Viessmann VITOCAL 300-A Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 300-A
Type AWCI-M-AC 301.A
Type AWO-M-AC 301.A
Air/water heat pump with electric drive, 230 V~
For applicability, see the last page
VITOCAL 300-A
5692 875 GB 7/2011 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
designed for qualified contractors.
■ Work on the refrigerant circuit must
only be carried out by qualified and
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 requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of 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 and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can lead to severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Before removing covers from
appliances, wait at least 4
minutes for the power to dissi-
pate.
■ Safeguard the system against unau-
thorised reconnection
Safety instructions
Safety instructions
5692 875 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
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.
Replace faulty components only
with original 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 orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 875 GB

4
Installation instructions
Preparing for installation
Product information.............................................................................................. 6
General information - electrical connection.......................................................... 6
Internal heat pump, type AWCI-M-AC 301.A....................................................... 7
External heat pump type AWO-M-AC 301.A........................................................ 14
Overview of possible system schemes................................................................ 24
System example 1, ID: 4605093_1006_01.......................................................... 25
System example 2, ID: 4605305_1006_01.......................................................... 33
DHW heating........................................................................................................ 41
Installation sequence
Removing the transport brackets......................................................................... 46
Fitting the outer panels......................................................................................... 48
Fitting the silencer hoods (only type AWO-M-AC 301.A)..................................... 55
Siting the heat pump............................................................................................ 56
Connecting the heating circuits and condensate drain........................................ 59
Electrical connections in the control panel........................................................... 63
Electrical connections in the heat pump control unit............................................ 71
Power supply........................................................................................................ 97
Closing the heat pump......................................................................................... 103
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 105
Further details regarding the individual steps....................................................... 106
Troubleshooting
Repair................................................................................................................... 120
Parts lists
Parts list type AWCI-M-AC 301.A......................................................................... 124
Parts list type AWO-M-AC 301.A......................................................................... 130
Commissioning/service reports
Hydraulic parameter report................................................................................... 138
Control parameters report.................................................................................... 138
Specification....................................................................................................... 144
Appendix
Heat pump commissioning order.......................................................................... 147
Index
Index
5692 875 GB

5
Certificates
Declaration of conformity...................................................................................... 148
Keyword index.................................................................................................... 149
Index
Index (cont.)
5692 875 GB

6
Type AWCI-M-AC 301.A
Reversible air/water heat pump with inte-
gral circulation pump (secondary pump),
3-way diverter valve and safety assem-
bly.
Type AWO-M-AC 301.A
Air/water heat pump without integral cir-
culation pump (secondary pump) or 3-
way diverter valve. A secondary pump
assembly (secondary pump and circula-
tion pump for cylinder heating) is availa-
ble as an accessory.
The 4 red cores in the heat pump control
unit must be removed for the external
circulation pumps to be connected (see
page 75).
General information - electrical connection
■Connecting cables from control
panel – heat pump control unit:
Observe information from page 63.
■Electrical connection of system
components (pumps, mixers, valves,
alarm facilities, contactors, function
extensions, sensors, etc.):
These connections are made inside
the heat pump control unit. Observe
information from page 71.
■Power supply:
The number of power cables from the
distribution board (meter box) to the
heat pump control unit and to the con-
trol panel depends on the system ver-
sion and tariffs used.
These connections are made inside
the heat pump control panel. Observe
information from page 97.
Preparing for installation
Product information
5692 875 GB

7
Installation room requirements
!Please note
Incorrect ambient conditions can
lead to system damage and can
put safe operation at risk.
■ The installation room must be
dry and free from the risk of
frost.
Ensure ambient temperatures
are higher than 0 °C and lower
than 35 ºC.
■ Prevent air contamination by
halogenated hydrocarbons
(e.g. as contained in paints,
solvents or cleaning fluids) and
excessive dust (e.g. through
grinding/polishing work).
■ Avoid continuously high humid-
ity levels (e.g. through frequent
drying of washing).
Note
Cool vapour is expelled from the air duct
on the discharge side during defrosting.
Take this into account when siting the
appliance (selecting the installation
room, determining the intake and dis-
charge sides).
!Please note
Overloading the floor can result in
building damage.
Observe the permissible floor
load.
■ Total weight type AWCI-M-AC 301.A:
289 kg
■ To prevent structure-borne noise,
never site the appliance on ceilings
with wooden joists (e.g. in the attic).
■ Observe minimum clearances.
■ Level the appliance horizontally.
■ Required room height at least 2.10 m.
■ Observe the minimum room volume
required to EN 378 of 16.5 m3.
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A
5692 875 GB
Installation

8
Siting
Minimum clearances and dimensions for installation in corners
A B
532
1330
830
990
880
1330
935
522
D
C
Discharge side on the left (delivered condition); hydraulic connections on the right
(on site)
AWall outlet, discharge side
BWall outlet, intake side
CPlaster finish
DTop edge, finished floor level
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A (cont.)
5692 875 GB

9
BA
CDE
F
G
C
E
D
= 700
80
810
95
118
522
845
532
127 117
810
686
80
379
Discharge side on the left (delivered condition); hydraulic connections on the right
(on site)
AExternal render
BWall
CWall outlet (EPP, can be trimmed to
the correct size from the outside
with a saw. Observe plaster thick-
ness)
DCompression sealing strip and
acrylic airtight seam (all-round)
EPU foam (all-round)
FPlaster finish/wall coating
GHydraulic connections and conden-
sate drain hose
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A (cont.)
5692 875 GB
Installation

10
Minimum clearances and dimensions for installation against the wall
B
F
E
G
D
C
AK
H
966
885
885
= 8 x 350
= 1 x 350
686
80
990
845
835
880
X
830
810
350
Discharge side on the left (delivered condition); hydraulic connections on the right
(on site)
AWall outlet on the discharge side
(made of EPP)
BWeather grille
CPartition (if required), see table
below
DWall outlet on the intake side (made
of EPP)
EAppliance connector, air duct,
intake side (made of EPP)
FHeat pump
GAppliance connector, air duct, dis-
charge side (made of EPP)
HStraight wall outlets as air ducts
(made of EPP)
K90° bend (made of EPP)
X Clearance of wall outlets
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A (cont.)
5692 875 GB

11
Number of
duct parts
Total length of duct
parts in mm
Clearance X in mm Partition C
required
1 350 650 Yes
2 700 1000 Yes
3 1050 1350 Yes
4 1400 1700 Yes
5 1750 2050 Yes
6 2100 2400 Yes
7 2450 2750 Yes
8 2800 3100 No
9 3150 3450 No
10 3500 3800 No
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A (cont.)
5692 875 GB
Installation

12
Connections
A
891
957
B
D
C
1870
95
639
113
437
219
329
614
A
447 379
E
D
B
E
880
C
790
946
Note
■ Air discharge optionally on the l.h. or r.h. side.
■ Hydraulic lines and condensate drain can be routed from the heat pump on the l.h.
or r.h. side. They are always fitted on the opposite side to the air discharge.
■ The connection hoses can be trimmed to size. The stated dimensions result from
the hose lengths in the delivered condition.
ACable entries
BHeating water return/DHW cylinder
return (see page 59)
CHeating water flow
DCondensate drain
EDHW cylinder flow (see page 59)
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A (cont.)
5692 875 GB

13
Cables
A
C
D
G
E
H
F
K
B
AHeat pump control unit
BPower cable for heat pump control
unit 230 V/50 Hz
Recommended cable: 3 x 1.5 mm2
(5 x 1.5 mm2 with power-off by the
power supply utility)
CConnection cables for further com-
ponents and functions (e.g. pumps,
sensors, fault messages etc.)
DTwo connecting cables, fully wired
(5, 15 or 30 m):
■Control cable 230 V~
■LV lead < 42 V
EPower cable for compressor/fan
(230 V/50 Hz; 1/N/PE)
Recommended cable: 3 x 4.0 mm2,
flexible
FPower cable, instantaneous heating
water heater (if installed), max. out-
put 9 kW
Recommended cable:
230 V/50 Hz; 1/N/PE: 7 x 2.5 mm2,
flexible
GInstantaneous heating water heater
(accessory)
HControl panel
KInternal heat pump
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 control
panel):
2.6 m from the cable entry
Preparing for installation
Internal heat pump, type AWCI-M-AC 301.A (cont.)
5692 875 GB
Installation

14
Positioning requirements
■ Provide a manual drain of the heating
water flow and return lines in any area
at risk from frost.
If the heat pump control unit and heat-
ing circuit pump are ready for opera-
tion, the frost protection function of the
heat pump control unit is enabled.
Drain the system if the heat pump is
shut down or there is a prolonged
power failure.
On heat pump systems where a power
failure cannot be recognised (holiday
home), operate the heating circuit with
a suitable antifreeze or drain it.
■ To prevent air "short circuits" and
higher sound emissions through
reflection, avoid installing the equip-
ment in recesses, on building corners
or between two walls. Lawn areas and
vegetation can reduce noise develop-
ment.
Only the heat pump foundations
should therefore be made from rever-
berative material (concrete).
■ Never install the heat pump next to liv-
ing rooms or bedrooms.
■ The air in the outlet section is approx.
10 K colder than the ambient air.
Therefore, black ice could develop in
the outlet area even at [ambient] tem-
peratures above freezing. Clearance
towards paths or patios ≥ 3 m.
Note
During defrosting, cool vapour escapes
from both air discharge apertures of the
heat pump. This must be taken into con-
sideration when positioning the appli-
ance (selection of installation location,
heat pump orientation).
Preparing for installation
External heat pump type AWO-M-AC 301.A
5692 875 GB

15
Siting
Minimum clearances
1500
1200
1200
1500
Foundations
Site the heat pump horizontally on a per-
manently solid surface. We recommend
laying concrete foundations as shown in
the following diagrams.
■ Provide an adequately sized
recess (see diagram below) in the
foundations to permit the lines (heat-
ing water flow and return, cables and
condensate drain) to be brought into
the heat pump from below.
■ Design the foundations, supporting
surface and cable ducts so that small
animals cannot get into the heat pump
or cable ducts.
■ Drain all condensate derived from the
air (subject to temperature and relative
humidity up to 20 l/h) via a DN 40 drain
pipe, which should be protected from
frost and provide a steady fall.
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 hose on site.
Technical guide
Weight (with silencer hoods): 309 kg
Preparing for installation
External heat pump type AWO-M-AC 301.A (cont.)
5692 875 GB
Installation

16
Foundation dimensions
100 400
100
400
100
1300
1080
100
1150
300
250
390320
165
315
340
75
145
240
D D
C
BA
E F G
H
Plan view of the foundations
Preparing for installation
External heat pump type AWO-M-AC 301.A (cont.)
5692 875 GB

17
AInstallation area of the heat pump on
concrete foundations
BConcrete foundations, consisting of:
■ Concrete plate C25/30,
BSt 500 S and M
■ Reinforcement with all-round wire
mesh made of Q 257 A
Observe local requirements and the
standard rules of building engineer-
ing, as well as the spot loads
through adjustable feet.
CFront of the heat pump
DSoft ground, gravel or crushed stone
EFoundation recess for routing the
lines for heating water flow and
return, condensate drain and elec-
tric cables/leads (low voltage and
control cables) as well as the power
cable to the control panel
FLine outlet for heating water flow
and return
GKG conduit DN 100 for connecting
cables (LV and control cables) and
power cable to the control panel
HCondensate drain DN 40
Connection dimensions, hydraulic connection kit in the foundations
400
≈500
≥900
≈300
400
/
D
E F
C
A
BC
8
37
A
B
D
Preparing for installation
External heat pump type AWO-M-AC 301.A (cont.)
5692 875 GB
Installation

18
AConcrete foundations as previously
described and according to local
requirements and in accordance
with the standard rules of building
engineering
BFrost protection (compacted
crushed stone, e.g. 0 to 32/56 mm),
thickness of layer subject to local
requirements and building rules
CHydraulic connection set (heating
water flow and return)
DSoft ground, gravel or crushed stone
EConnecting cables (LV and control
cables) and power cable to the con-
trol panel
FCondensate drain
Note
Before laying the concrete foundations,
trim the hydraulic connection pipes
(heating water flow and return), install
the connection fittings and provide frost
protection.
Preparing for installation
External heat pump type AWO-M-AC 301.A (cont.)
5692 875 GB

19
Connections
1885
1380
957
1265
DD
529
473
A
B
C
566
946
880
891
Side view, shown without silencer hood.
Note
Cable entries are cut into the sealing mat in the floor panel on site (see page 67).
Preparing for installation
External heat pump type AWO-M-AC 301.A (cont.)
5692 875 GB
Installation

20
ACondensate drain
BSecondary circuit flow (DHW cylin-
der/heating water flow; for installa-
tion see page 60)
CSecondary circuit return (DHW cyl-
inder/heating water return; for instal-
lation see page 60)
DSilencer hoods (for installation see
page 55)
Cables and hydraulic lines
Laying the lines underground and routing in through the exterior wall
D
B
H G
F
IC
C
B
L
400
20
≥ 900
D
E
C
D
G
K
B
J
A
Preparing for installation
External heat pump type AWO-M-AC 301.A (cont.)
5692 875 GB