Viessmann VITOCAL 150-A Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitocal 150-A
Type AWO(-M)-E-AC/AWO(-M)-E-AC-AF 151.A
Air source heat pump, monoblock version for heating and cooling operation, with
1 integrated heating/cooling circuit
VITOCAL 150-A
6171807 GB 10/2021 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
The outdoor unit contains easily flamma-
ble refrigerant in safety group A3
according to ISO 817 and
ANSI/ASHRAE Standard 34.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on the refrigerant circuit with
flammable refrigerant in safety group
A3 may only be carried out by author-
ised heating contractors. These heat-
ing contractors must be trained in
accordance with EN 378 Part 4 or
IEC 60335-2-40, Section HH. The cer-
tificate of competence from an industry
accredited body.
■Brazing/soldering work on the refriger-
ant circuit may only be carried out by
contractors certified in accordance with
ISO 13585 and AD 2000, Datasheet
HP 100R. And only by contractors
qualified and certified for the processes
to be carried out. The work must fall
within the range of applications pur-
chased and be carried out in accord-
ance with the prescribed procedures.
Soldering/brazing work on accumulator
connections requires certification of
personnel and processes by a notified
body according to the Pressure Equip-
ment Directive (2014/68/EU).
■Work on electrical equipment may only
be carried out by a qualified electrician.
■Before initial commissioning, all safety-
relevant points must be checked by the
particular certified heating contractors.
The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Safety instructions
Safety instructions
6171807

3
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Statutory requirements for pressure
equipment:
Pressure Equipment Directive
2014/68/EU
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
■Applicable regulations and guidelines
for operation, service, maintenance,
repair and safety of cooling, air condi-
tioning and heat pump systems con-
taining flammable and explosive refrig-
erant.
Safety instructions for working on the system
The outdoor unit contains flammable
refrigerant R290 (propane C3H8). If
there is a leak, the escaping refrigerant
may form a flammable or explosive
atmosphere in the ambient air. A safety
zone is defined in the immediate vicinity
of the outdoor unit, in which special
rules apply when working on the appli-
ance.
Working in the safety zone
Danger
Risk of explosion: Escaping refrig-
erant may form a flammable or
explosive atmosphere in the ambi-
ent air.
Take the following measures to pre-
vent fire and explosion in the safety
zone:
■Keep ignition sources away, e.g. naked
flames, hot surfaces, electrical devices
not free of ignition sources, mobile
devices with integrated batteries (e.g.
mobile phones, fitness watches, etc.).
■Permissible tools:
All tools for working in the safety zone
must be designed and explosion pro-
tected in accordance with the applica-
ble standards and regulations for
refrigerant in safety groups A2L and
A3, e.g. brushless machines (cordless
screwdrivers), extraction equipment,
disposal containers, installation aids,
vacuum pumps, conductive hoses,
mechanical tools of non-sparking
material, etc.
Note
The tools must also be suitable for the
pressure ranges in use.
Tools must be in perfect maintenance
condition.
■The electrical equipment must meet
the requirements for areas at risk of
explosion, zone 2.
■Do not use flammable materials, e.g.
sprays or other flammable gases.
■Discharge static: Before beginning
work, touch earthed objects, such as
heating or water pipes.
Safety instructions
Safety instructions (cont.)
6171807

4
■Do not remove, block or bridge safety
equipment.
■Do not make any changes:
Do not modify the outdoor unit, inlet/
outlet lines, electrical connections/
cables or the surroundings. Do not
remove any components or seals.
Working on the system
■Switch off the power supply to the
indoor unit and outdoor unit, e.g. at a
separate fuse or mains isolator. Check
that the system is no longer live.
Note
In addition to the control circuit there
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 covers from the
appliances, wait at least 4 minutes
until the voltage has completely
dropped out.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Danger
Hot surfaces and fluids can result in
burns or scalding. Cold surfaces
may cause frostbite.
■Prior to servicing or maintenance
tasks, switch off and allow the
equipment to cool down or warm
up.
■Do not touch hot or cold surfaces
on the appliance, fittings or pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Before beginning work, touch
earthed objects, such as heating or
water pipes, to discharge any static.
Work on the refrigerant circuit
R290 refrigerant (propane) is an air dis-
placing, colourless, flammable, odour-
less gas which forms explosive mixtures
with air.
Refrigerant drained must be properly
disposed of by authorised contractors.
Perform the following measures before
beginning work on the refrigerant circuit:
■Check the refrigerant circuit for leaks.
■Ensure very good ventilation especially
in the floor area and sustain this for the
duration of the work.
■Secure the area surrounding the work
area.
■Inform the following persons of the
type of work to be carried out:
–All maintenance personnel
–All persons in the vicinity of the sys-
tem.
■Inspect the area immediately around
the heat pump for flammable materials
and ignition sources:
Remove all flammable materials and
ignition sources.
■Before, during and after the work,
check the surrounding area for escap-
ing refrigerant using an explosion-proof
refrigerant detector suitable for R290.
This refrigerant detector must not gen-
erate any sparks and must be suitably
sealed.
Safety instructions
Safety instructions (cont.)
6171807

5
■A CO2 or powder extinguisher must be
to hand in the following cases:
–Refrigerant is being drained.
–Refrigerant is being topped up.
–Soldering or welding work is being
carried out.
■Display signs prohibiting smoking.
Danger
Escaping refrigerant can lead to fire
and explosions that result in very
serious injuries or death.
■Do not drill or apply heat to a
refrigerant circuit filled with refrig-
erant.
■Do not operate Schrader valves
unless a fill valve or extraction
equipment is attached.
■Take measures to prevent electro-
static charge.
■No smoking! Prevent naked
flames and sparks. Never switch
lights or electrical appliances on
or off.
■Components that contain or con-
tained refrigerant must be label-
led, and stored and transported in
well ventilated areas in accord-
ance with the applicable regula-
tions and standards.
Danger
Direct contact with liquid and gas-
eous refrigerant can cause serious
damage to health, e.g. frostbite
and/or burns. There is a risk of
asphyxiation if it is breathed in.
■Prevent direct contact with liquid
and gaseous refrigerant.
■Wear personal protective equip-
ment when handling liquid and
gaseous refrigerant.
■Never breathe in refrigerant
vapours.
Danger
Refrigerant is under pressure:
Mechanical loading of lines and
components can cause leaks in the
refrigerant circuit.
Do not apply loads to the lines and
components, e.g. by supporting or
placing tools.
Danger
Hot and cold metallic surfaces of
the refrigerant circuit may cause
burns or frostbite if skin contact is
made.
Wear personal protective equip-
ment to protect against burns or
frostbite.
!Please note
When refrigerant is being removed,
hydraulic components may freeze.
Drain heating water from the heat
pump beforehand.
Danger
Damage to the refrigerant circuit
can cause refrigerant to enter the
hydraulic system.
After completion of the work, vent
the hydraulic system correctly.
When doing so, ensure the area is
sufficiently ventilated.
Safety instructions
Safety instructions (cont.)
6171807

6
Installation
Frost protection
!Please note
Freezing can cause damage to the
heat pump.
■Thermally insulate all the
hydraulic lines.
■In order to activate the frost pro-
tection function, electrically con-
nect the heat pump before filling
the secondary circuit. Switch on
the power supply. Switch on the
ON/OFF switch on the indoor unit.
■Only fill the secondary circuit with
suitable fill water in accordance
with VDI 2035, not with media
containing antifreeze.
Connecting cables
Danger
With short electrical cables, should
there be leakage in the refrigerant
circuit, gaseous refrigerant may
reach the inside of the building.
Min. length of the electrical con-
necting cables between the indoor
and the outdoor unit: 3 m
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
■Replace faulty components only
with genuine Viessmann spare
parts.
■Do not undertake any repairs on
the inverter. Replace the inverter if
there is a defect.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
6171807

7
Safety instructions for operating the system
What to do if refrigerant escapes
Danger
Escaping refrigerant can lead to fire
and explosions that result in very
serious injuries or death. There is a
risk of asphyxiation if it is breathed
in.
■Ensure very good ventilation
especially in the floor area of the
outdoor unit.
■No smoking! Prevent naked
flames and sparks. Never switch
lights or electrical appliances on
or off.
■Evacuate any people from the
danger zone.
■From a safe position, switch off
the electricity supply for all system
components.
■Remove ignition sources from the
danger zone.
■Let the system user know that no
ignition source may be brought
into the danger zone for the dura-
tion of the repair.
■Repair work must be carried out
by an authorised contractor.
■Only recommission the system
after it has been repaired.
Danger
Direct contact with liquid and gas-
eous refrigerant can cause serious
damage to health, e.g. frostbite
and/or burns. There is a risk of
asphyxiation if it is breathed in.
■Prevent direct contact with liquid
and gaseous refrigerant.
■Never breathe in refrigerant
vapours.
If water escapes from the appliance
Danger
If water escapes from the appliance
there is a risk of electric shock.
Switch off the heating system at the
external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appli-
ance, there is a risk of scalding.
Never touch hot heating water.
What to do if the outdoor unit ices up
!Please note
A build-up of ice in the condensate
pan and in the fan area of the out-
door unit can cause damage to the
equipment.
Please note the following:
■Do not use mechanical items/aids for
the removal of ice.
■Before using electrical heating applian-
ces, check the refrigerant circuit for
leaks with a suitable measuring device.
–The heating appliance should not be
a source of ignition.
–The heating appliance must meet the
requirements of EN 60335-2-30.
■If ice regularly builds up on the outdoor
unit (e.g. in areas where frost and
heavy fog occur frequently), install fan
ring heating (accessories) that is suita-
ble for refrigerant R290 and/or an elec-
tric ribbon heater in the condensate
pan (accessories or factory-fitted).
Safety instructions
Safety instructions (cont.)
6171807

8
Safety instructions for storage of the outdoor unit
The outdoor unit is charged at the fac-
tory with refrigerant R290 (propane).
Danger
Escaping refrigerant can lead to fire
and explosions that result in very
serious injuries or death. There is a
risk of asphyxiation if it is breathed
in.
Store the outdoor unit in the follow-
ing conditions:
■An explosion prevention plan must be
in place for storage.
■Ensure there is sufficient ventilation at
the storage location.
■Temperature range for storage: –25 °C
to 70 °C
■Only store the outdoor unit in its ex-
factory protective packaging.
■Protect the outdoor unit against dam-
age.
■The maximum number of outdoor units
that may be stored in one place is
determined by local conditions.
Safety instructions
Safety instructions (cont.)
6171807

9
1. Information Disposal of packaging ............................................................................ 12
Symbols ................................................................................................. 12
Intended use .......................................................................................... 12
Product information ................................................................................ 13
■Layout and functions .......................................................................... 13
■System examples ............................................................................... 14
■Spare parts lists .................................................................................. 14
2. Preparing for installation Requirements for on-site connections ................................................... 15
■Outdoor unit ........................................................................................ 16
3. Installation sequence Installing the outdoor unit ....................................................................... 17
■Transport ............................................................................................ 17
■Installation information ........................................................................ 19
■Installation location ............................................................................. 21
■Minimum clearances ........................................................................... 24
■Draining condensate via a soakaway ................................................. 24
■Draining condensate via waste water system .................................... 25
■Floorstanding installation .................................................................... 25
■Wall mounting ..................................................................................... 29
■Connecting the hydraulic connection lines ......................................... 30
■Checking the transport bracket ........................................................... 31
Installing the indoor unit ......................................................................... 32
■Transport ............................................................................................ 32
■Requirements for the installation room ............................................... 32
■Minimum clearances ........................................................................... 34
■Minimum installation heights .............................................................. 34
■Fitting the indoor unit to the wall ......................................................... 34
Connecting the secondary circuit ........................................................... 35
■Fitting the connection pieces supplied ................................................ 36
■Making the hydraulic connections ...................................................... 36
■Temperature limiter ............................................................................. 37
■Contact humidistat .............................................................................. 37
■Connection on the DHW side ............................................................. 38
■Operation without outdoor unit ........................................................... 38
Indoor unit: Removing the front panel .................................................... 39
Electrical connection .............................................................................. 39
■Preparing the electrical connections ................................................... 39
■Overview of electrical terminal areas .................................................. 41
■Opening the electrical terminal areas ................................................. 41
■Indoor unit: Routing cables to the wiring chamber ............................. 43
■Notes regarding the connection values .............................................. 46
■Connection sockets: Sensors and BUS connections ......................... 47
■230 V~ junction box: 230 V~ components and switching contacts ..... 49
■HPMU electronics module: Accessory 230 V~ and BUS connection . 51
■Integrating a heat pump into a CAN bus system ................................ 53
■EHCU electronics module: Additional contact humidistat ................... 55
■Fitting the programming unit ............................................................... 56
■Outdoor unit: Electrical terminal area on the underside of the appli-
ance .................................................................................................... 59
■Indoor/outdoor unit CAN bus communication cable (accessories) ..... 59
Closing the indoor unit ........................................................................... 61
■Indoor unit: Fitting the front panel ....................................................... 62
Power supply ......................................................................................... 63
■Central power supply for types ... SP ................................................. 63
■Heat pump control unit power supply ................................................. 64
■Instantaneous heating water heater power supply ............................. 65
■Compressor power supply: Outdoor unit 230 V~ ................................ 66
■Compressor power supply: Outdoor unit 400 V~ ................................ 67
Index
Index
6171807

10
■Power supply with power-OFF: Without on-site load disconnect ....... 68
■Power supply with power-OFF: With on-site load disconnect ............ 69
■Mains power supply in conjunction with self-consumption ................. 70
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 71
5. Troubleshooting Message display on the programming unit ............................................ 97
Fault messages ..................................................................................... 98
Warning messages ................................................................................ 116
Further messages ..................................................................................120
■Service messages .............................................................................. 120
■Status messages ................................................................................ 120
■Information ..........................................................................................121
6. Indoor unit maintenance Overview of electrical components ........................................................ 124
Removing the programming unit and electronics module ......................124
■Removing the HMI programming unit ................................................. 125
■Removing the HPMU electronics module .......................................... 125
■Removing the EHCU electronics module ........................................... 126
Overview of internal components .......................................................... 128
Draining the indoor unit on the secondary side ..................................... 128
Removing hydraulic components and EPP insulating parts .................. 129
■Overview of torque settings for assembly ...........................................130
■Removing the integrated buffer cylinder ............................................. 131
■Removing hydraulic lines from the integral buffer cylinder ................. 132
■Removing the expansion vessel ......................................................... 134
■Removing the instantaneous heating water heater ............................ 135
■Removing the sensors ........................................................................ 137
■Removing the circulation pump head ................................................. 140
■Removing the hydraulic block .............................................................140
■Removing the additional EPP insulation pieces ................................. 141
Status display, internal circulation pump ................................................142
Checking the temperature sensors ........................................................143
■Viessmann NTC 10 kΩ (blue marking) ............................................... 144
Checking the pressure sensors ............................................................. 145
Checking the fuse .................................................................................. 145
7. Outdoor unit maintenance Overview of electrical components ........................................................ 146
Checklist for maintenance work .............................................................146
Overview of internal components .......................................................... 151
Refrigerant circuit flowchart ................................................................... 153
■Heating mode ..................................................................................... 153
■Cooling mode ..................................................................................... 154
Extracting the refrigerant ....................................................................... 155
Testing pressure resistance ................................................................... 156
Filling the refrigerant circuit ....................................................................156
Draining the outdoor unit on the secondary side ................................... 157
Removing the hydraulic components .....................................................158
■Removing the float air vent valve with quick-action air vent valve ......158
■Removing the ball valve with filter ...................................................... 159
Checking the temperature sensors ........................................................160
■NTC 10 kΩ (no marking) .....................................................................161
Checking the pressure sensors ............................................................. 162
Checking the fuses ................................................................................ 162
8. Commissioning/service
reports
................................................................................................................163
9. Specification ................................................................................................................164
Index
Index
6171807