Viessmann 302.DS230 Installation And Service Instructions For Contractors Download | Manualshive

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Parts lists

Components, hydraulic module defrost box, PCB

5837251

Components

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Summary of Contents for 302.DS230

Page 1: ...ns for contractors VIESMANN Vitocal 300 G Pro SPS Type BW 302 DS090 to 302 DS230 84 8 to 222 0 kW Brine water heat pumps 2 stage and hydraulic module defrost box HMD90 to HMD190 VITOCAL 300 G PRO SPS...

Page 2: ...may be several power circuits Danger Contact with live components can result in severe injuries Some components on PCBs remain live even after the power supply has been switched off Prior to removing...

Page 3: ...escapes from the appliance there is a risk of electrocution Switch OFF the heating system at the external isolator e g fuse box domestic distribution board Danger If water escapes from the appliance t...

Page 4: ...requirements hydraulic module defrost box 29 Hydraulic diagram 29 4 Installation procedure heat pump Siting the heat pump 30 Levelling the heat pump 30 Removing the transport brackets 31 Fitting the b...

Page 5: ...component overview 71 Overview of internal components hydraulic module defrost box 71 10 Parts lists Ordering parts 73 Components heat pump 74 Components heat pump PCB 76 Components hydraulic module d...

Page 6: ...ement all safety measures e g RCD circuit in accord ance with the following regulations IEC 60364 4 41 VDE regulations Technical connection requirements specified by the local power supply utility Dan...

Page 7: ...frigeration engi neer Wear suitable protective clothing Danger Refrigerant circuits of heat pumps develop extremely low 25 C and very high 130 C temperatures Work on heat pumps can result in life thre...

Page 8: ...with a tool Clean the sur face Dispose of component correctly Dispose of component at a suitable collec tion point Do not dispose of component in domestic waste The steps in connection with commission...

Page 9: ...sion valve EEV with an integral refrigerant circuit con troller in the SPS The Vitotronic SPS type 2 0 can control up to 4 heating cooling circuits with mixer All sensors are fitted inside sensor well...

Page 10: ...ow noise BW 302 DS230 HMD190 HE190 LN Heat pump Complete compact heat pump sound insulation is supplied separately Integral heat pump control unit with outside tempera ture sensor programming unit int...

Page 11: ...damage on the delivery note and notify the haulage contractor Lifting gear such as slings and cross beams must be provided on site The lifting capacity of each sling and that of the cross beam must b...

Page 12: ...truck or pallet truck Fig 4 Information regarding transport with forklift truck Select a fork length appropriate for the total heat pump length see Specification on page 82 onwards The heat pump s ce...

Page 13: ...th wooden joists e g in the attic Level the appliance horizontally Where floors are uneven distribute the load evenly across the feet Observe minimum room volume to EN 378 Observe additional country s...

Page 14: ...ibu tion Note In the case of corner installation enlarge the base by the minimum clearances see chapter Minimum clear ances on page 13 150 Fig 7 A Concrete B25 iron B Floor construction screed C Top e...

Page 15: ...eams must be provided on site The lifting capacity of each sling and that of the cross beam must be at least equal to the shipping weight See Specification Only use suitable equipment for unloading th...

Page 16: ...e for the weight see Specifica tion C Edge protection e g 2 or 3 layers of corrugated cardboard D Cross beam to relieve the load on the frame Handling by forklift truck or pallet truck Fig 11 Preparin...

Page 17: ...w level airborne and struc ture borne noise Recommendation Never install the appliance in living spaces or directly next to below or above quiet rooms bedrooms The requirements for hydraulic connectio...

Page 18: ...aulic 2 DN 65 C Primary circuit return outlet Victaulic 3 DN 80 D Secondary circuit return inlet Victaulic 2 DN 65 E Low voltage 50 V F Power supply 230 V 50 Hz G Power supply 400 V 50 Hz Note The wid...

Page 19: ...mary circuit return outlet Victaulic 3 DN 80 D Secondary circuit return inlet Victaulic 2 DN 65 E Low voltage 50 V F Power supply 230 V 50 Hz G Power supply 400 V 50 Hz Note The width of the heat pump...

Page 20: ...cuit return outlet Victaulic 3 DN 80 D Secondary circuit return inlet Victaulic 2 DN 65 E Low voltage 50 V F Power supply 230 V 50 Hz G Power supply 400 V 50 Hz Note The width of the heat pump is give...

Page 21: ...connection requirements Make on site hydraulic connections stress free Make the hydraulic connections between several heat pumps on site All components required for the cooling circuit must be provid...

Page 22: ...W cir culation A Residual heat extension ZK03853 function is part of the AW package B Well circuit groundwater standard unit ZK04292 C Cascade max 2 heat pumps one master and one slave Heat pump commu...

Page 23: ...of heat source groundwater or geothermal probe during the engineering process Equipment required Pos Designation 1 Heat pump 2 Heat pump control unit 3 2 way motorised damper heating water buffer cyl...

Page 24: ...ure sensor HC2 w W Temperature limiter HC2 w E 3 way diverter valve heating cooling HC2 w R Heating circuit pump HC2 w T 3 way mixer HC2 w Z Contact humidistat HC2 e P Heating cooling circuit HC3 e Q...

Page 25: ...T Circulation pump NC parallel t Z Temperature sensor NC parallel z P 3 way mixer secondary high temperature maintenance z Q Brine sensor drip pan air brine heat exchanger u P Heating cooling circuit...

Page 26: ...Extension for PLC ZK03850 Pumps 4 and 5 For heat recovery air water 0 10 V D Extension for heating circuit 1 HC1 ZK03862 E Extension for heating circuit 2 HC2 ZK03863 F Extension for heating circuit 3...

Page 27: ...ump 6 Outside temperature sensor 7 Safety assembly secondary circuit 8 Expansion vessel qQ Safety assembly primary circuit qW Pressure switch primary circuit qZ Dirt filter qI Refrigerant sensor qO Fl...

Page 28: ...ature sensor air brine heat exchanger air outlet r E Temperature sensor air brine heat exchanger brine inlet r R Temperature sensor air brine heat exchanger brine outlet r T Temperature sensor heat ex...

Page 29: ...ay motorised damper rXQ o Z Stem heater 3 way mixer iT Valve switching state on delivery Hydraulic connection requirements hydraulic module defrost box Make on site hydraulic connections stress free A...

Page 30: ...30 Levelling the heat pump Fig 21 Site and level the heat pump horizontally as described on page 13 onwards Installation procedure heat pump Siting the heat pump 5837251 Installation...

Page 31: ...out first removing the transport brackets may cause vibrations and excessive noise Remove all 4 transport brackets fully from below and dispose of them correctly Fig 22 A Transport locking screws Inst...

Page 32: ...anels and kicking plates Note After fitting the back panel make the hydraulic and electrical connections See following chapter 1 2 3 3 4 2x 6x 5 Fig 23 Installation procedure heat pump Siting the heat...

Page 33: ...2 DS230 A Primary circuit flow inlet Victaulic 3 DN 80 B Secondary circuit flow outlet Victaulic 2 DN 65 C Primary circuit return outlet Victaulic 3 DN 80 D Secondary circuit return inlet Victaulic 2...

Page 34: ...aulic coupling 3 primary circuit B Victaulic coupling 2 secondary circuit C Flange adaptor 3 DN 80 PN 10 short primary cir cuit without anti vibration elements D Flange adaptor 2 DN 65 PN 10 short sec...

Page 35: ...ic line fixings Fitting the Victaulic couplings Fig 28 1 Clean all Victaulic connections 2 Open Victaulic coupling B around 1 cm 3 Push Victaulic coupling B with inserted gasket as far as it will go o...

Page 36: ...e panel are seated correctly Make line entries airtight 4 Insulate primary lines inside the building with ther mally insulating and vapour diffusion proof materi als 5 Fill the primary circuit with Vi...

Page 37: ...e g if a wire becomes detached the wires cannot drift into the adjacent voltage area When routing on site power cables observe the loca tion of the cable entries into the appliance through the back p...

Page 38: ...re connected to the same terminal press both cores together in a single wire ferrule Wiring chamber front Fig 30 Note Diagram without terminal covers see also page 76 A Power supply power circuit comp...

Page 39: ...Specified lead type CV Clamps Function Explanation 100QB1 Power supply Max fuse rating 25 A Largest internal fuse LSC 13A 100XE1 Earth conductor PE 100XE8 Equipotential bonding system 192XD1 1 24 VDC...

Page 40: ...ut 4000 W 2200 W Voltage 400 V 230 V 202XD3 1 Start command EB 2 Start command EB 3 Operating message COM 4 Operating message NO Well circulation pump control sig nals groundwater Floating N O contact...

Page 41: ...V Contact closed Circulation pump operation heat exchanger de frosting residual heat water 206XD1 1 External conductor L1 2 External conductor L2 3 External conductor L3 N Neutral conductor PE Earth...

Page 42: ...act Closed Demand cylinder loading pump DHW heating high temperature maintenance Open No demand Signal 0 to 10 V Contact closed Operation cylinder loading pump DHW heating high temperature maintenance...

Page 43: ...ad heating circuit 4 Circuit protection from load fuse 104FC3 ob serve the total current of max 16 A Connection values Max output 2200 W Voltage 230 V 214XD3 1 Start command EB 2 Start command EB 3 Op...

Page 44: ...t exchanger control signals Closed Operation air brine heat exchanger Connection air brine heat exchanger terminal X_CTRL 1 COM 2 NO 380XD7 1 Brine sensor COM 2 Brine sensor NO Brine sensor drip pan a...

Page 45: ...Valve closed 3 24 VDC 4 0 VDC PE Earth conductor 2 way motorised damper heating water buffer cylinder inlet Connection values Voltage 24 VDC Max switching current 5 A 438XD1 1 Valve open 2 Valve clos...

Page 46: ...hing current 5 A 460XD1 1 24 VDC 2 0 VDC 3 Set value 0 10 V 4 GND PE Shield connection 3 way mixer low temperature maintenance frost protection Connection values Voltage 24 VDC Signal 0 to 10 V 460XD5...

Page 47: ...llel Connection values Voltage 24 VDC Signal 0 to 10 V 500XD1 1 Contact COM 2 Contact NO PE Earth conductor Pressure switch primary circuit Open Fault 501XD1 1 24 VDC 2 0 VDC 3 Contact NO Flow switch...

Page 48: ...nductor Contact humidistat heating circuit 4 Open Fault 552XD1 1 R 2 R Outside temperature sensor Pt 1000 552XD3 1 R 2 R Heating water buffer cylinder tem perature sensor top Pt 1000 552XD5 1 R 2 R He...

Page 49: ...erature sensor air brine heat exchanger air inlet Pt 1000 555XD3 1 R 2 R PE Shield connection Temperature sensor heat ex changer defrosting residual heat brine inlet Pt 1000 555XD5 1 R 2 R PE Shield c...

Page 50: ...al 24 VDC from heat pump Closed Active 600XD6 1 24 VDC 2 Signal digital Enable DHW cylinder External contact Potential 24 VDC from heat pump Closed Active 600XD7 1 24 VDC 2 Signal digital Operating me...

Page 51: ...values Max voltage 250 V Max switching current 5 A AC1 630XD7 1 External potential 2 Signal digital Demand immersion heater in DHW cylinder Floating N O contact Closed No demand Open Demand Connectio...

Page 52: ...l circuit A separate power supply for the control circuit necessitates a change to the internal wiring This may only be carried out by an electrical contractor according to the connection diagram Prot...

Page 53: ...the electronic soft starter are exceeded the soft starter will automatically separate the appliance from the mains Remove the cause if the relay has responded The relay does not need to be reset Star...

Page 54: ...as well as the programming unit are delivered inside the wiring chamber of the heat pump Only fit the programming unit after all electrical connections have been made 3 0 Off 2 1 Fig 33 3 Position the...

Page 55: ...Are all cables inside the wiring chamber sufficiently secured strain relief cable ties Has the programming unit been fitted and connec ted Have all earth conductors been fitted Have all cable entries...

Page 56: ...njury 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 res...

Page 57: ...that in the event of a fault e g if a wire becomes detached the wires cannot drift into the adjacent voltage area Strip the cables of a small amount of insulation close to the terminals If 2 component...

Page 58: ...ng and have a mini mum cross section of 0 5 mm2 Specified lead type CV Clamps Function Explanation 100QB1 Power supply Max fuse rating 25 A Largest internal fuse LSC 13A 100XE1 Earth conductor PE 100X...

Page 59: ...Closed Demand air brine heat exchanger Open No demand Connection values Max voltage 250 V Max switching current 5 A AC1 connection air brine heat exchanger terminal 1 2 380XD4 1 Set value 0 10 V 2 GN...

Page 60: ...ions can result in injuries from electrical current and dam age to the appliance Connect the power supply and implement all safety measures e g RCD circuit in accord ance with the following regulation...

Page 61: ...ble 63 6 Filling and venting on the secondary side 64 7 Checking expansion vessels and primary circuit secondary circuit pressure 65 8 Checking the electrical connections for firm seating 9 Commission...

Page 62: ...ied out by qualified electri cians 1 Remove top panel see page 55 2 When work is complete close the heat pump see page 55 Regarding commissioning this appliance see also the operating instructions Com...

Page 63: ...tightness of the internal and on site hydraulic connections In the event of leaks switch OFF the appli ance immediately Drain the primary circuit and check the seating of the seals Always replace dam...

Page 64: ...Commissioning when the secondary circuit is empty causes appliance damage Fill and vent the secondary circuit before con necting the power supply Note Before filling the system observe VDI 2035 part...

Page 65: ...onic SPS type 2 0 heat pump control unit otherwise the appliance warranty will be void Note Commissioning must only be carried out by trained and authorised contractors Configuration procedure Vitotro...

Page 66: ...put Note The current operating mode is displayed once the short cir cuit has been remedied No LED illuminates Operating voltage 19 VDC or power supply failure Carry out an operating display adjustment...

Page 67: ...not properly closed turn quadrant key as far as it will go Hydraulic line is touching the heat pump casing back panel Hydraulic line not connected free of load and torque stress Anti vibration elemen...

Page 68: ...Put the front panel to one side and ensure it cannot fall over 4 Carefully remove the top panel see page 55 Overview of electrical components See page 38 onwards Overview of internal components Vitoca...

Page 69: ...page 68 Connect the sensors See separate Connection and wiring diagram Sensor Test element Outside temperature sensor Secondary circuit flow temperature sensor Secondary circuit return temperature sen...

Page 70: ...es Replace if necessary Danger Incorrect or improperly fitted fuses can lead to an increased risk of fire Insert fuses without using any force Posi tion fuses correctly Only use structurally identical...

Page 71: ...al heat 4 Flow switch defrosting residual heat heat exchanger water 5 Safety valve 6 Air vent valve 7 3 way mixer 8 Circulation pump heat exchanger defrosting residual heat brine 9 2 way motorised dam...

Page 72: ...72 Repairs hydraulic module defrost box Overview of internal components hydraulic cont 5837251 Service...

Page 73: ...73 The following details are required when ordering parts Serial no see type plate Position number of the part from this parts list Parts lists Ordering parts 5837251 Components...

Page 74: ...2 0004 0001 0005 0001 0053 0072 0072 0071 0003 0008 0006 0013 0015 0013 0011 0017 0012 0016 0024 0007 0009 0010 0017 0073 0014 0051 0014 0014 0014 0052 0056 Fig 44 Parts lists Components heat pump 583...

Page 75: ...Ball shut off valve 0011 Low pressure sensor 0012 High pressure sensor 0013 Pressure switch 0014 Temperature sensor 0015 Sensor well 0016 Sensor clip 0017 Schrader set 0018 Programming unit 0024 Moto...

Page 76: ...0023 0026 0021 0021 0023 0023 0035 0044 0043 0037 0038 0039 0033 14x 12x 0045 0040 15x 0045 15x 0033 15x 0027 12x 0040 X1 X2 0032 0031 0030 0030 0030 0030 0032 0032 0031 0031 0029 0028 0028 0046 0028...

Page 77: ...terminal 0036 Coupler 0037 Installation terminal WKIS 2 5 D D 0038 Installation terminal WKIS 2 5 D D SL 0039 Installation terminal WKIS 2 5 N D SL 0040 Interface relay 0041 Terminal cover 0042 Power...

Page 78: ...78 0005 0002 0006 0001 0004 0003 Fig 46 Parts lists Components hydraulic module defrost box 5837251 Components...

Page 79: ...er air brine heat exchanger residual heat 0003 Stem heater 3 way mixer 0004 Stem heater 2 way motorised damper 0005 2 way motorised damper residual heat source 0006 2 way motorised damper air brine he...

Page 80: ...0008 0010 0009 0001 0001 0003 0003 0001 0001 0001 0001 0001 0001 0001 0011 0015 0016 0019 0018 0020 0021 0022 0023 0007 0024 0025 0026 0024 0025 0026 Fig 47 Parts lists Components hydraulic module de...

Page 81: ...minal 0010 Earth conductor terminal 0011 EtherCAT coupler 0015 Digital input 0016 Digital output 0018 Analogue input 0019 Analogue output 0020 Circuit breaker 0021 Circuit breaker 0022 Duo feed throug...

Page 82: ...1 0 14 6 17 9 24 3 28 8 Pressure drop at nominal flow rate total pressure drop evaporator plus connections kPa 6 7 8 10 10 Pressure drop at minimum flow rate kPa 3 4 4 5 6 Max flow temperature at prim...

Page 83: ...5 18 2 23 6 29 4 Pressure drop at nominal flow rate total pressure drop condenser plus connections kPa 8 7 10 2 12 1 15 9 16 7 Pressure drop at minimum flow rate kPa 3 4 4 6 6 Max flow temperature at...

Page 84: ...ng pressure 1 Primary circuit bar 10 10 10 10 10 Secondary circuit bar 10 10 10 10 10 Dimensions Total length mm 1383 1383 1972 1972 1972 Total width mm 911 911 911 911 911 Handling width without side...

Page 85: ...rtment of Viessmann Werke Specification Vitocal 300 G Pro with AW package Operation Air water A2 W35 heat recovery Note With air brine heat exchanger in standard Std or low noise version LN AW package...

Page 86: ...6 Max flow temperature at air A 2 C C 50 50 50 50 Max flow temperature at air A 5 C C 40 40 40 40 Air brine heat exchanger HE90 Std LN HE120 Std LN HE140 Std LN HE190 Std LN Performance data Primary...

Page 87: ...6 6 Rated current of compressors total A 56 4 70 1 89 1 111 2 Energy efficiency ratio EER 2 77 2 77 2 80 2 86 Primary circuit brine Spread K 5 5 5 5 Frost protection freezing point recom mended refri...

Page 88: ...in partial load operation Note The technical information in the datasheets and prod uct description describe purely physical characteristics Additional assurances or guarantees require a sepa rate con...

Page 89: ...d HE140 Std HE190 Std Electrical values Rated voltage 3L N PE 400 V 50 Hz Maximum power consumption kW 2 9 3 8 4 2 5 1 MCB fuse protection on site A 6 16 10 10 Maximum operating current A 4 2 8 4 7 4...

Page 90: ...2 Dry weight kg 1535 2003 2511 3948 Heat exchanger capacity l 231 307 384 597 Connections Inlet air brine heat exchanger flange 2 x DN 50 PN 10 2 x DN 50 PN 10 2 x DN 65 PN 10 2 x DN 65 PN 10 Outlet a...

Page 91: ...rcuits fully installed and filled Electrical installation completed Hydraulic lines fully thermally insulated All windows and external doors airtight Geothermal probes well and connection lines fully...

Page 92: ...isposal of components must be carried out by type The dismantling of refrigeration systems may only be carried out by qualified professio nals If permissible components marked with the Green Dot symbo...

Page 93: ...fied with the CE designation Using the serial number the full Declaration of Con formity can be found on the following website www viessmann co uk eu conformity The product characteristics determined...

Page 94: ...66 Heat pump draining 69 Heat pump opening 62 Heat transfer medium 36 High flow balancing flow switch 66 High pressure sensor 68 Hydraulic connections Heat pump 33 Hydraulic module defrost box 56 Hydr...

Page 95: ...ry circuit filling and venting 64 Secondary circuit connection 36 Sensors 68 Sensors checking 69 Sight glass refrigerant 69 Siting 18 Heat pump 11 Hydraulic module defrost box 15 Siting heat pump 30 S...

Page 96: ...Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com...

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