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
5516 436 GB

5
Certificates
Declaration of conformity...................................................................................... 116
Keyword index.................................................................................................... 117
Index
Index (cont.)
5516 436 GB

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
5516 436 GB

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

11
400
500
900
300
400
B
K
H
G
E
C
D
F A
H
C
G
E
D
B
K
AHeat pump
BConcrete foundation (300 mm thick)
consisting of:
■ Concrete slab C25/30, BSt 500 S
and M
■ Reinforcement with all-round wire
mesh made of Q 257 A
CKG conduit DN 100 for power cable
400 V/50 Hz (on site)
DKG conduit DN 100 for connecting
cables to the heat pump control unit
(on site): Control cable 230 V~, LV
cable < 42 V
EHydraulic connection set (acces-
sory): Hydraulic connection lines for
heating water flow and heating
water return
FHydraulic connections on the heat
pump (heating water flow and heat-
ing water return)
GCondensate drain DN 40 (on site)
HSoft ground, gravel or crushed stone
KFrost protection (compacted
crushed stone, e.g. 0 to 32/56 mm);
layer thickness subject to local
requirements and standard rules of
building engineering
Preparing for installation
Siting requirements (cont.)
5516 436 GB
Installation

12
Cables and hydraulic lines
Laying the lines underground and routing in through the exterior wall
O N
T
S
U
M
400
900
DCE
K
B
P
C
D
E
F
ON M
QR
ONM
P
BConcrete foundation (300 mm thick)
consisting of:
■ Concrete slab C25/30, BSt 500 S
and M
■ Reinforcement with all-round wire
mesh made of Q 257 A
CKG conduit DN 100 for power cable
400 V/50 Hz (on site)
DKG conduit DN 100 for connecting
cables to the heat pump control unit
(on site): Control cable 230 V~, LV
lead< 42 V
EHydraulic connection set (acces-
sory): Connection lines for heating
water flow and heating water return
FCondensate drain DN 40 (on site)
KFrost protection (compacted
crushed stone, e.g. 0 to 32/56 mm);
layer thickness subject to local
requirements and standard rules of
building engineering
Preparing for installation
Siting requirements (cont.)
5516 436 GB

13
MPower cable, compressor/fan (3/N/
PE 400 V/50 Hz, on site)
Recommended cable: 5 x 2.5 mm2,
flexible
N2 connecting cables inside DN 100
KG conduit (on site), fully wired (5,
15 or 30 m):
■Control cable 230 V~
■LV lead < 42 V
Note
The maximum cable length is
30 m. Extensions are not permis-
sible.
OHydraulic connection lines (heating
water flow and heating water return)
PUnderground channel
QWall duct with expanding mortar (on
site) for hydraulic connection line
RMoisture-proof and waterproof wall
ducts (on site)
SDrain & fill facility with shut-off valve
(for draining with compressed air)
TExpansion vessel with safety
assembly (accessories)
UClearance, house wall — founda-
tions:
■ Maximum clearance depends on
length of the connecting cables
and hydraulic connection lines:
Max. 23 m
■ Maintain the minimum clearance
to other objects (> 1.5 m) when
siting.
Heating water connection (hydraulic
connection lines O)
Use the hydraulic connection set (acces-
sory). The connection set is fully pre-
pared in different lengths. The flow and
return lines are flexible and have 2 adap-
tors each. The lines are located inside a
common thermal insulation.
■ Flow/return line: 2 x DN 32
■ Adaptor fittings: DN 32 to R 1¼
■Lines are fed into building Q through
a wall duct with expanding mortar (on
site).
■Provide a drain & fill facility S for
heating water flow and return in the
building near an external wall and
0.8 m below ground level.
Note
In buildings at ground level, provide a
thermally insulated duct or enable
draining of the heat pump with com-
pressed air.
Frost protection
If the heat pump control unit and heating
circuit pump are ready for operation, the
frost protection function of the heat pump
control unit is enabled. Drain the system
via the drain & fill facility S when the
heat pump is taken out of use or if the
power fails for a long period.
In heat pump systems where a power
failure would not be detected (holiday
home), the heating circuits can be oper-
ated with suitable antifreeze. Ensure that
the system components used are com-
patible with the antifreeze.
Preparing for installation
Siting requirements (cont.)
5516 436 GB
Installation

14
Power cable M
■Run power cable M to the heat pump
outside the building in a KG conduit
DN 100.
■ Cable length required in the heat pump
from top edge of foundation: Min.
0.7 m
■ Observe the regulations imposed by
your local power supply utility.
Connecting cables N
Route prepared connecting cables (con-
trol cable 230 V~, LV lead < 42 V) N
outside the building in a KG conduit
DN 100. Protect the plugs at the ends of
the cables from dirt and damage (e.g.
with bubble wrap).
Cable length required in the heat pump
from top edge of foundation
■ Control cable 230 V~: Min. 0.9 m
■ LV cable < 42 V: Min. 0.7 m
Routing KG conduits C, D
■Provide a wire pull for the cables (M,
N).
■ To facilitate the routing of cables D
through the KG conduit, avoid 90°
bends; instead use 3 x 30° or 2 x 45°.
■ Route the KG conduit with a slope
towards the heat pump and fit a con-
densate drain if required.
■Ensure that wall ducts R are mois-
ture-proof and waterproof.
■ Seal the apertures of the KG conduit
so that no animals or moisture can
enter the building.
Preparing for installation
Siting requirements (cont.)
5516 436 GB

15
Required cables and hydraulic lines
G
K
P
C
F
L
O Q
H
S
D
E
M
N
R
A
B
AHeat pump
BElectric terminal area in the heat
pump
CPower cable, compressor/fan (3/N/
PE 400 V/50 Hz, on site)
D2 connecting cables inside DN 100
KG conduit (on site), fully wired (5,
15 or 30 m):
■Control cable 230 V~
■LV cable < 42 V
Note
The maximum cable length is
30 m. Extensions are not permis-
sible.
Preparing for installation
Siting requirements (cont.)
5516 436 GB
Installation

16
EHeat pump control unit power
cable
Recommended cable: 3 x 1.5 mm2
(5 x 1.5 mm2 with power-OFF)
FConnection cables for further com-
ponents and functions (e.g. pumps,
sensors, fault messages, etc.)
GHeat pump control unit
HInstantaneous heating water heater
control
Recommended cable: 5 x 2.5 mm2
KSwitching module for instantaneous
heating water heater: connecting
chamber with 2 output relays; install
inside the building.
LPower cable, instantaneous heating
water heater (if installed), max. out-
put 9 kW
MConnecting cable with plug for con-
trol module/instantaneous heating
water heater, approx. 1.6 m long
NFlow temperature sensor, secon-
dary circuit: Install in the heating
water flow inside the building.
Cable with plug, 2.0 m long: Extend
on site if required.
OFlow, heating circuits with secon-
dary pump/flow, DHW cylinder with
circulation pump for cylinder heating
(both circulation pumps are acces-
sories): Alternatively, 1 secondary
pump and a 3-way diverter valve
can also be used (both accesso-
ries).
PInstantaneous heating water heater
(accessory; install in building)
QHeating water return
RHydraulic connection set (acces-
sory): Connection lines for heating
water flow and return
SDrain & fill facility with shut-off valve
(for draining with compressed air)
Required cable lengths:
■ For the heat pump control unit (wall
outlet centrally directly below the heat
pump control unit):
0.6 m from the wall outlet
■ Inside the heat pump (to the electric
terminal area):
0.7 m from the top edge of the foun-
dations
Preparing for installation
Siting requirements (cont.)
5516 436 GB

17
Observe the siting requirements: See
page 8.
4x
1.
2.
3.
4.
4x
4x
4x
Installation sequence
Installing the heat pump
5516 436 GB
Installation

18
Connect heating water flow and heating water return at the heat
pump
!Please note
Avoid appliance damage:
■ Fit supplied connecting hoses
(bends) so that they are free of
load and torque stress.
■ To prevent transmission of any
vibration, the connecting hoses
must not contact any other
components.
Note
■ The connecting hoses can be short-
ened.
■ Completely encase connecting hoses
in the supplied thermal insulation.
C
AB
1.
4.
3.
2x
2x
2.
AHeating water return
BHeating water flow
CHydraulic connection set (acces-
sory)
Installation sequence
Making the hydraulic connections
5516 436 GB

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Connect heating circuits and DHW cylinder in the building
1. Equip the secondary circuit on site
with an expansion vessel and safety
assembly (in accordance with
EN 12828).
Fit the safety assembly to the on-site
line in the heating water return.
2. Connect secondary lines to the lines
of the hydraulic connection set
(accessory).
!Please note
To prevent appliance dam-
age,
connect on-site secondary
lines so that they are free of
load and torque stresses.
Make tight hydraulic connec-
tions on the secondary side.
3. Fill and vent secondary circuit.
4. Thermally insulate pipes inside the
building.
5. Connect the drain hose to the safety
valve.
Connect the drain hose to the public
sewage system with a fall and a pipe
vent.
Note
■ In underfloor heating circuits, install a
temperature limiter to restrict the max-
imum temperature of underfloor heat-
ing systems.
■ Safeguard the minimum flow rate: see
"Specification".
Fitting the flow temperature sensor, secondary circuit
The flow temperature sensor for the sec-
ondary circuit is installed in the heating
water flow inside the building.
Note
If an instantaneous heating water heater
is installed, fit the flow temperature sen-
sor for the secondary circuit in the heat-
ing water flow downstream of the
instantaneous heating water heater.
Installation sequence
Making the hydraulic connections (cont.)
5516 436 GB
Installation

20
2.
3.
D
C
B
1.
A
1. Fit pipe section with sensor well A.
2. Secure flow temperature sensor for
secondary circuit C with spring clip
B in the sensor well.
3. Connect plug D of the sensor lead
and the cable to the heat pump con-
trol unit (cable with plug, length
2.0 m, extend on site if required).
Connect connector F8 inside the heat
pump control unit at the controller and
sensor PCB.
Connecting the condensate drain
Note
■ Subject to temperature and relative
humidity, the volume of condensate
accumulating from the air can be as
high as 20 l/h.
■ During the defrosting process, the
amount of condensate can be as high
as 20 l within 5 min.
Connect condensate drain via siphon
(backup level at least 60 mm) in the frost-
protected area to on-site drain connec-
tion (drainage or sewer system): See
page 12.
Route condensate drain (drain pipe
DN 40) with a constant fall of at least
2 %.
Installation sequence
Making the hydraulic connections (cont.)
5516 436 GB