Viessmann VITOCAL 300-A Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-A
Type AWO-AC 301.B11 to B14
Air/water heat pump with electric drive, 400 V~
For applicability, see the last page
VITOCAL 300-A
5516 436 GB 5/2014 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ National installation regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the relevant trade
associations.
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and
SVGW
Working on the system
■ Isolate the system from the power sup-
ply (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 power circuits.
Danger
Contact with 'live' components
can result in severe injuries.
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 dissipate.
■ Safeguard the system against recon-
nection.
Safety instructions
Safety instructions
5516 436 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only spare
parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5516 436 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Requirements concerning on-site connections.................................................... 7
Siting requirements.............................................................................................. 8
Installation sequence
Installing the heat pump....................................................................................... 17
Making the hydraulic connections........................................................................ 18
Electrical connections, heat pump........................................................................ 21
Electrical connections, heat pump control unit..................................................... 26
Power supply........................................................................................................ 51
Closing the heat pump......................................................................................... 57
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 60
Further details regarding the individual steps....................................................... 61
Troubleshooting
Repairs................................................................................................................. 78
Parts lists
Overview of assemblies....................................................................................... 85
Casing.................................................................................................................. 86
Base frame........................................................................................................... 88
Heat pump module............................................................................................... 90
Additional components......................................................................................... 93
Air module............................................................................................................ 95
Miscellaneous....................................................................................................... 97
Electrical equipment............................................................................................. 98
Heat pump control unit......................................................................................... 100
Commissioning/service reports
Hydraulic parameter report................................................................................... 102
Control parameters report.................................................................................... 102
Specification....................................................................................................... 113
Appendix
Commissioning order........................................................................................... 115
Index
Index
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5
Certificates
Declaration of conformity...................................................................................... 116
Keyword index.................................................................................................... 117
Index
Index (cont.)
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6
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions.
Depending on the version, the appliance
can only be used for the following pur-
poses:
■ Central heating
■ Central cooling
■ DHW heating
The range of functions can be extended
with additional components and acces-
sories.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than central heating/cooling
or DHW heating shall be deemed inap-
propriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect 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 oper-
ate the appliance safely.
Preparing for installation
Intended use
5516 436 GB

7
1998
100
Ø 1100
B/C
300
370
490
B
C
DA
211
945
ACable entries
BHeating water flow (connection
R 1¼)
CHeating water return (connection
R 1¼)
DCondensate drain hose (flexible)
Preparing for installation
Requirements concerning on-site connections
5516 436 GB
Installation

8
!Please note
Prevent damage to the appliance
during handling.
Never put weight on the top, front
or side panels of the appliance.
!Please note
Tilting the compressor at a steep
angle inside the heat pump can
result in appliance damage.
Max. tilting angle 45 °
Requirements of the heat pump installation site
The heat pump may only be sited out-
side the building on solid foundations
(see page 9).
■ Provide a manual drain for the heating
water flow and return lines in any area
at risk from frost.
Drain the system if the heat pump is
shut down or there is a prolonged
power failure.
■ If the heat pump control unit, secon-
dary pump and heating circuit pumps
are ready for operation, the frost pro-
tection function of the heat pump con-
trol unit is enabled.
In heat pump systems where a power
failure would not be detected, e.g. hol-
iday home: operate the heating circuit
with a suitable antifreeze or drain the
heating circuit.
■ To prevent an increase in noise level
due to reflection, avoid siting equip-
ment in recesses, at building corners
or between 2 walls.
■ Lawn areas and vegetation can
reduce noise development. Only the
heat pump foundations should there-
fore be made from reverberant mate-
rial (concrete).
■ Never install the heat pump next to liv-
ing rooms or bedrooms.
■ The air in the discharge area is approx.
10 K colder than the ambient air.
Therefore, black ice could develop in
the discharge area even at [ambient]
temperatures above freezing. Clear-
ance to paths or patios: ≥ 3 m
Requirements for the heat pump control unit installation location
The heat pump control unit may only be
installed inside the building on a wall
(see page 26).
!Please note
The installation room must be dry
and free from the risk of frost.
Ensure ambient temperatures
between 0 and 35 °C.
!Please note
Risk of explosion due to dust,
gases and vapours.
Avoid dust, gases and vapours in
the room.
Preparing for installation
Siting requirements
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9
Minimum clearances
1500
1500
1500
1500
Foundation
Site the heat pump level on a durable
and solid base. We recommend laying a
concrete foundation as described in the
following chapters. The thickness of
cover represents an average value and
should be matched to local conditions.
This must be done in accordance with
the standard rules of building engineer-
ing.
■No recess in the foundation for cables
and hydraulic lines required.
■ Design the foundations, mounting sur-
face and pipework in such a way as to
prevent small animals from entering
the heat pump and the cable ducts.
■ Drain all condensate derived from the
air via a DN 40 drain pipe, which must
be protected from frost and provide a
constant fall.
Amount of condensate: Subject to
temperature and relative humidity, up
to 20 l/h and up to 20 l in 5 min during
defrosting.
If possible connect the condensate
drain to a drainage or sewer system.
In this case, provide a siphon with a
backup level of at least 60 mm in the
frost-protected area.
Where the ground is able to absorb
water, the condensate can be soaked
away down to a frost-free depth into a
gravel bed.
■ Where appropriate, provide thermal
insulation or a ribbon heater around
the condensate drain pipe on site.
Technical guides for heat pumps
Preparing for installation
Siting requirements (cont.)
5516 436 GB
Installation

10
Weight including outer casing: 250 kg
Dimensions
198
291
411
514
B A
H H
H
860
700
53
83
70
F
G
CDE
Preparing for installation
Siting requirements (cont.)
5516 436 GB