. Troubleshooting Messages .............................................................................................. 32
■Red LED on the heat pump control unit ............................................. 32
■Messages on the programming unit ................................................... 32
■Acknowledging messages .................................................................. 32
7. Maintenance ................................................................................................................ 33
8. Parts lists, type WWK Overview of assemblies ......................................................................... 39
Heat pump module ................................................................................ 40
Cylinder module ..................................................................................... 42
Steatite flange ........................................................................................ 44
9. Parts lists, type WWKS Overview of assemblies ......................................................................... 47
Heat pump module ................................................................................ 48
Cylinder module ..................................................................................... 50
Flange (type WWKS only) ..................................................................... 52
Steatite flange (accessory for type WWKS) ........................................... 54
10. Connection and wiring dia-
gram
................................................................................................................ 56
11. Reports ................................................................................................................ 57
Index
Index
5788 057 GB

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12. Specification ................................................................................................................ 58
13. Certificates Declaration of conformity ....................................................................... 62
14. Keyword index ................................................................................................................ 63
Index
Index (cont.)
5788 057 GB

5
Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
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 connection with commissioning, inspec-
tion and maintenance 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 required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions.
The appliance may only be used for heating DHW.
The range of functions can be extended with additional
components and accessories.
Information
Disposal of packaging
5788 057 GB
Information

6
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial use for purposes other than
domestic hot water heating shall be deemed inappro-
priate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic
use, i.e. even users who have not had any instruction
are able to operate the appliance safely.
Product information
Vitocal 060-A, type WWK
Enamelled, externally heated DHW cylinder with inte-
gral heat pump for DHW heating. A dry well heater is
integrated for DHW reheating.
Vitocal 060-A, type WWKS
Type WWKS includes the function range of type WWK.
In addition, a solar thermal system or external heat
generator (e.g. oil/gas boiler) can be connected. The
dry well heater is available as an accessory.
Operating modes
The DHW heat pump is available for recirculation air
mode, outdoor air mode and recirculation air mode
with air discharge to the outside.
Recirculation air mode
In recirculation air mode, the ambient air (indoor air) in
the installation room is used for DHW heating.
When DHW is being heated, the installation room is
cooled and dehumidified.
Recirculation air mode with air discharge to the
outside
Ambient air from the installation room is supplied to the
DHW heat pump. A separate outdoor air aperture
simultaneously allows outdoor air to enter the installa-
tion room.
The ambient air that is cooled down during DHW heat-
ing is routed outdoors by the DHW heat pump.
Outdoor air mode
Outdoor air is supplied to the DHW heat pump via a
duct.
The outdoor air that is cooled down during DHW heat-
ing is routed outdoors by the DHW heat pump.
Information
Intended use (cont.)
5788 057 GB
Information

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Siting
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never put weight on the top or front of the appli-
ance or cylinder jacket.
The DHW heat pump can be transported vertically or
horizontally.
Note for horizontal transport
Set the DHW heat pump upright and allow it to stand
for at least 24 hours before commissioning.
Installation room requirements
■The installation room must be dry and free from the
risk of frost.
■The intake air must be kept free from dust, grease
and contamination through halogenated hydrocar-
bons (e.g. as contained in sprays, paints, solvents
and cleaning agents).
■To prevent the transmission of structure-borne noise,
never site the appliance on ceilings with wooden
joists (e.g. in the attic).
■A separately fused standard power socket must be
available.
■A condensate drain pipe must be available.
■Always maintain the minimum clearances for service
and maintenance work.
Fig. 1
Preparing for installation
Preparing for installation
5788 057 GB
Installation

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Minimum clearances
Recirculation air mode
V 20 m³
3 °C 35 °C
500 kg
2000
650
100
Fig. 2
ADHW heat pump
BCondensate drain pipe
Recirculation air mode with air discharge to the
outside
DN 160
V 20 m³
3 °C 35 °C
500 kg
2000
650
100
Fig. 3
ADHW heat pump
BCondensate drain pipe
Outdoor air mode
500 kg
2000
-5 °C 35 °C
650
100
Fig. 4
ADHW heat pump
BCondensate drain pipe
Minimum room height for outdoor air mode and
recirculation air mode with air discharge to the
outside
When using ductwork made from EPP (accessories),
the height of the room must be at least 2060 mm.
Preparing for installation
Preparing for installation (cont.)
5788 057 GB
Installation

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Overview of connections
B
A
C
D
E
R
F G
P
O
N
LM
K
H
G
F
R
P
M
H, K, L, N, O
160
802
907
1501
699
1755
1810
Ø631
73
255
555
927
1339
1403
1566
700
729
DN DN 160
175 177
86 88
Fig. 5
AProgramming unit
BHeat pump control unit
CSensor well for draw-off profile L
Factory-fitted temperature sensors:
■Cylinder temperature sensor
and
■High limit safety cut-out for DHW heat pump
DSensor well for draw-off profile XL
EInspection port, magnesium anode, immersion
heater (accessories type WWKS, standard delivery
type WWK)
FAir discharge
GAir intake
HCold water/drain outlet R 1
KFor type WWKS only:
■External heat generator:
Return G 1
■Solar collector:
Return G 1 and threaded elbow (accessories) for
lower cylinder temperature sensor
LFor type WWKS only:
Flow of external heat generator/solar collector G 1
Preparing for installation
Preparing for installation (cont.)
5788 057 GB
Installation

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MFor type WWKS only:
■Temperature sensor, external heat generator
or
■High limit safety cut-out for stopping the solar cir-
cuit pump
NDHW circulation R ¾
ODHW R ¾
PCondensate 7 20 mm
RPower cable, length 3 m
Preparing for installation
Preparing for installation (cont.)
5788 057 GB
Installation

11
!Please note
Incorrect handling can lead to irreparable dam-
age to the DHW heat pump.
■Never drill into the sheet steel casing of the
DHW heat pump.
■Never use the connectors as a transport aid.
■Carefully remove the DHW heat pump from
the pallet. The EPS padding underneath can
be removed for this.
35
!
3x
Fig. 6
Align the DHW heat pump vertically.
Installation sequence
Siting the DHW heat pump
5788 057 GB
Installation

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Converting the top panel
Note
The air discharge aperture is converted for recircula-
tion air mode with air discharge to the outside.
4.
2.
1.
3.
3x
Fig. 7
Installation sequence
Conversion to outdoor air mode
5788 057 GB
Installation

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5.
Fig. 8
AAir discharge cover grille
BAir intake cover grille
6.
Fig. 9
9.
8.
7.
2x
Fig. 10
!Please note
Leaks from the top panel can lead to conden-
sate on the casing and increased power con-
sumption.
■Ensure that the top panel sealing mat is
seated correctly.
■Ensure that the sealing mat and top panel are
positioned correctly.
Note
If the top panel is not sealed tightly, indoor air will be
drawn in. This causes negative pressure inside the
room.
Installation sequence
Conversion to outdoor air mode (cont.)
5788 057 GB
Installation

14
10.
3x
11.
12.
13.
Fig. 11
Installation sequence
Conversion to outdoor air mode (cont.)
5788 057 GB
Installation

15
Fitting the air intake/air discharge ductwork
!Please note
The simultaneous operation of open flue com-
bustion equipment (e.g. an open fireplace) and
the DHW heat pump in a space with combustion
air interconnection results in dangerous negative
pressure inside the room. Negative pressure
can result in flue gases re-entering the room.
■Never operate the DHW heat pump simultane-
ously with open flue combustion equipment
(e.g. an open fireplace).
■Operate combustion equipment exclusively in
room sealed mode with a separate supply of
combustion air. We recommend combustion
equipment with general certification as room
sealed combustion equipment, issued by the
Deutsches Institut für Bautechnik DIBt [or local
equivalent].
■Doors to boiler rooms where the combustion
air supply is not interconnected with the living
space must be airtight and must be kept shut.
Note
In recirculation air mode with air discharge to the out-
side, ensure an adequate supply of fresh air to the
installation room (on site), e.g. via separate vents
(min. DN 160).
■Thermally insulate the ductwork with vapour diffu-
sion-proof material.
■Always route the ducts for air intake and air dis-
charge with a 2 to 3° fall, so that rain and conden-
sate can drain away.
■Ensure air intake temperatures from -5 to 35 °C.
■Maximum permissible total pressure drop Δptotal
(ductwork and appliance): 100 Pa
■Fit silencers to avoid flow noise.
■Ducts, wall outlets and connections to the DHW heat
pump can be installed using anti-vibration insulation
to reduce noise (see diagram).
Connections and installation options which are not per-
missible:
■Connection of kitchen extractor hoods to the duct-
work
■Installation of a DHW heat pump with recirculation air
mode in a heated room
■Connection of the air intake duct to a mechanical
ventilation system
■Connection of the air intake duct to an air/geothermal
heat exchanger
■Connection of the air intake duct to a tumble dryer
■Reversed connections (air intake to the outside and
air discharge to the inside)
■Installation of the DHW heat pump in an attic
■Installation of the DHW heat pump in dusty rooms
■Operation of the DHW heat pump in conjunction with
an open flue boiler
Anti-vibration insulation
Fig. 12
ADHW heat pump
BFlexible hydraulic connections
CEPP insulated plastic pipes or insulated flexible
pipes (min. DN 160) for air intake/air discharge
ductwork
DAnti-vibration insulation for wall outlet
EAnti-vibration bracket for air intake duct
FAir intake silencer
GAir discharge silencer
HAnti-vibration bracket for air discharge duct
KAnti-vibration insulation for air discharge duct wall
outlet
LAnti-vibration insulation for floor
MAdjustable feet
1. Join individual duct sections together with connec-
tion pieces or female connections (see system dia-
gram on page 16).
!Please note
Drilling swarf can cause faults in the DHW
heat pump.
Never allow drilling swarf to fall into the
DHW heat pump air intake aperture or air
discharge aperture.
2. Secure joints with self-tapping screws or blind riv-
ets and make an airtight seal using shrink tape.
Installation sequence
Conversion to outdoor air mode (cont.)
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Installation

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System diagram
Fig. 13
ASupply air
BExhaust air
Ductwork DN
1Bend 90° 160
45° 160
2Folded spiral-seam tube or flexible
pipe
Length 3.0 m 160
3Outdoor air intake grille as air discharge duct wall outlet 160
4Exhaust air roof outlet Round, with protective grille and insu-
lation sleeve, for air discharge duct
160
5Vent Wall/external connection, for air in-
take duct
160
Check valve (on site)
Installation sequence
Conversion to outdoor air mode (cont.)
5788 057 GB
Installation

17
Air intake and air discharge duct through the wall
500
407
Fig. 14
AAir intake
BAir discharge
Air intake and air discharge duct through the roof
1000
Fig. 15
AAir intake
BAir discharge
Measures for minimising the pressure drop:
■Use as few bends as possible.
■As far as possible, avoid elements that increase the
pressure drop.
■Route the air intake duct above the air discharge
duct if possible.
Connecting the condensate drain
When heating DHW, condensate forms on the inside of
the heat pump module. This condensate needs to be
routed via the condensate drain to a sewer.
1. Secure the condensate drain hose to the conden-
sate drain connector with a hose clip.
!Please note
Mechanical stress will damage the conden-
sate connection.
To prevent water leaking out, never twist the
condensate drain connector on the appli-
ance.
2. Route the condensate hose as a U-bend and con-
nect with a constant fall and a pipe vent to the pub-
lic sewage system or a neutralising system. If nec-
essary, connect to an on-site trap. Ensure that the
trap is connected securely.
Note
Connecting the condensate drain to rainwater
downpipes is not permissible.
3. Check that the condensate can drain freely. Flush
the condensate drain if necessary.
4. !Please note
Freezing condensate in the heat pump leads
to appliance damage.
Should the condensate drain run partially
through unheated rooms, provide thermal
insulation or a ribbon heater around the con-
densate drain on site.
Installation sequence
Conversion to outdoor air mode (cont.)
5788 057 GB
Installation

18
Condensate drain via trap Condensate drain via water seal
Ø 20
≥ 60
Ø 20
≥ 60
Connections on the DHW side
The DHW heat pump is designed to be connected per-
manently to the water supply.
For connecting the DHW side, observe DIN 1988,
DIN 4753 and EN 806.
Furthermore observe the following:
■Connect all pipework with detachable fittings.
■Equip the DHW circulation pipe with a DHW circula-
tion pump, check valve and time switch. Gravity
operation is possible only to a limited extent.
A
B
C
D
S
M
E
F
G H K L M G
N
G M O P G RN
T
Fig. 16
ADHW
BDHW circulation pipe
If no DHW circulation pipe is connected, seal the
aperture provided for this purpose.
CDHW circulation pump
DSpring-loaded check valve
EVisible discharge pipe outlet point (tundish)
FSafety valve
GShut-off valve
HFlow regulating valve
KPressure gauge connection
LNon-return valve
MDrain valve
NCold water
ODrinking water filter
PPressure reducer
RNon-return valve/pipe separator
SExpansion vessel, suitable for potable water (not
c)
TAutomatic thermostatic mixing valve (on site)
Installation sequence
Connecting the condensate drain (cont.)
5788 057 GB
Installation

19
The safety assembly to DIN 1988 is available as an
accessory. The safety assembly contains the following
components:
■Shut-off valve
■Diaphragm safety valve
■Non-return valve and test connector
■Pressure gauge connector
Information on drinking water filter
According to DIN 1988-2, a drinking water filter must
be installed in systems with metal pipework. We also
recommend the installation of a drinking water filter
when using plastic pipes, according to DIN 1988, to
prevent contaminants entering the DHW system.
Information on the thermostatic mixing valve
The DHW heat pump can heat drinking water to above
60 °C. Therefore, as a protection against scalding, a
thermostatic mixing valve must be fitted in the DHW
pipe.
Information on the safety valve
If no safety assembly to DIN 1988 is installed, equip
the system with a type-tested diaphragm safety valve
as protection against excess pressure.
Installation information:
■Install the safety valve in the cold water line. Ensure
it cannot be shut off from the DHW cylinder.
■There must be no restrictions in the pipework
between the safety valve and the DHW cylinder.
■Never seal off the safety valve discharge pipe.
Ensure that any expelled water is safely and visibly
drained into a drainage system. Position a sign close
to the safety valve discharge pipe, or ideally on the
safety valve itself, with the following inscription: "For
safety reasons, water may be discharged from the
discharge pipe during heating. Never seal off."
■Install the safety valve above the top edge of the
DHW heat pump.
Technical requirements:
■Permissible temperature: 65 °C
■Permissible operating pressure 10 bar (1 MPa)
AT: 6 bar (0.6 MPa)
■Test pressure: 16 bar (1.6 MPa)
■Connections:
Cold water, DHW, DHW circulation: R ¾
Heating water flow, heating water return: G 1
CH: Additional requirements:
■When connecting the DHW cylinder to the DHW
installation, observe all applicable local and national
standards and SVGW regulations.
■According to SVGW regulations, installation of
expansion vessels in DHW pipework is not permit-
ted.
■Always install the type EA non-return valve between
the last shut-off valve and the safety valve in the
DHW cylinder flow direction.
Type WWKS: solar thermal system
Maximum collector area and sizing information
DHW heat pump technical guide
Connecting solar collectors
Solar collector installation instructions
For connections to the DHW heat pump, see pages 9
and 21.
Note
■The cylinder temperature sensor is fitted at the fac-
tory.
■A high limit safety cut-out (accessories) for stopping
the solar circuit pump must be fitted.
High limit safety cut-out (accessories) installa-
tion instructions
Note
In outdoor air mode, the immersion heater (accesso-
ries) is essential.
Installation sequence
Connections on the DHW side (cont.)
5788 057 GB
Installation

20
For connections to the DHW heat pump, see pages 9
and 21.
Fitting the temperature sensor
!Please note
Damage to the connecting cables and sensor
leads (capillaries) causes malfunctions.
■The connecting cables and sensor leads must
not come into contact with hot components.
When routing and securing connecting cables
and sensor leads, ensure that the maximum
permissible temperatures for these cables/
leads are not exceeded.
■Never kink the capillary tubes.
2.
4.
3.
5.
1.
Fig. 17
Adjusting the draw-off rate
If there is high demand for DHW, it is possible to
change the draw-off profile from L to XL. To do this, the
cylinder temperature sensor fitted at the factory is
removed from sensor well A and fitted in sensor well
B.
Note
The high limit safety cut-out for the DHW heat pump
must also be refitted.
Installation sequence
Type WWKS: external heat generator
5788 057 GB
Installation