Installation and service instructions for contractors VIESMANN Vitocal 300-A Type AWO-AC 301.B11 to B14 Air/water heat pump with electric drive, 400 V~ For applicability, see the last page VITOCAL 300-A 5/2014 Please keep safe.
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger This symbol warns against the risk of injury.! Please note This symbol warns against the risk of material losses and environmental pollution. Note Details identified by the word "Note" contain additional information. Target group These instructions are exclusively intended for qualified contractors. Work on the refrigerant circuit may only be carried out by authorised refrigeration engineers. Work on electrical equipment must only be carried out by a qualified electrician. The system must be commissioned by the system installer or a qualified person authorised by the installer.! Please note Electronic assemblies can be damaged by electrostatic discharge. Before beginning work, touch earthed objects, such as heating or water pipes, to discharge static loads. Repair work! Please note Repairing components that fulfil a safety function can compromise the safe operation of your system. Defective components must be replaced with genuine Viessmann spare parts. Auxiliary components, spare and wearing parts Please note! Spare and wearing parts that have not been tested together with the system can compromise its function. Installing non-authorised components and making non-approved modifications or conversions can compromise safety and may invalidate our warranty. For replacements, use only spare parts supplied or approved by Viessmann. Regulations Observe the following when working on this system: National installation regulations Statutory regulations regarding the prevention of accidents Statutory regulations regarding environmental protection Codes of practice of the relevant trade associations. All current safety regulations as defined by DIN, EN, DVGW, VDE and all locally applicable standards a ÖNORM, EN and ÖVE c SEV, SUVA, SVTI, SWKI and SVGW Working on the system Isolate the system from the power supply (e.g. by removing the separate fuse or by means of a mains isolator) and check that it is no longer 'live'. Note In addition to the control circuit, there may be several power circuits. Danger Contact with 'live' components can result in severe injuries. Some components on the PCBs will remain 'live' even after the power supply has been switched off. Prior to removing equipment covers, wait at least 4 min. to allow the voltage to dissipate. Safeguard the system against reconnection. 2
Index Index 1. Preparing for installation Intended use... 5 Requirements concerning on-site connections... 6 Siting requirements... 6 Requirements of the heat pump installation site... 7 Requirements for the heat pump control unit installation location... 7 Minimum clearances... 7 Foundation... 7 Cables and hydraulic lines... 10 2. Installation sequence Installing the heat pump... 13 Making the hydraulic connections... 13 Connect heating water flow and heating water return at the heat pump... 13 Connect heating circuits and DHW cylinder in the building... 14 Fitting the flow temperature sensor, secondary circuit... 14 Connecting the condensate drain... 15 Electrical connections, heat pump... 16 Opening the wiring chamber... 16 Connecting cables... 17 Electrical connections, heat pump control unit... 19 Fitting the heat pump control unit and inserting cables... 19 Connecting cables... 23 Adapting the heat pump control unit... 23 Plugging in the coding card... 24 Overview of electrical connections... 25 Main PCB... 26 Expansion PCB... 29 Cross connect PCB... 32 Controller and sensor PCB... 34 Power supply... 36 Heat pump control unit power supply 230 V~... 37 Compressor power supply 400 V~... 37 Power supply with power-off... 38 Mains power supply in conjunction with on-site power consumption. 40 Closing the heat pump... 40 3. Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance... 43 4. Troubleshooting Repairs... 56 Overview of electrical components... 56 Removing the side panel... 56 Overview of internal components... 57 Draining heat pump on the secondary side... 57 Checking sensors... 57 Checking MCB/fuses... 59 5. Parts lists Overview of assemblies... 60 Casing... 60 Base frame... 61 Heat pump module... 63 Additional components... 65 Air module... 66 Miscellaneous... 67 Electrical equipment... 68 Heat pump control unit... 69 6. Commissioning/service reports Hydraulic parameter report... 72 Control parameters report... 72 3
Index Index (cont.) 7. Specification... 79 8. Appendix Commissioning order... 81 9. Certificates Declaration of conformity... 82 10. Keyword index... 83 4
Intended use Preparing for installation The appliance is only intended to be installed and operated in sealed unvented heating systems that comply with EN 12828, with due attention paid to the associated installation, service and operating instructions. Depending on the version, the appliance can only be used for the following purposes: Central heating Central cooling DHW heating The range of functions can be extended with additional components and accessories. Intended use presupposes that a fixed installation in conjunction with permissible, system-specific components has been carried out. Commercial or industrial usage for a purpose other than central heating/cooling or DHW heating shall be deemed inappropriate. Any usage beyond this must be approved by the manufacturer for the individual case. Incorrect usage or operation of the appliance (e.g. the appliance being opened by the system user) is prohibited and results in an exclusion of liability. Incorrect usage also occurs if the components in the heating system are modified from their intended function. Note The appliance is intended exclusively for domestic use, i.e. even users who have not had any instruction are able to operate the appliance safely. Installation 5
Preparing for installation Requirements concerning on-site connections 100 211 1998 Installation D 300 370 490 B A C 945 B/C Ø 1100 Fig. 1 A Cable entries B Heating water flow (connection R 1¼) C Heating water return (connection R 1¼) D Condensate drain hose (flexible) Siting requirements! Please note Prevent damage to the appliance during handling. Never put weight on the top, front or side panels of the appliance.! Please note Tilting the compressor at a steep angle inside the heat pump can result in appliance damage. Max. tilting angle 45 6
Preparing for installation Siting requirements (cont.) Requirements of the heat pump installation site The heat pump may only be sited outside the building on solid foundations (see page 7). Provide a manual drain for the heating water flow and return lines in any area at risk from frost. Drain the system if the heat pump is shut down or there is a prolonged power failure. If the heat pump control unit, secondary pump and heating circuit pumps are ready for operation, the frost protection function of the heat pump control unit is enabled. In heat pump systems where a power failure would not be detected, e.g. holiday home: operate the heating circuit with a suitable antifreeze or drain the heating circuit. To prevent an increase in noise level due to reflection, avoid siting equipment in recesses, at building corners or between 2 walls. Lawn areas and vegetation can reduce noise development. Only the heat pump foundations should therefore be made from reverberant material (concrete). Never install the heat pump next to living rooms or bedrooms. The air in the discharge area is approx. 10 K colder than the ambient air. Therefore, black ice could develop in the discharge area even at [ambient] temperatures above freezing. Clearance to paths or patios: 3 m Installation Requirements for the heat pump control unit installation location The heat pump control unit may only be installed inside the building on a wall (see page 19). Please note! The installation room must be dry and free from the risk of frost. Ensure ambient temperatures between 0 and 35 C.! Please note Risk of explosion due to dust, gases and vapours. Avoid dust, gases and vapours in the room. Minimum clearances 1500 1500 1500 1500 Fig. 2 Foundation Site the heat pump level on a durable and solid base. We recommend laying a concrete foundation as described in the following chapters. The thickness of cover represents an average value and should be matched to local conditions. This must be done in accordance with the standard rules of building engineering. No recess in the foundation for cables and hydraulic lines required. Design the foundations, mounting surface and pipework in such a way as to prevent small animals from entering the heat pump and the cable ducts. 7
Preparing for installation Siting requirements (cont.) Drain all condensate derived from the air via a DN 40 drain pipe, which must be protected from frost and provide a constant fall. Amount of condensate: Subject to temperature and relative humidity, up to 20 l/h and up to 20 l in 5 min during defrosting. If possible connect the condensate drain to a drainage or sewer system. In this case, provide a siphon with a backup level of at least 60 mm in the frostprotected area. Where the ground is able to absorb water, the condensate can be soaked away down to a frost-free depth into a gravel bed. Where appropriate, provide thermal insulation or a ribbon heater around the condensate drain pipe on site. Dimensions Technical guides for heat pumps Weight including outer casing: 250 kg 860 H H H 700 G F 83 53 70 Installation Fig. 3 198 291 E 411 514 D CB A 8
Preparing for installation Siting requirements (cont.) G E D B C F A Installation K H B H 300 500 K 900 400 400 G E C D Fig. 4 A Heat pump B Concrete foundation (300 mm thick) consisting of: Concrete slab C25/30, BSt 500 S and M Reinforcement with all-round wire mesh made of Q 257 A C KG conduit DN 100 for power cable 400 V/50 Hz (on site) D KG conduit DN 100 for connecting cables to the heat pump control unit (on site): Control cable 230 V~, LV cable < 42 V E Hydraulic connection set (accessory): Hydraulic connection lines for heating water flow and heating water return F Hydraulic connections on the heat pump (heating water flow and heating water return) G Condensate drain DN 40 (on site) H Soft ground, gravel or crushed stone K Frost protection (compacted crushed stone, e.g. 0 to 32/56 mm); layer thickness subject to local requirements and standard rules of building engineering 9
Preparing for installation Siting requirements (cont.) Cables and hydraulic lines Laying the lines underground and routing in through the exterior wall Installation U ON M B K T C D E F S O N MQR P P 400 EDC 900 ONM Fig. 5 B Concrete foundation (300 mm thick) consisting of: Concrete slab C25/30, BSt 500 S and M Reinforcement with all-round wire mesh made of Q 257 A C KG conduit DN 100 for power cable 400 V/50 Hz (on site) D KG conduit DN 100 for connecting cables to the heat pump control unit (on site): Control cable 230 V~, LV lead< 42 V E Hydraulic connection set (accessory): Connection lines for heating water flow and heating water return F Condensate drain DN 40 (on site) K Frost protection (compacted crushed stone, e.g. 0 to 32/56 mm); layer thickness subject to local requirements and standard rules of building engineering M Power cable, compressor/fan (3/N/PE 400 V/ 50 Hz, on site) Recommended cable: 5 x 2.5 mm 2, flexible N 2 connecting cables inside DN 100 KG conduit (on site), fully wired (5, 15 or 30 m): Control cable 230 V~ LV lead < 42 V Note The maximum cable length is 30 m. Extensions are not permissible. O Hydraulic connection lines (heating water flow and heating water return) 10 P Underground channel Q Wall duct with expanding mortar (on site) for hydraulic connection line R Moisture-proof and waterproof wall ducts (on site) S Drain & fill facility with shut-off valve (for draining with compressed air) T Expansion vessel with safety assembly (accessories) U Clearance, house wall foundations: Maximum clearance depends on length of the connecting cables and hydraulic connection lines: Max. 23 m Maintain the minimum clearance to other objects (> 1.5 m) when siting. Heating water connection (hydraulic connection lines O) Use the hydraulic connection set (accessory). The connection set is fully prepared in different lengths. The flow and return lines are flexible and have 2 adaptors each. The lines are located inside a common thermal insulation. Flow/return line: 2 x DN 32 Adaptor fittings: DN 32 to R 1¼
Preparing for installation Siting requirements (cont.) Lines are fed into building Q through a wall duct with expanding mortar (on site). Provide a drain & fill facility S for heating water flow and return in the building near an external wall and 0.8 m below ground level. Note In buildings at ground level, provide a thermally insulated duct or enable draining of the heat pump with compressed air. Frost protection If the heat pump control unit and heating circuit pump are ready for operation, the frost protection function of the heat pump control unit is enabled. Drain the system via the drain & fill facility S when the heat pump is taken out of use or if the power fails for a long period. In heat pump systems where a power failure would not be detected (holiday home), the heating circuits can be operated with suitable antifreeze. Ensure that the system components used are compatible with the antifreeze. Power cable M Run power cable M to the heat pump outside the building in a KG conduit DN 100. Cable length required in the heat pump from top edge of foundation: Min. 0.7 m Observe the regulations imposed by your local power supply utility. Connecting cables N Route prepared connecting cables (control cable 230 V~, LV lead < 42 V) N outside the building in a KG conduit DN 100. Protect the plugs at the ends of the cables from dirt and damage (e.g. with bubble wrap). Cable length required in the heat pump from top edge of foundation Control cable 230 V~: Min. 0.9 m LV cable < 42 V: Min. 0.7 m Routing KG conduits C, D Provide a wire pull for the cables (M, N). To facilitate the routing of cables D through the KG conduit, avoid 90 bends; instead use 3 x 30 or 2 x 45. Route the KG conduit with a slope towards the heat pump and fit a condensate drain if required. Ensure that wall ducts R are moisture-proof and waterproof. Seal the apertures of the KG conduit so that no animals or moisture can enter the building. Installation 11
Preparing for installation Siting requirements (cont.) Required cables and hydraulic lines Installation G O Q E F H N A K D L M P R B C S Fig. 6 A Heat pump B Electric terminal area in the heat pump C Power cable, compressor/fan (3/N/PE 400 V/ 50 Hz, on site) D 2 connecting cables inside DN 100 KG conduit (on site), fully wired (5, 15 or 30 m): Control cable 230 V~ LV cable < 42 V Note The maximum cable length is 30 m. Extensions are not permissible. E Heat pump control unit power cable Recommended cable: 3 x 1.5 mm 2 (5 x 1.5 mm 2 with power-off) F Connection cables for further components and functions (e.g. pumps, sensors, fault messages, etc.) G Heat pump control unit H Instantaneous heating water heater control Recommended cable: 5 x 2.5 mm 2 K Switching module for instantaneous heating water heater: connecting chamber with 2 output relays; install inside the building. L Power cable, instantaneous heating water heater (if installed), max. output 9 kw M Connecting cable with plug for control module/ instantaneous heating water heater, approx. 1.6 m long N Flow temperature sensor, secondary circuit: Install in the heating water flow inside the building. Cable with plug, 2.0 m long: Extend on site if required. O Flow, heating circuits with secondary pump/flow, DHW cylinder with circulation pump for cylinder heating (both circulation pumps are accessories): Alternatively, 1 secondary pump and a 3-way diverter valve can also be used (both accessories). P Instantaneous heating water heater (accessory; install in building) Q Heating water return R Hydraulic connection set (accessory): Connection lines for heating water flow and return S Drain & fill facility with shut-off valve (for draining with compressed air) Required cable lengths: For the heat pump control unit (wall outlet centrally directly below the heat pump control unit): 0.6 m from the wall outlet Inside the heat pump (to the electric terminal area): 0.7 m from the top edge of the foundations 12
Installing the heat pump Installation sequence Observe the siting requirements: See page 6. 1. 4x Installation 4x 2. 4. 4x 3. 4x Fig. 7 Making the hydraulic connections Connect heating water flow and heating water return at the heat pump! Please note Avoid appliance damage: Fit supplied connecting hoses (bends) so that they are free of load and torque stress. To prevent transmission of any vibration, the connecting hoses must not contact any other components. Note The connecting hoses can be shortened. Completely encase connecting hoses in the supplied thermal insulation. 13
Installation sequence Making the hydraulic connections (cont.) Installation 2. 2x 1. A B 3. 4. 2x C Fig. 8 A Heating water return B Heating water flow C Hydraulic connection set (accessory) Connect heating circuits and DHW cylinder in the building 1. Equip the secondary circuit on site with an expansion vessel and safety assembly (in accordance with EN 12828). Fit the safety assembly to the on-site line in the heating water return. 2. Connect secondary lines to the lines of the hydraulic connection set (accessory).! Please note To prevent appliance damage, connect on-site secondary lines so that they are free of load and torque stresses. Make tight hydraulic connections on the secondary side. 3. Fill and vent secondary circuit. 4. Thermally insulate pipes inside the building. 5. Connect the drain hose to the safety valve. Connect the drain hose to the public sewage system with a fall and a pipe vent. Note In underfloor heating circuits, install a temperature limiter to restrict the maximum temperature of underfloor heating systems. Safeguard the minimum flow rate: see "Specification". Fitting the flow temperature sensor, secondary circuit The flow temperature sensor for the secondary circuit is installed in the heating water flow inside the building. Note If an instantaneous heating water heater is installed, fit the flow temperature sensor for the secondary circuit in the heating water flow downstream of the instantaneous heating water heater. 14
Installation sequence Making the hydraulic connections (cont.) 3. A 1. Installation C D 2. B Fig. 9 1. Fit pipe section with sensor well A. 2. Secure flow temperature sensor for secondary circuit C with spring clip B in the sensor well. 3. Connect plug D of the sensor lead and the cable to the heat pump control unit (cable with plug, length 2.0 m, extend on site if required). Connect connector F8 inside the heat pump control unit at the controller and sensor PCB. Connecting the condensate drain Note Subject to temperature and relative humidity, the volume of condensate accumulating from the air can be as high as 20 l/h. During the defrosting process, the amount of condensate can be as high as 20 l within 5 min. Connect condensate drain via siphon (backup level at least 60 mm) in the frost-protected area to on-site drain connection (drainage or sewer system): See page 10. Route condensate drain (drain pipe DN 40) with a constant fall of at least 2 %. A B Fig. 10 A Condensate drain hose B Condensate drain (drain pipe DN 40) 15
Installation sequence Electrical connections, heat pump Installation Danger Damaged cable insulation can cause injury and damage to the appliance. Route cables so that they cannot touch very hot, vibrating or sharp-edged components. Danger Incorrect wiring can lead to serious injury from electrical current and result in appliance damage. Observe the following points when making an electrical connection: Route LV cables < 42 V separately from cables > 42 V/230 V~/400 V~. Strip the insulation from the cables as close to the terminals as possible, and bundle tightly to the corresponding terminals. Secure cables with cable ties. If 2 components are connected to the same terminal, press both cores together in a single wire ferrule. This ensures that, in the event of a fault (e.g. when detaching a wire), the wires cannot drift into the adjacent voltage area. Opening the wiring chamber 2. 1. Fig. 11 16
Installation sequence Electrical connections, heat pump (cont.) Connecting cables Connecting cables from the heat pump control unit D Installation E F 5. 2x 4. 2. C 3. X3 40 < 42 V B X3 40 131 131 230 V~ A 1. Fig. 12 A Connecting cable: Control cable 230 V~ to heat pump control unit (accessory) B Connecting cable: LV cable < 42 V to heat pump control unit (accessory) C LV plug (< 42 V) D Fan terminals (connected at the factory) Power supply MCB/fuse 6.3 A (slow, H) Signal for control via Modbus E Compressor switching module F EEV PCB (refrigerant circuit controller [4]): See service instructions for "Vitotronic 200". 17
Installation sequence Electrical connections, heat pump (cont.) Installation Power cable! Please note An incorrectly connected power supply can result in appliance damage. Observe information from page 36 before connecting the power supply. H 400 V~ G 7. 6. 8. Fig. 13 G Mains terminals, compressor/fan 3/N/PE 400 V/ 50 Hz: Observe information from page 36. H Power cable 3/N/PE 400 V/50 Hz (on site, recommended cable: 5 x 2.5 mm 2 flexible) 18
Electrical connections, heat pump control unit Installation sequence Fitting the heat pump control unit and inserting cables Wall mounting base and casing base, fitting 1. Installation 2. Fig. 14 19
Installation sequence Electrical connections, heat pump control unit (cont.) Installation Fitting the casing front B X3 4. 2. X2 7. B 1. X3 A 3. X2 6. C X20 D 5. 8. Fig. 15 C Casing front D Controller and sensor PCB A Cross connect PCB B ON/OFF switch plug-in connection 20
Installation sequence Electrical connections, heat pump control unit (cont.) Installation Heat pump control unit, open 2. 1. 3. Fig. 16 21
Installation sequence Electrical connections, heat pump control unit (cont.) Cables, inserting and applying strain relief Installation A B Fig. 17 A Cables with moulded strain relief B On-site cables/leads 22
Installation sequence Electrical connections, heat pump control unit (cont.) Connecting cables A B Installation 9 8 7 6 5 4 3 2 1 BK BK D GN/YE C Fig. 18 A Cross connect PCB B Controller and sensor PCB C Connecting cable (accessory): LV cable < 42 V to heat pump D Connecting cable (accessory): Control cable 230 V~ to heat pump Adapting the heat pump control unit The secondary pump, the circulation pump for cylinder heating and/or the instantaneous heating water heater (accessory) can only be installed outside the heat pump. The wiring for this needs to be adapted. 23
Installation sequence Electrical connections, heat pump control unit (cont.) Installation X6 sya sxf Fig. 19 ABCD The red cores connect with the following terminals: A X6.6 211.2 B X6.4 211.4 C X6.2 211.3 D X6.1 224.4! Please note Incorrect core assignment can result in incorrect functions. Remove all 4 red cores. Plugging in the coding card Only insert the coding card supplied with the heat pump. 24
Installation sequence Electrical connections, heat pump control unit (cont.) B A Installation B X31 Fig. 20 A Coding card B Controller and sensor PCB Overview of electrical connections Note Route 230 V~ cables and LV cables separately and bundle them tightly together at the terminals. This ensures that, in the event of a fault, e.g. when detaching a wire, the wires cannot drift into the adjacent voltage area. Strip the insulation as close to the terminals as possible. If 2 components are connected to the same terminal, press both cores together in a single wire ferrule. 25
Installation sequence Electrical connections, heat pump control unit (cont.) Installation B a:c] A B C a:c] C D X31 X5 X3 X7 X25 F1 X2 X6 F3 X1 X24 C sxs sxd D sxf sxg sva X18 F3 J3 J4 F26 F20 F12 F4 F13 F14 F16 F7 F11 F0 F8 F6 avg sya sys B Fig. 21 A Cross connect PCB F1 MCB/fuse 6.3 A (slow) B Main PCB F3 Fuse 6.3 A (slow) C Expansion PCB D Controller and sensor PCB Main PCB 26 Set the required parameters during commissioning: See from page 49. Information regarding the connection values The specified output is the recommended connected load. The total output of all components connected directly to the heat pump control unit (e.g. pumps, valves, message facilities, contactors) must not exceed 1000 W. If the total output is < 1000 W, the individual rating of a component (e.g. pump, valve, message facility, contactor) can be greater than specified. However, the breaking capacity of the corresponding relay must not be exceeded. The stated current indicates the max. switching current of the switching contact (observe the total current of 5 A). Controls for external heat source and central fault messages are unsuitable for safety LV.
Installation sequence Electrical connections, heat pump control unit (cont.) Plug sya Terminals Function Explanation 211.2 Secondary pump (installation in the secondary circuit flow) 211.3 1. r Instantaneous heating water heater switching, stage 1 In systems without a heating water buffer cylinder, no other heating circuit pump is required (see terminal 212.2). Connect a temperature limiter to restrict the maximum temperature for underfloor heating circuits (if installed) in series. Connection values Output: 130 W Voltage: 230 V~ Max. switching current: 4(2) A Connection values Output: 10 W Voltage: 230 V~ Max. switching current: 4(2) A Installation 211.4 Connection values r M 211.5 AC Circulation pump for cylinder heating or 3-way diverter valve for "Central heating/dhw heating" 3-way diverter valves for heating water buffer cylinder bypass in the case of the active cooling function Output: 130 W Voltage: 230 V~ Max. switching current: 4(2) A Connection values Output: 10 W Voltage: 230 V~ Max. switching current: 4(2) A Connect 3-way diverter valves parallel to each other. Plug sys Terminals Function Explanation 212.2 A1 Heating circuit pump for heating circuit without mixer A1/HC1 If a heating water buffer cylinder is installed, this pump will be installed in addition to the secondary pump. Connect temperature limiter to restrict the maximum temperature for underfloor heating systems (if installed) in series: See the following chapter. Connection values: Output: 100 W Voltage: 230 V~ Max. switching current: 4(2) A 212.3 DHW circulation pump Connection values: Output: 50 W Voltage: 230 V~ Max. switching current: 4(2) A 27
Installation sequence Electrical connections, heat pump control unit (cont.) Connecting a temperature limiter as a maximum temperature limiter for underfloor heating Installation Connecting a general temperature limiter B X2.N X1.? A B Connecting the temperature limiter, part no. 7151 728, 7151 729 B X2.N X1.? A B sö Fig. 22 C M 1~ Fig. 23 C M 1~ Heating circuit without mixer A1/HC1 Connection A to control unit Circulation pump C Without heating water buffer cylinder 211.2 Secondary pump With heating water buffer cylinder 212.2 Heating circuit pump A1/HC1 Heating circuit with mixer M2/HC2 225.1 Heating circuit pump M2/HC2 Connecting the temperature limiter, part no. 7151 728, 7151 729 B to the mixer extension kit A sö B sö Fig. 24 C M 1~ A Connect plug sö to the extension kit. B Temperature limiter C Heating circuit pump M3/HC3 28
Installation sequence Electrical connections, heat pump control unit (cont.) Expansion PCB Information regarding the connection values The specified output is the recommended connected load. The total output of all components connected directly to the heat pump control unit (e.g. pumps, valves, message facilities, contactors) must not exceed 1000 W. If the total output is < 1000 W, the individual rating of a component (e.g. pump, valve, message facility, contactor) can be greater than specified. However, the breaking capacity of the corresponding relay must not be exceeded. The stated current indicates the max. switching current of the switching contact (observe the total current of 5 A). Controls for external heat source and central fault messages are unsuitable for safety LV. Set the required parameters during commissioning: See from page 49. Installation Plug sxs Terminals Function Explanation 222.1 Mixer motor control for external heat source Signal mixer CLOSED Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 0.2(0.1) A 222.2 Mixer motor control for external heat source Signal mixer OPEN Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 0.2(0.1) A 222.3 222.4 Control of external heat sources and 1 high limit safety cut-out each (on site, max. 70 C), to switch off or switch between the following components: Central heating: Secondary pump, heat pump Secondary pump, heat pump stage 2 (if installed) External heat generator DHW reheating: Circulation pump for cylinder heating or 3-way diverter valve for "Central heating/dhw heating" Floating contact Connection values (contact breaking capacity) Voltage: 230 V~ (not suitable for safety LV) Max. switching current: 4(2) A Connections for high limit safety cut-outs Central heating: In series to the secondary pump (terminal 211.2 on the main PCB) In series for controlling external heat generators (terminal 222.3) DHW reheating: In series with the circulation pump for cylinder heating or 3-way diverter valve "Heating/DHW heating" (terminal 211.4 on main PCB) 29
Installation sequence Electrical connections, heat pump control unit (cont.) High limit safety cut-out for heat pump in conjunction with an external heat source Installation 222.3 222.4 A X3.1 B C D K1 X2.N Fig. 25 A Terminals on extension PCB B Move jumper from X3.1 to 222.3 C Connection on the external heat source at terminals for external demand D High limit safety cut-out (max. 70 C) as heat pump protection K1 Relay; sizing in accordance with the external heat source; observe safety instructions Plug sxd Terminals Function Explanation 223.1 223.2 U Central fault message Floating contact: Closed: Fault Open: No fault Not suitable for safety LV Connection values (contact rating): Voltage: 230 V~ Max. switching current: 4(2) A Central fault message 223.1 A L1 230 V~, 0.5 A 223.2 Fig. 26 N A Terminals on extension PCB 30
Installation sequence Electrical connections, heat pump control unit (cont.) Plug sxd Terminals Function Explanation 224.4 2. r Instantaneous heating water heater switching, stage 2 Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 4(2) A Installation 224.6 Connection values: M Cylinder loading pump (DHW side) and 2-way shut-off valve See installation instructions for "instantaneous heating water heater" and "instantaneous heating water heater switching module". Output: 130 W Voltage: 230 V~ Max. switching current: 4(2) A 224.7 Connection values: Immersion heater (400 V~) Circulation pump for DHW reheating or Control of the immersion heater (for connection, see drawing in chapter "Immersion heater") Connect cylinder loading pump and 2-way shut-off valve in parallel. Output: 100 W Voltage: 230 V~ Max. switching current: 4(2) A L1 L2 L3 N? 224.7 B X2.N A Fig. 27 A Immersion heater, power supply 3/N/PE 400 V/50 Hz B Terminals of the heat pump control unit 31
Installation sequence Electrical connections, heat pump control unit (cont.) Installation Plug sxg Terminals Function Explanation 225.1 M2 r 225.2 M2 Heating circuit pump of the heating circuit with mixer M2/HC2 Mixer motor control, heating circuit M2/HC2 Signal mixer CLOSED Connect a temperature limiter to restrict the maximum temperature for underfloor heating circuits (if installed) in series. Connection values: Output: 100 W Voltage: 230 V~ Max. switching current: 4(2) A Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 0.2(0.1) A 225.3 M2 Mixer motor control, heating circuit M2/HC2 Signal mixer OPEN Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 0.2(0.1) A Cross connect PCB Set the required parameters during commissioning: See from page 49. Signal and safety connections Terminals Function Explanation F1 Fuse 6.3 A (slow) Note Observe a total load of 1000 W for all connected components. X1 Earth conductor X1.? Terminals for earth conductor of all associated system components X2 Neutral conductor X2.N Terminals for neutral conductor of all associated system components X3 X3.1 Switched phase Power supply terminals of control unit "L1" and auxiliary components Switched phase L1: X3.1, X3.2, X3.3, X3.7, X3.11, X3.13 Terminals for signal and safety connections Note Switched phase can be used for on-site system components. Observe max. output. 32
Installation sequence Electrical connections, heat pump control unit (cont.) Terminals Function Explanation X3.2 X3.14 "External blocking" signal: external blocking of compressor and pumps, mixer in control operation or CLOSE Requires zero volt N/O contact: Closed: Power-OFF enabled Open: No power-off Breaking capacity 230 V~, 2 ma Note These and further external functions, such as provision of external set values, can alternatively be connected via EA1 external extension. Installation instructions "EA1 extension" Installation X3.3 X3.4 Flow limiter Requires floating N/O contact (actuated): Closed: Heat pump in operation Open: Heat pump shut down Breaking capacity 230 V~, 0.15 A Note Connected with heat pump control cable 230 V~. X3.6 X3.7 G Power-OFF Requires zero volt N/C contact: Closed: No power-off (safety chain has continuity) Open: Power-OFF enabled Breaking capacity 230 V~, 0.15 A Note No parameters need to be set No jumper should be installed if a power-off contact is connected. The compressor is "forced" off as soon as the contact opens. The power-off contact signal switches off the supply voltage to the relevant components, subject to power supply utility. For the instantaneous heating water heater, the stages to be switched off can be selected ("Output for instant. htg wtr heater at power-off 790A"). The power supply for the heat pump control unit (3 x 1.5 mm 2 ) and the cable for the power-off signal can be combined in a single 5-core cable. X3.8 X3.9 Contact humidistat or Jumper Requires zero volt N/C contact: Closed: Safety chain has continuity Open: Safety chain interrupted; heat pump shut down Breaking capacity 230 V~, 0.15 A X3.10 X3.11 Fault message, lag heat pump in a cascade or Jumper Insert jumper if no safety components are installed. Requires zero volt N/C contact: Closed: No fault Open: Fault Breaking capacity 230 V~, 0.15 A No jumper should be installed if a message contact is connected. 33
Installation sequence Electrical connections, heat pump control unit (cont.) Installation Terminals Function Explanation X3.12 X3.13 "External demand" signal: external starting of compressor and pumps; mixer in control mode or OPEN, changeover of the operating status of several system components Requires zero volt N/O contact: Closed: Demand Open: No demand Breaking capacity 230 V, 2 ma Note These and further external functions, such as provision of external set values, can alternatively be connected via EA1 external extension. Installation instructions "EA1 extension" X3.17 X3.18 MCB/fuse F1 6.3 A (slow) X3.18 Heat pump control unit power supply: Phase L1 X1.1 Earth conductor connection X2.1 Neutral conductor connection X5/X7 Connections for heat pump control cable 230 V~ Power supply 230 V~ Controller and sensor PCB Set the required parameters during commissioning: See from page 49. Plug Sensor/component Type F0.1/F0.2 Outside temperature sensor NTC 10 kω F0.2/F0.3 Radio clock receiver (accessories) DCF F4 Buffer temperature sensor NTC 10 kω F6 (X25.5/X25.6) F7 (X25.7/X25.8) F8 (X25.9/X25.10) Cylinder temperature sensor, top Cylinder temperature sensor, bottom Flow temperature sensor, secondary circuit F11 Contact humidistat 24 V Note If a 230 V~ contact humidistat (connection to X3.8/X3.9) is used for cooling, set a jumper, otherwise the heat pump will not start (message "CA Protectn device primry"). NTC 10 kω NTC 10 kω Pt500A (PTC) F12 Flow temperature sensor heating circuit with mixer M2/HC2 NTC 10 kω F13 F14 F16 System flow temperature sensor (downstream of the heating water buffer cylinder and external heat source) Flow temperature sensor, cooling circuit (heating circuit without mixer A1/HC1 or separate cooling circuit SKK) Room temperature sensor, cooling circuit Required for separate cooling circuit SKK Recommended for heating/cooling circuit without mixer A1/HC1 NTC 10 kω NTC 10 kω NTC 10 kω F20 Boiler water temperature sensor, external heat source NTC 10 kω F26 Buffer temperature sensor, cooling NTC 10 kω 34
Installation sequence Electrical connections, heat pump control unit (cont.) Plug Sensor/component Type avg sva KM BUS (wires interchangeable) Use the KM BUS distributor (accessories) if several devices are connected. KM BUS subscriber (examples): Mixer extension kit for heating circuit M3/HC3 Remote control Vitotrol 200A or Vitotrol 300B: Set heating circuit assignment at the remote control. EA1 extension, AM1 extension Communication interface Vitocom 100, type GSM2 Modbus 2 (wires not interchangeable) Connection for photovoltaic system electricity meter a:db PWM signal, secondary pump a:dc PWM signal, cylinder loading pump J3 Jumper for terminator Modbus 2 Terminator enabled (delivered condition) Terminator disabled J4 Jumper for setting master/slave Modbus 2 Heat pump control unit is slave Heat pump control unit is master (delivered condition) X18 Modbus 1 Connection for EEV PCB in the heat pump (refrigerant circuit controller [4]): See service instructions for "Vitotronic 200". Installation X24 Note If other Viessmann appliances are to be connected to Modbus 1 (e.g. Vitovent 300-F), insert Modbus distributor (accessory): See installation instructions for "Modbus distributor". Connection, LON communication module (accessory): See installation instructions for"lon communication module". X25 LV cable < 42 V to heat pump (accessory) X31 Coding card slot Note Flow temperature sensor for heating circuit with mixer M3/HC3: The flow temperature sensor for one heating circuit with mixer M3/HC3 is connected to the mixer extension kit (accessory). Swimming pool heating Note Swimming pool heating is controlled via extension EA1 with KM BUS. Make connections to extension EA1 only according to the following diagram. A filter circuit pump cannot be controlled via the heat pump control unit. 35
Installation sequence Electrical connections, heat pump control unit (cont.) Installation A 0-10V f-]a [{A DE [{S DE [{D DE [{{] 1 2 3 4 5 6 + - E L1 B N H C D F G L1 N M 1~ 1 2 K Fig. 28 A Extension EA1 B Power supply 1/N/PE 230 V/50 Hz C Junction box (on site) D Fuses and contactor for circulation pump for swimming pool heating (accessories) E Jumper F 3-way diverter valve for "Swimming pool" (zero volt: heating the heating water buffer cylinder) G Circulation pump for swimming pool heating (accessory) H Thermostat for swimming pool temperature control (floating contact: 230 V~, 0.1 A, accessories) K Connection on controller and sensor PCB Power supply Isolators for non-earthed conductors The mains isolator (if installed) must simultaneously isolate from the mains all non-earthed conductors with a minimum contact separation of 3 mm. We additionally recommend installing an AC/DCsensitive RCD, type B, for DC (fault) currents that can occur with energy efficient equipment. RCDs of type A must not be used or installed upstream of the RCD type B. If no mains isolator is installed, all non-earthed conductors must be isolated from the mains by the upstream circuit breakers with a minimum contact separation of 3 mm. Danger Incorrectly executed electrical installations can result in injuries from electrical current and in appliance damage. Connect the power supply and implement all safety measures (e.g. RCD circuit) in accordance with the following regulations: IEC 60364-4-41 VDE regulations Technical connection requirements specified by the local power supply utility 36
Installation sequence Power supply (cont.) Danger If system components are not earthed, serious injury from electric current can result if an electrical fault occurs. Connect the appliance and pipework to the equipotential bonding of the building in question. Danger Incorrect core allocation can result in serious injury and damage to the appliance. Never interchange cores "L" and "N". In negotiations with your power supply utility, different supply tariffs for the main power circuits may be offered. Observe the technical connection conditions of the power supply utility. If the compressor and/or instantaneous heating water heater are operated at an economy tariff (power-off), either provide an additional cable (e.g. 3 x 1.5 mm 2 ) for the power-off signal from the distribution board (meter box) to the heat pump control unit or Combine the cable for the power-off signal and for the heat pump control unit power supply (3 x 1.5 mm 2 ) in a 5-core cable. The assignment of the power-off (for compressor and/or instantaneous heating water heater) is made via the type of connection and by setting parameters in the heat pump control unit. In Germany, the power supply can be cut off for up to 3 x 2 hours per day (24 h). The heat pump control unit/pcb must be supplied without power-off. Tariffs subject to possible shutdown must not be used here. In conjunction with on-site power consumption (use of power generated by the PV system to meet own requirements): During the power-off period, it is not possible to operate the compressor with power generated on site. Protect the power supply to the heat pump control unit with an MCB/ fuse of max. 16 A. For accessories and external components that are not to be connected to the heat pump control unit, connect the power supply on the same phase as the heat pump control unit; we recommend using the same MCB/fuse. Connection to the same MCB/fuse provides additional safety when the power is switched off. Observe the power consumption of the connected consumers. Information regarding the compressor power supply! Please note An incorrect phase sequence can cause damage to the appliance. Make the compressor power supply only in the phase sequence specified (see terminals) with a clockwise rotating field. Characteristics of the compressor power fuses: see "Specification". Installation Heat pump control unit power supply 230 V~ A X3.18 X2.1 X1.1 Fig. 29 max.16 A L1 N? 1/N/PE 230 V / 50 H A Mains terminals inside the heat pump control unit Note This supply must never be blocked. Max. fuse rating 16 A Standard tariff: No optional economy tariff with power-off for the heat pump control unit Recommended power cable: 3 x 1.5 mm 2 Recommended power cable with power-off for compressor/ instantaneous heating water heater: 5 x 1.5 mm 2 Compressor power supply 400 V~ 3/N/PE 400 V/50 Hz? N L3 L2 PE N L3 L2 MCB/fuse protection in accordance with the compressor rating: see "Specification". Economy tariff and power-off can be used Fig. 30 L1 L1 37
Installation sequence Power supply (cont.) Installation No parameters need to be set when using economy tariff with power-off. The compressor is shut down during the power-off time. Recommended power cable: 5 x 2.5 mm 2 Max. cable length: 25 m Power supply with power-off Power-OFF without on-site load disconnection The power-off signal is connected directly to the heat pump control unit. The compressor is "forced" off when power-off is enabled. Parameter "Output for instant. htg wtr heater at power-off 790A" determines whether and at what stage an instantaneous heating water heater stays operational during the power-off period. Note Observe the technical connection conditions of the relevant power supply utility. A X3.7 X3.6 B C D 3 5 4 3 kwh 3/N E 4 G F 3 kwh 3/N H 4 K 4 Fig. 54 Diagram excluding MCB/fuses and RCD A Heat pump control unit B Instantaneous heating water heater C Compressor D Heat pump control unit power supply E Standard tariff meter F Backup fuse ripple control receiver G Ripple control receiver (contact open: power-off enabled) TNC system feed H Economy tariff meter K Feed: TNC system Power-OFF with on-site load disconnection The power-off signal is connected to the on-site contactor of the economy tariff power supply and to the heat pump control unit. The compressor and instantaneous heating water heater are "forced" off when power-off is enabled. Note Observe the technical connection conditions of the relevant power supply utility. 38
Installation sequence Power supply (cont.) A D L X3.7 X3.6 3 B C 5 4 Installation 3 3 kwh kwh 3/N E G 3/N H 4 F 4 Fig. 55 K 4 Diagram excluding MCB/fuses and RCD A Heat pump control unit B Instantaneous heating water heater C Compressor D Heat pump control unit power supply E Standard tariff meter F Backup fuse ripple control receiver G Ripple control receiver (contact open: power-off enabled) with backup fuse H Economy tariff meter K Feed: TNC system L Mains isolator 39
N E1E2 D /D L1 L1 L2 L2 L3 L3 Installation sequence Power supply (cont.) Mains power supply in conjunction with on-site power consumption Installation Without power-off A A B ~ = D F F C F E F G H K kwh kwh kwh L L M M Fig. 33 N N A Heat pump B Additional consumers (of power generated on site) in the household C Electricity meter D Inverter E Isolator for the PV system F Terminal G Double-tariff meter (for special tariff for heat pump) Not permissible in conjunction with PV systems for on-site power consumption H Bi-directional meter (for PV systems to consume power on site): Energy taken from power supply utility and energy fed into power supply utility K Meter with reverse block: For energy generated by PV system L Isolator for the domestic power supply connection (distribution panel) M Distribution panel N Domestic distribution box Closing the heat pump! Please note Seal the appliance so it is soundproof and diffusion-proof. Check tightness of internal hydraulic connections.! Please note To prevent the formation of condensate and the excessive development of noise, tightly seal the casing door. 40
Installation sequence Closing the heat pump (cont.) 1. Installation Fig. 34! Please note The protective foil can no longer be removed once the outer casing has been fitted. Pull off the protective foil before fitting the outer casing. Information on step 2 Use a weatherproof marker. A 2. AWO-AC 301.B11 AWO-AC 301.B14 Fig. 35 A Logos 41
Installation sequence Closing the heat pump (cont.) 3 Nm Installation 10. 4x 8. 9. 7. 4x 6. 4x 4x 5. 3 Nm 3. 3x 4. Fig. 36 42
Steps - commissioning, inspection and maintenance Commissioning, inspection, maintenance Commissioning steps Inspection steps Maintenance steps Page 1. Opening the heat pump... 44 2. Preparing reports... 44 3. Checking the refrigerant circuit for leaks... 44 4. Filling and venting on the secondary side... 45 5. Checking the expansion vessel and heating circuit pressure... 46 6. Checking the electrical connections for firm seating 7. Cleaning the interior... 46 8. Commissioning the system... 47 9. Closing the heat pump... 55 10. Instructing the system user... 55 43
Commissioning, inspection, maintenance Opening the heat pump Danger Contact with 'live' components can lead to serious injury from electric current. Never touch terminal areas Heat pump control unit: See page 25. Terminal area in the heat pump: See page 17. Danger The absence of component earthing can result in serious injury from electrical current and in component damage in the event of an electrical fault. Always remake all earth connections. 1. Remove outer casing: Steps 2 to 8 on page 42 in reverse order. 2. If necessary, open casing door: See page 16. 3. If necessary, open heat pump control unit: See page 19. 4. When work is complete, assemble heat pump and heat pump control unit.! Please note Wait at least 30 min between the installation and commissioning of the appliance to prevent equipment damage. Work on the refrigerant circuit may only be carried out by certified personnel (in accordance with EC 842/2006 and 303/2008). Preparing reports Enter readings taken during commissioning into the reports from page 72 and into the operator's log. Checking the refrigerant circuit for leaks Danger The refrigerant is a non-poisonous gas that displaces air. Unregulated escape of refrigerant in enclosed spaces can result in difficulties in breathing and suffocation. Always observe regulations and guidelines for handling this type of refrigerant. Note Work on the refrigerant circuit must only be carried out by certified personnel (in accordance with EC 842/2006 and 303/2008). Danger Direct contact with refrigerant can be harmful to skin. Wear safety goggles and protective gloves when working on the refrigerant circuit. Check the floor area, valves and all visible solder joints for traces of oil. Note Traces of oil indicate a leak in the refrigerant circuit. Have your heat pump checked over by a refrigeration engineer. 44
Filling and venting on the secondary side Commissioning, inspection, maintenance Unsuitable fill and top-up water increases the level of deposits and corrosion. This can lead to system damage. Observe VDI 2035 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. Soften fill water with a water hardness above 16.8 dh (3.0 mol/m 3 ), e.g. with the small softening system for heating water: See the Vitoset pricelist.! Please note Avoid appliance damage. Protect electrical components inside the heat pump from escaping liquids. Note Before filling the system, observe VDI 2035 part 1. A B Fig. 37 A Manual air vent valve B Drain valve 1. Open any non-return valves installed on site. 2. Check the pre-charge pressure of the expansion vessel: See page 46. 3. Fill the secondary circuit via the on-site BDF valve (flush) and vent the circuit. 4. Check the system pressure at the pressure gauge (on site): Top up with water if required. Minimum system pressure: 0.8 bar (80 kpa) Permiss. operating pressure: 3 bar (0.3 MPa) 5.! Please note To prevent equipment damage, check the flow and return connections of the heat pump secondary circuit for leaks. In the case of leaks, drain off water via drain valve B. Check the seating of seal rings. Always replace dislodged seal rings. 6. Close the on-site BDF valve. 7. To prevent damage to electrical components, connect an on-site hose to manual air vent valve A. Open manual air vent valve. 8. Close manual air vent valve A after venting has been completed. 45