Viessmann Vitocal 100-A Series User guide

1 6020930

2 6020930
This manual has been drawn up for informative purposes. The company disclaims any liability for the results of any design or any installation based on the
explanations and on the technical specifications provided in this manual. Even the partial reproduction of the texts and figures in this manual is prohibited under
any form. Translation of original manual. The data in this manual are not binding and can be changed by the manufacturer without prior notice
Even partial reproduction PROHIBITED © Copyright

3 6020930
CONTENTS
1 PURPOSE AND CONTENTS OF THE MANUAL .............................................................................................................. 5
1.1 HOW TO KEEP THE MANUAL ........................................................................................................................................... 5
1.2 GRAPHIC SYMBOLS USED IN THE MANUAL ................................................................................................................ 5
2 NORMATIVE REFERENCES ............................................................................................................................................... 6
3 PERMITTED USE ................................................................................................................................................................... 6
4 GENERAL SAFETY GUIDELINES ...................................................................................................................................... 6
4.1 WORKERS’ HEALTH AND SAFETY ................................................................................................................................. 7
4.2 PERSONAL PROTECTIVE EQUIPMENT ........................................................................................................................... 8
4.3 SAFETY SIGNS ..................................................................................................................................................................... 8
4.4 REFRIGERANT SAFETY DATA SHEET ............................................................................................................................ 9
4.5 SPECIFIC R32 GAS WARNINGS....................................................................................................................................... 10
4.6 R32 GAS CHARGE ............................................................................................................................................................. 11
4.7 R32 GAS DISPOSAL ........................................................................................................................................................... 11
4.8 SAFETY RULES FOR R32 GAS TRANSPORT AND STORAGE .................................................................................... 11
5 INSTALLATION .................................................................................................................................................................... 11
5.1 GENERAL ........................................................................................................................................................................... 11
5.2 LIFTING AND HANDLING ............................................................................................................................................... 12
5.3 POSITIONING AND MINIMUM TECHNICAL CLEARANCES ..................................................................................... 13
5.4 DIMENSIONS ..................................................................................................................................................................... 15
5.4.1 Model Vitocal 100-A 06 / 08 ....................................................................................................................................... 15
5.4.2 Model Vitocal 100-A 10 / 12 ....................................................................................................................................... 15
5.4.3 Model Vitocal 100-A 14 / 16 ...................................................................................................................................... 16
5.5 ACCESSING THE INNER PARTS ..................................................................................................................................... 16
5.5.1 Mod. Vitocal 100-A 06 / 08 ......................................................................................................................................... 16
5.5.2 Mod. Vitocal 100-A 10 / 12 ......................................................................................................................................... 17
5.5.3 Mod. Vitocal 100-A 14 / 16 ......................................................................................................................................... 18
5.6 PLUMBING CONNECTIONS ............................................................................................................................................ 18
5.6.1 Features of the circuit water ....................................................................................................................................... 19
5.6.2 Typical plumbing diagram .......................................................................................................................................... 19
5.6.3 Handbook .................................................................................................................................................................... 20
5.6.4 Condensation discharge system .................................................................................................................................. 20
5.6.5 Filling the system ........................................................................................................................................................ 20
5.6.6 Discharge of the plant ................................................................................................................................................. 20
5.6.7 Service sleeves ............................................................................................................................................................ 21
5.6.8 Air venting valve ......................................................................................................................................................... 21
5.6.9 Vitocal 100-A 06 / 08 .................................................................................................................................................. 22
5.6.10 Vitocal 100-A 14 / 16 .................................................................................................................................................. 24
5.7 ELECTRICAL CONNECTIONS ......................................................................................................................................... 25
5.7.1 Access to the electric panel ......................................................................................................................................... 25
5.7.2 Power supply terminal block ...................................................................................................................................... 26
5.7.3 User terminal block .................................................................................................................................................... 27
5.7.4 Control logics ............................................................................................................................................................. 28
5.7.5 Fuses ........................................................................................................................................................................... 28
6 STARTUP ................................................................................................................................................................................ 28
6.1 SWITCHING ON THE UNIT .............................................................................................................................................. 29
7 INSTRUCTIONS FOR THE USER ...................................................................................................................................... 29
8 SHUTDOWNS FOR LONG PERIODS ................................................................................................................................ 30
9 MAINTENANCE AND PERIODIC CHECKS.................................................................................................................... 30
9.1 CLEANING THE FINNED COIL ........................................................................................................................................ 31
9.2 EXTRAORDINARY MAINTENANCE .............................................................................................................................. 32
9.3 ENVIRONMENTAL PROTECTION .................................................................................................................................. 32
10 DECOMMISSIONING .......................................................................................................................................................... 32

4 6020930
10.1 RESIDUAL RISKS .................................................................................................................................................................... 33
11 TECHNICAL DATA .............................................................................................................................................................. 40
11.1 TECHNICAL SHEET .......................................................................................................................................................... 40
11.2 UNIT AND AUXILIARY ELECTRICAL DATA ............................................................................................................... 43
12 OPERATING LIMITS ........................................................................................................................................................... 43
12.1 EVAPORATOR WATER FLOW RATE ............................................................................................................................. 43
12.2 COLD WATER PRODUCTION (SUMMER MODE) ......................................................................................................... 44
12.3 HOT WATER PRODUCTION (WINTER MODE) ............................................................................................................. 44
12.4 AMBIENT AIR TEMPERATURE AND SUMMARISED TABLE .................................................................................... 44
13 USER INTERFACE - CONTROLLER ................................................................................................................................ 47
13.1 MENU .................................................................................................................................................................................. 48
13.2 SETPOINT MENU ............................................................................................................................................................... 48
13.3 ALARMS MENU [ERR] ....................................................................................................................................................... 48

5 6020930
The manual of the Vitocal 100-A units contains all the necessary information for optimal use of the
equipment under safe conditions for the operator.
1 PURPOSE AND CONTENTS OF THE MANUAL
This manual provides basic information as to the selection, installation, operation and maintenance of the
Vitocal 100-A unit. It is intended for the operators of the appliance and it enables them to use the
equipment efficiently, even if they do not have any previous specific knowledge.
CAUTION: Although this manual has been drafted for the end user, some of the operations
described are the responsibility of skilled personnel having technical or professional
qualifications to perform the activities herein. They must also be kept up-to-date by attending
refresher courses acknowledged by the competent authorities. These tasks include: installation,
routine and extraordinary maintenance, decommissioning of the appliance and any other
operation indicated “by qualified personnel”.
When the installation and/or maintenance operations are over, the qualified operator must
correctly inform the end user regarding use of the appliance and the necessary periodical
inspections.
The operator has the responsibility of submitting all of the documentation necessary (including
this manual) and of explaining that it all must be kept with care, in the vicinity of the appliance
and always available.
The manual describes the machine at the moment it was sold. It must therefore be considered adequate
with respect to the state-of-the-art in terms of potentiality, ergonomics, safety and functionality.
The company also performs technological upgrades and does not consider itself obliged to update the
manuals of previous machine versions which could even be incompatible. Therefore make sure to use the
supplied manual for the installed unit.
The user is recommended to follow the instructions contained in this booklet, especially those concerning
safety and routine maintenance.
1.1 HOW TO KEEP THE MANUAL
The manual has to always be kept together with the unit it refers to. It has to be stored in a safe place, away
from dust and moisture. It must be accessible to all users who shall consult it any time they are in doubt on
how to operate the equipment.
The company reserves the right to modify its products and related manuals without necessarily updating
previous versions of the reference material. We also decline any responsibility for possible inaccuracies in
the manual if due to printing or transcription errors.
The customer shall store any updated copy of the manual or parts of it delivered by the manufacturer as an
attachment to this manual.
The company is available to give any detailed information about this manual and to give information
regarding the use and the maintenance of its own units.
1.2 GRAPHIC SYMBOLS USED IN THE MANUAL
Indicates operations that can be dangerous for people and/or disrupt the correct operation of the
unit
Indicates prohibited operations.
Indicates important information that the operator has to follow in order to guarantee the correct
operation of the unit in complete safety.

6 6020930
2 NORMATIVE REFERENCES
Vitocal 100-A units have been designed in compliance with the following directives and harmonized
standards on the safety of machinery:
 EC directives, 2014/35/UE, 2014/30/UE, 2011/65/UE, 2012/19/UE, 2014/68/UE
 Standard UNI EN 12735-1
 Standard IEC EN 60335-1, IEC EN 60335-2-40
 Standards IEC EN 55014-1, IEC EN 55014-2, IEC EN 61000-3-2, IEC EN 61000-3-3, IEC EN 61000-3-11, IEC
EN 61000-3-12
 EN 50581
And the following directives, regulations and standards on ecodesign and energy labelling:
 Community directive 2009/125/EU and subsequent transposal
 Community directive 2010/30/EU and subsequent transposal
 EU Regulation n.811/2013
 EU Regulation n.813/2013
 EN 14511-1:2018. EN 14511-2:2018. EN 14511-3:2018. EN 14511-4:2018
 EN 14825:2018
3 PERMITTED USE
 The company excludes any contractual and extra contractual liability for damage caused to persons,
animals or objects, by incorrect installation, setting and maintenance, improper use of the equipment,
and the partial or superficial reading of the information contained in this manual.
 These units are built for the heating and/or cooling of water. Any other use not expressly authorised by
the manufacturer is considered improper and therefore not allowed.
 The installation place and the water and electric circuit must be established by the plant designer and
must take into account both technical requirements as well as any applicable local laws and specific
authorisations.
 All the work must be executed by skilled and qualified personnel, competent on the existing regulations
in country of installation.
 This appliance is intended to be used by expert or trained operators in shops, light industry and in
factories, or for commercial use by non-expert personnel.
 The appliance may be used by children at least 8 years old and by persons with reduced physical,
sensory or mental capabilities or without experience or the necessary knowledge as long as they are
supervised or after they themselves have received instructions on the safe use of the appliance and
understand the relevant dangers. Children must not play with the appliance. The cleaning and
maintenance which the user is expected to carry out on the unit cannot be done by children without
supervision.
4 GENERAL SAFETY GUIDELINES
Before starting any type of operation on the Vitocal 100-A units, every operator must be perfectly familiar
with the operation of the machine and its controls and must have read and understood all the information
in this manual.
It is strictly forbidden to remove and/or to tamper with any safety device.
Children or unassisted disabled persons are not allowed to use the appliance.
Do not touch the appliance when barefoot or parts of the body are wet or damp.
It is forbidden to perform any cleaning operation when the master switch is ‘ON’.
It is forbidden to pull, detach or twist the appliance’s electric cables, even if unplugged.
Do not step on, sit down on and/or place any type of object on the appliance.

7 6020930
Do not spray or pour water directly on the unit.
Do not dispose of, abandon or leave within reach of children packaging materials (cardboard,
staples, plastic bags, etc.) as they may represent a hazard.
Any routine or extraordinary maintenance operation must be carried out with the machine
stopped and disconnected.
Do not place your hands or introduce screwdrivers, spanners or any other tools on moving
parts.
The machine operator an
d maintenance personnel must receive suitable training for the
performance of their tasks in safety.
Operators must know how to use personal protective equipment and the accident
-
prevention
rules of national and international laws and regulations.
4.1 WORKERS’ HEALTH AND SAFETY
The European Union has issued some directives regarding the safety and health of workers, including:
89/391/EEC, 89/686/EEC, 2009/104/EC, 86/188/EEC and 77/576/EEC and subsequent amendments which
every employer is obliged to follow and have followed. We observe therefore that:
Do not tamper with or replace parts of the unit without the specific consent of the manufacturer.
The manufacturer shall have no responsibility whatsoever in case of unauthorised operations.
Using components, consumables or spare parts that do not correspond to those recommended
by the manufacturer and/or listed in this manual may be dangerous for the operators and/or
damage the unit.
The operator’s workplace has
to be kept clean, tidy and clear of objects that may hinder free
movement. Appropriate lighting of the work place shall be provided so as to allow the operator
to carry out the required operations safely. Poor or excessive lighting can cause risks.
Ensure that work places are always adequately ventilated and that the extraction systems are
working, in good condition and in compliance with the requirements of the laws in force.
The unit works with R32 refrigerant, which is included in the list of greenhouse gases (GWP 675) which are
subject to the requirements in EU regulation n. 517/2014 called “F-GAS” (mandatory in the European zone).
Among the provisions of this regulation, it sets forth that operators working on systems running with
greenhouse gases be in possession of a certification, issued or acknowledged by the competent authorities,
attesting that they have passed a test authorising them to perform this work. In particular
 Up to 3kg total refrigerant in the appliance: category 2 certification.
 3kg and more total refrigerant in the appliance: category 1 certification.
The gaseous form of R32 refrigerant is heavier than air and if released into the environment, most of it
tends to concentrate in poorly ventilated areas. Inhaling it can cause dizziness and sensations of suffocation
and can develop lethal gas if in contact with naked flames or hot objects (see the refrigerant’s safety data
sheet in paragraph 4.4.
Pay attention to the fact that refrigerant fluids can be odourless

8 6020930
For any operation on the heat pump system:
Wear the appropriate PPE (specifically gloves and goggles).
Make sure that the workplace is well ventilated. Do not work in closed env
ironments or ditches
with little air circulation.
Do not operate on the refrigerant in the vicinity of hot parts or naked flames.
Do not release the refrigerant into the environment and pay special attention to accidental
leakage from pipes and/or fittings even after having emptied the plant.
4.2 PERSONAL PROTECTIVE EQUIPMENT
When operating and servicing the Vitocal 100-A units, the following personal protective equipment must be
used:
Clothing: Maintenance technicians and operators
must wear protective clothing that complies
with the basic safety requirements currently in force. In case of slippery floors, they must also
wear safety shoes with non-slip soles.
Gloves: During maintenance or cleaning operations, appropriate protective gloves must be used.
Mask and goggles: Respiratory protection (mask) and eye protection (goggles) should be
used during cleaning operations.
4.3 SAFETY SIGNS
The unit features the following safety signs, which must be complied with:
Generic hazard
Dangerous electric voltage
Moving parts
Surfaces which can cause injuries
Boiling surfaces which can cause burns
Fire hazard

9 6020930
4.4 REFRIGERANT SAFETY DATA SHEET
Name:
R32.
HAZARDS IDENTIFICATION
Main hazards:
Asphyxiation.
Specific hazards:
Quick evaporation could cause it to freeze.
FIRST AID MEASURES
General information:
Do not administer to people who are unco
nscious.
Inhalation: Immediately remove to fresh air.
Use oxygen or artificial respiration as required.
The use of adrenaline or similar drugs should be avoided.
Eye contact:
Carefully rinse with plenty of water for at least 15 minutes and get medica
l attention.
Skin contact: Wash immediately with plenty of water for at least 15 minutes. Apply a sterile gauze.
Immediately remove contaminated clothing.
FIRE FIGHTING MEASURES
Extinguishing media:
Water spray, dry powder.
Specific hazards: Breakage or explosion of vessel.
Specific methods:
Cool down the containers with a water spray from a safe position. Stop the product
leakage if possible. Use water spray, if possible, to abate the fumes. Move the vessels
away from the area of the fire if this can be done without posing any risks.
ACCIDENTAL RELEASE MEASURES
Personal precautions:
Try to stop the leak.
Evacuate personnel to safety areas.
Eliminate the ignition sources.
Ventilate appropriately.
Use personal protective equipment.
Environmental
precautions: Try to stop the leak.
Cleaning methods: Ventilate the area.
HANDLING AND STORAGE
Handling:
technical
measures/precautions:
Allow efficient air exchange and/or suction the work environments.
advice for safe use:
Do not breath in fumes or
aerosol.
Storage: Close carefully and store in a cool, dry and well ventilated area.
Keep in original containers. Incompatible products: explosive, flammable materials,
organic peroxide
EXPOSURE CONTROLS/PERSONAL PROTECTION
Control parameters:
OEL
–
data not available.
DNEL: Derived no effect level (workers)
long-term – systemic effects, inhalation = 7035 mg/m3.
PNEC: Predicted no-effect concentration
water (fresh water) = 0.142 mg/l
aquatic, intermittent releases = 1.42 mg/l
sediment, fresh water = 0.534 mg/kg dry weight
Respiratory
protection: Not required.
Eye protection: Safety goggles.
Hand protection:
Latex gloves.

10 6020930
Hygienic measures: No smoking.
PHYSICAL AND CHEMICAL PROPERTIES
Colour:
Colourless.
Odour:
Ethereal. Hard to perceive at low c
oncentrations.
Boiling point:
-
51.7°C at atm. press.
Flash point: 648 °C.
Relative gas density
(air =1)
Relative liquid density
(water =1)
1.8.
1.1.
Solubility in water: 280000 mg/l.
STABILITY AND REACTIVITY
Stability:
Stable under normal conditions.
Materials to avoid:
Air, oxidizing agents, humidity.
Decomposition
products
Under normal storage and use conditions, hazardous decomposition products should
not be generated.
hazardous:
TOXICOLOGICAL INFORMATION
Acute toxicity: LD/LC50/inhalation/4 hours/on rat >1107000 mg/m
3
.
Local effects:
No known effect.
Long
-
term toxicity:
No known effect.
ENVIRONMENTAL INFORMATION
Global warming
potential 675
GWP (R744=1):
Ozone Depletion
Potential ODP (R11=1):
0
Disposal
considerations:
Refer to the supplier’s gas retrieval program. Avoid direct release into the
atmosphere.
4.5 SPECIFIC R32 GAS WARNINGS
The R32 refrigerant gas:
- is odourless;
- is flammable, but only if there are naked flames;
- it may cause an explosion, but only if a given concentration in air is reached.
It is good practice to adhere to the following indictions:
- do not smoke near the unit;
- affix a no smoking sign near the unit;
- keep the premises where the unit is installed properly aerated;
- do not pierce or burn the unit;
- do not place the unit near ignition sources, such as naked flames, electric heaters etc.;
- every extraordinary maintenance or repair on the unit must be performed by skilled technicians or
qualified personnel;
- a gas leak test must be performed after installation.

11 6020930
4.6 R32 GAS CHARGE
The procedures described below may only be performed by skilled technicians or qualified personnel:
- ensure the R32 is not contaminated by any other types of refrigerant;
- keep the gas cylinder in an upright position when charging;
- ground the refrigerant circuit
- apply the appropriate label on the unit after charging;
- do not charge more refrigerant gas than needed;
- when charging is completed, perform leak tests before the operating test;
- once all the above operations have been completed, a second leak test should be performed.
4.7 R32 GAS DISPOSAL
The procedures described below may only be performed by skilled technicians or qualified personnel:
- do not dispose of the gas in areas at risk of explosive mixtures forming with air The gas should be
disposed of in an appropriate torch with backfiring stop device. Contact the supplier should you
require operating instructions.
4.8 SAFETY RULES FOR R32 GAS TRANSPORT AND
STORAGE
Before opening the unit’s packaging, ensure there are no gas leaks in the environment with an appropriate
gas detector. Ensure there are no fire ignition sources near the unit.
No smoking is allowed near the unit.
Transport and storage must be performed in accordance with the national regulations in force. Specifically,
according to ADR provisions, the total maximum quantity by transport unit in terms of net mass for
flammable gases is 333 kg.
5 INSTALLATION
CAUTION: All the operation described below must be done by QUALIFIED PERSONNEL ONLY.
Before any operation on the unit, make sure that power is disconnected. Also make sure that
power cannot be accidentally switched back on until all the operations are over, by means of
specific locks.
5.1 GENERAL
When installing or intervening on the chiller unit, it is necessary to strictly follow the rules listed in this
manual, to observe all the indications on the unit and however to take all possible precautions. Failure to
comply with the rules reported on this manual can create dangerous situations.
After receiving the unit,
immediately check its integrity. The unit left the factory in perfect
condition; any damage must be immediately reported to the carrier and recorded on the
Delivery Note before signing it.
The company must be informed, within 8 days, of the extent of the damage. The Customer should prepare a
written statement of any severe damage.

12 6020930
CAUTION: The units are designed for outdoor installation. The outside temperature must never
exceed 46°C. Beyond this value, the unit is no longer covered by the current regulations in the
field of safety of pressure equipment.
CAUTION: The installation place must be without any fire risks. Therefore all the necessary
measures should be adopted in order to prevent the risk of fire at the installation place. The
appliance must not be placed near naked flames and ignition sources
CAUTION: The unit must be installed so as to allow free movement for repair and maintenance
operations. The warranty does not cover costs for platforms or other lifting equipment needed for
any interventions.
All the maintenance operations and tests must be done by QUALIFIED PERSONNEL ONLY.
Before any operation on the unit, make sure that power is disconnected.
Do not use equipment to speed up the defrost process or for cleaning except for those
recommended by the manufacturer
The appliance must be placed in a room without ignition sources constantly runnin
g (for example
naked flames, a running gas-fired appliance or a running electric heater)
Do not perforate or burn
CAUTION: There are some moving components inside the unit. Pay the utmost attention when
operating in their vicinity, even if power is disconnected.
The heads and delivery pipe of the compressor are normally quite hot.
Be careful when working near the condensing coils.
The aluminium fins are very sharp and can cause serious injuries.
After the maintenance operations, close the panels by fixing them with screws.
5.2 LIFTING AND HANDLING
During unloading and positioning of the unit, utmost
care must be taken to avoid abrupt or violent
manoeuvres in order to protect the internal
electronic components. The units can be lifted by
means of a forklift or, in alternative, with belts,
being sure not to damage the side panels and the
cover. It is important to keep the unit horizontal
during these operations.

13 6020930
5.3 POSITIONING AND MINIMUM TECHNICAL CLEARANCES
All models of the Vitocal 100-A range are designed and constructed for outdoor installations.
It is advisable to create an adequately sized support base for the unit. The units transmit a small amount of
vibrations to the ground: it is nonetheless advisable to apply vibration dampers between the base frame
and support surface. It is very important to avoid recirculation between intake and delivery air, so as not to
downgrade performance of the unit or even to interrupt its normal operation.
At least 5 m from the appliance there must be no shafts or manholes where gases might build up
and generate an explosive atmosphere.
This is why the Minimum clearances shown below must be strictly guaranteed.
Do not obstruct or cover the vents on the top cover.
MODEL A [mm] B [mm] C [mm] D [mm] E [mm]
AWO
-
M
-
AC 101.A06
1500 500 400 400 500
AWO-M-AC 101.A08 1500 500 400 400 500
AWO-M-AC 101.A10 1500 500 400 400 500
AWO-M-AC 101.A12 1500 500 400 400 500
AWO-M-AC 101.A14
AWO-AC 101.A14 1500 500 400 400 500
AWO-M-AC 101.A16
AWO-AC 101.A16 1500 500 400 400 500
MODEL
L [mm]
AWO-M-AC 101.A06 500
AWO-M-AC 101.A08 500
AWO-M-AC 101.A10 500
AWO-M-AC 101.A12 500
AWO-M-AC 101.A14
AWO-AC 101.A14 500
AWO-M-AC 101.A16
AWO-AC 101.A16 500

14 6020930
In the event of side-by-side units, the minimum Lmin
distance between them is 1 m.
Covering with canopies or placing near plants or walls should be
avoided to prevent air recirculation.
In the event of winds stronger than 2.2 m/s the use of wind
barriers is recommended.
CAUTION:
It is mandatory to install the unit on a stable base capable of bearing its weight.
Considering the weight of the unit, possible vibrations and the ensuing generation of noise, it
should not be installed suspended; the company in this case will not be held liable for damage
or discomfort resulting thereof.
Lmin

15 6020930
5.4 DIMENSIONS
5.4.1 Model Vitocal 100-A 06 / 08
IN/OUT: 1”M G
E: power supply input
5.4.2 Model Vitocal 100-A 10 / 12
IN/OUT: 1”M G
E: power supply input
IN
OUT
OUT
IN

16 6020930
5.4.3 Model Vitocal 100-A 14 / 16
IN/OUT: 1”M G
E: power supply input
5.5 ACCESSING THE INNER PARTS
5.5.1 Mod. Vitocal 100-A 06 / 08
OUT
IN
DETAIL A
SCALE 1 : 3
DETAIL B
SCALE 1 : 4
Interlocking tab

17 6020930
1)
Remove the cover
2) Undo the screws (number 2; 3; 4) of the sheet metal cover of the user interface and the screw
(number 1) of the side panel to separate the front sheet metal from the side panel (Detail A).
3) Undo in sequence the screws (number 5; 6;7) in order to move the front panel slightly forward and to
be able to reach the screw (number 8) visible in detail B.
4) Undo the screws (number 8; 9 visible in detail B) and those on the coil side of the unit. To remove the
side panel, pull it upwards (to free the tab at the base indicated as C in detail B) and remove it.
5.5.2 Mod. Vitocal 100-A 10 / 12
1) Remove the cover by undoing the screws (number 1; 2; 3; 4; 5; 6; 7; 8).
2) Undo the screws (number 9; 10) of the front sheet and then push the panel downwards to remove
the tabs (Detail A); pull the panel forward to remove it.
3) Undo the screws (number 11; 12;13) and those on the coil side of the unit. To remove the side panel,
pull it upwards (to free the tab at the base indicated as C in detail B) and remove it.
Interlocking tab
DETAIL B
SCALE 1 : 5

18 6020930
5.5.3 Mod. Vitocal 100-A 14 / 16
1)
Remove the cover by undoing the screws (number 1; 2; 3; 4; 5; 6; 7; 8;9).
2) Undo the screws (number 10; 11) of the front sheet and then push the panel downwards to remove
the tabs (Detail A); pull the panel forward to remove it.
3) Undo the screw (number 12) and those on the coil side of the unit. To remove the side panel, pull it
upwards (to free the tab at the base indicated as C in detail B) and remove it.
5.6 PLUMBING CONNECTIONS
The plumbing connections must be made in accordance with national and/or local regulations; pipes can be
made of steel, galvanised steel or PVC. Pipes must be accurately sized according to the nominal water flow
rate of the unit and the pressure drops of the water circuit. All pipes must be insulated with closed-cell
material of adequate thickness. The chiller must be connected to the pipes using new flexible joints, not
reused ones. The water circuit should include the following components:
 Well thermometers to monitor the circuit’s temperature.
 Manual gate valves to isolate the chiller from the water circuit.
 Metal Y filter and dirt separator (installed on the return pipe) with metal mesh no larger than 1 mm.
 Loading group and exhaust valve where necessary.
CAUTION: when sizing the pipes, make sure not to exceed the maximum pressure drop on plant
side reported in the technical data table in Paragraph 11 (see useful head).
CAUTION: connect the pipes to their fittings always using the key to key method.
CAUTION: the expansion vessel on the unit has a limited capacity. The installer is in charge of
making sure that the expansion vessel is suited to the real capacity of the system, and if not, of
providing an additional expansion vessel.
CAUTION: The return pipe from the system must be installed near the label “WATER INLET”
otherwise the evaporator could freeze.
CAUTION: It is mandatory to install a metal filter (with mesh no larger than 1 mm) and a dirt
separator on the return pipe from the system labelled “WATER INLET”. If the flow switch is
manipulated or altered, or if the metal filter and dirt separator are missing, the warranty will
terminate immediately. The filter and dirt separator must be kept clean. Therefore after
installing the unit, you must make sure that they are still clean and check them regularly.
Tab
DETAIL A
SCALE 1 : 1
DETAIL B
SCALE 1 : 2

19 6020930
DHW
probe
secondary
pump
of fancoil
from
fancoil
to radiant panel
from water supply
to DHW fixtures
All of the units leave the company supplied with flow switch (installed in factory). If the flow
switch is altered or removed or if the water filter and dirt separator are missing from the unit,
the guarantee will be void. Refer to the wiring diagram attached to the unit to connect the flow
switch.
The heating system and the safety valves must comply with the requirements of standard EN
12828.
5.6.1 Features of the circuit water
To guarantee correct operation of the unit, the water must be appropriately filtered (see the instructions at
the start of this paragraph) and there must be only a minimum amount of dissolved substances. The
maximum allowed values are shown below
MAXIMUM CHEMICAL
-
PHYSICAL PROPERTIES ALLOWED FOR THE CIRCUIT
WATER
PH
7.5
-
9
Electrical conductivity 100 - 500 μS/cm
Total hardness
4.5
–
8.5 dH
Temperature
˂ 65°C
Oxygen content
< 0.1 ppm
Max glycol quantity
40 %
Phosphates (PO4) ˂ 2ppm
Mangan
ese (Mn)
< 0.05 ppm
Iron (Fe) < 0.3 ppm
Alkalinity (HCO3)
70
–
300 ppm
Chloride ions (Cl
-
)
< 50 ppm
Sulphate ions (SO4)
< 50 ppm
Sulphide ions (S)
None
Ammonium ions (NH4) None
Silica (SiO2)
< 30 ppm
5.6.2 Typical plumbing diagram
A recommended connection diagram is shown below.

20 6020930
5.6.3 Handbook
If you need more information about the possible configurations, there is a handbook which is a technical
notebook including a series of system diagrams that have been highlighted regarding the installation
configuration of our high efficiency heat pumps. The Handbook is also intended to show the symbiosis
potential with some of our elements found in the catalogue.
Consult the technical notebook at our headquarters.
5.6.4 Condensation discharge system
All Vitocal 100-A units are built in such a way that the base of the unit acts as a condensate drip tray. A
plastic fitting is standard supplied to be connected below the base in the specific slot in order to connect a
pipe which channels the condensate.
Each unit is therefore fitted with a hole on the base of the hydronic kit (on the coil side) to drain
condensation which could drip from the pipes of the plumbing system. Since these pipes are well insulated,
a minimum amount of condensation is produced anyway and therefore it is not mandatory to connect a
drain pipe to this fitting.
5.6.5 Filling the system
CAUTION: supervise all filling/top-up operations.
CAUTION: before filling/topping up the system, disconnect power to the units.
CAUTION: the system must always be filled/topped up in controlled pressure conditions (max 1
bar). Make sure that a pressure reducer and safety valve have been installed on the filling/top-
up line.
CAUTION: the water on the filling/top
-
up line must be ap
propriately pre
-
filtered from any
impurities and suspended particles. Make sure that a removable cartridge filter and dirt
separator are installed on the line.
CAUTION: regularly check and vent the air built up in the system.
CAUTION: install an automatic air venting valve at the highest point of the system.
5.6.6 Discharge of the plant
If the unit needs to be drained completely, first close the manual inlet and outlet gate valves (not included
in supply) and then detach the pipes on the outside of the water inlet and outlet to drain liquid from the
unit (to make this operation easier, it is recommended to install two drain valves between the unit and
manual gate valves on the outside of the water inlet and outlet).
All in bottom panel of
outdoor unit
Gasket
Gasket
Drain fitting