VIESMANN VITOVALOR 300-P Micro CHP unit based on a fuel cell with integral gas condensing boiler 750 W el, 1.0 to 25.2 kw th

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1 VIESMNN VITOVLOR 00-P Micro CHP unit based on a fuel cell with integral gas condensing boiler 750 W el, 1.0 to 25.2 kw th Technical guide VITOVLOR 00-P Type CT Micro CHP unit based on a fuel cell with integral gas condensing boiler to cover peak loads, for room sealed operation For natural gas E and LL Compact system consisting of 2 units: Fuel cell module with stack and integrated reformer for generating hydrogen-rich gas from natural gas and for generating power and heat Gas condensing module with gas condensing boiler for covering peak loads, heating water buffer cylinder and DHW cylinder, Vitotronic control unit plus hydraulics and sensors 5/2017

2 Index Index 1. Vitovalor 00-P 1. 1 Product description... 5 Generation of heat and power... 5 Product description... 6 Operating conditions Specification... 9 Specification... 9 Dimensions Variable speed circulation pump Connections to the gas condensing module on the gas and water sides with connection sets (accessories) Notes regarding electrical output... 1 Influence of geodetic head and gas quality on electrical output Degradation Influence of the heating water return temperature on the efficiency levels Installation accessories 2. 1 DHW cylinder DHW convenience set ccessories for Vitovalor 00-P Connection set for installation on finished walls, for upward connection Connection set for installation on finished walls, for connection to the right or left. 17 Connection set for DHW circulation pump Connection set for external heating water expansion vessel Divicon heating circuit distributor Mixer extension kit in conjunction with Divicon heating circuit distributor Further accessories Vitoflow automatic hydraulic balancing Safety assembly to DIN Thermostatic DHW circulation set utomatic thermostatic mixing valve Neutralising system Neutralising granulate Condensate lifting system Heating water softening Refill pack for heating water softening Filling case for mobile filling of heating system with softened water in accordance with VDI CO limiter Drain outlet kit Connection bend DN 40 for condensate drain DI water Dirt separator Vitocharge, type S Design information. 1 Siting, installation... 0 Siting conditions for open flue operation (appliance type )... 0 Siting conditions for room sealed operation (appliance type C)... 0 Space requirement and minimum clearances... 0 Installation preparations Electrical connection... 1 Vitovalor 00-P in mains parallel mode... 1 Metering generated power... 2 Property boundaries and transfer point without power storage system... Property boundaries and transfer point with power storage system... 4 Connection for excess export without power storage system, with photovoltaic system... 5 Connection for excess export with power storage system and photovoltaic system... 6 Cable sizing... 7 Fuse protection Gas connection... 8 Gas supply pipe... 9 Thermally activated safety shut-off valve... 9 Sizing recommendation, gas flow switch DHW heating... 9 Information on water quality Condensate connection... 9 Condensate drain pipe and neutralisation Hydraulic connection General VIESMNN VITOVLOR 00-P

3 Index (cont.) Installation examples Expansion vessel Low loss header... 4 pplication... 4 Low loss header in conjunction with Divicon Low loss header from the Vitoset range Flue systems System certification Room sealed operation Flue gas high limit safety cut-out Lightning protection CE designation for the PPs flue systems (rigid and flexible) Flue system installation options for room sealed operation Inside occupied rooms (living space) with one or more full storeys above In occupied rooms (living space) immediately below the roof or with only the roof space above Design and sizing information for connection on the flue gas side Plastic (PPs) balanced flue system for routing in a shaft for room sealed operation (type C 92x to CEN/TR 1749) Plastic (PPs) balanced flue system for vertical roof outlets through a pitched or flat roof (type C 2x to CEN/TR 1749) Plastic (PPs) balanced flue system for routing flues over external walls (type C 52x to CEN/TR 1749) Plastic (PPs) balanced flue system for routing through a lightweight shaft Components for the flue systems alanced flue system components Components for routing a flue over an external wall Single pipe system components Roof elements Intended use Control unit 4. 1 Vitotronic 200 RF, type HO1E, for weather-compensated operation Design and functions Functions Connectivity Control characteristics Time switch Setting the operating programs for central heating and DHW heating Selection of operating modes for the fuel cell Frost protection function Summer mode djusting the heating curves (slope and level) Heating systems with low loss header oiler water temperature sensor Cylinder and outlet temperature sensor Wireless outside temperature sensor Outside temperature sensor Internal H1 extension LON communication module Vitocom 00, type LN Specification Vitotronic 200 RF, type HO1E Vitotronic ccessories Notes regarding room temperature hook-up (RS function) for remote control units 74 Information on the Vitotrol 200- and Vitotrol Vitotrol Vitotrol Information on the Vitotrol 200-RF and Vitotrol 00-RF Vitotrol 200-RF Vitotrol 00-RF with table-top dock Vitotrol 00-RF with wall mounting bracket Vitoconnect 100, type OPTO Wireless repeater Room temperature sensor Immersion temperature sensor Mounting base for programming unit Radio clock receiver KM US distributor Mixer extension kit with integral mixer motor Mixer extension kit for separate mixer motor Immersion thermostat Contact thermostat... 8 VITOVLOR 00-P VIESMNN

4 Index (cont.) M1 extension... 8 E1 extension Vitogate 200, type KNX LON communication module LON connecting cable for data exchange between control units Extension of the connecting cable ppendix 5. 1 Regulations / Directives Regulations and directives Keyword index VIESMNN VITOVLOR 00-P

5 Vitovalor 00-P 1.1 Product description Generation of heat and power Government policies such as the withdrawal from nuclear energy by 2022, the reduction of power generation from coal-fired power stations and the expansion of renewables amount to a turnaround in the provision of energy in Germany. gainst this backdrop, decentralised power generation using combined heat and power (CHP) is becoming increasingly more significant. Fuel cell: Number one efficiency technology Fuel cells in decentralised installations in private households are the number one efficiency technology. Unlike conventional power generation through combustion of fossil fuels, the fuel cell generates electricity through highly efficient electrochemical processes. The concomitantly generated heat can be used for central heating or DHW heating. There are no losses arising from the transport of power to consumers, a phenomenon typically encountered with centralised power stations. Fuel cell heating systems are therefore particularly environmentally responsible and protect resources. 1 Separate generation of heat and power Micro CHP unit: Parallel generation of heat and power Conventional power station (power) 1.97 kwh Primary energy.06 kwh kwh Primary energy Gas condensing boiler (heat) Efficiency 8 % 62 % 0.02 kwh 1.22 kwh Efficiency 98 % 2 % 0.75 kwh el 1.07 kwh th Efficiency. % Efficiency 47.7 % 1.24 kwh 0.4 kwh 81 % 19 % Vitovalor 00-P (heat & power) 2.25 kwh Primary energy Energy usage for Vitovalor 00-P = 100 % (2.25 kwh) Energy usage separate generation = 16 % (.06 kwh) Primary energy savings up to 6 % ll values refer to the gross calorific value. Combined heat and power generation represents a very efficient method of decentralised energy provision, as only the energy actually required is converted and this is done with high efficiency directly at the point of consumption. The heat generated through the power generation is available to provide DHW and central heating. This way, combined heat and power generation can make a vital contribution to reducing the consumption of primary energy, and consequently to environmental protection. In Germany, around 20 million heating systems are installed, mostly in private buildings (source: DH-Statistik 2012). Replacing older heat generators in detached and two-family houses with a micro CHP unit can potentially save substantial amounts of energy and is therefore highly worthwhile. The Federal Government subsidises the deployment of micro CHP units according to the German CHP ct (KWKG). VITOVLOR 00-P VIESMNN 5

6 Vitovalor 00-P (cont.) Product description 1 Gas condensing boiler for covering peak loads DHW cylinder C Inox-Radial heat exchangers made from stainless steel D MatriX cylinder burner with gas train E Weather-compensated control unit F Hydraulic unit G Heating water buffer cylinder H Internal indirect coil for DHW heating K Cartridge for deionised water L Trap M Reformer N Electricity meter, CHP unit P Fuel cell stack Q Inverter Layout and function The Vitovalor is a micro CHP unit with a fuel cell (type NT-PEM = low temperature proton exchange membrane fuel cell) for the decentralised generation of heat and power incorporating a gas condensing boiler for covering peak loads. Fuel cells convert chemical energy of a fuel directly to electricity. This conversion is highly efficient as, unlike with conventional energy generation, no thermomechanical intermediate steps are required. Unlike internal combustion engines, fuel cells are not subject to limitation of the Carnot efficiency. Like batteries, fuel cells generate a direct current at low voltage. Unlike batteries, fuel cells require a constant supply of reactants (natural gas and oxygen). Vitovalor 00-P uses a low temperature fuel cell, type NT-PEM (or polymer electrolyte fuel cell) which uses a gas-tight proton conducting plastic (polymer) membrane as the electrolyte between the electrodes. In operation, hydrogen is supplied to the anode and is oxidised there. The protons (H + ions) produced at the anode pass through the ion exchange membrane and to the cathode where they come into contact with the oxidant (oxygen or ambient air). n external circuit (consumer) passes the electrodes from the anode to the cathode. Here, oxygen from the ambient air binds these electrodes and reacts with the protons to form water. n inverter converts the DC current of the external circuit to C current and feeds it into the grid. Fuel cell stack The heat generated during the reaction in the fuel cell is absorbed by water in the cooling channels of the fuel cell stack. This heat can be used for central heating or DHW heating via a heat exchanger. 6 VIESMNN VITOVLOR 00-P

7 Vitovalor 00-P (cont.) The hydrogen required is derived from the supplied natural gas in an upstream gas reforming process. The fuel cell stack and the gas condensing module are supplied via a common gas line. oth modules have a common flue system. This makes installation as easy as for a wall mounted gas condensing boiler. Energy management The Vitovalor 00-P has a heat bias and is designed for power-optimised operation. The prevailing heat demand will always be covered. The savings through utilisation of power generated on site are significantly higher than the feed-in remuneration. The rate of power consumed on site (ratio of power consumed on site to power generated on site) should therefore be as high as possible. The fuel cell module has a constant electrical output of 750 W and can be switched on once a day. If the energy manager is enabled, it selects a start time that optimises the rate of power consumed on site. It takes into account recorded power consumption data and the temperature in the integral heating water buffer cylinder. The energy manager is self-learning and does not need to be configured. If the energy manager is disabled, the fuel cell module is started subject to the temperature in the heating water buffer cylinder. The energy manager and the cylinder volumes (heating water buffer cylinder 10 l, DHW cylinder 46 l) enable long runtimes of the fuel cell. This can cover a large proportion of the power demand, thus increasing the rate of on-site consumption. Excess power can always be exported into the public grid. Remuneration is according to the total electrical energy generated, regardless of whether this power was consumed on site or exported. Installation and electrical connection Electrical connection of the Vitovalor 00-P follows the same pattern as that of conventional wall mounted gas boilers, that is via a -core power cable. The integral net electricity meter makes any on-site retrofitting superfluous. This makes the Vitovalor 00-P particularly easy to service and install. The mains monitoring system prevents island operation. This ensures high operational reliability. The prefitted components make installation quick and easy. The heat exchanger fitted in the heating water buffer cylinder provides system separation between the fuel cell and the heating system. Nevertheless, fill water for the buffer cylinder circuit does need softening as specified in VDI 205 on commissioning. Vitovalor 00-P is suitable for self-supporting installation. This ensures straightforward positioning and installation. The fuel cell module and the gas condensing module are supplied separately. This facilitates transportation and makes for easier handling within tight spaces. pplication recommendations The Vitovalor 00-P is optimised for maximum runtimes, thereby creating great potential for reducing electricity bills. With an electrical output of 750 W and a heating output of 1.0 kw, the fuel cell is suitable for base level provision in single-family or two-family houses. Together with the gas condensing boiler that starts as required to cover peak loads, a total heating output of 20 kw or 27 kw is available (up to 0 kw with DHW heating). This makes the Vitovalor 00-P ideal for new builds and modernisation (single- and two-family house) with low heat demand, ideally with underfloor heating. For an optional linking into the heating system, see "System examples". The following conditions must be met for the Vitovalor 00-P to operate: Gas quality: Natural gas E or LL Heating circuit return temperature < 50 C Minimum temperature in the installation room > C Installation altitude < 1000 m above sea level The Vitovalor 00-P can only be operated in combination with a solar thermal system by using the DHW convenience set available as an accessory. This enables the solar energy to be used for DHW heating. Using solar energy for central heating backup is not recommended. This would otherwise reduce the runtimes of Vitovalor 00-P and economically efficient operation would no longer be guaranteed. If combining with a photovoltaic system, ensure that the electricity meter is arranged correctly. See page 1. n incorrectly arranged electricity meter would distort the statistical data of the energy manager. s a result, the runtimes of Vitovalor 00-P would be reduced and economically efficient operation would no longer be guaranteed. Service Fuel cell module: Maintenance required every 2 years, including replacing the air filter and the deionisation cartridge for deionising the fuel cell cooling circuit The gas sensors have to be replaced every 5 years. Gas condensing module: Maintenance is required annually. enefits at a glance Fuel cell: 750 W el, 1 kw th Overall efficiency 81. % (H s ) [gross cv] Electrical efficiency 7 % Gas condensing module: Up to 18.9 kw or 25.2 kw (DHW up to 0 kw) Efficiency 98 % (H s ) [gross cv] Innovative technology of the future Environmentally responsible up to 50 % CO 2 reduction compared with separate power and heat generation Low emissions Maintenance-free desulphurisation Parallel generation of power and heat to minimise electricity costs Simple and rapid installation due to fully integrated hydraulics (similar to gas condensing boilers), only one flue system required Easy handling thanks to separate shipping of fuel cell module and gas condensing module Space saving due to compact design in standard kitchen unit dimensions, footprint only 0.65 m 2 No additional water supply for the fuel cell required Integrated system separation through plate heat exchanger ensures safe and robust operation. Integral electricity, gas and heat meter (to provide billing information for state subsidies and tax rebates) Optional remote control and call up of current data via an app Ideal for new builds and modernisation (single- and two-family houses) Uncomplicated engineering due to the fact that many of the installation accessories are recognisable from the wall mounted gas boiler range Delivered condition Vitovalor 00-P comprising the fuel cell module, gas condensing module with integral gas condensing boiler, buffer cylinder (10 l) and DHW cylinder (46 l) Integral system separation through plate heat exchanger Integral calibrated meter for generated electricity Control unit for weather-compensated operation, with internal H1 extension, wireless interface, LON communication module with Vitocom 00, type LN Safety valve for fuel cell and heating circuits Flue system pack High efficiency circulation pumps Filling aid for fuel cell module with deionised water (DI water) 5 l DI water for initial filling of the fuel cell module External electricity meter (fuel cell input for power-optimised operation) 1 VITOVLOR 00-P VIESMNN 7

8 Vitovalor 00-P (cont.) 1 Note To sell fuel cell heating appliances, qualifying training is required. In addition, all systems are commissioned by the Viessmann technical service. For further information, contact your local Viessmann sales offices. Tested quality CE designation according to current EC Directives Operating conditions Min. Max. Heating water flow rate through the appliance 0 l/h 1200 l/h Heating water return temperature 6 C 50 C Room temperature C 5 C The operation of booster heaters within the system is not recommended as these booster heaters reduce the micro CHP system runtime. The system requires hydronic balancing. Under certain conditions, it is possible for the DHW outlet temperature to exceed 60 C. Provide scalding protection on site. We recommend installing a dirt separator: See page VIESMNN VITOVLOR 00-P

9 Vitovalor 00-P (cont.) 1.2 Specification Specification Micro CHP unit based on a fuel cell with integral gas condensing module Electrical output (gross) kw el T F /T R = 50/0 C Rated heating output range (to EN 50465: 2015) kw th 0.6 to to 24.0 T F /T R = 60/40 C Rated heating output range kw th 1.0 to to 25.2 T F /T R = 50/0 C Rated heating output range for DHW heating kw 1.0 to to 29. Rated heat load range kw 2.1 to to 0.5 Frequency (generated power) Hz 49.5 to to 50. Product ID CE-0085CP0028 Protection class I Protection rating (for room sealed operation) IP 20 to EN Permiss. ambient temperature Operation C to 5 to 5 Storage and transport C 20 to to 65 Gas supply pressure *1 Natural gas E and LL mbar kpa 2 2 Max. permissible gas supply pressure *1 Natural gas E and LL mbar kpa Power consumption (max.) W Circulation pump (delivered condition) W Weight Total kg Fuel cell module kg Gas condensing module kg Total content of gas condensing module l Max. flow rate l/h Limit for the use of hydraulic separation Rated circulation water volume in the appliance at T F /T R = 50/0 C l/h Permiss. heating circuit operating pressure bar MPa Fuel cell module dimensions Length mm Width mm Height mm Gas condensing module dimensions Length mm Width mm Height mm Min. required room height mm Gas connection (male thread) R ½ ½ DHW loading cylinder *2 Capacity l Permiss. operating pressure (DHW side) bar MPa 1 1 Continuous DHW output kw Initial DHW output l/10 min For DHW heating from 10 to 45 C Performance factor N L * Connection value Relative to max. load Natural gas E m /h.2.2 Natural gas LL m /h *1 If the gas supply pressure is higher than the maximum permitted value, install a separate gas pressure governor upstream of the system. *2 If the DHW output is not sufficient, this can be increased using the DHW convenience set that is available as an accessory. * t 70 C average boiler water temperature and cylinder storage temperature Tcyl = 60 C. DHW performance factor NL depends on cylinder storage temperature Tcyl. Standard values: Tcyl = 60 C 1.0 NL Tcyl = 55 C 0.75 NL Tcyl = 50 C 0.55 NL Tcyl = 45 C 0. NL. VITOVLOR 00-P VIESMNN 9

10 Vitovalor 00-P (cont.) 1 Micro CHP unit based on a fuel cell with integral gas condensing module Electrical output (gross) T F /T R = 50/0 C Rated heating output range (to EN 50465: 2015) T F /T R = 60/40 C Rated heating output range T F /T R = 50/0 C kw el kw th 0.6 to to 24.0 kw th 1.0 to to 25.2 Flue gas parameters *4 Flue gas category to G 65/G 66 G 52 /G 51 G 52 /G 51 Temperature (at a return temperature of 0 C) t rated heating output C t partial load C 5 5 Temperature (at a return temperature of 60 C) *5 C Mass flow rate t rated heating output kg/h t partial load kg/h vailable draught *6 Pa mbar CO 2 content t rated heating output % of amount t partial load % NO x, category 6 mg/kwh verage condensate volume (PL) With natural gas and at T F /T R = 50/0 C l/h Condensate connection (hose nozzle) Ø mm 20 to to 24 Flue gas connection Ø mm Ventilation air connection Ø mm Power cable mm 2 x 2.5 x 2.5 Sound power level d() Primary energy factors fixed primary energy factor can be assumed for the Vitovalor 00-P. For list of primary energy factors, see Energy efficiency class Heating ++ + DHW heating, draw-off profile XL *4 Calculation values for sizing the flue system to EN 184. Flue gas temperatures as actual gross values at 20 C combustion air temperature. The flue gas temperature at a return temperature of 0 C is significant for the sizing of the flue system. The flue gas temperature at a return temperature of 60 C is used to determine the application range of flue pipes with max. permissible operating temperatures. *5 Under certain circumstances, return temperatures can exceed 60 C during operation. However, in standard mode, the return temperature should not exceed 40 C. *6 CH: vailable draught 200 Pa (2.0 mbar) 10 VIESMNN VITOVLOR 00-P

11 Vitovalor 00-P (cont.) Dimensions Ø Fuel cell module to the right of the gas condensing module Condensate drain in the wall C Fuel cell module to the right of the gas condensing module C Fuel cell module to the left of the gas condensing module Note The power cable is connected to the gas condensing module. The power supply of the fuel cell is established via a connecting cable to the gas condensing module. Variable speed circulation pump Matching the pump rate of the circulation pump to the individual system conditions reduces the power consumption of the heating system. Note In conjunction with a low loss header, heating water buffer cylinder and mixer, the internal circulation pump runs at a constant speed. This speed can be adapted to requirements via the corresponding code in the control unit. Power consumption Max. W 7 Min. W Output modulation % 10 to 100 Energy efficiency class VITOVLOR 00-P VIESMNN 11

12 Vitovalor 00-P (cont.) Residual head of the circulation pump L 50 K H 40 Residual head mbar kpa E G F C D Flow rate in l/h Power consumption in W lack line: Residual head Grey line: Power consumption Pump rate, circulation pump 10 % 20 % C 0 % D 40 % E 50 % F 60 % G 70 % H 80 % K 90 % L 100 % 12 VIESMNN VITOVLOR 00-P

13 Vitovalor 00-P (cont.) Connections to the gas condensing module on the gas and water sides with connection sets (accessories) ll possible connection sets are shown (connection to the right, left or top) C DEF F E C D D C E F C D E F 50 ll connections male thread Heating flow R ¾ DHW R ½ C Gas connection R ½ D DHW circulation R ½ E Cold water R ½ F Heating return R ¾ 1. Notes regarding electrical output The electrical output of 750 W relates to the value on commissioning. This value was determined to EN under the following conditions: Natural gas H (G20) with H i [ net cv] = 4.02 MJ/m Power supply 20 V/50 Hz Return temperature 0 C ±2 K Installation room ambient temperature 20 C ±2 K ir pressure mbar (101.5 kpa) Natural gas pressure 20 mbar (2 kpa) VITOVLOR 00-P VIESMNN 1

14 Vitovalor 00-P (cont.) 1 Note Different operating conditions can result in increased or reduced electrical output. Influence of geodetic head and gas quality on electrical output Power Output in kw D C Geodetic head in m (altitude above sea level) Electrical output when operating with limit gas lower Wobbe index (natural gas E and LL) Electrical output when operating with standard test gas (natural gas E and LL) C Electrical output to EN D Electrical output when operating with limit gas upper Wobbe index (natural gas E and LL) Limits of gas quality for natural gas E and LL (G21) 16 Wobbe index in kwh/m³ (G20) (G21) C, mbar (101. kpa) 1.1 (G26) 12.2 (G25) 10 (G271) Natural gas E Natural gas LL Degradation In addition to gas quality and geodetic head, the electrical output is influenced by the effect of degradation. Degradation describes the decrease of the electrical efficiency of a fuel cell over time. The operating strategy of the Vitovalor 00-P is for operation with constant heat input (gas input) and constant overall efficiency. This means that the ratio of electrical output to thermal output changes over the service life. s the overall output remains constant, electrical output decreases over the service life while thermal output increases. 14 VIESMNN VITOVLOR 00-P

15 Vitovalor 00-P (cont.) Influence of the heating water return temperature on the efficiency levels The efficiency levels of the fuel cell module depend on the heating water return temperature. In order to achieve efficiency levels that are as high as possible, the heating water return temperatures must be as low as possible. 1 Efficiency in % C Heating water return temperature in C Overall efficiency Thermal efficiency C Electrical efficiency VITOVLOR 00-P VIESMNN 15

16 2 Installation accessories 2.1 DHW cylinder DHW convenience set Part no. Z DHW cylinder adjacent to the boiler for increasing the DHW output. With connecting cables. DHW cylinder Vitocell 100-V, type CV with 00 l capacity For further details, see the technical guide to the Vitodens 200-W, 222-W, 00-W Vitovalor internal connecting cables to interface of the connection set Cylinder temperature sensor with.75 m long connecting cable Note If the DHW convenience set is used and DHW consumption is greater than 250 l/day, we recommend installing a water treatment system. ccording to DIN 1988, a water treatment system should be installed if the water hardness is > 14 dh. Otherwise increased limescale deposits may occur in the plate heat exchanger of the Vitovalor 00-P, which will require more extensive maintenance. 16 VIESMNN VITOVLOR 00-P

17 Installation accessories (cont.) 2.2 ccessories for Vitovalor 00-P Connection set for installation on finished walls, for upward connection Part no. ZK01 18 Connection pipes with thermal insulation Shut-off valves for heating water flow and return (R ¾), with boiler drain & fill valve 2 connectors for DHW (R ½) Gas shut-off valve with thermally activated safety shut-off valve (R ½) 2 Connection set for installation on finished walls, for connection to the right or left Part no. ZK01 19 Connection pipes with thermal insulation Shut-off valves for heating water flow and return (R ¾), with boiler drain & fill valve 2 connectors for DHW (R ½) Gas shut-off valve (R ½) with thermally activated safety shut-off valve Note The fuel cell module should not be installed in the same direction as the connection set. Connection set for DHW circulation pump Part no. ZK For installation in the appliance High efficiency circulation pump Flow regulating valve Pipe assembly with thermal insulation Connection set for external heating water expansion vessel Part no Expansion vessel connection: R ½ Divicon heating circuit distributor Layout and function vailable with R ¾, R 1 and R 1¼ connections. With heating circuit pump, check valve, ball valves with integral thermometers and -way mixer or without mixer. Quick and simple installation due to pre-assembled unit and compact design. ll-round thermal insulation shells for low radiation losses. High efficiency pumps and optimised mixer curve ensure low electricity costs and precise control characteristics. The bypass valve for hydraulic balancing of the heating system is available as an accessory and is provided as a threaded component for inserting into the prepared hole in the cast body. Individually wall mounted or with a double or triple manifold. lso available as a kit. For further details see the Viessmann pricelist. VITOVLOR 00-P VIESMNN 17

18 Installation accessories (cont.) For part numbers in conjunction with the different circulation pumps, see the Viessmann pricelist. The dimensions of the heating circuit distributor are the same, with or without mixer. 142 HV 120 HR a 151 HV 120 HR a 2 C C HV HR G 1½ D HV HR G 1½ Divicon without mixer (wall mounting, shown without thermal insulation) Divicon with mixer (wall mounting, shown without thermal insulation or mixer drive extension kit) HR Heating return HV Heating flow all valves with thermometer (as programming unit) Circulation pump C ypass valve (accessories) D Mixer- Heating circuit connection R ¾ 1 1¼ Flow rate (max.) m /h a (female) Rp ¾ 1 1¼ a (male) G 1¼ 1¼ 2 HR Heating return HV Heating flow all valves with thermometer (as programming unit) Circulation pump C all valve Heating circuit connection R ¾ 1 1¼ Flow rate (max.) m /h a (female) Rp ¾ 1 1¼ a (male) G 1¼ 1¼ 2 Installation example: Divicon with triple manifold HV HR a b d HV c HR (shown without thermal insulation) HR Heating return HV Heating flow 18 VIESMNN VITOVLOR 00-P

19 Installation accessories (cont.) Dimension Manifold with heating circuit connection R ¾ and R 1 R 1¼ a b c d G 1¼ G 2 Determining the required nominal diameter Flow rate in m³/h C D 1 5 ΔT= 5K ΔT= 10K ΔT= 15K ΔT= 20K ΔT= 0K Mixer control characteristics Heating circuit output in kw Divicon with mixer- The operating ranges marked to D provide optimum control characteristics with the Divicon mixer: Divicon with mixer- (R ¾) pplication range: 0 to 1.0 m /h C Divicon with mixer- (R 1) pplication range: 0 to 1.5 m /h D Divicon with mixer- (R 1¼) pplication range: 0 to 2.5 m /h Example: Heating circuit for radiators with a heating output of ² = 11.6 kw Heating system temperature 75/60 ºC (ΔT = 15 K) ² = µ c ΔT c = 1.16 Wh kg K µ (1 kg 1 dm³) c Specific thermal capacity µ Mass flow rate ² Heating output Flow rate Circulation pump curves and pressure drop on the heating water side The residual pump head results from the differential between the selected pump curve and the pressure drop curve of the respective heating circuit distributor or further components (pipe assembly, distributor, etc.). The following pump graphs show the pressure drop curves of the different Divicon heating circuit distributors. Maximum flow rate for Divicon: With R ¾ = 1.0 m /h With R 1 = 1.5 m /h With R 1¼ = 2.5 m /h Example: Flow rate = m /h = ² c ΔT = W kg K kg 1.16 Wh (75-60) K = 665 m³ h h Select the smallest possible mixer within the application limit with the value. Result of this example: Divicon with mixer- (R ¾) Selected: Divicon with mixer R ¾ Wilo Yonos PR 25/6 circulation pump, variable differential pressure operating mode and set to maximum delivery head Pump rate 0.7 m /h Head of the relevant pump curve: Divicon pressure drop: Residual head: 48 kpa.5 kpa 48 kpa.5 kpa = 44.5 kpa. Note For further components (pipe assembly, distributor, etc.) determine the pressure drop and deduct it from the residual head. VITOVLOR 00-P VIESMNN 19

20 Installation accessories (cont.) 2 Differential pressure-dependent heating circuit pumps ccording to the [German] Energy Saving Ordinance (EnEV), circulation pumps in central heating systems must be sized in accordance with current technical rules. Ecodesign Directive 2009/125/EC requires high efficiency circulation pumps to be used throughout Europe from 1 January 201, if the pumps are not installed in the heat generator. Design information The use of differential pressure-dependent heating circuit pumps requires heating circuits with variable pump rates. These include, for example, single and twin line heating systems with thermostatic valves and underfloor heating systems with thermostatic or zone valves. Wilo Yonos PR 25/6 Particularly power saving high efficiency pump Operating mode: Constant differential pressure Pressure drop/head mbar kpa Δp-C max. 10 C Flow rate in m³/h Divicon R ¾ with mixer Divicon R 1 with mixer C Divicon R ¾ and R 1 without mixer Operating mode: Variable differential pressure Pressure drop/head mbar kpa Δp-V 10 C Flow rate in m³/h max Wilo Yonos PR Opt. 25/7.5 Operating mode: Constant differential pressure Pressure drop/head mbar kpa Δp-C max Flow rate in m³/h Divicon R 1¼ with mixer Divicon R 1¼ without mixer Operating mode: Variable differential pressure Pressure drop/head mbar kpa Δp-V max Flow rate in m³/h Divicon R 1¼ with mixer Divicon R 1¼ without mixer Divicon R ¾ with mixer Divicon R 1 with mixer C Divicon R ¾ and R 1 without mixer 20 VIESMNN VITOVLOR 00-P

21 Installation accessories (cont.) Grundfos lpha With power consumption display With utoadapt function (automatic matching to the pipework) With night setback function ypass valve Part no For hydraulic balancing of the heating circuit with mixer. To be inserted into the Divicon M K 00 0 Pressure drop/head mbar kpa 20 L H 10 E C D Flow rate in m³/h G F Divicon R ¾ with mixer Divicon R 1 with mixer C Divicon R 1¼ with mixer D Divicon R ¾, R 1 and R 1¼ without mixer E Stage 1 F Stage 2 G Stage H Min. proportional pressure K Max. proportional pressure L Min. constant pressure M Max. constant pressure VITOVLOR 00-P VIESMNN 21

22 Installation accessories (cont.) Manifold With thermal insulation. For wall mounting with separately ordered wall mounting bracket. The connection between boiler and manifold must be made on site. For 2 Divicon Part no for Divicon R ¾ and R 1. Pressure drop HV 120 HR 180 HV 120 HR G 1½ G 1½ Pressure drop mbar 10 0 kpa Flow rate in m³/h 2.5 HV 120 HR G 1½ Rp ¾ Manifold for Divicon R ¾ and R 1 Manifold for Divicon R 1¼ Connection option for expansion vessel HV Heating water flow HR Heating water return Part no for Divicon R 1¼. 495 HV 120 HR 180 HV 120 HR G 1½ G 1½ G 2 HV Rp ¾ G 2 HR Connection option for expansion vessel HV Heating water flow HR Heating water return 22 VIESMNN VITOVLOR 00-P

23 Installation accessories (cont.) For Divicon Part no for Divicon R ¾ and R 1. Pressure drop 784 HV HR HV HR HV HR G 1½ G 1½ G 1½ G 1½ 120 HV HR Rp ¾ Pressure drop mbar 10 0 kpa Flow rate in m³/h 2.5 Connection option for expansion vessel HV Heating water flow HR Heating water return Part no for Divicon R 1¼ Manifold for Divicon R ¾ and R 1 Manifold for Divicon R 1¼ 784 HV HR HV HR HV HR G 1½ G 1½ G 1½ HV G 2 G 2 HR Rp ¾ Connection option for expansion vessel HV Heating water flow HR Heating water return Wall mounting bracket Part no For individual Divicon. With screws and rawl plugs. Part no For manifold. With screws and rawl plugs. a a For Divicon With mixer Without mixer a mm For Divicon R ¾ and R 1 R 1¼ a mm VITOVLOR 00-P VIESMNN 2

24 Installation accessories (cont.) Low loss header Part no Max. flow rate 4.5 m /h. With thermal insulation and integral sensor well. The connection between boiler and low loss header must be made on site HV 120 HR 447 Pressure drop Pressure drop mbar kpa Flow rate in m³/h HV G 1½ 50 Rp 1 HR Sensor well Optional blow-down HV Heating water flow HR Heating water return Part no Max. flow rate 7.5 m /h. With thermal insulation and integral sensor well. The connection between boiler and low loss header must be made on site. 295 HV G 2 HR Pressure drop Pressure drop mbar kpa Flow rate in m³/h HV G Rp 2 HR 24 VIESMNN VITOVLOR 00-P

25 Installation accessories (cont.) Mixer extension kit in conjunction with Divicon heating circuit distributor Part no Flow temperature sensor (immersion sensor) Components: Mixer PC with mixer motor Flow temperature sensor (immersion sensor for installation in the Divicon) Connection plug for heating circuit pump, power supply, flow temperature sensor and KM US connection Mixer PC Specification, flow temperature sensor Lead length 0.9 m, fully wired IP rating IP 2 to EN 60529; ensure through design/installation Sensor type Viessmann NTC 10 kω at 25 C Permissible ambient temperature Operation 0 to +120 C Storage and transport 20 to +70 C 160 Mixer PC specification Rated voltage 20 V~ Rated frequency 50 Hz Rated current 2 Power consumption 5.5 W IP rating IP 2D to EN 60529; ensure through design/installation Safety category I Permissible ambient temperature Operation 0 to +40 C Storage and transport 20 to +65 C Rated relay output breaking capacity for heating circuit pumpsö 2(1), 20 V~ Runtime for 90 pprox. 120 s 2. Further accessories Note For accessories for the heating circuit distributor, see the technical guide Vitodens 200-W from 45 kw. Vitoflow automatic hydraulic balancing Service accessory with reusable components for quick and easy hydraulic balancing in single-family houses and apartment buildings (up to 6 units). See the Viessmann pricelist. Safety assembly to DIN 1988 For on-site installation on finished walls (DN 15, R ¾) Part no bar (1.0 MPa) Shut-off valve Non-return valve and test connector Pressure gauge (part no and ) or Pressure gauge connector (part no and ) Diaphragm safety valve VITOVLOR 00-P VIESMNN 25

26 Installation accessories (cont.) 2 Thermostatic DHW circulation set Part no. ZK For limiting the DHW outlet temperature in DHW heating systems with DHW circulation pipe Thermostatic mixing valve with bypass line Integral non-return valves Removable insulation shells R / Specification Connections R ¾ Weight kg 1.45 Temperature range C 5 to 60 Max. temperature of the medium C 95 Operating pressure bar 10 MPa 1 Non-return valve utomatic thermostatic mixing valve Part no For limiting the DHW outlet temperature in DHW heating systems without DHW circulation pipe. Specification Connections G 1 Temperature range C 5 to 60 C Max. temperature of the medium C 95 Operating pressure bar/mpa 10/1.0 Neutralising system Part no With neutralising granulate 10 DN Neutralising granulate Part no x 1. kg Condensate lifting system Part no. ZK utomatic condensate lifting system for condensate with a ph value 2.5 from gas condensing boilers 4 connection apertures 7 0 mm for condensate drain with connector 7 max. 40 mm) Drain hose 7 10 mm (5 m long) Components: Condensate container 2.0 l Centrifugal pump Non-return valve Connecting cable (1.5 m long) for fault messages Power cable (1.5 m long) with plug 26 VIESMNN VITOVLOR 00-P

27 Installation accessories (cont.) Specification Rated voltage 20 V~ Rated frequency 50 Hz Power consumption 70 W IP rating IP 20 Permissible medium temperature +65 C Max. head 50 kpa Max. pump rate 500 l/h larm contact Changeover contact (floating), breaking capacity 250 V/ Condensate drain 4 x condensate inlet with drain plug Heating water softening Part no To protect heating systems against scale deposits with fully or partially softened water Large soft water capacity for filling heating circuits with a volume of up to 750 l with soft water of < 0.1 dh (with untreated water hardness of 20 dh). Spent exchange resin can be disposed of with domestic waste. Digital capacity control Inlet & outlet side shut-off facilities Wall mounting bracket lending valve Cartridge with 4 l resin Specification Connection (male thread) R ½ Nominal pressure bar 10 MPa 1 Nominal flow rate 0.2 bar pressure m /h 0.5 differential (20 kpa) Operating pressure bar 1 to 6 MPa 0.1 to 0.6 Operating temperature C 0 to 0 Dry weight kg VITOVLOR 00-P VIESMNN 27

28 Installation accessories (cont.) Refill pack for heating water softening Part no With filling instructions and filling funnel 4 l litre capacity Filling case for mobile filling of heating system with softened water in accordance with VDI Part no Connection centre with 4 l cartridge for heating water softening FillCombi with integral system separation and pressure reducer 2 connection hoses R ½, 1.5 m, with quick coupling system Hardness testing kit Specification Max. operating pressure FillCombi bar 10 MPa 1 Connection centre bar 6 MPa 0.6 Max. operating temperature FillCombi input C 0 FillCombi output C 65 Connection centre C 0 Medium DHW CO limiter Part no. Z Monitoring device for safety shutdown of the boiler in the event of escaping carbon monoxide. Wall mounting in the ceiling area near the boiler Components: Casing with Integral CO sensor Mode, fault and alarm indicators coustic alarm system Communication cable for interface (2.5 m). Interface inside the casing with power cable (1.2 m) and connecting lead for burner shutdown relay (1.2 m) Fixing materials Specification Rated voltage 20 V~ Rated frequency 50 Hz Power consumption 2 W Rated breaking capacity 8 20 V~ of the relay output larm threshold 55 ppm CO to EN Protection class II VIESMNN VITOVLOR 00-P

29 Installation accessories (cont.) IP rating Permissible ambient temperature IP 20 to EN 60529; ensure through design/installation 0 C to 40 C Drain outlet kit Part no Drain outlet with trap and rose for connecting the drain lines of the safety valves and condensate drain Drain connection G 1 2 Connection bend DN 40 for condensate drain Part no Connection line from the appliance: DN 20 DI water Part no. ZK Distilled water for maintenance every 2 years 5 l litre capacity Dirt separator For installation in the heating circuit. When installing the Vitovalor 00-P, we recommend that you always install a dirt separator in the appliance return. See the Vitoset pricelist. Vitocharge, type S Flexible electricity marketing for maximising yield Standalone system for greater independence from electricity suppliers Ideal supplement to existing energy systems Mains substitution function for high supply reliability in the event of mains failure Combination with renewable energy system for charging electric vehicles Island mode for electrification of properties without a mains connection Vitocharge, type S with battery module, type.2 Efficient power storage unit with high charge and discharge rate Optimised use of on-site power in combination with a photovoltaic and/or CHP system to reduce electricity costs Vitocharge, type S20.0 with battery module, type 4.7 ttractively priced power storage unit with high battery capacity Ideal solution for detached houses to significantly increase utilisation of power generated on site and independence in combination with photovoltaic and heat pump systems Optimised use of on-site power in combination with a photovoltaic and/or CHP system to reduce electricity costs System for greater independence from electricity suppliers Ideal supplement to existing energy systems Mains substitution function for high supply reliability in the event of mains failure in combination with photovoltaic and fuel cell heating systems Note For further information about the Vitocharge, see the "Vitocharge" technical guide. VITOVLOR 00-P VIESMNN 29

30 Design information.1 Siting, installation Siting conditions for open flue operation (appliance type ) Vitovalor 00-P may only be used in room sealed operation. Siting conditions for room sealed operation (appliance type C) The Vitovalor 00-P can be installed as equipment type C 2x, C 52x or C 92x to CEN/TR 1749 for room sealed operation independent of size and ventilation of the installation room. Installation is possible in the following spaces: Recreation rooms and other living spaces Unventilated adjacent rooms Recesses without compulsory clearance towards combustible materials ttic rooms (pitched attics and long panes) where the balanced flue pipe can be routed directly through the roof Space requirement and minimum clearances Since the flue pipe connection piece for room sealed operation is surrounded by combustion air (coaxial pipe), no clearances to combustible parts need to be maintained (for further details, see the "Flue systems" chapter). The installation room must be safe from the risk of frost. Provide a condensate drain and a discharge pipe for the safety valve in the installation room. Electrical interlocks for extractors (extractor hoods, etc.) are not required with room sealed operation. The Vitovalor 00-P must be installed with the gas condensing module downstream from the fuel cell module in the flue gas flow direction. Note Minimum room height 2047 mm Fuel cell module to the left of the gas condensing module Observe the minimum clearances for maintenance or service work. Fuel cell module to the right of the gas condensing module Wiring area Wiring area Installation preparations If possible, leave the fuel cell module and the gas condensing module on the pallet during handling. 0 VIESMNN VITOVLOR 00-P

31 Design information (cont.) Fuel cell module When transporting the fuel cell module, keep it upright at all times if possible and only set it down on the pallet or its base. Thanks to further advances in technology, the appliance no longer needs to be monitored with tilt indicators while being transported. The appliance must be transported in an upright position. When handling the appliance, however, there is no restriction with regard to tilting. Note To avoid damage to the equipment, always keep the appliance base lower than the appliance top when transporting it up or down stairs. ppliance top Gas condensing module Note To avoid damaging the appliance during transport, never lay the gas condensing module on its front or side, or subject it to pressure. If space constraints make it necessary, the gas condensing module can be split for handling..2 Electrical connection The electrical connection and commissioning must be carried out by a qualified authorised electrician in line with applicable regulations and technical connection conditions. The power supply must comply with the requirements of your local power supply utility and current VDE [or local] regulations. Select cable cross-sections in accordance with applicable DIN VDE [or local] regulations: See page 7. The specifications in this technical guide are minimum requirements. Install an isolator in the power cable which simultaneously isolates all non-earthed conductors from the mains with contact separation of at least mm. The main circuit breaker integrated into the Vitovalor 00-P fulfils this function. Provide a separate fuse/mc for the Vitovalor 00-P. It must not be connected to the same supply as other consumers. To enable the energy manager to record the energy consumption in the building, the enclosed bidirectional meter must be installed in the domestic distribution box and connected. Recommended connecting cable for bidirectional meter Vitovalor 00-P: J-Y(ST)Y 2 x 2 x 0.8 Power cables and accessories are connected at terminals inside the respective connection enclosures of the Vitovalor 00-P. Ensure the low resistance of the earth connection. To ensure that the Vitovalor 00-P can be operated via the Vitotrol app, there must be a LN socket in the vicinity of the installation location. Never start the Vitovalor 00-P prior to commissioning by a qualified contractor. Operation of the Vitovalor 00-P in wet rooms The Vitovalor 00-P is approved for protection rating IP 20 and must not be installed in wet rooms. Vitovalor 00-P in mains parallel mode During operation of the Vitovalor 00-P, 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 00-P 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: Current technical connection conditions for connections to the LV grid. These connection conditions must be obtained from the relevant power supply utility. The applicable DIN VDE guidelines, specifically DIN VDE 0100, Part 701, DIN VDE , DIN VDE and DIN VDE R-N 4105 Connect the power supply (20 V/50 Hz) via a permanent connection. Regulations on safety at work and those of appropriate trade associations LV connection ordinances as well as supplementary conditions of the relevant grid operator ny applicable statutory or local regulations Only for E: The Vitovalor 00-P must not be connected in the supply area of a TT network. Notify the local grid operator before commissioning the Vitovalor 00-P. We recommend you contact the local grid operator prior to installation and clarify any technical points as well as the acceptance procedure. Hand the relevant application forms as per VDE R-N 4105 [or local regulations] to the relevant grid operator. pplication forms [for German grid operators] are available at VITOVLOR 00-P VIESMNN 1

32 Design information (cont.) Note Different documentation may be required by grid operators in other regions. Metering generated power net C meter (Z2) is integrated into the Vitovalor 00-P. This meter captures total electrical power generated, minus that consumed by the Vitovalor 00-P itself. The meter is MID-calibrated and is approved for billing according to DIN VDE R-N 4105: and the German CHP ct (KWKG). The calibration of the integral meter is valid for 8 years. fter 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 LV 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. rrangement of excess export system when connected into a sub-distribution board H kwh Z kwh Z1 G RCD K F RCD kwh Z2 1~ ~ E M D C N 400 V / 20 V~L Vitovalor 00-P Internal circulation pump C Internal consumers D GS protection E ON/OFF switch F Sub-distribution board G On-site consumers H Meter cupboard K Property boundary L Low voltage grid M Inverter (DC/C converter) S EMX = 1.5 kv N Fuel cell stack Z1 alancing bidirectional meter Z2 Net electricity meter (standard delivery Vitovalor 00-P) Z idirectional energy management meter (not relevant for billing by the grid operator) rrangement of excess export when connected into a main LV distribution board kwh Z kwh Z1 G F RCD RCD kwh Z2 1~ ~ E M D C N H C 400 V / 20 V~K Vitovalor 00-P Internal circulation pump C Internal consumers D GS protection E ON/OFF switch F Meter cupboard G On-site consumers H Property boundary K Low voltage grid M Inverter (DC/C converter) S EMX = 1.5 kv N Fuel cell stack Z1 alancing bidirectional meter Z2 Net electricity meter (standard delivery Vitovalor 00-P) Z idirectional energy management meter (not relevant for billing by the grid operator) 2 VIESMNN VITOVLOR 00-P

33 Design information (cont.) Property boundaries and transfer point without power storage system 400 V / 20 V~ E F kwh Z1 C D kwh Z H G K L M kwh Z2 1~ 1~/N/PE N ~ O P Source: VDE R-N 4105 Low voltage grid Main power supply C Domestic distribution box D Property boundary E Grid operator F Customer G Power distribution H On-site consumers K Short circuit protection L Overload protection, RCD M Vitovalor 00-P N GS protection O Inverter (DC/C converter) S EMX = 1.5 kv P Fuel cell Z1 alancing bidirectional meter (observe meter circuit) Z2 Net electricity meter (standard delivery Vitovalor 00-P) Z idirectional energy management meter (not relevant for billing by the grid operator) VITOVLOR 00-P VIESMNN

34 Design information (cont.) Property boundaries and transfer point with power storage system 400 V / 20 V~ E F kwh Z1 C D kwh Z4 kwh Z G H K L U V ~ kwh Z2 1~ 1~/N/PE M N ~ O P Source: VDE R-N 4105 Low voltage grid Main power supply C Domestic distribution box D Property boundary E Grid operator F Customer G Power distribution H On-site consumers K Short circuit protection L Overload protection, RCD M Vitovalor 00-P N GS protection O Inverter (DC/C converter) S EMX = 1.5 kv P Fuel cell U Power storage system inverter V Power storage unit Z1 alancing bidirectional meter (observe meter circuit) Z2 Net electricity meter (standard delivery Vitovalor 00-P) 4 Z idirectional VIESMNN energy management meter (not relevant for billing VITOVLOR 00-P by the grid operator) Z4 idirectional power storage management meter (power storage

35 Design information (cont.) Connection for excess export without power storage system, with photovoltaic system On-site energy consumption to paragraphs and 4() CHP [Germany] 400 V / 20 V~ C E F kwh Z1 D Zb Z2a G G kwh Z K K L L H M 1~/N/PE kwh Z2b 1~/N/PE N R O ~ ~ S P T = Low voltage grid Main power supply C Domestic distribution box D Property boundary E Grid operator F Customer G Power distribution H On-site consumers K Short circuit protection L Overload protection, RCD M Vitovalor 00-P N GS protection O Inverter (DC/C converter) S EMX = 1.5 kv P Fuel cell R GS protection for PV system S PV inverter T Photovoltaic system Z1 alancing bidirectional meter (observe meter circuit) Electricity meter for power export and drawing Z2a Export/generation meter, PV system power generation Z2b Export/generation meter for power generation by Vitovalor 00-P (standard delivery with Vitovalor 00-P) Z idirectional energy management meter (optional, not relevant to billing by the grid operator) Zb Export/generation meter for Vitovalor 00-P alone VITOVLOR 00-P VIESMNN 5

36 Design information (cont.) Connection for excess export with power storage system and photovoltaic system On-site energy consumption to paragraphs and 4() CHP [Germany] 400 V / 20 V~ C E F kwh Z1 D kwh Z4 kwh Zb Z2a kwh Z G K L G K L H M 1~/N/PE kwh Z2b 1~/N/PE U ~ V N R O ~ ~ S P T = Low voltage grid Main power supply C Domestic distribution box D Property boundary E Grid operator F Customer G Power distribution H On-site consumers K Short circuit protection L Overload protection, RCD M Vitovalor 00-P N GS protection O Inverter (DC/C converter) S EMX = 1.5 kv P Fuel cell R GS protection for PV system S PV inverter T Photovoltaic system U Power storage system inverter V Power storage unit Z1 alancing bidirectional meter (observe meter circuit) Electricity meter for power export and drawing Z2a Export/generation meter, PV system power generation Z2b Export/generation meter for power generation by Vitovalor 00-P (standard delivery with Vitovalor 00-P) 6 VIESMNN VITOVLOR 00-P

37 Design information (cont.) Z idirectional energy management meter (optional, not relevant to billing by the grid operator) Zb Export/generation meter for Vitovalor 00-P alone Z4 idirectional power storage management meter (power storage system standard delivery) Cable sizing Inadequate cross-sections result in yield losses when generating power. Consequently, select larger cross-sections for the Vitovalor 00-P power cable than is technically required. Cross-sections recommended in line with economic considerations: Cable lengths in m Recommended cable 5 NYM x 2.5 mm 2 > 5 55 NYM x 4 mm 2 > NYM x 6 mm 2 Sample calculation of the maximum cable length considering impedance and voltage drop Rated voltage 20 V~ Rated current Vitovalor 00-P. External grid impedance, building and supply 00 mω network Z 1 (assumption) Impedance downstream of protection Z mω Total impedance Z V = Z 1 + Z mω Maximum voltage drop 1 % Selected cross-section 2.5 mm 2 Selected MC 10 The maximum cable length for observing the shutdown conditions to DIN VDE is based on supplementary sheet 2 to DIN VDE with the following relevant parameters: Length correction due to external impedance: ΔI = (Z VO Z V ) fl = (00 mω 400 mω) 0.5 m/10 mω = 5 m Max. permissible length l max1 : 227 m 5 m = 222 m The following applies to the maximum required voltage drop of 1 % ( 2. V): l max2 = (ΔU Κ ) / (2 I cosφ) = (2. V 56 m/ωmm mm 2 ) / (2. 1) = 49 m I max2 is < I max1 ; therefore the max. cable length for NYM 2.5 mm 2 = 49 m for economical reasons Fuse protection The Vitovalor 00-P has been factory-tested as a unit that is ready for connection. Only an adequately sized power cable needs to be connected on site. This cable should be routed either to the main LV distribution board (mains distribution or meter cupboard) or to the nearest suitable sub-distribution board. The Vitovalor 00-P is protected by a mains isolator. Depending on the nature of the domestic grid, or as required by DIN VDE , a residual current device (RCD) may also be required. Mains isolator: response characteristics 1-pole Response current 10 Design breaking capacity to EN 60898: 10 k Design voltage 20 V/400 V RCD: RCD 25 2-pole For C and pulsating DC fault currents Design residual current 0 m Design voltage 20/400 V Surge current resistance 1 k Never install the Vitovalor 00-P downstream of existing fuses/ MCs. In the case of a consumer short circuit there is a risk that high currents may flow which are impermissible and load the cables to excess. The heating system emergency shutdown must not be installed in a new installation. In older buildings, the existing emergency shutdown must be removed. During installation, the electrician must also test the selectivity of the residual current device (RCD) and the protective equipment (overload/short circuit protection) VITOVLOR 00-P VIESMNN 7

38 Design information (cont.) D E kwh Z RCD C RCD RCD F kwh Z2 1~ kwh Z1 L G H M N ~ 400 V / 20 V~K Example: Selective sizing of the protective devices RCD (on site) e.g. 40 /0.5, 4-pole On-site consumers C Fuse/MC to the sub-distribution board, e.g. x 5 D On-site consumers E Vitovalor 00-P F RCD Vitovalor 00-P 25 /0 m, single pole (if required) G Selective mains circuit breaker x 6 H Property boundary K Low voltage grid L GS protection M Inverter (DC/C converter) S EMX = 1.5 kv N Fuel cell stack Z1 alancing bidirectional meter (observe meter circuit) Z2 Net electricity meter (standard delivery Vitovalor 00-P) Z idirectional energy management meter (not relevant for billing by the grid operator) Ensure adequate selectivity if any new RCD is installed downstream of any existing circuit breaker. In order to ensure complete selectivity of two residual current devices connected in series, the fault current of upstream RCD must be at least times as high as that of RCD F used to protect the Vitovalor 00-P. djust the activation times of both RCDs connected in series such that the disconnection time of RCD F is less than the shortest disconnection time for RCD. oth conditions ensure that RCD F of the Vitovalor 00-P responds earlier than upstream RCD F t in s l in Response characteristics of the residual current devices. Gas connection Gas installations must only be carried out by a qualified contractor authorised by the relevant gas supply utility. Connect and size the mains gas according to CEN/TR 1749 and TRF 1996 [or local regulations]. a Connect the mains gas according to ÖVGW-TR Gas (G1) and the regionally applicable uilding Regulations. Max. test pressure 150 mbar. We recommend installing a gas filter to DIN 86 into the gas supply line. 8 VIESMNN VITOVLOR 00-P

39 Design information (cont.) Gas supply pipe The following table is designed to assist in the approximate sizing of the on-site gas supply pipe. For each 90 bend 1 m is deducted from the max. possible pipe length. We recommend a final calculation in accordance with CEN/TR 1749 and TRF. Sizing of the on-site gas supply line for natural gas E Gas type Connection value in m /h Nominal diameter of the gas supply pipe DN 15 DN 20 DN 25 Max. possible pipe length in m Natural gas E Natural gas LL Thermally activated safety shut-off valve ccording to paragraph 4, section 5 of the FeuVo 2008 [or local regulations], thermally activated shut-off equipment must be installed in combustion equipment or in gas supply lines immediately upstream of the combustion equipment. This shut-off equipment must interrupt the gas supply if the external temperature exceeds 100 C. The valves must isolate the gas supply for at least 0 min up to a temperature of 650 C. This is intended to prevent the formation of explosive gas mixtures in the event of a fire. Sizing recommendation, gas flow switch In supply areas with H I below 8.6 kwh/m and gas appliances compliant with category I 2N, determine a fictitious rated heat input. This fictitious rated heat input results from the rated heat input (Q N ) of the appliance, multiplied by a factor of 1.2 (ratio H I 8.6/7.0 kwh/m ). Select the gas flow switch and size the pipework to CEN/TR 1749 [or local regulations] using this fictitious rated heat input. The gas shut-off valve supplied for the Vitovalor 00-P is equipped with an integral thermally activated safety shut-off valve. Recommendation: Gas flow switch GS 6 The sizing recommendation for the gas flow switch does not negate the requirement for sizing the pipework correctly..4 DHW heating Information on water quality During DHW heating, settling of lime on the surfaces of the plate heat exchanger cannot be completely prevented. The tendency towards limescale build-up depends on various conditions, predominantly on the substances contained in the water, the amount of water that is heated (DHW consumption) and the DHW temperature. lthough scale deposits inside the plate heat exchanger are generally minor enough not to cause any reduction in DHW output, such impairment cannot be excluded with increased water hardness. From a water hardness of 20 dh (.5 mol/m ) and higher, we therefore recommend the use of DHW cylinders with internal indirect coils or a water treatment system in the cold water supply when heating DHW. Please note that regional water supply utilities frequently specify an average water hardness. Higher levels of water hardness may therefore occur from time to time. This may make the use of a water treatment facility advisable even from 17 dh (>.0 mol/m ) upwards. Note If the DHW convenience set is used and DHW consumption is greater than 250 l/day, we recommend installing a water treatment system. ccording to DIN 1988, a water treatment system should be installed if the water hardness is > 14 dh. Otherwise increased limescale deposits may occur in the plate heat exchanger of the Vitovalor 00-P, which will require more extensive maintenance..5 Condensate connection Route the condensate pipe with a constant fall to the public sewage system. Route the condensate from the flue system (if equipped with a drain) together with the condensate from the fuel cell module and the gas condensing module directly or (if required) via a neutralising system (accessory) to the public sewage system. Note pipe vent valve must be installed between the trap and the neutralising system. VITOVLOR 00-P VIESMNN 9

40 Design information (cont.) CD Condensate drain pipe, fuel cell module Condensate drain pipe, gas condensing module C Drain outlet kit, accessory D Public sewage system Condensate drain pipe and neutralisation Drain the condensate created during heating operation in the gas condensing module and in the flue pipe, in accordance with appropriate regulations. With gas combustion, the ph values are between 4 and 5. Code of Practice DW- 251 on "Condensate from condensing boilers" determines conditions for draining condensate from condensing boilers into the public sewer system. This Code of Practice is generally based on the local waste water regulations [in Germany]. The composition of condensate drained from the Vitovalor 00-P meets the requirements specified in Code of Practice DW The condensate drain pipe to the sewer connection must be freely accessible for inspection. It must be installed with a continuous fall and must contain a stench trap. lso provide a suitable facility for sampling. Condensate drain pipes may only be made from corrosion-resistant materials (e.g. reinforced hose). Never use any zinc-plated materials or those containing copper for pipes, connection pieces, etc. trap is installed in the condensate drain to prevent flue gases escaping. Local water regulations and/or specific technical circumstances may prescribe designs, which vary from those described in the above Codes of Practice. Contact your local authority responsible for waste water management in good time prior to installation, to find out about local regulations. ccording to the Code of Practice DW- 251, these materials include: Clay pipes Hard PVC pipes PVC pipes PE HD pipes PP pipes S/S pipes Stainless steel pipes orosilicate pipes Condensate from gas combustion equipment up to 200 kw combustion output Up to a rated heating output of 200 kw, the condensate from a gas condensing boiler can generally be introduced into the public sewage system without prior neutralisation. lso ensure that your domestic drainage systems are made from materials that are resistant to acidic condensate. 40 VIESMNN VITOVLOR 00-P

41 Design information (cont.) Neutralising system Install a condensate lifting system (accessory) if the Vitovalor 00-P has been installed below the waste water anti-flooding level. Since the consumption of neutralising granulate depends on the operating mode of the system, carry out regular checks during the first year of operation to determine the required top-up volume. One fill can last longer than one year. Condensate lifting system (accessory) C Condensate drain Neutralising system Where required, a separate neutralising system (accessory) can be supplied. ny condensate is piped to and processed in the neutralising system. The condensate drain pipe to the sewer connection must be accessible for inspection. Install it with a fall and a stench trap on the sewer side, and provide a suitable facility for extracting samples. Condensate inlet Condensate lifting system C Condensate drain.6 Hydraulic connection General System design Viessmann condensing boilers can generally be installed in any fully pumped hot water heating system (sealed unvented system). The circulation pump is an integral part of the appliance. Minimum system pressure 1.0 bar (0.1 MPa) The boiler water temperature is limited to 82 C. The heat generator must be correctly sized and designed. To minimise distribution losses, we recommend sizing the heat distribution system to a max. flow temperature of 70 C. Chemical anti-corrosion agents In correctly installed and operated sealed unvented heating systems corrosion is generally avoided. Never use chemical anti-corrosion additives. Some manufacturers of plastic pipes recommend the use of chemical additives. In such cases, only use anti-corrosion additives offered by the heating trade that have been approved for boilers with DHW heating via single-walled heat exchangers (instantaneous water heater or DHW cylinder). Observe VDI guideline 205. Heating circuits For heating systems with plastic pipes, we recommend the use of impermeable pipes to prevent the diffusion of oxygen through the pipe walls. Provide system separation in heating systems with plastic pipes that are permeable to oxygen (DIN 4726). We supply separate heat exchangers for this purpose. Install a dirt separator in underfloor heating systems; see the Vitoset pricelist. Underfloor heating systems and heating circuits with very large water content (>15 l/kw) should be connected to the boiler, even if a condensing boiler, via a -way mixer. See the technical guide "Underfloor heating" or the "system examples". Install a temperature limiter in the flow of the underfloor heating circuit to restrict the maximum temperature. Observe DIN Plastic pipework for radiators In connection with plastic pipework for heating circuits with radiators, we also recommend installing a temperature limiter to restrict the maximum temperature. ttic heating centre The installation of a low water indicator, compulsory according to the DVGW [Germany], is not required when installing the Vitovalor 00-P in an attic heating centre. The gas condensing module is protected against water shortage in accordance with EN VITOVLOR 00-P VIESMNN 41

42 Design information (cont.) Safety valve safety valve in accordance with TRD 721 is integrated in the Vitovalor 00-P (opening pressure bar (0. MPa)). Route the discharge pipe in accordance with EN into a drain outlet (drain outlet kit available as an accessory). The drain outlet incorporates a siphon as a stench trap. Low water indicator ccording to EN 12828, a low water indicator can be omitted for boilers up to 00 kw, as long as heating can be reliably prevented when there is a water shortage. The Vitovalor 00-P is equipped with a low water indicator (boil-dry protection). Tests have verified that the burner will be automatically switched off in the event of water shortage due to a leak in the heating system and simultaneous burner operation, before the boiler or the flue system reaches unacceptably high temperatures. Water quality/frost protection Unsuitable fill and top-up water increases the level of deposits and corrosion and may lead to boiler damage. Observe VDI 205 [or local regulations] regarding quality and amount of heating water, including fill and top-up water. Flush the heating system thoroughly before filling. Only fill with water of potable quality. Fill and top-up water with a water hardness in excess of the following values must be softened, e.g. with the small softening system for heating water (see the Viessmann Vitoset pricelist): Total permissible hardness of the fill and top-up water Total heating Specific system volume output kw < 20 l/kw 20 l/kw to 50 l/kw < 50 l/kw 50.0 mol/m (16.8 dh) 2.0 mol/m (11.2 dh) < 0.02 mol/m (0.11 dh) > 50 to mol/m (11.2 dh) 1.5 mol/m (8.4 dh) < 0.02 mol/m (0.11 dh) For systems with a specific system volume in excess of 20 l/kw heating output, use the output of the smallest boiler in multi boiler systems. Special antifreeze (category 1 to ) suitable for heating systems can be added to the fill water. The antifreeze manufacturer must verify its suitability, since otherwise damage to gaskets and diaphragms can occur as well as noisy heating operation. Viessmann accepts no liability for any resulting damage or consequential losses. When designing the system, observe the following: Install shut-off valves in each section. This prevents the need for draining all the heating water in the case of repairs or system expansion. In systems > 50 kw, install a water meter to record the volume of fill and top-up water. Record the amount of water filled into the system and the water hardness. Operating information: Commission the system step by step, starting with the lowest boiler output and a high heating water flow rate. This prevents localised concentration of limescale deposits on the heating surfaces. In multi boiler systems, start all boilers simultaneously to prevent the total amount of limescale deposits settling in the heat exchanger of just one boiler. During expansion or repair work, only drain the necessary pipework sections. Where water treatment is required, treat even the first fill of the heating system prior to commissioning. This also applies to any subsequent filling, e.g. when adding top-up water or after a repair, or for any system expansion. Check, clean and activate filters, dirt traps and other blow down or separating facilities in the heating water circuit more frequently after commissioning and in new installations. Later on this can be carried out subject to the requirements of the water treatment applied (e.g. water softening). Installation examples For installation examples for the Vitovalor 00-P, see "System examples" technical guide. Expansion vessel In accordance with EN 12828, water heating systems must be equipped with a pressure expansion vessel. The size of the expansion vessel is subject to the heating system specification and should be determined to EN Determining the size of the expansion vessel The following steps will enable you to make a rough estimate. V DEV = f ((V + V K ) f + 2.4) V DEV = Volume of the expansion vessel f = Expansion factor (= 2 for expansion vessel) V = System volume V K = oiler water volume f = Heating water expansion factor Observe the specified system schemes. Heating system 50/0 C: verage water temperature approx. 40 C f = V DEV = 2 (( ) ) l V DEV = l Result: n expansion vessel with a capacity of at least 12 l must be installed in the system. Example: System with multi mode heating water buffer cylinder: Vitovalor 00-P oiler water volume 5 l Rated heating output 20 kw System volume approx. 450 l Heating system 50/0 C Calculation: 42 VIESMNN VITOVLOR 00-P

43 Design information (cont.) Calculating the heating system volume (approximate values) Calculating the expansion factor f verage water temperature in C Expansion factor f System volume in litres D C Heating output in kw Convectors Panel radiators C Radiators D Underfloor heating system.7 Low loss header pplication Design rules for system hydraulics: When balancing the low loss header, adjust the flow rate on the equipment side to approx. 10 to 0 % below the flow rate on the system side (reducing the return temperature). The low loss header should be sized for the max. flow rate which may occur in the overall system. The low loss header separates the heat generator circuit (boiler circuit) from the downstream heating circuits. Install a low loss header if the max. flow rate of an individual design is greater than the corresponding value shown in the "Specification" table. Note Only use a low loss header with a heating water flow rate > 1.2 m /h. Using it with lower heating water flow rates may lead to higher return temperatures. The runtimes of the Vitovalor 00-P may be reduced as a result. Principle of operation T1 Vprimary T2 T Vsecond. T4 For installation designs in conjunction with low loss headers, see "System examples". oiler circuit The circulation pump in Vitovalor 00-P must be able to supply the required water volume against the (mostly low) pressure drop of the boiler circuit. The pressure drop of the low loss header is negligible. The pump diagrams serve to determine the correct residual head for the internal pipe diameters, subject to the water volume circulating in the boiler circuit. Heating circuit The heating circuit pumps to be installed on site must be able to deliver the water volume in the heating circuits against their pressure drop. They must be sized accordingly. V primary V secondary T 1 T 2 T T 4 Q primary Q secondary V primary Heating water volume in the boiler circuit (approx. 10 to 0 % less than V secondary ) Heating water volume, heating circuit Flow temperature, boiler circuit Return temperature, boiler circuit Flow temperature, heating circuit Return temperature, heating circuit mount of heat supplied by the boiler mount of heat transferred by the heating circuit < V secondary T 1 > T T 2 T 4 Q primary = Q secondary VITOVLOR 00-P VIESMNN 4

44 Design information (cont.) Note Thermometers in the flow and return of the low loss header make adjustments easier. Low loss header in conjunction with Divicon Max. flow rate in m /h Low loss header R ¾ 4.5 R Divicon heating circuit distributor R ¾ 1.0 R HV HR C HR Heating return HV Heating flow HV HR HR Heating return HV Heating flow Divicon heating circuit distributor Manifold C Low loss header Low loss header from the Vitoset range See the Vitoset pricelist. 44 VIESMNN VITOVLOR 00-P

45 Design information (cont.) d e KV HV b c HR a KR HR Heating return HV Heating flow KR oiler return KV oiler flow Max. flow rate m /h 4 Connections, female thread Rp 1 Dimension a mm 500 b mm 60 c mm 270 d mm 80 e mm 50.8 Flue systems The following requirements regarding design and installation apply to flue systems for condensing combustion equipment: Prior to starting work on the flue system, your heating contractor should confer with the responsible flue gas inspector [where applicable]. Gas combustion equipment must be connected to the domestic chimney on the same floor where it is installed (no transition through separating ceilings). Here, differentiation is required as to whether the Vitovalor 00-P should be installed in the living space (occupied rooms) or in the non-living space (installation room). Siting in the living space is feasible, subject to the flue inside the living space being routed inside a protective pipe and being surrounded by ventilation air (balanced flue system, room sealed operation). The flue system is connected to the flue system pack of the Vitovalor 00-P. VITOVLOR 00-P VIESMNN 45

46 Design information (cont.) Fuel cell module to the left of the gas condensing module Fuel cell module to the right of the gas condensing module Flue system pack System certification System certification to DVGW-VP 11 and EC Gas ppliances Directive 2009/142/EC in conjunction with PPs flue pipes from Skoberne: CE-0085CM0150. The aforementioned conditions are generally met when one of the flue systems (accessories) that are CE designated with the Vitovalor 00-P is used. The following Viessmann balanced flue systems for room sealed operation are tested to DVGW and are CE designated with the Vitovalor 00-P: Vertical roof outlet External routing through a coaxial pipe The Vitovalor 00-P must only be operated with the flue systems approved by Viessmann and certified to EN 14471: See page 51 onwards. The flue pipe available as an accessory is CE designated and approved to EN Note cascade on the flue gas side is not possible with the Vitovalor 00-P. dvantages of single structural units: No calculated performance verification for flues to EN 184 is required in individual cases Simplified visual inspection by the local flue gas inspector every 2 years No additional approval certificate by the flue pipe manufacturer is required Room sealed operation The sealed combustion chamber of the Vitovalor 00-P micro CHP units enables their use in room sealed operation. They are categorised as C 2x, C 52x or C 92x according to CEN/TR common approval for the Vitovalor 00-P and balanced flue system applies to these types of appliance. The tightness test (overpressure test) by the flue gas inspector during commissioning as well as the verification of the "General uilding Regulations approval" by the DIt may be omitted for this type of construction. Every approved flue system can be used for type C 62x. This flue system is not tested together with the Vitovalor 00-P. Maintain the dimensions specified from page 51. The combustion air is supplied and the flue gas extracted through one concentric coaxial pipe (balanced flue system). The combustion air is supplied through the annular gap between the external aluminium ventilation air pipe and the flue pipe. Flue gases are extracted through the internal plastic pipe (PPs). For balanced flue systems tested together with the Vitovalor 00-P, there is no requirement for a tightness test (overpressure test) during commissioning by the flue gas inspector. In this case, we recommend that your heating contractor carries out a simple tightness test during the commissioning of your system. For this it would be sufficient to check the CO 2 concentration in the combustion air at the annular gap of the balanced flue pipe. The flue pipe is deemed to be gas-tight if the CO 2 concentration in the combustion air is no higher than 0.2 % or the O 2 concentration is at least 20.6 %. Check the flue system for tightness by pressure testing if higher CO 2 or lower O 2 values are established. In conjunction with the concentric twin pipe (balanced flue system), the surface temperature of the Vitovalor 00-P or that of the balanced flue system will never exceed 85 C. Therefore, clearances to combustible components according to CEN/TR 1749 are not required. 46 VIESMNN VITOVLOR 00-P

47 Design information (cont.) Install the connection lines (horizontal distribution) with a fall of at least to the boiler. We recommend using clips spaced about 1 m apart to support the connection line. The balanced flue system is CE designated and approved to EN 14471: See page 46. The boiler casing creates a system that is sealed against its surroundings. ny leaks caused by escaping flue gas are returned via the combustion air, thereby preventing flue gas from entering the living space. ccording to CEN/TR 1749, flues that bridge several floors must be routed inside a shaft with a fire rating of at least 90 min, and for buildings in categories 1 and 2, a fire rating of at least 0 min. The flue gas/ventilation air is routed in a balanced flue pipe up to the chimney or shaft. The flue pipe is then routed inside the chimney or shaft to above the roof. Ventilation air ducts with which oil or solid fuel boilers were previously used must not contain any sulphur or soot deposits on the inner surfaces of the chimney. Sulphur and soot deposits cause faults. If thorough cleaning is not possible, a balanced flue pipe must be laid through the shaft. lternatively, a separate balanced flue can be routed. Viessmann accepts no liability for damages caused by a failure to observe these stipulations. Where no suitable shaft is available, the flue may be routed to the roof through a retrofitted shaft. For this shaft, a uilding Regulations test certificate or a CE designation corresponding to the design of the shaft is required. The shaft must have a fire rating of L0 or L90. Flue gas high limit safety cut-out ccording to CE designation to EN the plastic flue pipe (PPs) can be used for flue gas temperatures of up to 120 C (type ). Measures inside the equipment ensure that the flue gas temperature of 90 C will never be exceeded. Lightning protection If a lightning protection system is installed, any metallic flue system should be included in the lightning protection scheme. flue gas high limit safety cut-out is therefore not required. VITOVLOR 00-P VIESMNN 47

48 Design information (cont.) CE designation for the PPs flue systems (rigid and flexible) 48 VIESMNN VITOVLOR 00-P