Viessmann NC-Box Operating instructions

Installation and service instructions
for contractors
VIESMANN
NC-Box
Pre-assembled unit for implementing the natural cooling function in conjunction
with brine/water heat pumps up to 17 kW
For applicability, see the last page
NC-Box
5675 869 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 869 GB

3
1. Information Symbols ................................................................................................. 4
Product information ................................................................................ 4
2. Preparing for installation Hydraulic connection with on-site pipework ........................................... 5
Hydraulic connection with hydraulic connection set .............................. 5
Siting and transport requirements .......................................................... 6
■Transport ............................................................................................ 6
■Installation room requirements ........................................................... 6
3. Installation sequence Fitting the NC-Box ................................................................................. 7
Opening the NC-Box .............................................................................. 8
Hydraulic connection ............................................................................. 8
■Preparation for retrofitting ................................................................... 8
■Required connections ......................................................................... 9
■Connection with hydraulic connection set .......................................... 10
■Installing the contact humidistat 24 V– ............................................... 10
Electrical connection .............................................................................. 12
■Required connections ......................................................................... 12
Power supply ......................................................................................... 14
Closing the NC-Box ............................................................................... 15
4. Commissioning and
adjustment
.................................................................................................................. 16
5. Parts lists Overview of assemblies ......................................................................... 18
■Parts not shown .................................................................................. 19
Hydraulics .............................................................................................. 20
Electrical equipment .............................................................................. 22
Connection set ....................................................................................... 24
6. Connection and wiring dia-
gram
.................................................................................................................. 26
7. Specification .................................................................................................................. 27
8. Declaration of conformity .................................................................................................................. 28
9. Keyword index .................................................................................................................. 29
Index
Index
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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 NC-Box includes all hydraulic and electrical com-
ponents required for cooling a heating/cooling circuit or
a separate cooling circuit in conjunction with a brine/
water heat pump.
The temperature level of the primary circuit is directly
transferred to the cooling circuit for central cooling.
Hydraulic connections
The heating/cooling circuit or the separate cooling cir-
cuit and the primary circuit (brine) are hydraulically
connected directly to the NC-Box. The hydraulic con-
nection between the heat pump and the NC-Box can
be made on site or via the hydraulic connection set
(accessories).
Electrical connection
The NC-Box and the heat pump are connected electri-
cally. The cable for switching the NC-Box (NC signal)
is connected inside the NC-Box and routed outside at
the factory.
Product validity
The NC-Box can be used in conjunction with the fol-
lowing heat pumps:
■Vitocal 200-G
■Vitocal 222-G
■Vitocal 242-G
■Vitocal 300-G, types BW/BWC 301.A06 to A17
■Vitocal 300-G, types BW/BWC 301.B06 to B17
■Vitocal 333-G, types BWT 331.B06 to B10
■Vitocal 343-G
■Vitocal 350-G, type BW/BWC 351.A07
Information
Symbols
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Information

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For
■Vitocal 222-G/242-G and Vitocal 333-G/343-G
■Vitocal 200-G, Vitocal 300-G and Vitocal 350-G with-
out sufficient installation space above the heat
pump, e.g. when retrofitting
1. Fit the NC-Box near the heat pump on a wall capa-
ble of bearing the load.
2. Connect on-site connection lines so that they are
free of load and torque stress.
Hydraulic connection with hydraulic connection set
Vitocal 200-G, Vitocal 300-G and Vitocal 350-G with
sufficient installation space above the heat pump: See
page 7.
223
Fig.1
ANC-Box
BReturn, heating/cooling circuit or separate cooling
circuit
CFlow, heating/cooling circuit or separate cooling
circuit
DPrimary circuit flow (NC-Box brine entry)
ESecondary circuit return to heat pump
FSecondary circuit flow to the NC-Box
GHeat pump
HPrimary circuit flow (heat pump brine inlet)
KPrimary circuit BDF valve (brine)
LSecondary circuit BDF valve (heating water)
Preparing for installation
Hydraulic connection with on-site pipework
5675 869 GB
Installation

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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
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
Dust, gases and vapours can be damaging to
health and trigger explosions.
Avoid dust, gases and vapours in the installation
room.
Preparing for installation
Siting and transport requirements
5675 869 GB
Installation

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■Installation without hydraulic connection set:
Fit the NC-Box near the heat pump on a wall capable
of bearing the load.
■Installation with hydraulic connection set:
Fit the NC-Box above the heat pump with the clear-
ances shown in Fig. 2.
160
760
223
2.
2.
1.
Fig.2
Installation sequence
Fitting the NC-Box
5675 869 GB
Installation

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2.
1.
1.
Fig.3
Note
Should there be insufficient space for working, front
casing part B can also be removed. First, remove
casing cover D and pull out the panel with cable
entries E.
ATerminal box
BFront casing part
CPower cable, heat pump connecting cables (NC
signal) and contact humidistat (connected at the
factory)
DCasing cover
EPanel with cable entries and strain relief fittings
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.
Preparation for retrofitting
1. Close ball valves and sliders. 2. Open the primary circuit (brine) and the secondary
circuit (heating water) at a suitable position and
drain the heat transfer medium.
Installation sequence
Opening the NC-Box
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Installation

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Required connections
Subject to the type of cooling circuit, the NC-Box can
be connected to the heat pump in two different ways.
Heating/cooling circuit, e.g. underfloor heating
Required hydraulic connection between the NC-Box
and heat pump:
■Primary circuit flow
■Secondary circuit flow and return
Separate cooling circuit, e.g. fan convector
Required hydraulic connection between the NC-Box
and heat pump:
■Primary circuit flow
For this, note the following:
■Seal the secondary circuit connector on the NC-Box.
■Connect the secondary circuit flow and return directly
on the heat pump.
■Equip a separate cooling circuit with a dedicated
expansion vessel and a safety valve (2.5 bar/
0.25 MPa).
Installation sequence
Hydraulic connection (cont.)
5675 869 GB
Installation

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Connection with hydraulic connection set
A
B
C
1.
2.
Fig.4
Tightening torques for fitting the union nuts
Line Connection to
Heat
pump
NC-Box
Primary circuit flow A (heat
pump brine inlet)
70 Nm 70 Nm
Secondary circuit flow B70 Nm 50 Nm
Secondary circuit return C70 Nm 50 Nm
Installing the contact humidistat 24 V–
The contact humidistat monitors the formation of con-
densate on the flow of the heating/cooling circuit or of
the separate cooling circuit.
■Where the heating/cooling circuit extends over sev-
eral rooms with different relative humidity levels, it
may become necessary to provide several contact
humidistats.
■Where several contact humidistats are used, connect
all contact humidistats electrically in series.
■In the delivered condition, the contact humidistat
switches at a relative humidity of 80 %. This value
can be adjusted.
Contact humidistat installation instructions
Note
In the delivered condition, the contact humidistat is
located outside the NC-Box casing and is electrically
connected at the control panel. The associated con-
necting cable is routed through the cable entry in the
NC-Box.
Installation conditions: The flow and return of the heat-
ing/cooling circuit or the separate cooling circuit are
connected to the NC-Box.
Installation sequence
Hydraulic connection (cont.)
5675 869 GB
Installation

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1.
Fig.5
AFlow, heating/cooling circuit or separate cooling
circuit
BContact humidistat 24 V–
CTerminal box
DPower cable and heat pump connecting cable (NC
signal)
EPanel with cable entries
FContact humidistat connecting cable
1. Fit the contact humidistat above the NC-Box to the
flow of the heating/cooling circuit or the separate
cooling circuit. If necessary remove parts of the
thermal installation in order to provide direct contact
with the pipe.
2. Thermally insulate all lines on site with vapour diffu-
sion-proof material. Thermally insulate the pipe
joints and the area around the contact humidistat
with vapour diffusion-proof adhesive tape.
Installation sequence
Hydraulic connection (cont.)
5675 869 GB
Installation

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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.
Danger
Incorrect wire assignment can result in serious
injury and damage to the appliance.
Never interchange cores "L" and "N".
Colour coding to IEC 60757
L BN Brown
N BU Blue
?GNYE Green/yellow
Required connections
Heat pump connecting cable ("NC signal")
Switching signal 230 V~ for switching the NC-Box. The
natural cooling function is activated as soon as this
signal is issued.
Note
The heat pump connecting cable is connected to the
NC-Box terminal box and routed to the outside through
the cable entry at the factory.
KM BUS cable
For switching the mixer extension kit in the NC-Box.
Installation sequence
Electrical connection
5675 869 GB
Installation

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aVG
X6
15
1
5
11
F0
F2
4
B
aVG
D
4 3 2 1
X5
X2
AC
N
?
3
2
1N N N N
1? ? ?
123
X6
X1
X2
123
sYÖsYAsYSsYD
4 1235
G
F E 12
Fig.6
ANC-Box
BMixer extension kit
aVG KM BUS to the heat pump control unit or to
the KM BUS distributor in the case of several
KM BUS subscribers
CNC-Box terminal box
X2 230 V~ terminal strip
■Power supply 1/N/PE 230 V/50 Hz across
X2.1 and X2.2 via on-site power distribution
board
■Switching the NC-Box (NC signal) across
X2.3 and X2.4 by the heat pump control unit
X5 Earth conductor terminal strip
DCross connect PCB or luster terminals
X1 Earth conductor terminal strip
X2 Neutral conductor terminal strip
EMain PCB (function components 230 V~)
FController and sensor PCB
GVitotronic 200 heat pump control unit
"Vitotronic 200" service instructions
Installation sequence
Electrical connection (cont.)
5675 869 GB
Installation

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Isolators for non-earthed conductors
■Install an isolator in the power cable to provide
omnipolar separation from the mains for all active
conductors, corresponding to overvoltage category
III (3 mm) for full isolation. This isolator must be fitted
in the permanent electrical installation in line with
installation requirements, e.g. mains isolator or
upstream circuit breaker.
■We additionally recommend installing an AC/DC-
sensitive RCD (RCD class B ) for DC (fault)
currents that can occur with energy efficient equip-
ment.
■Class A RCDs must not be used and not installed
upstream of the class B RCD.
Connection information
■The power cable is connected to the NC-Box termi-
nal box and routed to the outside through the cable
entry at the factory.
■We recommend connecting NC-Box power supply at
the power supply of the heat pump control unit.
Connection to the same fuse provides additional pro-
tection in the case of faults and when the power is
switched off. For this, take the power consumption of
the connected consumer into account (fuse protec-
tion, heat pump control unit, max. 16 A).
Heat pump installation and service instructions
Danger
Incorrect electrical installations can lead to seri-
ous injury from electrical current and result in
appliance damage.
Connect the power supply and implement all
safety measures (e.g. RCD circuit) in accord-
ance with the following regulations:
■IEC 60364-4-41
■VDE regulations
■Technical connection requirements specified
by the local power supply utility
■Protect the power cable with a fuse/MCB of
max. 16 A.
Danger
The absence of system component earthing can
lead to serious injury from electrical current and
component damage in the event of an electrical
fault.
The appliance and pipework must be connected
to the equipotential bonding of the building.
Danger
Incorrect core assignment can lead to serious
injury from electrical current and result in equip-
ment damage.
Never interchange cores "L" and "N".
Colour coding to IEC 60757
L BN Brown
N BU Blue
?GNYE Green/yellow
Installation sequence
Power supply
5675 869 GB
Installation

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L1
N
F
A
B
C
D
E
4321
X5
X2
Fig.7
ANC-Box terminal box
X2 230 V~ terminal strip
■Power supply 1/N/PE 230 V/50 Hz across
X2.1 and X2.2 via on-site power distribution
board
■Switching the NC-Box (NC signal) across
X2.3 and X2.4 by the heat pump control unit
X5 Terminal strip for earth conductor
BPower distribution board (on-site)
CHeat pump control unit
DMains isolator (optional)
EFuse F1 (max. 16 A)
FPower supply 1/N/PE 230 V/50 Hz
Closing the NC-Box
Fit in reverse order to Fig. 3 on page 8.
Installation sequence
Power supply (cont.)
5675 869 GB
Installation

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Fig.8
ASecondary circuit BDF valve (heating water)
BPrimary circuit BDF valve (brine)
1. Fill and vent the primary and secondary circuits of
the system and check for leaks.
2. Set the parameters for cooling operation at the heat
pump control unit.
"Vitotronic 200" service instructions
Commissioning and adjustment
Commissioning and adjustment
5675 869 GB
Commissioning

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Commissioning and adjustment
Commissioning and adjustment (cont.)
5675 869 GB
Commissioning

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The following details are required when ordering parts:
■Serial no. (see type plate A)
■Assembly (from this parts list)
■Position number of the individual part within the
assembly (from this parts list)
A
B C
D
Fig.9
AType plate
BHydraulic assembly
CElectrical equipment assembly
DConnection set assembly
Parts lists
Overview of assemblies
5675 869 GB
Components

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Parts not shown
The following details are required when ordering parts:
■Serial no. (see type plate A in Fig. 9)
■Position number of the part (from this parts list)
Pos. Part
0004 Touch-up paint stick, Vitosilver
0005 NC-Box installation and service instructions
0006 Touch-up spray paint, Vitosilver
Parts lists
Overview of assemblies (cont.)
5675 869 GB
Components

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0009
0016
0016
0016
0016
0016
0016
0016
0016
0016
0016
0016
0016
0016
0016
0016
0029
0029
0012
0028
00130002
0007
0029
0010
0004
0027
0008
0005
0025
0012
0029
0001
0020
0022
0021
0023
0006
0018
0017
0019
00190003
0002
0024
0011
0015 0014
0026
Fig.10
Parts lists
Hydraulics
5675 869 GB
Components