Viessmann Vitovalor PA2 Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitovalor PA2
Type E00T
Micro CHP unit on fuel cell basis
0.75 kW (Pel)
Natural gas version
VITOVALOR PA2
5839343 GB 10/2019 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on gas installations may only be
carried out by a registered gas fitter.
■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 per-
son 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
■Relevant country-specific safety regu-
lations
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, e.g. by removing the separate fuse
or by means of a mains isolator, and
check that it is no longer live.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
5839343

3
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5839343

4
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not 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.
■Evacuate any people from the
danger zone.
■Notify your gas or electricity sup-
ply utility from outside the building.
■Have the power supply to the
building shut off from a safe place
(outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening
poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be
harmful to health.
Never let condensate touch your
skin or eyes and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion air can cause life threatening
poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good
working order. Vents for supplying
combustion air must be non-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
5839343

5
Danger
The simultaneous operation of the
boiler and appliances that exhausts
air to the outside can result in life
threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5839343

6
1. Information Disposal of packaging ............................................................................ 9
Symbols ................................................................................................. 9
Intended use .......................................................................................... 9
Product information ................................................................................ 10
■Vitovalor PA2 ...................................................................................... 10
■Vitovalor PA2 in systems with photovoltaic and solar thermal equip-
ment .................................................................................................... 10
■System examples ............................................................................... 10
■Spare parts lists .................................................................................. 11
2. Preparing for installation Handling ................................................................................................. 12
Siting ...................................................................................................... 12
■Installation room requirements ........................................................... 12
■Dimensions ......................................................................................... 13
Preparing for installation ........................................................................ 14
Notes on connecting to the mains supply .............................................. 14
■Vitovalor PA2 in mains parallel mode ................................................. 14
■Metering generated power .................................................................. 15
■Property boundaries and transfer point without power storage sys-
tem ...................................................................................................... 17
■Property boundaries and transfer point with power storage system ... 18
■Connection for excess export without power storage system ............ 19
■Connection for excess export with power storage system ................. 21
■Fuse protection ................................................................................... 22
3. Installation sequence Installing and aligning the Vitovalor PA2 ................................................ 24
■Fitting the connection set .................................................................... 24
■Removing the front panels .................................................................. 25
■Routing drain lines .............................................................................. 26
■Aligning the heat generator at the installation site .............................. 27
Balanced flue connection ....................................................................... 27
■Connecting the downstream balanced flue pipe ................................. 27
■Connecting the Vitovalor and Vitodens to a shared flue system ........ 28
Condensate connection ......................................................................... 29
Gas connection ...................................................................................... 29
Opening the wiring chamber .................................................................. 30
HMU heat management unit electrical connections .............................. 30
■Overview of electrical connections ..................................................... 30
■Routing connecting cables/leads ........................................................ 31
■Checking the CAN bus terminator switch setting ............................... 31
Electrical connections for EM-MX mixer extension kit (ADIO electron-
ics module) ............................................................................................ 31
■Fitting the EM-MX mixer extension kit ................................................ 31
■Overview of electrical connections ..................................................... 32
■Connect PlusBus to HMU heat management unit .............................. 34
■Rotary switch S1 for subscriber number addressing .......................... 34
■Power supply to HMU heat management unit .................................... 35
System power supply ............................................................................. 35
Closing the wiring chamber ................................................................... 36
Fitting the front panels ........................................................................... 37
■Fitting the programming unit ............................................................... 37
Removing the side panels ..................................................................... 38
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 39
5. System configuration
(parameters)
Calling up parameters ............................................................................ 57
General .................................................................................................. 57
Fuel cell ................................................................................................. 58
Index
Index
5839343

7
6. Diagnosis and service
checks
Calling up the service menu .................................................................. 61
■Service menu overview ...................................................................... 61
■Exiting the service menu .................................................................... 61
Changing the service password ............................................................. 61
Resetting all passwords to the factory setting ....................................... 62
Diagnosis ............................................................................................... 62
■Checking operating data ..................................................................... 62
■Calling up operating data .................................................................... 62
Checking outputs (actuator and sensor test) ......................................... 62
Checking the power generated .............................................................. 63
Checking the gas consumption to reclaim fuel tax ................................ 63
Checking the operating condition .......................................................... 63
Checking grid monitoring parameters .................................................... 64
Removing the SD card ........................................................................... 64
Inserting the SD card and saving the fuel cell module data .................. 65
7. Troubleshooting Fault display and other messages on the programming unit ................. 66
■Acknowledging messages .................................................................. 66
■Calling up acknowledged messages .................................................. 66
■Calling up messages from the message history ................................. 66
Calling up fault messages on the programming unit of the fuel cell
module ................................................................................................... 67
■Resetting fault messages ................................................................... 67
Message overview ................................................................................. 67
■HMU heat management unit / fuel cell module fault messages ......... 67
■"Service messages" ......................................................................... 72
■"Warnings" ........................................................................................ 74
Repairs .................................................................................................. 75
■Moving the programming unit to the service position ......................... 75
■Draining the system on the heating water side ................................... 76
■Checking the temperature sensors ..................................................... 77
■Checking the plate heat exchanger system separation ...................... 79
■Information on replacing the HMU heat management unit ................. 80
■Replacing the power cable ................................................................. 80
■Replacing the HMI connecting cable .................................................. 80
■Mains distributor box service position ................................................. 80
■Removing the secondary circuit circulation pump .............................. 81
■Removing the hydraulic unit ............................................................... 82
■Replacing the power cable ................................................................. 83
■Checking the fuse ............................................................................... 83
■Mixer extension kit .............................................................................. 83
8. Function description Control unit ............................................................................................ 86
■Operating the fuel cell module ............................................................ 86
Electrical output of the fuel cell .............................................................. 86
9. Connection and wiring dia-
grams
Overview connection diagrams .............................................................. 87
Mains distributor box .............................................................................. 88
HMU heat management unit connection diagram ................................. 89
EM-MX mixer extension kit (ADIO electronics module) ......................... 90
10. Commissioning/service
reports
................................................................................................................ 91
11. Specification ................................................................................................................ 92
12. Disposal Final decommissioning and disposal ..................................................... 93
13. Certificates Declaration of conformity ....................................................................... 94
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 94
Index
Index
5839343

8
14. Keyword index ................................................................................................................ 95
Index
Index (cont.)
5839343

9
Please dispose of packaging waste in line with statu-
tory regulations.
Symbols
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.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for the heating of water that is
of potable water quality and for power generation.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Information
Disposal of packaging
5839343
Information

10
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and results in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Product information
Vitovalor PA2
The Vitovalor PA2 is a fuel cell based micro combined
heat and power unit. To generate heat and power, the
Vitovalor PA2 is operated with natural gas. The
Vitovalor PA2 can be integrated into existing systems.
The Vitovalor PA2 may in principle be supplied only to
the countries indicated on the type plate. For deliveries
to other countries, approved contractors must arrange
individual approval on their own initiative and in
accordance with the law of the country in question.
Fuel cell module
The integral reformer generates the required hydrogen
from natural gas.
Preset for operation with natural gas E, adjustable to
natural gas LL
Hydraulics
The fuel cell heats the heating water, which is then
pumped into the secondary circuit by the integral high
efficiency circulation pump. Depending on the system
configuration, the heating water can be used for cen-
tral heating and/or for DHW heating.
Control unit
The Vitovalor PA2 is suitable for heat biased and
power-optimised operation. By means of the integrated
energy manager, the fuel cell can be operated in a
manner optimised for own consumption.
Cylinder
A range of cylinders can be connected to the
Vitovalor PA2, such as DHW cylinders or heating water
buffer cylinders.
Vitovalor PA2 in systems with photovoltaic and solar thermal equipment
It is not possible to operate the Vitovalor PA2 in con-
junction with a solar thermal system.
If combining with a photovoltaic system, ensure that
the electricity meter is arranged correctly. An incor-
rectly arranged electricity meter would distort the stat-
istical data of the energy manager.
Either combination would reduce the runtimes of the
Vitovalor PA2 and economically efficient operation
would no longer be guaranteed.
System examples
System examples with hydraulic and electrical connec-
tion diagrams and function descriptions are available
to help setting up the heating system.
Detailed information on system examples can be found
at: www.viessmann-schemes.com
Information
Intended use (cont.)
5839343
Information

11
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Product information (cont.)
5839343
Information

12
■As far as possible, leave the appliance in its packag-
ing while handling.
Note
If necessary, the weight of the Vitovalor PA2 can
be reduced for handling.
To do this, remove the appliance's side panels: See
page 38.
■When transporting, keep upright at all times on the
pallet or its base.
■If possible, do not remove the appliance from the
pallet until the final installation site has been
reached.
■Never subject the module to strong vibrations or
shaking.
■Always store standing up.
■May be tilted briefly up to max. 90° during handling:
See diagram below.
!Please note
To prevent damage to the appliance, when
transporting up or down
stairs, always keep the underside of the appli-
ance lower than the top.
A
Fig. 1
AAppliance top
!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
Prevent damage to the appliance during han-
dling.
Never set the appliance down on its front or
sides, or apply any load to these surfaces.
Siting
Installation room requirements
■Required room height: At least 1800 mm
■Ensure there is sufficient space next to the appliance
for the condensate drain pipe.
■No clearance is required behind the appliance
!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.
■Minimum temperature in the installation room:
+3 °C
Information on installation in coastal areas
In order to prevent damage through corrosion, position
the appliance so that the flue gas and ventilation air
apertures do not come into direct contact with saline
air.
Preparing for installation
Handling
5839343
Installation

13
Dimensions
A
590
22
352
1600
1717
1240
1310
600
185
476
C
B
1742
3°
3°
Fig. 2
ACondensate drain
Observe the necessary fall.
BThe balanced flue bend can be positioned to the
left or right
CWiring area
Note
■Ensure there is sufficient space next to the appliance
for the condensate drain pipe.
■All height dimensions have a tolerance of +15 mm
on account of the adjustable feet.
Preparing for installation
Siting (cont.)
5839343
Installation

14
Use the connection set supplied to make the connec-
tions on the gas and water sides.
Preparing connections on site:
Connection set installation instructions
!Please note
Avoid damaging the appliance.
Connect all pipework free of load and torque
stress.
Gas and water connections with connection set (stand-
ard delivery)
1600
1677
1689
55
300
CBA
Fig. 3
AHeating flow R ¾
BGas shut-off valve
CHeating return R ¾
1. Prepare the connections on the heating water side.
Thoroughly flush the heating system.
Note
Fit the on-site expansion vessel (if required) to the
heating return.
2. Install an on-site pressure gauge into the heating
circuit.
3. Prepare gas connection to TRGI [or local regula-
tions].
4. Prepare electrical connections: See following chap-
ter.
The appliance is delivered fitted with a power cable
(approx. 2 m long).
!Please note
Switching off by means of an emergency
stop switch for the heating system can dam-
age the appliance.
Never connect the fuel cell module to any
emergency stop switch that may have been
fitted in conjunction with an existing heating
system.
Cables for accessories
Use flexible cables with the required number of
cores for external connections.
Notes on connecting to the mains supply
Vitovalor PA2 in mains parallel mode
During operation of the Vitovalor PA2, any generated
power is fed into the building distribution system and/or
exported to the grid. This operating mode is described
as mains parallel mode. For this, the Vitovalor PA2 is
mechanically coupled to the grid.
Separate guidelines and regulations apply to this mode
of operation which must be taken into account when
making the electrical connection to the mains:
■TAR medium voltage VDE-AR-N-4110
■The applicable DIN VDE guidelines, specifically
DIN VDE 0100, Part 701, DIN VDE 0100-551,
DIN VDE 0126-1-1 and DIN VDE AR-N 4105
Preparing for installation
Preparing for installation
5839343
Installation

15
■Connect the power supply (230 V/50 Hz) via a per-
manent connection.
■Regulations on safety at work and those of appropri-
ate trade associations
■Low voltage connection ordinances as well as sup-
plementary conditions of the relevant grid operator
■Any applicable statutory or local regulations
Notify the local grid operator before commissioning the
Vitovalor PA2. We recommend you contact the local
grid operator prior to installation and clarify any techni-
cal points as well as the acceptance procedure. Hand
the relevant application forms as per VDE AR-N 4105
[or local regulations] to the relevant grid operator.
Application forms [for German grid operators] are
available at www.viessmann.de.
Note
Different documentation may be required by grid oper-
ators in other regions.
Metering generated power
A net AC meter (Z2) is integrated into the
Vitovalor PA2. This meter captures total electrical
power generated, minus that consumed by the
Vitovalor PA2 itself. This meter is MID-calibrated and is
licensed for statements to DIN VDE AR-N
4105:2011-08 and the combined heat and power act
(KWKG) (Germany).
The calibration of the integral meter is valid for 8 years.
After expiry of this time, the meter must be recalibrated
or be replaced by a qualified contractor. The power
supply utility must also be notified of any new meter.
Replace any existing main electricity meter installed in
the low voltage distribution board (meter cupboard)
with a balancing bidirectional meter if excess power is
exported to the grid [check local regulations]. The
change of meter with all necessary formalities must be
undertaken by an authorised electrician in agreement
with the grid operator.
Preparing for installation
Notes on connecting to the mains supply (cont.)
5839343
Installation

16
Arrangement of excess export system when con-
nected into a sub-distribution board
RCDRCD
M400V / 230V~ N
L
K
HkWh
Z2
1~
BC
F
G
E
~
PO
kWh
Z1
kWh
A
D
S1
Fig. 4
AVitovalor PA2
BFuel cell module ON/OFF switch
CControl unit ON/OFF switch
DControl unit
EInternal circulation pump
FInternal consumers
GGS protection
HSub-distribution board
KOn-site consumers
LMeter cupboard
MProperty boundary
NLow voltage grid
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell stack
S1 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter
Z2 Export meter (standard delivery on Vitovalor PA2)
Arrangement of excess export system when con-
nected into a mains low voltage (LV) distribution
board
RCDRCD
kWh
Z1
L
AC 400V / 230V~ M
K
HkWh
Z2
1~
F
G
E
kWh
S1
~
ON
BC
A
D
Fig. 5
AVitovalor PA2
BFuel cell module ON/OFF switch
CControl unit ON/OFF switch
DControl unit
EInternal circulation pump
FInternal consumers
GGS protection
HMeter cupboard
KOn-site consumers
LProperty boundary
MLow voltage grid
NInverter (DC/AC converter) SEMAX = 0.75 kVA
OFuel cell stack
S1 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter
Z2 Export meter (standard delivery on Vitovalor PA2)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5839343
Installation

17
Property boundaries and transfer point without power storage system
B
C
D
E
F
G
K
L
Z2
1~
A
N
O
H
1~/N/PE
M
400V / 230V~
~
P
kWh
Z1
kWh
S1
kWh
Fig. 6 Source: VDE AR-N 4105
ALow voltage grid
BMain power supply
CDomestic distribution box
DProperty boundary
EGrid operator
FCustomer
GPower distribution
HOn-site consumers
KShort circuit protection
LOverload protection, RCD
MVitovalor PA2
NGS protection
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell stack
S1 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter (observe meter cir-
cuit)
Z2 Export meter (standard delivery on Vitovalor PA2)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5839343
Installation

18
Property boundaries and transfer point with power storage system
B
C
D
E
F
G
K
L
Z2
1~
A
N
O
H
1~/N/PE
M
400V / 230V~
~
P
kWh
Z1
kWh
S2
kWh
kWh
S1
~
U
V
Fig. 7 Source: VDE AR-N 4105
ALow voltage grid
BMain power supply
CDomestic distribution box
DProperty boundary
EGrid operator
FCustomer
GPower distribution
HOn-site consumers
KShort circuit protection
LOverload protection, RCD
MVitovalor PA2
NGS protection
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell stack
UPower storage system inverter
VPower storage unit
S1 Bidirectional power storage management meter
(power storage system standard delivery)
S2 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter (observe meter cir-
cuit)
Z2 Export meter (standard delivery on Vitovalor PA2)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5839343
Installation

19
Connection for excess export without power storage system
On-site energy consumption according to
paragraphs 33 and 4(3) of the German CHP Act
(KWKG)
B
C
D
E
F
G
K
L
Z3
A
N
O
H1~/N/PE
M
400V / 230V~
~
P
kWh
Z1
kWh
Z4
G
K
L
Z2
=
R
S
T
1~/N/PE
~
kWh
S1
kWh kWh
Fig. 8
ALow voltage grid
BMain power supply
CDomestic distribution box
DProperty boundary
EGrid operator
FCustomer
GPower distribution
HOn-site consumers
KShort circuit protection
LOverload protection, RCD
MVitovalor PA2
NGS protection
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell stack
RGS protection for photovoltaic system
SPhotovoltaic inverter
TPhotovoltaic system
S1 Bidirectional energy management meter (optional,
not relevant to billing by the grid operator)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5839343
Installation

20
Z1 Balancing bidirectional meter (observe meter cir-
cuit)
Electricity meter for power export and drawing
Z2 Export meter for photovoltaic system power gener-
ation
Z3 Export meter for power generation by
Vitovalor PA2 (standard delivery with
Vitovalor PA2)
Z4 Export meter for Vitovalor PA2 alone
Preparing for installation
Notes on connecting to the mains supply (cont.)
5839343
Installation