Viessmann VITOCAL 300-G User manual

Installation and dismantling instructions
for contractors
VIESMANN
Vitocal 300-G
Type BW 301.C17
Brine/water heat pump with R290 refrigerant for operation in ESyCool container
VITOCAL 300-G
5800 908 GB 8/2017

2
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 intended for quali-
fied contractors.
■Work on the refrigerant circuit involving flammable
refrigerants may only be carried out by authorised
contractors (certification from an industry accredited
body required).
■Work on electrical equipment may 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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRF, VDE and all locally applicable stand-
ards
aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and
ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions
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Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
Note
In addition to the control circuit there may be several
power circuits.
Danger
Contact with live components can result in
severe injuries. Some components on PCBs
remain live even after the power supply has
been switched off.
Prior to removing covers from the appliances,
wait at least 4 minutes until the voltage has
completely dropped out.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the appliance, fit-
tings or pipework.
Danger
Risk of explosion: Electrostatic discharge can
cause sparks which may be ignited by escaping
refrigerant.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Danger
Risk of explosion: Electrical components can
cause sparks which may be ignited by escaping
refrigerant.
After every time the control panel is opened or
closed, check the casing door for vapour tight-
ness to EN 60079-15.
Danger
Risk of explosion: Escaping refrigerant can enter
the control panel along short electrical cables
(zone entrainment). In this case, vapour tight-
ness of the control panel is no longer ensured.
Do not trim existing cables.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Work on the refrigerant circuit
R290 refrigerant (propane) is an air displacing, colour-
less, flammable, odourless gas which forms explosive
mixtures with air.
Perform the following measures before beginning work
on the refrigerant circuit:
■Check refrigerant circuit for leaks.
■Ensure very good ventilation especially in the floor
area and sustain this for the duration of the work.
■Inform the following people about the nature of the
work to be carried out:
–All maintenance personnel
–Everyone who is present in the vicinity of the sys-
tem.
■Inspect the area immediately around the heat pump
for flammable materials and ignition sources:
Remove any flammable materials and ignition sour-
ces found.
■Cordon off the area around the ESyCool container.
■Before, during and after the work, check the sur-
rounding area for escaping refrigerant using an
explosion-proof refrigerant detector suitable for
R290.
This refrigerant detector must not generate any
sparks and must be sealed appropriately.
■In the following cases, a CO2 or powder fire extin-
guisher must be close at hand:
–When the system is being recharged with refriger-
ant.
–When soldering or welding work is being carried
out.
■Display signs prohibiting smoking.
Danger
Handling refrigerant can cause serious damage
to health. There is a risk of asphyxiation if it is
breathed in.
■Avoid direct contact with liquid refrigerant.
Wear personal protective equipment when
handling liquid gas.
■Never breathe in refrigerant vapours.
Danger
Escaping refrigerant can lead to explosions
resulting in extremely serious injury.
■Never drill into or ignite the refrigerant circuit.
■Take measures to prevent electrostatic
charge.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
Safety instructions (cont.)
5800 908 GB

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Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
■Replace faulty components only with genuine
Viessmann spare parts.
■Service work must be carried out in accord-
ance with the information provided by
Viessmann.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the heat pump
■The heat pump may only be operated in the ESyCool
container with explosion protection provided for this
purpose; max. 4 heat pumps in one container.
■No permanent ignition sources may be installed in
this container, e.g. open flames, other gas applian-
ces or electric heaters.
■The heat pump may only be operated at ambient
temperatures of between 0 and 35 °C.
■Always keep the ventilation apertures in the front
panel free so that refrigerant can flow out of the heat
pump unobstructed in the event of a leak.
What to do if refrigerant escapes
Danger
Escaping refrigerant can lead to explosions
resulting in extremely serious injury.
■Ensure very good ventilation especially in the
floor area.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Evacuate any people from the danger zone.
■Notify contractors authorised to work on the
refrigerant circuit from outside the ESyCool
container.
■Shut off the power supply to the ESyCool con-
tainer from a safe place (outside the con-
tainer).
Safety instructions (cont.)
5800 908 GB

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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 7
Product information ................................................................................ 7
2. Preparing for installation Requirements for on-site connections ................................................... 8
3. Installation sequence Installation room requirements .............................................................. 9
Transport ............................................................................................... 9
Siting the heat pump .............................................................................. 9
■Removing the transport brackets and levelling the heat pump ........... 10
■Removing the top panel ...................................................................... 11
Making the hydraulic connections .......................................................... 11
■Connecting the primary circuit ............................................................ 11
■Connecting the secondary circuit ....................................................... 12
Electrical connections, heat pump ......................................................... 13
■Required cable lengths in the heat pump ........................................... 13
■Recommended compressor power cable ........................................... 13
■Routing the cables to the heat pump wiring chamber ........................ 13
■Connecting the cables to the heat pump control unit ......................... 14
■Overview of the electrical connections in the heat pump ................... 14
■Checking the control panel for vapour tightness ................................ 15
Installing the heat pump control unit ...................................................... 16
■Fitting the wall mounting base and casing base ................................. 16
■Fitting the casing front ........................................................................ 17
■Opening the heat pump control unit ................................................... 18
Heat pump control unit electrical connections ....................................... 18
■Required cable lengths from the wall outlet ........................................ 18
■Recommended heat pump control unit power cable .......................... 18
■Inserting the cables and applying strain relief .................................... 19
■Connecting the cables to the heat pump ............................................ 19
■Inserting the coding card .................................................................... 20
■Overview of the electrical connections in the heat pump control unit . 21
■Expansion PCB (230 V~ function components) ................................. 21
■Cross connect PCB (signal and safety connections) .......................... 22
■Controller and sensor PCB ................................................................. 23
Power supply ......................................................................................... 24
■Heat pump control unit power supply 230 V~ ..................................... 24
■Compressor power supply (400 V~) ................................................... 24
■Phase monitor .................................................................................... 25
Checking the refrigerant circuit for leaks ............................................... 25
Filling and venting the primary side ....................................................... 26
Filling and venting the secondary side ................................................... 26
Closing the heat pump ........................................................................... 27
Check the diaphragm grommets ............................................................ 28
4. Commissioning Starting the heat pump .......................................................................... 29
5. Dismantling ................................................................................................................ 30
6. Specification ................................................................................................................ 31
7. Keyword index ................................................................................................................ 33
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbols in these instructions
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Symbols on the heat pump
Symbol Meaning
Follow the operating manual
(ISO 7000 - 0790)
Follow the instructions for use/operating in-
structions (ISO 7000 - 1641)
Service display:
Refer to the operating manual
(ISO 7000 - 1659)
Disposal of packaging
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The appliance is only intended to be installed and
operated in the ESyCool container, with due attention
paid to the associated installation and dismantling
instructions as well as the operating and service
instructions. The container must be equipped with gas
sensors and a safety concept suitable for R290 refrig-
erant (propane). The safety concept must include a
safety heat exchanger outside the building which pre-
vents refrigerant entering the building in the case of a
refrigerant or water leak. Equivalent measures are per-
missible.
The appliance can only be used for the following pur-
poses:
■Central heating
■Cooling in conjunction with refrigerators and cold-
rooms
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial use for a purpose other than
central heating and cooling in conjunction with refriger-
ators and coldrooms shall be deemed inappropriate.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heat pump
and system are modified from their intended function.
Product information
■Brine/water heat pump with R290 refrigerant (pro-
pane) and Vitotronic 200 heat pump control unit for
operation in ESyCool container
■A primary source can be a refrigerator from which
heat is constantly extracted.
■The heat generated is used for central heating as
required or expelled via a dry cooler.
■The heat pump is controlled by a higher ranking con-
trol unit, via contact X3.12/X3.13 (floating contract
required).
■The heat pump control unit transfers parameters and
measured values for heat pump operation to the
higher ranking control unit via Modbus.
■The compressor always runs at full output. The set
flow temperature is fixed at 50 °C.
Intended use
5800 908 GB

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80
108
155
243
303
479
536
603
80
108
155
243
303
479
536
603
136
579
665665
795
891
965
230V~
<42V
Fig. 1
Secondary circuit flow (heating water flow)
Secondary circuit return (heating water re-
turn)
Primary circuit return (heat pump brine out-
let)
Primary circuit flow (heat pump brine inlet)
Requirements for on-site connections
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The installation room must meet the requirements of
ISO 5149-1 for machinery rooms.
!Please note
Unfavourable ambient conditions can lead to
malfunctions and appliance damage.
■The installation room must be dry and free
from the risk of frost.
■Ensure ambient temperatures between 0 and
35 °C.
Danger
In rooms with an insufficient air supply, escaping
refrigerant can lead to explosions which result in
extremely serious injury.
■Only install the heat pump in the ESyCool con-
tainer. A maximum of 4 heat pumps may be
installed in one ESyCool container.
■Never operate any ignition sources in the
installation room, e.g. open flames, running
gas appliance, electric heater, etc. Never
smoke in the installation room.
■Electrical equipment located at a distance of
1 m around refrigerant-carrying parts of the
system must meet the requirements for areas
at risk of explosion, zone 2.
Danger
Dust, gases and vapours can be damaging to
health and trigger explosions.
Avoid dust, gases and vapours in the installation
room.
!Please note
Overloading the floor can result in damage to
the building structure.
■Observe the permissible floor load. Take the
total weight of the appliance into account: See
"Specification".
■Align the appliance horizontally.
If the adjustable feet are used to compensate
for an uneven floor (max. 10 mm), the pres-
sure load on the feet must be distributed
evenly.
Transport
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never apply loads/weight to the top, front or
side panels of the appliance.
!Please note
Steep tilting of the compressor in the heat pump
can result in appliance damage.
Max. tilting angle: 30°
Siting the heat pump
Danger
Escaping refrigerant can lead to explosions
resulting in extremely serious injury.
■Use non-sparking tools for all work.
■Never use electrical tools, e.g. drills or cord-
less screwdrivers.
Installation room requirements
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Removing the transport brackets and levelling the heat pump
4x
4x
1.
3.
4x
6.
4x
4x
4.
4x
2.
5.
Fig. 2
1. Remove the transport brackets.
!Please note
Operating the appliance without first remov-
ing the transport brackets may cause vibra-
tions and excessive noise.
Remove all 4 transport brackets.
2. Site the heat pump. Level it horizontally.
Siting the heat pump (cont.)
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Removing the top panel
1.
Fig. 3
Making the hydraulic connections
For arrangement of hydraulic connections: See
page 8.
Connecting the primary circuit
!Please note
The heat transfer medium can cause corrosion
damage to on-site lines and components.
The components and lines used must be resist-
ant to the heat transfer medium. Never use zinc-
plated/galvanised pipes.
Siting the heat pump (cont.)
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1. Equip the primary circuit with an expansion vessel
and safety valve (to DIN 4757).
Note
■The expansion vessel must be approved to
DIN 4807. The diaphragms of the expansion ves-
sel and safety valve must be suitable for the heat
transfer medium.
■The blow down and drain pipes should terminate
in a container. This container must be able to
hold the maximum possible expansion volume of
the heat transfer medium.
2. Provide thermal insulation and anti-vibration meas-
ures for all line entries.
3. Connect the primary lines to the heat pump.
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Connect on-site lines so that they are free of
load and torque stress.
!Please note
Leaking hydraulic connections lead to appli-
ance damage.
Ensure the diaphragm grommets at the hose
outlets are seated correctly. Seal hose out-
lets with sealing tape if necessary.
4. Apply thermal and vapour diffusion-proof insulation
to all lines.
5. Fill the primary circuit with Viessmann heat transfer
medium and vent.
Note
Ensure frost protection down to –19 °C.
Viessmann heat transfer medium is a ready-mixed
ethylene glycol-based medium. It contains inhibi-
tors for corrosion protection. The heat transfer
medium can be used at temperatures down to
–19 °C.
6. Check the diaphragm grommets: See page 28.
Connecting the secondary circuit
1. Equip the secondary circuit on site with an expan-
sion vessel and safety assembly (to DIN 4757).
Fit the safety assembly to the on-site line in the
heating water return.
2. Connect the secondary lines to the heat pump
(7 ≥ 28 mm).
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Connect on-site secondary lines to the heat
pump so they are free of load and torque
stresses.
!Please note
Leaking hydraulic connections lead to appli-
ance damage.
Ensure the diaphragm grommets at the hose
outlets are seated correctly. Seal hose out-
lets with sealing tape if necessary.
3. Fill and vent secondary circuit.
4. Thermally insulate all lines.
5. Check the diaphragm grommets: See page 28.
Note
Ensure the minimum flow rate, e.g. by means of an
overflow valve: See "Specification" on page 31.
Making the hydraulic connections (cont.)
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Required cable lengths in the heat pump
1.0 m for 400 V~ power cable and other connecting
cables
Recommended compressor power cable
Cable Max. cable length
5 x 2.5 mm250 m
Routing the cables to the heat pump wiring chamber
Danger
Damaged wiring insulation wiring can lead to
serious injury from electrical current and result in
appliance damage.
Route cables so that they cannot touch very hot,
vibrating or sharp-edged components.
Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
Take the following measures to prevent drifting
of wires into the adjacent voltage area:
■Route LV leads < 42 V separately from cables
> 42 V/230 V~/400 V~ and secure with cable
ties.
■Only strip the minimum of insulation from
cables as close as possible to the terminals
and bundle tightly to the corresponding termi-
nals.
■If 2 components are connected to the same
terminal, press both cores together in a single
wire ferrule.
When routing the connecting cables, observe the loca-
tion of the cable entries into the appliance through its
back panel: See page 8.
230 V~
< 42 V
Fig. 4
Electrical connections, heat pump
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1. Route LV leads through the "< 42 V" opening to the
wiring chamber. Provide strain relief using the
cable ties supplied.
2. Route 230 V cables and the compressor power
cable through the "230 V~" opening to the wiring
chamber. Provide strain relief using the cable ties
supplied.
Power supply: See from page 24.
Note
Route LV leads and 230 V cables as far apart as
possible.
Connecting the cables to the heat pump control unit
230 V~
< 42 V
B C
A
aVG
?aDaJ
aS
?aSaDaJ aVG
B
C
1.
Fig. 5
AHeat pump wiring chamber
BConnecting cable to the heat pump control unit: LV
< 42 V
CConnecting cable to the heat pump control unit:
230 V~ control cable
Overview of the electrical connections in the heat pump
Danger
Risk of explosion: Electrical components can
cause sparks which may be ignited by escaping
refrigerant.
After every time the control panel is opened or
closed, check the casing door for vapour tight-
ness to EN 60079-15: See chapter "Checking
the control panel for vapour tightness".
Electrical connections, heat pump (cont.)
5800 908 GB

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B
C
H
G
F
E
D
MK L
A
Fig. 6
AVapour tight control panel
BTransformer EEV PCB: Make no connections.
CEEV PCB (refrigerant circuit controller): Make no
connections.
DCompressor contactor
ECompressor thermal relay
FSafety high pressure switch coupling relay
GPower supply unit for safety high pressure switch
HPhase monitor: See 25.
KConnecting cable to the heat pump control unit: LV
< 42 V
LConnecting cable to the heat pump control unit:
230 V~ control cable
MMains terminals: See page 24.
Checking the control panel for vapour tightness
Danger
Risk of explosion: Electrical components can
cause sparks which may be ignited by escaping
refrigerant.
After every time the control panel is opened or
closed, check the casing door for vapour tight-
ness to EN 60079-15.
Use a suitable testing device to check for vapour tight-
ness, e.g. the handheld vapour tightness tester availa-
ble from R. Stahl Schaltgeräte GmbH.
Electrical connections, heat pump (cont.)
5800 908 GB

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A
Fig. 7 Vapour tight control panel on the casing door
AVapour tightness test connector
1. Remove the red plug from vapour tightness test
connector A.
2. Insert the hose of the testing device into the test
connector.
3. Tighten the test connector fitting. Ensure tightness.
4. Generate negative pressure of 3 mbar (0.3 kPA)
using the hand pump of the testing device.
5. Observe the pressure for the next 90 s.
After 90 s the negative pressure should still be
1.5 mbar (0.15 kPA).
Danger
Risk of explosion: Electrical components can
cause sparks which may be ignited by
escaping refrigerant.
If the negative pressure is less than
1.5 mbar (0.15 kPA) after 90 s, vapour tight-
ness of the control panel is not ensured:
■Do not commission the heat pump.
■Check the control panel gaskets. Replace
the gaskets if necessary. Repeat the test.
6. Remove the hose of the testing device.
7. Refit the red plug. Ensure tightness.
Installing the heat pump control unit
Fitting the wall mounting base and casing base
1.
2.
Fig. 8
Electrical connections, heat pump (cont.)
5800 908 GB

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Fitting the casing front
2.
1.
Fig. 9
3.
A
5.
D
X3
C
B
6.
X2
X20
X3
X2
B4.
7.
Fig. 10
ACross connect PCB
BPlug-in connection ON/OFF switch
CCasing front
DController and sensor PCB
Installing the heat pump control unit (cont.)
5800 908 GB

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8.
Fig. 11
Opening the heat pump control unit
1.
2.
3.
Fig. 12
Heat pump control unit electrical connections
Required cable lengths from the wall outlet
0.6 m where the cables come out of the wall centrally
directly below the heat pump control unit
Recommended heat pump control unit power cable
Cable Max. cable length
3 x 1.5 mm240 m
Installing the heat pump control unit (cont.)
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Inserting the cables and applying strain relief
A
B
Fig. 13
ACables with moulded strain relief
BOn-site cables
Connecting the cables to the heat pump
DC
X5
X7
X25
X1 X15
A B
Fig. 14
ACross connect PCB
BController and sensor PCB
CConnecting cable to the heat pump: LV < 42 V
DConnecting cable to the heat pump: 230 V~ control
cable
Heat pump control unit electrical connections (cont.)
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Inserting the coding card
Only insert the coding card supplied with the heat
pump.
B
X31
A
B
Fig. 15
ACoding card
BController and sensor PCB
Heat pump control unit electrical connections (cont.)
5800 908 GB