Viessmann VITOCAL 300-A Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitocal 300-A
Type AWC-I-M, AW-O-M
Compact heat pump with electric drive, 230 V~
For applicability, see the last page
VITOCAL 300-A
5366 060 GB 6/2008 Please keep safe.

Please follow these safety instructions 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
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations.
&all current safety regulations as
defined by DIN, EN, DVGW, VDE
and all locally applicable standards
Workingonthesystem
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electrostatic dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components that ful-
fil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Safety instructions
2
Safety instructions
5366 060 GB

Ancillary components, spare and
wearing parts !Please note Spare and wearing parts that
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications or conversions
can compromise safety and
may invalidate our warranty.
For replacements, use only ori-
ginal spare parts supplied or
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5366 060 GB

Installation instructions
Preparing for installation
Product information .................................................................................... 8
General information regarding electrical connection .................................... 8
Internal heat pump, type AWC-I-M............................................................... 9
External heat pump type AW-O-M ............................................................... 20
Overview of possible system diagrams........................................................ 34
Function description for the system versions ............................................... 34
System version 1 ........................................................................................ 37
System version 2 ........................................................................................ 42
System version 3 ........................................................................................ 47
DHW heating 1 ........................................................................................... 55
DHW heating 2 ........................................................................................... 57
Installation sequence
Installing the heat pump.............................................................................. 59
Primary side connections............................................................................ 60
Secondary side connections (heating circuits)............................................. 61
Electrical connections in the control panel................................................... 64
Electrical connections in the control unit...................................................... 70
Power supply.............................................................................................. 95
Closing the heat pump ................................................................................ 100
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 103
Further details regarding the individual steps .............................................. 104
Troubleshooting
Control unit diagnostics .............................................................................. 116
Measures in case the room temperature is constantly too low ...................... 129
No programming unit display....................................................................... 130
Control settings
Menu structure overview –main menu ........................................................ 131
Control settings by the contractor................................................................ 131
System definition control settings
System diagram.......................................................................................... 132
Language selection .................................................................................... 132
Temperature differential heating.................................................................. 132
Swimming pool ........................................................................................... 133
Cascade control ......................................................................................... 134
Index
4
Index
5366 060 GB

Number of external heat pumps .................................................................. 134
Output lag heat pump.................................................................................. 134
External extension...................................................................................... 135
External operating mode changeover heating circuits.................................. 135
External operating mode changeover effect ................................................ 136
External operating mode changeover duration ............................................ 137
External demand/mixer OPEN .................................................................... 137
External blocking/mixer CLOSED................................................................ 138
External blocking effect............................................................................... 140
Vitosolic type .............................................................................................. 141
Vitocom 100 ............................................................................................... 141
Additional output with switching times (e.g. DHW circulation pump) ............. 142
Compressor control settings
Compressor enable .................................................................................... 143
Heat pump output ....................................................................................... 143
Temperature for defrost stop ....................................................................... 143
Control settings, external heat source
External heat source................................................................................... 145
Priority of external heat sources.................................................................. 145
Dual-mode temperature .............................................................................. 145
External heat source for DHW ..................................................................... 146
DHW control settings
Cylinder temperature DHW ......................................................................... 147
DHW switching times .................................................................................. 147
Minimum temperature ................................................................................. 147
Max. temperature ....................................................................................... 147
Hysteresis/Hysteresis booster heater.......................................................... 148
Start optimisation DHW............................................................................... 150
Stop optimisation DHW............................................................................... 150
DHW auxiliary function................................................................................ 150
Set DHW temperature 2 .............................................................................. 150
Temp. sensor 2 ........................................................................................... 150
Booster heater............................................................................................ 151
DHW with electric heating ........................................................................... 151
Control settings, electric heater
Instantaneous heating water heater (accessory) ......................................... 152
Electric heating........................................................................................... 152
Max. stage electric booster heater .............................................................. 152
Stage at power-OFF ................................................................................... 153
Index (cont.)
5
Index
5366 060 GB

Control settings, hydraulics
Heat pump for drying buildings.................................................................... 154
Screed program.......................................................................................... 154
Set flow temperature for external demand ................................................... 156
Control settings, heating water buffer cylinder
Heating water buffer cylinder....................................................................... 157
Switching times, heating water buffer cylinder ............................................. 157
Set temperature for fixed value (switching times)......................................... 157
Hysteresis .................................................................................................. 158
Max. temperature ....................................................................................... 158
Control settings, heating circuits
Room temperatures and switching times ..................................................... 160
Activating the remote control....................................................................... 160
Heating curve slope/level............................................................................ 160
Influence of room temperature hook-up ....................................................... 160
Room temperature hook-up (heating circuits) .............................................. 161
Maximum flow temperature ......................................................................... 162
Date/time control settings
Date and time ............................................................................................. 163
Automatic summer/winter time changeover ................................................. 163
Components
Temperature sensor resistance curves........................................................ 164
Appliance fuse protection............................................................................ 164
Connection and wiring diagrams
Overview of the PCBs and connection options............................................. 166
Safety chain, control circuit, main power circuit ........................................... 174
Parts lists
Parts list, type AWC-I-M.............................................................................. 185
Parts list, type AW-O-M............................................................................... 192
Commissioning/service reports
Hydraulic parameters report........................................................................ 199
Control parameters report ........................................................................... 199
Specification............................................................................................. 203
Index (cont.)
6
Index
5366 060 GB

Appendix
Vitocal 300-A commissioning order ............................................................. 206
Certificates
Declaration of conformity ............................................................................ 207
Keyword index .......................................................................................... 208
Index (cont.)
7
Index
5366 060 GB

Vitocal 300-A, type AWC-I-M
Air-water heat pump with integral circulation pump (secondary pump), three-
way diverter valve, safety assembly and diaphragm expansion vessel.
Vitocal 300-A, type AW-O-M
Air-water heat pump without integral circulation pump (secondary pump) and
without three-way diverter valve. A secondary pump group (secondary pump
and circulation pump for cylinder heating) is available as an accessory.
The four red cores in the control unit must be removed for the external circula-
tion pumps to be connected (see page 79).
General information regarding electrical connection
&The total output of all components
connected directly to the control unit
(e.g. pumps, valves, message facil-
ities, contactors) must not exceed
1000 W.
If the total output ≤1000 W, the indi-
vidual rating of a component (e.g.
pump, valve, message facility, con-
tactor) can be greater than speci-
fied.
&If two components are connected to
the same terminal, press both cores
together into a single wire ferrule.
&If the compressor and/or instanta-
neous heating water heater (acces-
sories) are operated at a lower tariff
(power-OFF), provide an additional
cable for the power-OFF signal (e.g.
NYM 3 x 1.5 mm
2
) from the distribu-
tion board (meter box) to the heat
pump control unit (see page 98).
&The number of power supply cables
from the distribution board (meter
box) to the control unit and heat
pump (control panel) depends on
the system version and tariffs used.
&The KM BUS wires are interchange-
able.
For further information see control
panel (page 66), control unit
(page 70) and power supply connec-
tion (page 95).
Product information
8
Preparing for installation
5366 060 GB

!Please note
Avoid damaging the appliance
during handling.
Never load the top, front or
side panels of the appliance.
!Please note
If the compressor is at a steep
angle in the heat pump, lubri-
cant will enter the refrigerant
circuit and damage the appli-
ance.
Never tilt the heat pump more
than 45° during handling and
installation.
Requirements of the installation room
&The installation room must be dry
and safe from the risk of frost.
!Please note
High floor loading can result
in building damage.
Observe the permissible floor
load.
Total weight type AWC-I-M: 255 kg
&To prevent structure-borne noise,
never set up the appliance on ceil-
ings with wooden joists (e.g. in the
attic).
&Observe minimum clearances.
&Level the appliance.
&Required room height at least
2.10 m.
Internal heat pump, type AWC-I-M
9
Preparing for installation
5366 060 GB
Installation

Minimum clearances
Outlet side on the left (delivered con-
dition)
APower supply
BHydraulic connection and conden-
sate drain
Outlet side on the right
APower supply
BHydraulic connection and conden-
sate drain
Internal heat pump, type AWC-I-M (cont.)
10
Preparing for installation
5366 060 GB

Installation
Installation position overview (outlet side on the left)
AEPP connection, inlet side (air
inlet)
BEPP connection, outlet side (air
outlet)
CWeather grille
DEPP wall outlet/duct part
EEPP 90° bend
EPP Expanded polypropylene
Internal heat pump, type AWC-I-M (cont.)
11
Preparing for installation
5366 060 GB
Installation

Shell dimensions, wall outlets (outlet side on the left)
AEPP wall outlet
BTop edge –finished floor
x For dimension x see the follow-
ing diagram
EPP Expanded polypropylene
Internal heat pump, type AWC-I-M (cont.)
12
Preparing for installation
5366 060 GB

Outlet side on the left, inlet side on
the right
AWall outlet
BEPP wall outlet
CTop edge –finished floor
EPP Expanded polypropylene
In unfinished buildings, the relevant
thickness of render and plasterboard
must be taken into account for
dimension x:
x = 509.5 mm + end coating/thickness
of render
Example:
End coating/thickness of
render = 15 mm
x = 509.5 mm + 15 mm = 524.5 mm
Internal heat pump, type AWC-I-M (cont.)
13
Preparing for installation
5366 060 GB
Installation

Dimensions for installation against the wall (outlet side on the left)
AEPP wall outlet/duct part
BWeather grille
CEPP connection, inlet side (air
inlet)
DHeat pump
EEPP connection, outlet side (air
outlet)
FEPP 90° bend
EPP Expanded polypropylene
Internal heat pump, type AWC-I-M (cont.)
14
Preparing for installation
5366 060 GB

Dimensions for installation in a corner (outlet side on the left)
AExternal rendering
BWall
CEPP duct part (can be trimmed
to the required size from the out-
side. Observe thickness of ren-
der)
DCompression sealing strip and
acrylic airtight seam (all-round)
EPU foam (all-round)
FPlaster finish/wall coating
EPP Expanded polypropylene
Internal heat pump, type AWC-I-M (cont.)
15
Preparing for installation
5366 060 GB
Installation

Connections
Diagram without front panels
ACable entries
BDHW cylinder flow (see page 62)
CCondensate drain
DHeating water flow (see page 62)
EDHW cylinder return/heating
waterreturn(seepage62)
Internal heat pump, type AWC-I-M (cont.)
16
Preparing for installation
5366 060 GB

Note
Hydraulic lines B,D,Eand con-
densate drain Ccan be routed out of
the heat pump to the left or right.
The electrical cables can only be rou-
ted into the heat pump from the right.
Electrical cables (for installation see from page 64)
AHeat pump control unit
Wall outlet for cables centrally
below the control unit.
Required cable length inside the
control unit: 0.5 m
BControl unit power supply 230 V/
50 Hz
CPower cables for further compo-
nents and functions:
&Pumps/pump control
&Mixers
&Sensors
&Auxiliary functions (power-OFF,
external blocking, external
demand, external heat source
control, etc.)
&Fault messages
&Two-way shut-off valve
&Communication facilities
&KM BUS
&Remote control
Internal heat pump, type AWC-I-M (cont.)
17
Preparing for installation
5366 060 GB
Installation

DTwo electrical connecting cables,
wired ready to plug in (5, 15 or
30 m):
Control cable 230 V~, required
cable length inside the heat pump:
1.85 m
LV cable < 42 V, required cable
length inside the heat pump:
1.70 m
ECompressor/fan power supply
(230 V/50 Hz; 1/N/PE)
Required cable length inside the
heat pump: 2.50 m
FInstantaneous heating water hea-
ter power supply
(230 V/50 Hz; 1/N/PE; max. out-
put 9 kW)
Required cable length inside the
heat pump: 2.50 m
GInstantaneous heating water hea-
ter (accessory)
HHeat pump type AWC-I-M
Internal components
AHeating water return
BSecondary return temperature
sensor
CCondenser
DLPG temperature sensor
ESafety high pressure switch
FElectronic expansion valve (EEV)
GEvaporator
HAir outlet temperature sensor
KAir inlet temperature sensor
LLow pressure sensor
MSuction gas temperature sensor
NDigital scroll valve
OCompressor
PHigh pressure sensor
RHot gas temperature sensor
SFour-way diverter valve
TInstantaneous heating water hea-
ter (accessory)
USecondary heating circuit pump
VSecondary flow temperature sen-
sor
WDHW cylinder flow
XThree-way diverter valve
yHeating water flow
Internal heat pump, type AWC-I-M (cont.)
18
Preparing for installation
5366 060 GB

Diagram with instantaneous heating
water heater (accessory)
BSecondary return temperature
sensor
DLPG temperature sensor
ESafety high pressure switch
ISchrader valve, high pressure
side
JSchrader valve, low pressure side
LLow pressure sensor
MSuction gas temperature sensor
PHigh pressure sensor
RHot gas temperature sensor
VSecondary flow temperature sen-
sor
ZFill & drain valve
1Quick-acting air vent valve
2Safety valve
3Manual air vent valve
Internal heat pump, type AWC-I-M (cont.)
19
Preparing for installation
5366 060 GB
Installation

!Please note
Avoid damaging the appliance
during handling.
Never load the top, front or
side panels of the appliance.
!Please note
If the compressor is at a steep
angle in the heat pump, lubri-
cant will enter the refrigerant
circuit and damage the appli-
ance.
Never tilt the heat pump more
than 45° during handling and
installation.
Requirements
&Provide a manual draining facility
for the heating flow and return lines
intheareaatriskfromfrost(see
page 24).
The control unit frost protection
function is enabled if the control unit
and the heating circuit pump are
ready for operation.
Drain the system if the heat pump is
shut down or there is a prolonged
power failure.
In heat pump systems where a
power failure would not be detected
(holiday home), operate the heating
circuit with suitable antifreeze or
drain the circuit (see page 26).
&To prevent air "short circuits" and
higher sound emissions through
reflection, avoid installing the equip-
ment in recesses, on building cor-
ners or between two walls. Lawn
areas and vegetation can reduce
noise development.
Only the heat pump foundations
should therefore be made from
reverberative material (concrete).
&Never install the heat pump next to
living rooms or bedrooms.
&The air in the outlet section is
approx. 10 K colder than the ambi-
ent temperature. Therefore, black
ice could develop in the outlet area
even at [ambient] temperatures
above freezing. Clearance to pave-
ments or terraces: ≥3m.
External heat pump type AW-O-M
20
Preparing for installation
5366 060 GB