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
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Index
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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.)
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Index
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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.)
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Index
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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
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&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
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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.)
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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.)
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On-site connection requirements
Positioning (cont.)
11
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Installation

ATop entry area for sensor leads
and cables for accessories and
auxiliary functions.
&Cable/lead length approx. 1 m
plus wall clearance (see
page 66).
BLower entry area on the appliance
back for 1 to 3 power cables with
cable grommets.
&Length of the power cable ≥
2.00 m, if it is routed together
with the power-OFF signal cable
as 5-core cable (see page 89).
&Length of the power cable ≥
1.50 m plus wall clearance (see
power connection, page 91)
Note
&The number of power cables from
the meter box to the heat pump
results from the extent of the system
and the applicable power tariffs (see
power connection, page 89).
Overview of possible system diagrams
The following table provides an overview of all possible system diagrams.
Schemes 2, 4 and 10 (see from page 29) represent examples of 3 typical ver-
sions of heat pump systems.
Positioning (cont.)
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System diagram (number of parameters/ID 7000
programmed in the control unit)
0 1 2 3 4 5 6 7 8 9 10 11
Heating
circuit
A1 - X X - - X X - X X -
M2 - - - X X X X X X X X -
M3 - - - - - - X X X X -
DHW cylinder X - X - X - X - X - X -
Heating water buffer cy-
linder
- X X X X X X X X X X -
Options
External heat
source
-0 0 X X X X X X X X -
Cooling at HC
A1
- X X - - X X - - X X -
Cooling at HC
M2
- - - X X X X X X X X -
Cooling at HC
M3
- - - - - - - X X X X -
separate cool-
ing circuit
X X X X X X X X X X X -
Swimming pool X X X X X X X X X X X -
Solar X - X - X - X - X - X -
External heat source:
0In scheme 1 and 2, use only
together with a heating water buf-
fer cylinder, in all other schemes
as option.
Note
&The cooling option can only be used
respectively on one heating or cool-
ing circuit.
&In addition, the swimming pool and
solar options can be freely selected.
&The solar option is only feasible in
conjunction with the Vitosolic 100 or
200.
Overview of possible system diagrams (cont.)
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Preparing for installation
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Installation

Note
The sample applications are recommendations and must be checked for com-
pleteness and functionality on site. Please observe the applicable regulations
and directives for design, installation and operation.
Heating circuit
Heat pumps require a minimum
throughput of heating water (see
specification on page 208). Ensure
that the values specified in the rele-
vant datasheet are maintained.
Accurately calculated radiator heating
systems generally have a small sys-
tem water content. With systems like
these, use a heating water buffer
cylinder with an appropriate capacity
to prevent the heat pump from being
switched on and off at frequent inter-
vals.
Heat pumps can be shut off by the
power supply utility at peak load peri-
ods depending on the power tariff. For
this reason install a heating water buf-
fer cylinder in rapidly cooling build-
ings.
The system versions with heating
water buffer cylinder do not use a sec-
ondary pump but a separate circula-
tion pump as heating circuit pump. We
recommend the use of a heating cir-
cuit pump with a slower flow rate than
the secondary pump.
Systems with large water volumes, e.
g. underfloor heating systems, can
operate without a heating water buffer
cylinder. In these heating systems
install an overflow valve at the under-
floor heating system heating circuit
distributor that is furthest away from
the heat pump. This ensures that the
minimum circulation volume is pro-
vided, even in closed heating circuits.
In conjunction with an underfloor
heating system, install a temperature
limiter (accessory, order no. 7151 728
or 7151 729) (connection, see
page 78).
Heating water buffer cylinder operated in parallel
Heating water buffer cylinders provide
a hydraulic separation of the flow in
the heat pump and heating circuits.
For example, the flow rate in the heat
pump circuit remains constant, even if
the heating circuit flow rate is reduced
by thermostatic valves.
Use of the heating water buffer cylin-
der:
&Bridging power-OFF periods
&Constant flow rate through the heat
pump
&Longer heat pump operating times
Because of the increased water
volume of the heat source and the fact
that it may have a separate shut-off
facility, an additional (or bigger)
expansion vessel should be provided.
Function description in connection with the system versions
14
Preparing for installation
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Protection of the heat pump in accor-
dance with EN 12828 [or local regula-
tions].
Systems without heating water buffer cylinder
Maintain the minimum heating water
circulation volume (see specification
on page 210):
&e.g. fit an overflow valve.
&Never install mixers.
Natural cooling (NC) function
During the summer months the tem-
perature level of the primary circuit
can be used to cool the building "natu-
rally".
The natural cooling (NC) function is a
method of cooling buildings that
saves a considerable amount of
energy. All that is needed is a small
amount of electricity for the circulation
pumps to access the "cooling source"
in the ground.
During cooling operation, the heat
pump will only be started to produce
DHW. The heat pump control system
regulates the circulation pumps,
changeover valves and mixers and
records the temperature via the nat-
ural cooling extension kit (accessory).
Alternatively, this function can also be
covered by on-site components (for a
suggested on-site connection, see
technical guide).
A contact humidistat monitors the dew
point.
The capacity of the natural cooling
function cannot generally be com-
pared with that of air-conditioning
equipment. Natural cooling provides
no dehumidification.
The refrigerating capacity depends on
the temperature, which is subject to
seasonal fluctuations. Experience has
shown that the cooling capacity is
higher at the beginning of summer
than at the end.
In addition, the water source tempera-
ture curve is subject to the cooling
demand of the building. Large window
areas or internal heat sources
(lighting, electrical equipment)
increase the temperature in the
ground (geothermal probe) more
rapidly during the course of a year
than in building with fewer heat gen-
erators, reducing the effect of natural
cooling.
Underfloor heating systems and con-
crete core tempering are available for
cooling the building; radiator heating
systems are unsuitable for this pur-
pose. Ensure that any installed room
thermostats are able to be opened
manually or by servomotors when
using the cooling function.
Function description in connection with the system . . . (cont.)
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Installation

Active cooling (AC) function
The AC-Box enables, together with a
suitable brine/water heat pump active
cooling (AC operation) and natural
cooling (NC operation). The AC-Box
is linked directly to the brine and DHW
circuit of the heat pump and enables
an external circuit reversal to actively
cool living areas in summer. The fol-
lowing can, for example, be con-
nected to the AC-Box: Fan
convectors, cooling ceilings/sails and
underfloor cooling. During NC opera-
tion, the heat pump remains switched
off; only the primary pump is switched
on.
This operation prevails until AC
operation (active cooling with acti-
vated heat pump) becomes necessary
through an excessive cooling load. In
this case, the resulting heating energy
at the condenser is primarily used for
DHW heating or for heating swimming
pool water, and is secondarily stored,
as far as possible, in the ground for
the following winter.
DHW heating
In the delivered condition, DHW heat-
ing through heat pump takes priority
over the heating circuit.
The control unit switches the DHW cir-
culation pump OFF during cylinder
heating to prevent cylinder heating
from being impaired.
Instantaneous heating water heater
An instantaneous heating water hea-
ter can be installed in the unit (acces-
sory, see separate installation
instructions).
Subject to the available mains, the
system may be supplied with either
230 V~ or 400 V~.
Protect the instantaneous heating
water heater via a separate connec-
tion.
The heat pump control unit regulates
this function.
Function description in connection with the system . . . (cont.)
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Power-OFF
It is possible for the power supply uti-
lity to shut down the compressor and
instantaneous heating water heater
together.
This is done through switching off the
main contactor (see page 93).
This must not shut down the control
unit power supply.
Function description in connection with the system . . . (cont.)
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Installation

Internal components type BW/WW
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AElectronic expansion valve (EEV)
BEvaporator
CLow pressure sensor (0 to 15 bar)
DSuction gas temperature sensor
ECompressor
FHigh pressure sensor (1 to 35
bar)
GHot gas temperature sensor
HCondenser
ILPG temperature sensor
JSafety high pressure switch
KInstantaneous heating water hea-
ter (accessories)
LPrimary flow temperature sensor
MPrimary return temperature sen-
sor
NPrimary pump (accessory)
OBrine pressure switch (accessory)
PPrimary return (brine OUT)
RPrimary flow (brine IN)
TSecondary pump, heating circuit
(accessory)
UCirculation pump for cylinder
heating (accessories)
VSecondary flow temperature sen-
sor
WSecondary return temperature
sensor
XHeating water flow
YDHW cylinder flow
ZDHW cylinder return/heating
water return
Internal components type BW/WW (cont.)
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Installation

Internal components type BWC/WWC
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