Viessmann VITOCAL 300 Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitocal 300
Vitocal 300, type BWC and WWC
For applicability, see the last page
VITOCAL 300
5592 901 GB 6/2007 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 gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5592 901 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&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 electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5592 901 GB

Preparing for installation
Positioning ................................................................................................. 9
Overview of possible system versions ......................................................... 9
Function description for the individual system versions................................ 11
System design on the primary side.............................................................. 14
System version 1 ........................................................................................ 18
System version 2 ........................................................................................ 21
System version 3 ........................................................................................ 24
Additions to the system versions ................................................................. 28
Installation sequence
Overview of electrical connections .............................................................. 32
Room temperature sensor (part no. 9532 653)............................................. 32
Three-way diverter valve, heating/DHW ...................................................... 33
Central fault message ................................................................................. 35
Primary pump (only for type WWC) ............................................................. 35
Information regarding the hydraulic connection ........................................... 36
Connection on the primary side................................................................... 38
Connections on the heating circuit side ....................................................... 39
Power supply.............................................................................................. 39
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 41
Further details regarding the individual steps .............................................. 43
Troubleshooting
Control unit diagnostics .............................................................................. 57
Diagnosis ................................................................................................... 64
Control unit settings
Menu structure overview –Main menu ........................................................ 65
Menu structure overview –Information........................................................ 66
Menu structure overview –Programming..................................................... 68
Menu structure overview –Technical service level....................................... 71
Control settings made by contractors .......................................................... 76
Enabling the technical service level............................................................. 76
Adjusting sensor temperatures.................................................................... 77
Checking signal inputs................................................................................ 78
Controlling the relays and mixers manually ................................................. 78
System definition control settings
System design............................................................................................ 80
Index
4
Index
5592 901 GB

Language ................................................................................................... 80
Average time; outside temperature.............................................................. 80
Heating limit < T room (heating limit temperature)........................................ 80
Temperature limit for reduced temperature mode......................................... 81
Frost protection temperature....................................................................... 82
Primary pump ON for natural cooling........................................................... 82
Heat pump control settings
Maximum flow temperature ......................................................................... 84
Minimum return temperature ....................................................................... 84
min. T. primary in/Hysteresis T primary........................................................ 85
Minimum runtime ........................................................................................ 85
Min. compressor OFF ................................................................................. 86
Flow, primary/secondary pump ................................................................... 86
Optimum runtime ........................................................................................ 87
Electric heater control settings
Power-OFF................................................................................................. 89
Electric heating........................................................................................... 89
Electric DHW heating.................................................................................. 89
Maximum flow temperature ......................................................................... 90
Heater rod delay ......................................................................................... 90
Electric heater threshold ............................................................................. 90
Maximum stage; electric heater................................................................... 91
Power failure blocking time ......................................................................... 91
Failure OFF stage....................................................................................... 91
Stage for power-OFF .................................................................................. 92
Internal hydraulics control settings
Heat pump for drying buildings.................................................................... 93
Time for drying buildings ............................................................................. 93
External heat source for drying buildings..................................................... 94
Hysteresis, flow .......................................................................................... 94
Internal pump run-on................................................................................... 94
DHW control unit settings
DHW cylinder temperature .......................................................................... 95
DHW program temperature ......................................................................... 95
DHW circulation pump program................................................................... 95
Operating mode.......................................................................................... 95
DHW cylinder maximum.............................................................................. 96
Hysteresis DHW electric heater/hysteresis.................................................. 96
Start optimisation........................................................................................ 98
Index (cont.)
5
Index
5592 901 GB

Stop optimisation........................................................................................ 98
DHW auxiliary function................................................................................ 98
Second set DHW temperature..................................................................... 98
Second DHW temperature sensor, bottom................................................... 98
Excess reaction .......................................................................................... 99
DHW priority ............................................................................................... 99
Maximum DHW runtime .............................................................................. 100
Maximum DHW interruption ........................................................................ 100
Temperature rise per hour ........................................................................... 100
E heater rod (immersion heater inside the DHW cylinder) ............................ 101
Heating circuit control settings
Standard temperature................................................................................. 102
Reduced temperature ................................................................................. 102
Temperature program, heating circuit .......................................................... 102
Remote control ........................................................................................... 102
Operating mode.......................................................................................... 102
Maximum flow temperature ......................................................................... 103
Minimum flow temperature .......................................................................... 103
DHW during party mode.............................................................................. 104
Excess reaction .......................................................................................... 104
Room temperature sensor........................................................................... 105
Slope, room temperature hook-up ............................................................... 105
Room temperature hook-up ........................................................................ 105
Start optimisation........................................................................................ 106
Maximum flow temperature correction......................................................... 106
Room temperature control .......................................................................... 107
Setting the slope and level of the heating curve ........................................... 107
Integral room temperature controller ........................................................... 107
Excessive room temperature....................................................................... 108
Excessive flow temperature ........................................................................ 108
Mixer runtime.............................................................................................. 108
Screed function .......................................................................................... 109
Mixer active zone/dead zone....................................................................... 110
"natural cooling" (at the heating circuit) ....................................................... 111
Cooling limit > room temperature (cooling limit temperature)........................ 112
Level/Slope, cooling curve .......................................................................... 112
Natural cooling (at the heating circuit) with mixer......................................... 113
Active zone/dead zone natural cooling mixer............................................... 114
Cooling mixer runtime ................................................................................. 114
Buffer cylinder control settings
When are these settings available?............................................................. 115
Index (cont.)
6
Index
5592 901 GB

Buffer cylinder ............................................................................................ 115
Buffer cylinder program............................................................................... 115
Fixed temperature ...................................................................................... 115
Hysteresis temperature............................................................................... 116
Maximum temperature ................................................................................ 116
Stop optimisation........................................................................................ 117
Excess reaction .......................................................................................... 117
Second temperature sensor ........................................................................ 117
Control settings "natural cooling"
When are these settings required?.............................................................. 118
"Natural cooling circuit" (separate) .............................................................. 118
Room temperature...................................................................................... 118
Room temperature hysteresis ..................................................................... 118
Room temperature control .......................................................................... 119
Room temperature hook-up slope ............................................................... 119
Level/Slope, cooling curve .......................................................................... 120
Integral room temperature controller ........................................................... 120
Minimum flow temperature .......................................................................... 120
"Natural cooling" with mixer ........................................................................ 120
Cooling mixer runtime ................................................................................. 121
Mixer active zone/dead zone ...................................................................... 121
Control settings, external heat source
External heat source................................................................................... 122
Priority, external heat source....................................................................... 122
Temperature limit for operation.................................................................... 122
Threshold, external heat source.................................................................. 123
Delay, external heat source......................................................................... 123
Mixer temperature limit ............................................................................... 124
Minimum runtime ........................................................................................ 124
Runtime without demand ............................................................................ 124
Mixer active zone/dead zone....................................................................... 124
Flow temperature excess ............................................................................ 125
Power-OFF................................................................................................. 125
Components
Sensor resistance curves............................................................................ 126
Fuse........................................................................................................... 126
Phase monitor ............................................................................................ 127
Connection and wiring diagrams
Sensor connections and function ................................................................ 130
Index (cont.)
7
Index
5592 901 GB

Terminals inside the control panel (230 V∼) ................................................. 130
Power circuit/operating circuit ..................................................................... 132
Connection PCB, sensors and remote control ............................................. 133
Safety chain ............................................................................................... 135
Control PCB ............................................................................................... 137
Parts lists.................................................................................................. 139
Commissioning/service reports
Hydraulic parameter reports........................................................................ 142
Reports of control parameters..................................................................... 143
Specification type BWC ............................................................................ 149
Specification type WWC ........................................................................... 151
Appendix
Order to commission the Vitocal 300 ........................................................... 153
Certificates
Declaration of conformity ............................................................................ 154
Keyword index .......................................................................................... 155
Index (cont.)
8
Index
5592 901 GB

Positioning
Wall clearances (viewed from above)
&The installation location must be
free from the risk of frost and must
be able to be adequately ventilated.
&The thermal insulation of cold com-
ponents should be improved in
accordance with standard practice
to prevent condensation.
Overview of possible system versions
In the following, 3 typical heat pump
system designs are shown by way of
an example.
The heating system installation also
applies to Viessmann heat pumps
type WWS (comprising type BWC and
a conversion kit), giving due consid-
eration to type-specific features.
The table gives an overview of all pos-
sible system versions (combination of
standard equipment level and a line of
options for each system design).
Positioning
9
Preparing for installation
5592 901 GB

Sys-
tem
de-
sign
Standard equipment Additional equipment "Natural cool-
ing"
(only one option per
system design)
Direct
heat-
ing
circuit
Heat-
ing
circuit
with
mixer
DHW
cylin-
der
Buffer
cylin-
der
Low
loss
header
exter-
nal heat
source
with
mixer
with-
out
mixer
0X X
1X X
XX
XX
XX
2X X X
XX
XX
XX
3XX X
4XXX X
5XX X
XX
XX
XX
6XXX X
XX
XX
XX
F The Vitocal 300 responds only to external demand signals. All exter-
nal sensors (e.g. room temperature sensors) and relay outputs are
disabled.
When a demand is issued by an external signal, primary pump, sec-
ondary pump and compressor start (prerequisite: Activation condi-
tions such as temperature limits have been met).
Overview of possible system versions (cont.)
10
Preparing for installation
5592 901 GB

Heating circuit
Heat pumps require a minimum heat-
ing water flow rate. Ensure that the
values specified in the relevant data-
sheet are maintained.
The minimum flow rate may be safe-
guarded through a heating water buf-
fer cylinder or an overflow valve in
that heating circuit which is the furth-
est removed from the heat pump.
This safeguards a minimum volume of
circulating water, even when the ther-
mostatic valves are closed. Equip
underfloor heating circuits with a tem-
perature limiter (accessories).
Pump protection
To protect the circulation pumps
against seizing up during longer idle
periods (standby mode during holi-
days, heating circuit pumps in sum-
mer), all pumps directly controlled by
the heat pump control unit are started
for 10 s every day at 13:00 h.
Low loss header
When using a low loss header, ensure
that the flow rate at the heating circuit
side is greater than the flow rate at the
secondary side of the heat pump.
The heat pump control unit treats a
low loss header like a small buffer
cylinder.
The low loss header must therefore
be configured as a buffer cylinder in
the control unit settings (see
page 115).
Systems without heating water buffer cylinder
Never install a mixer to safeguard the
minimum heating water circulation
volume.
Function description for the individual system versions
11
Preparing for installation
5592 901 GB

Heating water buffer cylinder
Where a heating water buffer cylinder
is installed, the secondary side flow
rate should be greater than the flow
rate at the heating circuit side. Where
a heating water buffer cylinder is used
with only one flow and return connec-
tion respectively, this is an absolute
must.
Natural cooling function
During the summer months the tem-
perature level of the primary circuit
canbeusedtocoolthebuilding.
The natural cooling function can be
achieved in two ways:
&On a heating circuit also used for
heating(seesystemversion1to3
from page 18)
&With a separate cooling circuit
installed in addition to the heating
circuits (see page 28). In that case,
install a separate room temperature
sensor to regulate the cooling cir-
cuit.
During the cooling operation, the heat
pump will only be started to produce
DHW. The control unit enables the
natural cooling function as soon as
the outside temperature exceeds the
cooling temperature limit, which can
be adjusted at the control unit. The
primary pump starts and the cooling
circuit pump, the three-way diverter
valve "heating/cooling" and the solar
circuit shut-off valve are controlled via
the natural cooling extension kit.
Furthermore, the natural cooling
extension kit processes the signals
from a contact humidistat and a frost
stat.
The cooling circuit mixer will be regu-
lated by the control unit.
The brine/water heat exchanger
installed for system separation trans-
fers the low brine temperatures to the
heating or cooling circuit.
The capability of the natural cooling
function cannot generally be com-
pared with air-conditioning equipment
or water chillers.
The cooling capacity depends on the
heat source temperature, which itself
is subject to seasonal fluctuations.
Radiator heating systems are not sui-
table for cooling buildings. With
underfloor heating circuits ensure that
any installed room thermostats are
opened manually or by servomotors
when the cooling function is utilised.
Function description for the individual system . . . (cont.)
12
Preparing for installation
5592 901 GB

DHW heating
DHW heating takes priority.
The heat demand is issued via the top
cylinder temperature sensor.
DHW heating is terminated when the
actual temperature at the cylinder
temperature sensor exceeds the
value selected at the control unit.
TheDHWcylindercanalsobe
equipped with a second cylinder tem-
perature sensor.
Theinstallationofanimmersionhea-
ter is possible. This would be con-
trolled by the first cylinder
temperature sensor.
Protect the immersion heater via a
separate connection.
The contactor is controlled by the heat
pump control unit.
Blocking (Power-OFF)
Implement the heat pump blocking by
the power supply utility (power-OFF)
via a zero volt contact. The heat pump
operation will be impaired if the power
supply is completely cut off.
For this, the power-OFF conversion
kit (accessory for three-phase shut-
down) can be used that keeps the
system and the pump operational via
an additional control phase.
Function description for the individual system . . . (cont.)
13
Preparing for installation
5592 901 GB

Brine/water heat pump
Required devices
Pos. Description Qty.
1Heat pump Vitocal 300, type BWC,
with integral primary pump 2, secondary pump 3and
electric heater 4
1
5Ground probe or ground collector min. 1
6Brine distributor for ground probes or collectors 1
7Brine pressure switch (option) 1
System design on the primary side
14
Preparing for installation
5592 901 GB

Connection diagram
8Inserting the jumper or connecting
the brine pressure switch
9Optional connection of a power-
OFF conversion kit
System design on the primary side (cont.)
15
Preparing for installation
5592 901 GB

Water/water heat pump
AFlow direction of the groundwater BIntermediate circuit
!Please note
Operating the intermediate circuit without antifreeze can result in equip-
ment damage.
Fill the intermediate circuit with heat transfer medium (frost protection
down to –15 °C).
System design on the primary side (cont.)
16
Preparing for installation
5592 901 GB

Required devices
Pos. Description Qty.
1Heat pump Vitocal 300, type WWC = type BWC plus
conversion kit (with frost stat 2and flow switch 3)
with integral intermediate circuit pump 4, secondary
pump 5and instantaneous heating water heater 6
1
7Delivery well as required
8Return well as required
9Primary pump (groundwater vacuum pump) as required
qP Dirt trap 1
qQ Volume choke 1
qW Intermediate circuit heat exchanger 1
qE Brine pressure switch for intermediate circuit (option) 1
qZ Contactor (on-site) for switching the primary pump 91
Connection diagram
AThe connection may be made in
parallel at coil terminal K32
qR Remove jumper when making this
connection
qT Optional connection of a power-
OFF conversion kit
qU Power supply to the primary
pump 3/N/PE 400 V∼(on-site)
System design on the primary side (cont.)
17
Preparing for installation
5592 901 GB

One direct heating circuit, DHW heating and natural cooling
at the heating circuit
Note
Select system design 2 at the control unit.
AConnection at the primary side
(see from page 14)
BDHW cylinder connection (see
from page 30)
DMinimum clearance 500 mm
System version 1
18
Preparing for installation
5592 901 GB

Connection diagram
|Open
~CLOSE
System version 1 (cont.)
19
Preparing for installation
5592 901 GB

APower supply from the control
panel (230 V)
BInternally connected heating cir-
cuit pump. When using a tempera-
ture limiter for underfloor heating
system qO, disconnect the pump
from terminal 14 and switch the
temperature limiter in series.
Required devices
Pos. Description Qty.
1Vitocal 300 heat pump 1
2Three-way diverter valve, heating/DHW 1
4Diaphragm expansion vessel 1
qW Outside temperature sensor 1
qE Room temperature sensor of the direct heating circuit 1
qT Overflow valve 1
qZ Direct heating circuit (underfloor heating circuit)
qO Temperature limiter (only required for the underfloor heat-
ing circuit)
as required
rO Zero volt contact for central fault messaging (acoustic or
optical alarm equipment, on site)
1
Natural cooling option
qI Contact humidistat 1
wP Three-way diverter valve heating/cooling 1
wR Vitotrans plate-type heat exchanger 1
wT Frost stat 1
wZ Circulation pump (primary cooling circuit pump) 1
wU Mixer-3 (primary cooling circuit) 1
wI Two-way motorised ball valve 1
rE Natural cooling extension kit 1
rR Flow temperature sensor for mixer wU 1
rI Circulation pump (secondary cooling circuit pump) 1
System version 1 (cont.)
20
Preparing for installation
5592 901 GB