Viessmann AC-Box Operating instructions

Installation and service instructions
for contractors
VIESMANN
AC-Box
Pre-assembled unit for implementing the natural cooling and active cooling
functions in conjunction with brine/water heat pumps up to 17 kW
For applicability, see the last page
AC-Box
5675 895 GB 2/2015 Please keep safe.

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 author-
ised contractors.
■Work on the refrigerant circuit may only be carried
out by authorised refrigeration engineers.
■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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
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
load 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.
Wait at least 4 minutes before removing equip-
ment covers, to allow the voltage to dissipate.
■Safeguard the system against reconnection.
!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.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Replace faulty components with genuine
Viessmann spare parts.
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 replacement, use only spare parts supplied
or approved by Viessmann.
Safety instructions
Safety instructions
5675 895 GB

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1. Information Symbols ................................................................................................. 4
Product information ................................................................................ 4
■Information regarding operation ......................................................... 5
2. Preparing for installation Hydraulic function diagram .................................................................... 6
Hydraulic connection with on-site pipework ........................................... 7
Hydraulic connection with AC-Box connection accessories .................. 7
Siting and transport requirements .......................................................... 8
■Transport ............................................................................................ 8
■Installation room requirements ........................................................... 8
■Minimum clearances ........................................................................... 8
3. Installation sequence Siting the AC-Box .................................................................................. 9
Hydraulic connection ............................................................................. 9
■Connection with AC-Box connection accessories .............................. 10
■Installing the contact humidistat 24 V– (accessories) ......................... 11
Electrical connection .............................................................................. 11
■Required connections ......................................................................... 11
■Additional connections ........................................................................ 12
■Overview of electrical connections ..................................................... 15
■Switching to heat pump control unit (NC / AC signal) ......................... 16
■Shutdown signal for heat pump 230 V~ .............................................. 16
■Contact humidistat 24 V– .................................................................... 18
■Additional frost stat (accessories) ....................................................... 18
■Contact humidistat signal 24 V– ......................................................... 19
Power supply ......................................................................................... 19
■Connections on plug fÖ ...................................................................... 20
Closing the AC-Box ............................................................................... 20
4. Upkeep Internal components .............................................................................. 21
5. Parts lists Overview of assemblies ......................................................................... 22
■Parts not shown .................................................................................. 23
Casing .................................................................................................... 24
Electrical equipment .............................................................................. 26
Hydraulics .............................................................................................. 28
Connection set ....................................................................................... 30
6. Connection and wiring dia-
gram
.................................................................................................................. 32
7. Specification .................................................................................................................. 33
8. Declaration of conformity .................................................................................................................. 34
9. Keyword index .................................................................................................................. 35
Index
Index
5675 895 GB

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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.
Product information
Design and function
The AC-Box includes all hydraulic and electrical com-
ponents required for cooling a heating/cooling circuit
without mixer or a separate cooling circuit in conjunc-
tion with a brine/water heat pump. Subject to the cool-
ing demand, either the natural cooling or the active
cooling function starts.
In natural cooling mode, the temperature level of the
primary circuit is directly transferred to the cooling cir-
cuit. In active cooling mode, the compressor starts. As
a result, the available cooling capacity is significantly
higher compared to natural cooling.
Hydraulic connections
The heating/cooling circuit or the separate cooling cir-
cuit and the primary circuit (brine) are hydraulically
connected directly to the AC-Box. The hydraulic con-
nection between the heat pump and the AC-Box can
be made on site or via the AC-Box connection acces-
sories.
Electrical connection
The AC-Box and the heat pump are connected electri-
cally. The electrical cables and power cable required
are connected inside the AC-Box at the factory and
routed outside through the back of the appliance.
Information
Symbols
5675 895 GB
Information

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Product validity
The AC-Box can be used in conjunction with the fol-
lowing heat pumps:
■Vitocal 300-G, types BW/BWC 301.A06 to A17
■Vitocal 300-G, types BW/BWC 301.B06 to B17
■Vitocal 350-G, type BW/BWC 351.A07
Information regarding operation
■In order to safeguard the transfer of the cooling
capacity at all times, we recommend connecting fan
convectors to the AC-Box.
■If cooling by means of an underfloor heating system,
a contact humidistat is required: See page 11.
Information
Product information (cont.)
5675 895 GB
Information

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M
M
M
M
M
M
M
A
S
O
P R
V
W
B
C
D
E
F
G
H
K
LM
UT
N
Fig.1
Note
■Valve switching states without switching by the heat
pump.
■Component layout inside the appliance: See
page 21.
Direction of flow, 3-way diverter valve
Valve open
Valve closed
A2-way valve V1
B2-way valve V2
C2-way valve V3
D2-way valve V7
E2-way valve V5
F2-way valve V6
G3-way diverter valve V4
HHigh efficiency circulation pump M2
KHigh efficiency circulation pump M1
LPlate heat exchanger 1
MPlate heat exchanger 2
NFrost stat
OAC-Box
PContact humidistat 24 V– (accessories)
RFlow, heating/cooling circuit or separate cooling
circuit
SReturn, heating/cooling circuit or separate cool-
ing circuit
TGeothermal probe
UHeat pump
VDHW cylinder flow
WDHW cylinder return
Switching states of the integral 2-way valves and circulation pumps
Active signal V1 AV2 BV3 CV5 EV6 FV7 DM1 KM2 H
None 0 0
NC signal \ 0
AC signal \ \
Valve open
Valve closed
\ON
0OFF
Preparing for installation
Hydraulic function diagram
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Installation

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If the AC-Box cannot be installed immediately to the
left of the heat pump:
1. Install the AC-Box near the heat pump.
2. Connect on-site connection lines so that they are
free of load and torque stress.
Hydraulic connection with AC-Box connection accessories
The AC-Box connection accessories comprise 4 ther-
mally insulated connecting pipes, each with 1 air vent
valve and gaskets.
10
Fig.2
AAC-Box
BPrimary circuit connection line: AC-Box brine inlet
CPrimary circuit connection line: AC-Box brine outlet
DPrimary circuit flow: AC-Box brine outlet
EPrimary circuit return: AC-Box brine inlet
FFlow, heating/cooling circuit or separate cooling
circuit
GReturn, heating/cooling circuit or separate cooling
circuit
HSecondary circuit connection line: AC-Box heating
water outlet
KSecondary circuit connection line: AC-Box heating
water inlet
LSecondary circuit connection line: Heat pump
heating water inlet
MDHW cylinder flow
NSecondary circuit connection line: Heat pump
heating water outlet
PPrimary circuit connection line: Heat pump brine
inlet
Preparing for installation
Hydraulic connection with on-site pipework
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Installation

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RPrimary circuit connection line: Heat pump brine
outlet
SHeat pump
Siting and transport requirements
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.
Installation room requirements
!Please note
Unfavourable ambient conditions can lead to
malfunction 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
Dust, gases and vapours can be damaging to
health and cause 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.
Minimum clearances
A B
200
400400
1500
Fig.3
AAC-Box
BHeat pump
Preparing for installation
Hydraulic connection with AC-Box connection… (cont.)
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Installation

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1. Site the AC-Box on a level surface, to the left of the
heat pump with no gap between them: See Figs. 2
and 3.
2. Level the appliance with its adjustable feet.
Hydraulic connection
To prevent corrosion damage, provide all hydraulic
pipes with thermal insulation as vapour diffusion-proof
installation (on the brine and cold water sides) in
accordance with current engineering standards.
Installation sequence
Siting the AC-Box
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Installation

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Connection with AC-Box connection accessories
1.
4x
2.
4.
2x
5.
2x
3.
2x
2x
Fig.4
Note
Thermally insulate the connections of the AC-Box and
the heat pump with vapour diffusion-proof adhesive
tape.
A to DHydraulic connection lines: See the following
table
Installation sequence
Hydraulic connection (cont.)
5675 895 GB
Installation