Viessmann VITOCAL 300-A Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitocal 300-A
Type AWC-I, AW-O
Compact heat pump with electric drive
For applicability, see the last page
VITOCAL 300-A
5355 955 GB 5/2008 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,
&the Code of Practice of relevant
trade associations.
&all current safety regulations as
defined by DIN, EN, DVGW, VDE
and all locally applicable standards
Working on the system
&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
5355 955 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
5355 955 GB

Installation instructions
Preparing for installation
General information regarding electrical connection .................................... 8
Internal heat pump, type AWC-I .................................................................. 8
External heat pump type AW-0 .................................................................... 13
Connections, type AWC-I............................................................................ 20
Overview of possible system diagrams........................................................ 21
Function description for the system versions ............................................... 22
Internal components, type AWC-I................................................................ 25
Internal components, type AW-O................................................................. 26
System version 1 (type AW-O) .................................................................... 26
System version 2 (type AW-O) .................................................................... 31
System version 3 (type AW-O) .................................................................... 37
DHW heating 1 ........................................................................................... 45
DHW heating 2 ........................................................................................... 48
Installation sequence
Preparing the installation ............................................................................ 51
Opening the heat pump............................................................................... 52
Connections on the primary side ................................................................. 56
Connections on the secondary side (heating circuits) .................................. 56
Electrical connections................................................................................. 60
Positioning of all electrical connections ....................................................... 72
Connection of external electrical components ............................................. 77
Power supply.............................................................................................. 87
Closing the heat pump ................................................................................ 101
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 102
Further details regarding the individual steps .............................................. 103
Troubleshooting
Control unit diagnostics .............................................................................. 113
Diagnosis ................................................................................................... 130
Control unit settings
Menu structure overview –main menu ........................................................ 131
Control unit settings by the contractor ......................................................... 131
System definition control settings
System diagram.......................................................................................... 132
Language selection .................................................................................... 132
Index
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Index
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Temperature differential heating.................................................................. 132
Swimming pool ........................................................................................... 133
Cascade control (lead appliance) ................................................................ 133
Cascade control (lag appliance).................................................................. 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 ............................................ 136
External demand/mixer OPEN .................................................................... 137
External bocking/mixer CLOSE................................................................... 138
Vitosolic type .............................................................................................. 139
Vitocom 100 ............................................................................................... 139
External blocking effect............................................................................... 139
Additional output with switching times (e.g. DHW circulation pump) ............. 141
Compressor control settings
Compressor enable .................................................................................... 142
Heat pump output ....................................................................................... 142
Number of external heat pumps .................................................................. 142
Control settings, external heat source
External heat source................................................................................... 144
Priority........................................................................................................ 144
Dual-mode temperature .............................................................................. 144
External heat source for DHW ..................................................................... 145
DHW control settings
Cylinder temperature DHW ......................................................................... 146
DHW switching times .................................................................................. 146
Min. temperature ........................................................................................ 146
Max. temperature ....................................................................................... 146
Hysteresis/Hysteresis booster heater.......................................................... 147
Start optimisation DHW............................................................................... 148
Stop optimisation DHW............................................................................... 148
DHW auxiliary function................................................................................ 148
Set DHW temperature 2 .............................................................................. 149
Temperature sensor 2 ................................................................................. 149
Booster heater............................................................................................ 149
DHW with electric heating ........................................................................... 150
Control settings, electric heater
Instantaneous heating water heater ............................................................ 151
Index (cont.)
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Index
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Electric heating........................................................................................... 151
Max. stage electric booster heater .............................................................. 151
Stage for power-OFF .................................................................................. 152
Control settings, hydraulics
Heat pump for drying buildings.................................................................... 153
Screed program.......................................................................................... 153
Set flow temperature, external demand ....................................................... 155
Control settings, heating water buffer cylinder
Buffer cylinder ............................................................................................ 156
Buffer cylinder switching times .................................................................... 156
Fixed temperature ...................................................................................... 156
Hysteresis .................................................................................................. 157
Max. temperature ....................................................................................... 157
Control settings, heating circuits
Standard room temperature ........................................................................ 158
Reduced room temperature ........................................................................ 158
Heating circuit switching times .................................................................... 158
Activating the remote control....................................................................... 158
Heating curve level ..................................................................................... 159
Heating curve slope .................................................................................... 159
Room hook-up slope................................................................................... 159
Room temperature hook-up (heating circuits) .............................................. 159
Maximum flow temperature ......................................................................... 160
Control settings, time
Automatic summer/winter time changeover ................................................. 161
Components
Sensor resistance curves............................................................................ 162
Appliance fuse protection............................................................................ 162
Connection and wiring diagrams
Overview of the PCBs and connection options............................................. 163
PCB 1: Message and safety components .................................................... 163
PCB 2: Function components 230 V ............................................................ 166
PCB 3: Sensors and KM BUS...................................................................... 171
Safety chain (explanations)......................................................................... 173
Safety chain (part 1) ................................................................................... 174
Safety chain (part 2) ................................................................................... 175
Control circuit (part 1) ................................................................................. 176
Index (cont.)
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Index
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Control circuit (part 2) ................................................................................. 177
Control circuit (part 3) ................................................................................. 178
Power circuit - compressor.......................................................................... 179
Power circuit - instantaneous heating water heater...................................... 180
Parts lists
Parts list, type AWC-I.................................................................................. 181
Parts list, type AW-O................................................................................... 188
Commissioning/service reports
Hydraulic parameter report ......................................................................... 195
Control parameter report............................................................................. 195
Specification............................................................................................. 199
Appendix
Order to commission the Vitocal 300-A........................................................ 202
Certificates
Declaration of conformity ............................................................................ 203
Keyword index .......................................................................................... 204
Index (cont.)
7
Index
5355 955 GB

&The total output of all connected
appliances must not exceed
1000 W. If the total output ≤1000 W,
the individual rating of a component
(e.g. pump, valve, message facility,
contactor) can be greater than spe-
cified.
&If two components are connected to
the same terminal, press both cores
together into a single wire ferrule.
&If the compressor and/or the instan-
taneous heating water heater are
operated at a lower tariff (power-
OFF), provide an additional cable
for the switching contact "Power-
OFF" (e.g. NYM 3 x 1.5 mm
2
) from
the distribution board (meter box) to
the heat pump (see additional infor-
mation from page 88).
&The KM BUS wires are interchange-
able.
Note
For overview and further information
regarding cable lengths, see page 62.
Internal heat pump, type AWC-I
!Please note
Avoid appliance damage dur-
ing transportation, particularly
without a pallet.
Never load the top, front or
side panels of the appliance.
Note
The maximum permissible tilting
angle of the compressor and there-
fore of the appliance during handling
and installation is 45°.
Requirements of the installation room
&The installation room must be dry
and safe from the risk of frost.
&To prevent damage to the building
structure, please pay attention to
the permissible load-bearing capa-
city of the floor.
&To prevent structure-borne noise,
never set up the appliance on ceil-
ings with wooden joists (e.g. in the
attic).
&Observe required wall clearances
as shown in the following diagram.
&Level the appliance.
&Required room height at least
2.10 m.
General information regarding electrical connection
8
Preparing for installation
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Clearance dimensions (floor plan)
Version 1
APower supply
BHydraulic connection and conden-
sate drain
Version 2
APower supply
BHydraulic connection and conden-
sate drain
Installation and dimensions
!Please note
High floor loading can result in
building damage.
Observe the permissible floor
load.
Note
For an overview of power cables and
cable lengths, see page 60.
Weight
Type AWC-I
Total weight in kg 255
Internal heat pump, type AWC-I (cont.)
9
Preparing for installation
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Installation

Example: Installation against the wall,
connection to a duct, l.h. discharge
EPP Expanded polypropylene (par-
ticle foam)
AEPP inlet connection
BEPP outlet connection
CWeather grille
DEPP wall outlet / duct part
E90° EPP bend
Internal heat pump, type AWC-I (cont.)
10
Preparing for installation
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Example: Dimensions for installation
against the wall, l.h. discharge
AEPP wall outlet / duct part
BWeather grille
CEPP inlet connection
DHeat pump
EEPP outlet connection
F90° EPP bend
Internal heat pump, type AWC-I (cont.)
11
Preparing for installation
5355 955 GB
Installation

Example: Corner installation, l.h. dis-
charge
AExternal rendering
BWall
CEPP duct part (can be trimmed to
the correct size from the outside.
Observe plaster thickness)
DCompression sealing strip and
acrylic airtight seam (all-round)
EPU foam (all-round)
FPlaster finish/wall coating
Internal heat pump, type AWC-I (cont.)
12
Preparing for installation
5355 955 GB

&The maximum permissible tilting
angle during transportation and
installation is 45º.
&Provide a manual draining facility
for the heating flow and return lines
in the area at risk from frost (see
page 18).
&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 cannot be detected
(holiday home), operate the heating
circuit with suitable antifreeze or
drain the circuit (see page 18).
&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: ≥3 m.
Minimum clearances
External heat pump type AW-0
13
Preparing for installation
5355 955 GB
Installation

Foundations
The heat pump must be placed hori-
zontally on a permanently solid sur-
face. We therefore recommend laying
down concrete foundations as shown
in the following diagrams.
Provide an adequately sized
recess Bin the foundations to permit
the lines (heating flow and return,
electrical cables and condensate
drain) to be brought into the heat
pump from below.
The foundations, supporting surface
and cable ducts must be designed to
prevent rodents from entering the
heat pump and the cable ducts.
The condensate that is created must
either be led out via an existing drain
pipe or be able to soak away into a
coarse bed of gravel.
Technical guide
Weight
Type AW-O
Total weight in kg 275
Foundations floor plan excl. silencer
hoods
AConcrete foundations in accor-
dance with local requirements and
the standard rules of building
engineering (observe spot loads
of adjustable feet)
BRecess in the foundations to route
the heating flow and return lines,
condensate drain and electric
cables (sensor leads, control
cables, power supply)
CFront of the heat pump
External heat pump type AW-0 (cont.)
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Preparing for installation
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Foundations floor plan incl. silencer
hoods
AConcrete foundations in accor-
dance with local requirements and
the standard rules of building
engineering (observe spot loads
of adjustable feet)
BRecess in the foundations to route
the heating flow and return lines,
condensate drain and electric
cables (sensor leads, control
cables, power supply)
ESoft ground, gravel or crushed
stone
FFront of the heat pump
External heat pump type AW-0 (cont.)
15
Preparing for installation
5355 955 GB
Installation

Sectional / side view of foundations
AConcrete foundations in accor-
dance with local requirements and
the standard rules of building
engineering
BFrost protection (compacted
crushed stone); the thickness of
the layer is subject to local condi-
tions and the standard rules of
building engineering
CHeating flow and return of the
hydraulic connection set, electric
cables (sensor leads, control
cables, power supply) and con-
densate drain
Drain all condensate derived from the
air (subject to temperature and the
relative humidity up to 20 l/h) via a DN
70 drain pipe, which should be pro-
tected from frost and provide a steady
fall. Versions offering the option of
connection to a drainage or sewer
system are preferred. In this case,
provide a siphon with a hydraulic seal
of at least 60 mm in the frost-pro-
tected 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.
External heat pump type AW-0 (cont.)
16
Preparing for installation
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Connecting cables
AControl cable, control unit/heat
pump (accessory)
BSensor lead, control unit/heat
pump (accessory)
CHeat pump control unit
DPower cable (on site)
EHydraulic connection line (acces-
sory)
FCondensate drain (on-site)
GKG pipe DN 100 for external con-
nections, control unit/heat pump
(on-site)
HPipe liner with wall seal flange for
hydraulic connection line (acces-
sory)
KMoisture-proof and waterproof
wall ducts (on site)
LShut-off and drain valves
MMaintain the maximum clearance
between sensor lead Band
power cable D.
External heat pump type AW-0 (cont.)
17
Preparing for installation
5355 955 GB
Installation

Heating water connection
Use the hydraulic connection
set (accessory), pre-assembled in dif-
ferent lengths. The set comprises one
flexible flow line and one flexible
return line (both PE 32 x 2.9) in
shared thermal insulation Eand 2
screw-type unions for the transition
from DN 32 to R 1" (male).
Route the pipes into the building via a
suitable pipe liner with wall seal
flanges H(both accessories).
Provide a fill & drain valve Linside
the building shortly downstream of the
entry point of the heating water con-
nections (at a depth of 0.8 m below
ground level in all cases) for the heat-
ing water flow and return.
In buildings level with the ground, pro-
vide a suitable insulated duct or
enable draining with compressed air.
The frost protection of the control unit
can function provided the control unit
and the heating circuit pump are
ready for operation. If the heat pump
is taken out of operation or there is a
prolonged power cut, drain the system
via fill & drain valve L.
Where heat pump systems not neces-
sarily indicate a power failure (e.g. in
a holiday home), the heating circuits
can also be operated as an alternative
with a suitable antifreeze.
Power cable
Outside the building, implement cable
Das an earth cable (NYY), or route
an NYM cable inside KG conduit G
(see technical guide for sizing).
Observe the regulations imposed by
your local power supply utility.
Ensure on-site wall duct Kis moist-
ure-proof and waterproof. Allow a
cable length of at least 2.5 m for rout-
ing inside the heat pump casing.
Control cable and sensor lead
Route the connecting cables/leads
(control cables and sensor leads A
and B), pre-assembled in different
lengths, inside DN 100 KG conduit
G. When routing KG conduit G,
insert a wire pull for the control cables
and sensor leads at the same time.
To prevent excessive resistance when
pulling the electrical cables/leads
through the conduit, avoid installing
90º bends (it would be better to install
3 x 30º bends, or at least 2 x 45º
bends).
When pulling the cables/leads
through the conduit towards the heat
pump, protect the round plugs with
bubble wrap or similar against con-
tamination and damage.
External heat pump type AW-0 (cont.)
18
Preparing for installation
5355 955 GB

Also protect the plugs on the side of
the control unit against damage (e.g.
by being stepped on) until they are
connected. Ensure on-site wall duct
Kis moisture-proof and waterproof.
KG conduit Gshould be routed with
a slope towards the heat pump and
may need a condensate drain.
Observe the permissible bending
radius of KG conduit G; never kink
the conduit. Seal the apertures of KG
conduit Garound the cables/leads
so that animals cannot enter the build-
ing.
Condensate drain
Drain all condensate derived from the
air (subject to temperature and the
relative humidity up to 20 l/h) via a
DN 70 drain pipe F, which should be
protected from frost and provide a
steady fall.
Technical guide
Secondary flow sensor
A secondary flow sensor must be installed, independent of whether an instanta-
neous heating water heater is integrated.
Connection in the control unit to the
sensor PCB (LP3; see page 68).
Note
If the cable supplied (length approx.
2 m) is not long enough, it can be
extended on site.
External heat pump type AW-0 (cont.)
19
Preparing for installation
5355 955 GB
Installation

AInlet for electric cables
BDHW cylinder flow
CCondensate drain
DHeating water flow
EDHW cylinder return / heating
water return
Connections, type AWC-I
20
Preparing for installation
5355 955 GB