Viessmann VITOCAL 300-G Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitocal 300-G
Type BW/BWC, WW/WWC
Compact heat pump with electric drive
For applicability, see the last page
VITOCAL 300-G
5355 757 UAE 4/2008 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, TRGI,
TRF, 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 757 UAE

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 757 UAE

Installation instructions
Preparing for installation
General information regarding the electrical connection .............................. 8
Handling..................................................................................................... 8
Positioning ................................................................................................. 8
Overview of possible system diagrams........................................................ 12
Function description in connection with the system versions........................ 14
Internal components type BW/WW .............................................................. 18
Internal components type BWC/WWC ......................................................... 20
Connections on the primary side type BW (brine/water) ............................... 22
Connections on the primary side type BWC (brine/water) ............................ 23
Connections on the primary side type WW (water/water) ............................. 25
System on the primary side WWC (water/water) .......................................... 28
System version 1 (type BW/WW)................................................................. 29
System version 2 (type BW/WW)................................................................. 35
System version 3 (type BW/WW)................................................................. 42
DHW heating 1 ........................................................................................... 52
DHW heating 2 ........................................................................................... 54
Installation sequence
Installation preparations ............................................................................. 58
Opening the heat pump............................................................................... 59
Overview of power connections................................................................... 61
Inserting cables/leads................................................................................. 66
Positioning of all terminals .......................................................................... 68
Connection of electrical components........................................................... 78
Power supply.............................................................................................. 89
Connection on the primary side (brine)........................................................ 100
Connections on the secondary side (heating circuits) .................................. 100
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 102
Further details regarding the individual steps .............................................. 103
Troubleshooting
Control unit diagnostics .............................................................................. 117
Diagnosis ................................................................................................... 135
Control unit settings
Menu structure overview –main menu ........................................................ 136
Control unit settings by the contractor ......................................................... 136
Index
4
Index
5355 757 UAE

System definition control settings
System diagram.......................................................................................... 137
Language selection .................................................................................... 137
Temperature differential heating.................................................................. 137
Temperature differential cooling .................................................................. 138
Swimming pool ........................................................................................... 139
Cascade control (lead appliance) ................................................................ 139
Cascade control (lag appliance).................................................................. 140
Output lag heat pump.................................................................................. 140
External extension...................................................................................... 141
External operating mode changeover heating circuits.................................. 141
External operating mode changeover effect ................................................ 142
External operating mode changeover duration ............................................ 143
External demand/mixer OPEN .................................................................... 143
External Blocking/mixer CLOSE.................................................................. 144
Type Vitosolic ............................................................................................. 145
Vitocom 100 ............................................................................................... 146
External blocking effect............................................................................... 146
Additional output with switching times (e.g. DHW circulation pump) ............. 147
Compressor control settings
Compressor enable .................................................................................... 148
Heat pump output ....................................................................................... 148
Number of external heat pumps .................................................................. 149
Control settings, external heat source
External heat source................................................................................... 150
Priority........................................................................................................ 150
Dual-mode temperature .............................................................................. 150
External heat source for DHW ..................................................................... 151
DHW control settings
Cylinder temperature DHW ......................................................................... 152
Switching times, DHW ................................................................................ 152
Min. temperature ........................................................................................ 152
Max. temperature ....................................................................................... 152
Hysteresis/Hysteresis booster heater.......................................................... 153
Start optimisation DHW............................................................................... 154
Stop optimisation DHW............................................................................... 155
DHW auxiliary function................................................................................ 155
Set DHW temperature 2 .............................................................................. 155
Temp. sensor 2 ........................................................................................... 155
Booster heater............................................................................................ 156
Index (cont.)
5
Index
5355 757 UAE

DHW with electric heating ........................................................................... 156
Control settings, electric heater
Instantaneous heating water heater ............................................................ 157
Electric heating........................................................................................... 157
Max. stage electric booster heater .............................................................. 157
Stage for power-OFF .................................................................................. 158
Control settings, hydraulics
Heat pump for drying buildings.................................................................... 159
Screed program.......................................................................................... 159
Set flow temperature, external demand ....................................................... 161
Control settings, heating water buffer cylinder
Buffer cylinder ............................................................................................ 163
Buffer cylinder switching times .................................................................... 163
Fixed temperature ...................................................................................... 163
Hysteresis .................................................................................................. 164
Max. temperature ....................................................................................... 165
Control settings, heating circuits
Standard room temperature ........................................................................ 166
Reduced room temperature ........................................................................ 166
Heating circuit switching times .................................................................... 166
Activating the remote control....................................................................... 166
Heating curve level ..................................................................................... 167
Heating curve slope .................................................................................... 167
Room hook-up slope................................................................................... 167
Room temperature hook-up (heating circuit)................................................ 168
Maximum flow temperature ......................................................................... 168
Cooling control settings
Cooling....................................................................................................... 169
Cooling circuit............................................................................................. 169
Room temperature separate cooling circuit ................................................. 169
Min. flow temperature ................................................................................. 170
Room hook-up slope, separate cooling circuit ............................................. 170
Cooling curve level/slope............................................................................ 170
Control settings, time
Automatic summer/winter time changeover ................................................. 172
Index (cont.)
6
Index
5355 757 UAE

Components
Sensor resistance curves............................................................................ 173
Appliance fuse protection............................................................................ 173
Connection and wiring diagrams
Overview of the PCBs and connection options............................................. 174
PCB 1: Message and safety components .................................................... 174
PCB 2: Function components 230 V ............................................................ 177
PCB 3: Sensors and KM BUS...................................................................... 182
Safety chain (explanations)......................................................................... 184
Safety chain (part 1) ................................................................................... 185
Safety chain (part 2) ................................................................................... 186
Control circuit (part 1) ................................................................................. 187
Control circuit (part 2) ................................................................................. 188
Power circuit - compressor.......................................................................... 189
Power circuit - instantaneous heating water heater...................................... 190
Parts lists
Parts lists type BWC ................................................................................... 191
Parts lists type BW...................................................................................... 197
Commissioning/service reports
Hydraulic parameter reports........................................................................ 203
Control parameter report............................................................................. 203
Specification............................................................................................. 208
Appendix
Order to commission the Vitocal 300-G ....................................................... 213
Certificates
Declaration of conformity ............................................................................ 214
Keyword index .......................................................................................... 215
Index (cont.)
7
Index
5355 757 UAE

&The total output of all connected
appliances must not exceed
1000 W. If the total output ≤1000 W,
the individual rating of a component
can be greater than specified.
&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 3x1.5 mm
2
) from
the distribution board (meter box) to
the heat pump (see additional infor-
mation from page 89).
&The KM BUS wires are interchange-
able.
Handling
The max. permitted tilting angle for
the compressor during transportation
and installation is 45°. !Please note
Avoid appliance damage dur-
ing handling, particularly when
transporting the appliance off
its pallet.
Never load the top, front or
side panels of the appliance.
Positioning
Installation room requirements
&The installation room must be dry
and safe from the risk of frost.
&To prevent corrosion damage, pro-
vide the brine-side heat pump
installation with thermal insulation in
accordance with current rules as
vapour diffusion proof installation.
&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 when utilising
the connection panel: 2,050 mm
(min).
General information regarding the electrical connection
8
Preparing for installation
5355 757 UAE

Clearance dimensions (plan view)
Clearance AHeat pump posi-
tioning
(including addi-
tional accessories
adjacent on the
left)
no limitation Heat pump alone
≥400 Heat pump with
AC-Box
no limitation Heat pump (lead
appliance) with lag
heat pump (stage
2)
variable Heat pump in a
cascade
Installation instructions AC-
Box
Positioning (cont.)
9
Preparing for installation
5355 757 UAE
Installation

Dimensions of the top panels and connections
APrimary return (brine) OUT
BPrimary flow (brine) IN
CSafety assembly (only for type
BWC/WWC)
DHeating water flow
EDHW cylinder flow
FDHW cylinder return/heating
water return
Positioning (cont.)
10
Preparing for installation
5355 757 UAE