Vitotherm VCU220 User manual

Instruction
manual
CO2set
CO2dosing unit &
control panel
EN (English) original instructions

Original instructions
The original manual is written in UK English. All other
language versions are translations of the original manual.
Copyright
All rights reserved ©  Vitotherm BV.
No part of this publication may be reproduced and/or
published by print, photoprint, microfilm or any other means
without the written consent of Vitotherm BV.
Disclaimer of liability
The manufacturer cannot be held responsible for personal
injury, damage to the COset or property damage caused
by incorrect use, foreseeable misuse or failure to follow the
instructions in this manual. This also applies to unauthorised
modifications of the COset and the use of non-approved
spare parts, tools or accessories.
The manufacturer reserves the right to modify this manual
without notification beforehand.
Customer service
Our customer service department is available  hours a day to
provide any required technical information and support.
Please have the type plate information of the COset available
when you contact our customer service department (see §..).
+ ()    
Warranty
The equipment supplied by Vitotherm has a one-year warranty
covering materials from date of commissioning against defective
parts, limited to the delivery of parts only. Warranty is only
valid when the installation has been realised in accordance with
our instructions and commissioning is executed by a Vitotherm
engineer or by Vitotherm authorised personnel.
During the period of the warranty any failures to Vitotherm
equipment will be repaired within - days. Our local service
expert for future regular maintenance will be at our daily rate.

CO set | Instruction manual rev-_May 
1.Introduction 2
1.1.About this document 2
1.2.Symbols and labels 2
1.3.Used terms and definitions 3
1.4.Conformity 3
2.Safety 4
2.1.Introduction 4
2.2.Intended use 4
2.3.Reasonably foreseeable misuse 5
2.4.Qualification of personnel 5
2.5.Protective measures 6
2.6.Residual risks 7
2.7.Warning labels 8
2.8.Safety precautions 8
3.Design and function 9
3.1.System overview 9
3.2.CO2dosing unit 10
3.3.Control panel 11
3.4.Frequency drive 12
3.5.Optional components 13
3.6.Type plate 14
3.7.Technical data 15
3.8.Configurations 15
4.Installation 16
4.1.Checking the delivery 16
4.2.Preparing the elevation structure 16
4.3.Mounting the CO2dosing unit 17
4.4.Connecting the CO2dosing unit 19
4.5.Electrical connections 24
Table of Contents
5.Commissioning 25
6.Operation 26
6.1.Control panel 26
6.2.Switching the CO2set on or o 26
6.3.Performing a system reset 26
7.Troubleshooting 27
8.Maintenance 28
8.1.Pre-emptive parts replacement schedule 28
8.2.Annual Periodic Maintenance 28
9.Transport and storage 30
9.1.Transport 30
9.2.Storage 30
10.Decommissioning and disposal 31
10.1.Decommissioning 31
10.2.Dismantling the CO2dosing unit 31
10.3.Disposal 32
Appendices 33
A CO2dosing unit orientations 33
B Technical data 34
C Declaration of conformity 35

CO set | Instruction manual rev-_May 
.Introduction
..About this document
This manual contains instructions and safety information for operation, installation, commissioning and maintenance of the
Vitotherm COset.
This manual is intended for:
• the owner of the COset
• the worker that operates the COset
• the qualified technician that performs the installation of the COset
• the engineer that is authorized by Vitotherm to perform (re)commissioning, adjustments, troubleshooting,maintenance
and repairs of the COset.
..Symbols and labels
...Safety warnings
This manual contains safety warnings that may result in injury when ignored. Each safety warning is indicated with a signal
word. The signal word corresponds with the level of risk of the described hazardous situation:
Signal word Level of risk If not avoided
6DANGER! High Will result in death or serious injury
6WARNING! Medium Could result in death or serious injury
6CAUTION! Low Could result in moderate or minor injury
Safety warnings given at the start of a section apply to the entire section.
Format example of a safety warning:
6WARNING! Contact with live parts can cause electric shocks, burns or even death.
fOnly perform work on electrical equipment if you are an authorised electrician.
fBefore you start working on electrical equipment: Switch o and lock out the power supply
isolator and verify that no voltage is present.

CO set | Instruction manual rev-_May 
...Notices
Messages that are not hazard-related are indicated with the signal word NOTICE. These messages do not have a safety alert
symbol.
Format example of a message that is not hazard-related:
NOTICE Operating the engine at an oil level below the minimum limit value can damage the engine.
fRegularly check the oil level and refill when necessary.
...Other symbols
This symbol identifies a reference to an external document, such as an OEM manual.
..Used terms and definitions
Term Definition
COset The combination of the CO dosing unit and control panel.
COdosing unit The pre-assembled collection of components that transports the flue gases from the boiler to a
greenhouse.
Greenhouse distribution
system The network that transports COgas to one or more greenhouses.
Boiler The heating appliance to which the COdosing unit is connected. A water boiler is the most
common type of heating appliance and will be used as the main example in this document.
Boiler house The building in which the COset and boiler are installed.
OEM manual User manual of the original equipment manufacturer.
..Conformity
Vitotherm COsets carry the CE and EAC marks as a proof of compliance to the following directives:
. MD --EG
. EMC --EU
. LVD --EU
See Appendix D for the full declaration of conformity.

CO set | Instruction manual rev-_May 
.Safety
..Introduction
Observe the instructions in this manual before you start working with the COset. If you fail to follow the instructions from
this manual you can put persons, surroundings, the environment and the COset at risk. Store this manual in an accessible
place near the COset for future reference.
fAlways comply with the information, such as labels and the type plate, attached directly to the CO2set and keep the
information in a legible condition.
fAlways comply with applicable local laws and regulations.
A Vitotherm COset is used in combination with a Vitotherm Automatic forced draught burner system.
Refer to the instruction manual of the burner system for more information.
The COset is equipped with several safety components that ensure safe interaction with the machine.
..Intended use
The Vitotherm COset is intended to be used in the following ways:
• As an electrically powered fan to collect the flue gases from a boiler system.
• To mix the collected flue gases with clean air to create COgas with the desired temperature.
• To deliver the dosed flue gases to the distribution system of a greenhouse.
• OPTIONAL – To mix the collected flue gases with clean air to regulate the under pressure in the connected COcollector.
The Vitotherm COset is intended to be used under the following conditions:
• The COset must only be installed, operated, commissioned and maintained according to the instructions in this
manual.
• The COset must only be used for an application in compliance with the requirements in the order confirmation.
• The COset must only be used under ambient conditions in compliance with the requirements in the order confirmation.
• The COset must only be used in compliance with applicable local laws and regulations.
Safe use of the COset is only guaranteed if it is used as intended.

CO set | Instruction manual rev-_May 
..Reasonably foreseeable misuse
The following is considered foreseeable misuse:
• Use of the COset that deviates from the intended use as described in the previous section.
• Failure to comply with the instructions in this manual.
• Failure to eliminate faults, malfunctions or defects of the COset that impose safety risks.
• Failure to carry out the inspections and maintenance operations as described in this manual.
• Unauthorized removal or modification of parts or safety components of the COset.
• Use of spare parts or accessories that have not been approved by the manufacturer.
• Operation in a closed-o or poorly ventilated room.
..Qualification of personnel
Only authorised personnel is allowed to operate and clean the COset. They must possess the following qualifications:
• are legal of age
• are familiar with and abide by the safety instructions and sections of this manual related to operating the COset
• are familiar with and abide by the applicable local, national and international laws and regulations
• are ocially trained and certified by Vitotherm B.V.
• have received adequate training to operate and clean the COset
• have obtained authorisation to access the COset.
Only authorised technicians are allowed to perform installation and maintenance of the COset. They must possess the
following qualifications:
• are legal of age
• are familiar and abide by the safety instructions and sections of this manual related to installation and maintenance of
the COset
• are familiar with and abide by the applicable local, national and international laws and regulations
• are able to recognize the possible dangers of the COset and take the necessary measures to protect persons and
property
• have received adequate training in the safe maintenance of the COset
• have obtained authorisation to access the COset.

..Protective measures
...Personal protective equipment (PPE)
Personnel that operates the COset must equip themselves
with the following:
Technicians that install or perform maintenance on the CO
set must equip themselves with the following:
Wear foot protection Wear foot protection
Wear eye protection Wear eye protection
Wear ear protection (above  dB) Wear protective gloves
Wear head protection (during lifting
work)
...Organizational measures
The owner is responsible for carrying out the necessary organizational measures to ensure safe use. Amongst other measures
this is achieved by, but not limited to:
• Training and authorising personnel. Vitotherm is responsible for distributing passwords to authorised personnel only.
• Performing hazard assessments of the complete system that incorporates the COset and informing personnel of the
possible dangers and protective measures.
• Performing good housekeeping in the facility that houses the COset.
• Running a preventive maintenance program.

CO set | Instruction manual rev-_May 
..Residual risks
Despite the safe design and construction of the COset and the prescribed protective measures, the COset poses residual
risks. This manual provides safety messages to indicate these risks. The formatting and appearance of safety messages that
are dedicated to a particular section or sentence are explained in chapter . Overall safety messages are grouped in the
following sections.
...Electricity
6WARNING! Contact with live parts can cause electric shocks, burns or even death.
fOnly perform work on electrical equipment if you are an authorised electrician.
fPerform the work on electrical equipment in accordance with the local safety standards.
fDo not make changes to the CO2set if you are not qualified to do so.
fBefore you start working on electrical equipment: Switch o and lock out the power supply
isolator and verify that no voltage is present.
fUse fuses that correspond with the installed power of the CO2set.
fRegularly check the electrical wiring for loose connections and damage and repair them
without delay.
...Mechanical
6WARNING! The COset contains moving, pressurized and sharp parts that can crush, cut or hit.
fDo not operate the CO2set with covers or guards removed.
fDo not operate the CO2set with missing pipework or components.
fNever touch the air damper box during operation.
fBe aware of sharp edges.
...Transport and storage
6WARNING! The COdosing unit may drop or topple when transported incorrectly.
fUse suitable hoisting equipment.
fMake sure no personnel is below or near the object when lifting or hoisting.
6CAUTION! The frame of the COset is made of steel and is sensitive to corrosion damage.
fAlways store the CO2set in a dry, indoor location.
fDo not unpack the CO2set from the optional transport crate until you are ready to install it.

CO set | Instruction manual rev-_May 
..Warning labels
Always comply with warning labels and information signs on the COset. The warning labels and information signs must be
kept legible and must be replaced if necessary. For this purpose, contact the manufacturer.
Symbol Description Location
Do not insert your hands or limbs into the
air inlet of the COdosing unit. Next to the air inlet of the COdosing unit.
..Safety precautions
A COset is equipped with several safety components that help prevent hazardous situations.
For more information about the integration of the safety components into the system, please refer to
the electrical wiring diagram.
...Maximum temperature safety switch
The maximum temperature safety switch shuts down the COset if the flue gas temperature exceeds the set limit of  oC.
...Air inlet grid
A protective grid is mounted on the air inlet of the COdosing unit. The grid prevents hands or limbs from entering the air
inlet. Additionally, the grid prevents foreign objects or small animals from entering the air inlet and damaging the -way
valve inside.

CO set | Instruction manual rev-_May 
.Design and function
The Vitotherm COset is designed to dose the flue gases from a boiler and transport the gas to a greenhouse, where it
contributes to a healthy increase of crop growth.
..System overview
The COset consists of the following components:
21 3
4 5 6
1)Boiler
2)Boiler chimney
3)CO2dosing unit
4)Control panel & frequency drive (optional)
5)Vitotherm CO detector (optional)
6)Elevation structure (optional)
The fan of the COset sucks in the flue gases from the boiler chimney as well as clean air from the boiler house. A -way valve
is integrated in the T-piece and modulates the ratio of flue gas and clean air, to control the temperature of the CO gas that is
transported to the greenhouse.
The air mixture is transported to the greenhouse via the air outlet on the fan housing. The fan housing can be mounted in
dierent configurations to better align with the inlet of the greenhouse distribution system (see §..for more information).

CO set | Instruction manual rev-_May 
..COdosing unit
2
1
7
8
15
4
5
3
6
17
19
16
14
19
13
18
12
9
10
11
1)Junction box
2)Fan housing
3)Modulating temperature controller
4)Air pressure sensor (LD3) - Transport
monitoring
5)Maximum thermostat
6)Pressure transmitter (only with
optional frequency control)
7)Connection sleeve with hose clamps
(fan outlet)
8)Mounting frame
9)Air inlet & filter grid
10)2-way valve (air inlet)
11)2-way valve transmission arm
12)2-way valve servomotor
13)2-way valve (flue gas inlet)
14)Connection sleeve with hose clamps
(flue gas inlet)
15)Type plate
16)Junction box fan motor
17)Fan motor
18)Hoisting holes
19)Elevation structure connections
NOTICE The exact location of the electronic components may dier based on the configuration of the fan
housing (see §..).

CO set | Instruction manual rev-_May 
NOTICE The variation of the COset that is connected to a COcollector has a dierent dosing unit. The
following components are not included in this variation:
fAir inlet
f2-way valve & servomotor
fModulating temperature controlller
..Control panel
The COset is controlled with a separate control panel. It is recommended to install the control panel at an accessible height,
close to the COset.
2 3 4 51
6 7 8 9
The following switches and lights are available on a standard control panel:
No. Description Function
 Max. temperature
failure light
Lights up red when the maximum flue gas temperature is exceeded.
 Valve failure (ES) light Lights up red when a valve failure is detected.
Only included together with the frequency control option (see §..).
 Fan overload light Lights up red when the load on the fan becomes too high.
 Air pressure failure light Lights up red when an air pressure failure is detected
COrequest indication
light
Lights up green when CO dosing is requested.
 Keyholes Unlocks the control panel so that it can be opened.
 Control
switch
Computer Switches the control to the external computer.
O Switches the control o.
 Reset button Resets the COset.
 Main power switch Switches the COset on and o.
NOTICE More information about the failures indicated by the lights on the control panel can be found in
chapter .of this manual.

CO set | Instruction manual rev-_May 
..Frequency drive
For VCU  - 
The frequency drive is located next to the control panel and is used to control the fan motor. The frequency drive is operated
via the interface in the top left corner.
The frequency drive comes in two options:
•  -  V
•  -  V
Both options are equipped with a pressure sensor ( –  mbar).
NOTICE The factory settings of the frequency drive have been set by Vitotherm.
Auto
on Reset
Hand
on
Status Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status 1(0)
1234rpm 10,4A 43,5Hz
Run OK
43,5Hz
On
Alarm
Warn.
Auto
on Reset
Hand
on
Status Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status 1(0)
1234rpm 10,4A 43,5Hz
Run OK
43,5Hz
On
Alarm
Warn.
Auto
on Reset
Hand
on
Status Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status 1(0)
1234rpm 10,4A 43,5Hz
Run OK
43,5Hz
On
Alarm
Warn.
Auto
on Reset
Hand
on
Status Quick
Menu
Main
Menu
Alarm
Log
Back
Cancel
Info
OK
Status 1(0)
1234rpm 10,4A 43,5Hz
Run OK
43,5Hz
On
Alarm
Warn.
1
2
3
4
1)Graphical display with status information
2)Menu buttons and indicator LEDs
3)Navigation buttons and indicator LEDs
4)Operation buttons and indicator LEDs
For more information, please refer to the OEM manual.

CO set | Instruction manual rev-_May 
..Optional components
The following options are available for a Vitotherm COset.
...Vitotherm CO detector
type VCD with sampling pump
A Vitotherm CO detector checks the flue gas that is transported from the burner to external applications (e.g. greenhouses)
for carbon monoxide. The CO detector is mounted near the flue gas exhaust.
21
43 5
1)Interface & display
2)Failure feedback light
3)Key lock
4)Control switch
5)Cable connectors
For more information, please refer to the Vitotherm CO detector user manual.
...Seaworthy packaging
If the COset needs to be well protected or
shipped overseas, it can be packed in wooden
crates treated according to ISPM .

...Liquid COcontrol
Built in the control panel
Control system which adds additional COin liquid form to the flue gases, in order to increase the COconcentration of the gas
supplied to the greenhouse.
...Frequency control
A frequency control system can be added to the COset. This system uses a pressure transmitter to maintain a constant gas
pressure inside the dosing unit.
..Type plate
The COset is marked with a type plate in accordance with the applicable legislation requirements.
Vitotherm BV
2641 NE Pijnacker
Overgauwseweg 8
Tel:[phone]
Fax:[phone]
.. A
Hz..
..
V..
Current:
Frequency:
..
Voltage:
Destination country:
Production year:
..Serial nr.:
VCUType:
When servicing the CO2 fan the main switch must be switched off at all times.
Before the CO2 fan is installed and put into operation, the instruction manual must be read.
The electrical part of the CO2 fan is built according tothe EN 60529, the voltage and amperage is as indicated on the nameplate of the fan.
This CO2 fan must be installed according tothe rules in force, and should be used only in a well ventilated area.
1
2
3
4
5
6
7
Lorentzstraat 1
2665 JG Bleiswijk
Tel: [phone]
1. Type
2. Serial number
3. Year of manufacture
4. Country of destination
5. Voltage (V)
6. Frequency (Hz)
7. Current (A)
NOTICE The location of the type plate is indicated in §..

CO set | Instruction manual rev-_May 
..Technical data
For EU ( Hz)
This section contains the standard dimensions, materials and performance data of a Vitotherm COset.
For technical data regarding your specific COset, please refer to the type plate (see §..) or the order confirmation. For
performance data in imperial units, please refer to Appendix C of this manual.
Type Fan motor
power
* Motor voltage -way valve
control
Inlet diameter
(suction side)
Outlet
diameter
(pressure side)
Material fan
housing,
T-piece, fan.
kW VAC @ Hz - Ø mm Ø mm -
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
VCU , @ Modulating   SS 
*Motor voltage may vary per country (, ,  or  V @ Hz).
..Configurations
The fan housing can be mounted in  dierent orientations to better align with the inlet of the greenhouse distribution
system. See appendix A for an overview of the dierent orientations.
NOTICE The standard configuration shown in this document is RD (R).

CO set | Instruction manual rev-_May 
.Installation
This chapter provides instructions for the basic installation of a COset onto a boiler or other heating appliance. For
information about a custom set-up, please contact Vitotherm.
6CAUTION! The COset may only be installed by qualified personnel. Handling the COset and supporting
components without the required knowledge and experience may damage the COset or cause
hazardous situations during installation and use.
6WARNING! The COset may only be installed in a suciently ventilated boiler house.
NOTICE The COset must always be installed according to national and local laws and regulations.
..Checking the delivery
Required tools:
• Forklift truck with adequate lifting capacity.
To check the delivery:
. Transport the crate(s) to an accessible place near the boiler.
. When delivered in an optional transport crate:
a. Remove the lid of the crate(s).
b. Remove the sides of the crate(s).
c. Remove the lashing straps and packaging materials.
d. Remove any screws that connect parts to the bottom of the crate(s).
. Check if all parts have been delivered according to the agreed scope. If a part is missing, contact Vitotherm immediately.
. Check all delivered parts for damage.
6WARNING! Damaged parts can aect the correct and safe functioning of the COset.
fDo not install damaged parts.
fIf any parts are damaged upon delivery, please contact Vitotherm.
. Check if the delivered COset will fit in the designated area of the room. For the dimensions of the COset, see §...
..Preparing the elevation structure
The COdosing unit can be installed on a supporting elevation structure. The mounting frame of the dosing unit can be
expanded with legs to create this elevation structure.
The COdosing unit can also be installed on the floor. In this scenario, support feet can be attached to the mounting frame.
NOTICE The elevation structure or support feet are not part of the standard delivery and may have to be
created as part of the installation process.

CO set | Instruction manual rev-_May 
Connection materials:
• Square steel tubing ( x  mm)
• Connection brackets
To prepare the elevation structure:
. Measure the required installation height and determine the required length of the frame legs. Use the dimensions in
§..as a reference.
. Cut four pieces of square steel tubing with the required length.
. Increase the stability of the structure:
a. Weld footpads onto the bottom of the frame legs.
b. Attach crosswise connector pieces between the frame legs.
..Mounting the COdosing unit
Required tools:
• Mobile crane with adequate lifting capacity.
• Suitable hoisting equipment:
• D-shackles
• Round sling
• Elevation structure
• Power drill with steel drill head (Ø mm)
• Ring wrenches or adjustable spanners
6WARNING! The COdosing unit may drop or topple when transported incorrectly.
fUse suitable hoisting equipment.
fMake sure no personnel is below or near the object when lifting or hoisting.
To hoist the COdosing unit:
1)Connect your hoisting equipment to
the hoisting eyes of the fan housing.
2)Carefully lift the dosing unit.
3)Place the elevation structure below
the dosing unit.

CO set | Instruction manual rev-_May 
4)Align the mounting frame of the dosing unit
with the elevation structure.
5)Lower the dosing unit onto the elevation
structure.
6)Drill a hole through the bolt hole on the side
of the connection point.
Use a Ø12 mm steel drill.
7 Insert a Ø12 mm metal pin or bolt into the
drilled hole.
8)Tighten the bolts in the connection points to
secure the elevation structure. Use a 16 mm
wrench.