Viessmann OC208HM Service Instructions For Contractors Download

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VIESMANN

Service instructions

for contractors

Vitoclima 200-C

Chillers for external installation as 230 V version
For cooling as well as for cooling and heating operation

For applicability, see the last page

VITOCLIMA 200-C

5692 695 GB

2/2007

Please keep safe.

Summary of Contents for OC208HM

Page 1: ...s for contractors Vitoclima 200 C Chillers for external installation as 230 V version For cooling as well as for cooling and heating operation For applicability see the last page VITOCLIMA 200 C 5692 695 GB 2 2007 Please keep safe ...

Page 2: ...king on this system all legal instructions regarding the prevention of accidents all legal instructions regarding environmental protection the Code of Practice of relevant trade associations all current safety regulations as defined by DIN EN VDE and all locally applicable standards Working on the system Isolate the system from the power supply and check that it is no longer live e g by removing a...

Page 3: ... and wearing parts Please note Spare and wearing parts that have not been tested together with the heating system can compromise its function Instal ling non authorised compo nents and non approved modifications or conversions can compromise safety and may invalidate our warranty For replacements use only ori ginal spare parts supplied or approved by Viessmann Safety instructions cont 3 Safety ins...

Page 4: ...g mode HEA 31 Selecting the set value for cooling mode Coo 32 Scanning sensor values 32 Components Differential pressure regulator 34 Refrigerant circuits Unit for cooling mode 35 Unit for heating and cooling mode 36 Parts lists Parts list Vitoclima 200 C type OC208 37 Parts list fan convectors type V202H to V209H 37 Parts list ceiling cassette devices type C202H to C205H 38 Parts list duct mounte...

Page 5: ...ent valve on the flow B ON OFF switch C Programming unit D Cover for the circulation pump E Phase monitor only for 400 V ver sion F Diaphragm expansion vessel G Fill drain valve Unit layout 5 Unit layout 5692 695 GB ...

Page 6: ...s low pressure side C Service valve high pressure side D Safety valve hydraulic circuit Connection and wiring diagrams The connection and wiring diagrams are affixed to the inside of the front panel Unit layout cont 6 Unit layout 5692 695 GB ...

Page 7: ...ing the function of the safety valve 10 Checking the tightness of electrical connections 13 11 Switching ON connecting the main fuse 12 Switching the system ON OFF switch ON if installed 13 Placing the unit in standby mode 14 14 Ensuring that load is drawn 14 15 Switching the unit ON 14 16 Adjusting parameters HEA and H31 15 17 Adjusting the throughput in the hydraulic circuit 15 18 Checking the s...

Page 8: ...cking the oil sump heater 20 27 Checking the compressor power consumption 20 28 Checking the fan power consumption 21 29 Checking the contactors 21 30 Checking the protective motor switch 21 31 Checking the thermostat 21 32 Checking the cables 21 33 Checking the temperature sensors 21 34 Checking the relays 22 35 Instructing the system user Steps commissioning inspection and cont 8 Commissioning i...

Page 9: ...ndling of refrigerant Danger Touching components of the refrigerant circuit can cause burns or frostbite Touch these components only with protective gloves Check the interior of the equipment with a refrigerant leak detector or leak detection spray for refrigerant leaks 1 Remove the front panel 2 Check the floor area valves and all visible solder joints for traces of oil 3 Check the thermal insula...

Page 10: ...the handling of antifreeze on page 20 5 Check the system pressure see page 11 6 Return the non return valves if installed into their operating posi tion Checking the diaphragm expansion vessel and the pressure of the hydraulic circuit Carry out this test on a cold system 1 Drain the system on the heating water side and reduce the pressure until the pressure gauge indicates 0 2 If the inlet pressur...

Page 11: ... filter Note Clean the water filter installed on site for the first time after 2 hours of opera tion Please note Dirt inside the heat exchanger of the hydraulic circuit heating or cooling circuit can lead to the plate type heat exchanger icing up which would result in severe equipment damage Only fill the hydraulic circuit with clean water regularly clean the water filter 1 Close the shut off valv...

Page 12: ...her with compressed air or with a soapy solution Danger Touching live components or bringing live components into contact with water can result in the transfer of dangerous body currents and equipment damage Before cleaning the air heat exchanger isolate the equip ment from the power supply check that it is no longer live and safeguard against unauthorised reconnection Please note The edges and sh...

Page 13: ...ease note Excessive air pressure can result in the deformation of the aluminium fins of the heat exchanger Only point the compressed air gun at the heat exchan ger from the front of the fan side and at an adequate dis tance Air forced at the alu minium fins from the side will result in their deforma tion Blow compressed air through the air heat exchanger 4 Check the aluminium fins of the heat exch...

Page 14: ...t in this state for approx 4 h Ensuring that load is drawn Prior to switching the unit ON ensure a load of at least 60 of the rated output is drawn in the respective operating mode heating cooling For this fully open the valves in the heating or cooling circuit as well as any other control elements that may be installed Switching the unit ON Please note Starting the compressor in a cold state can ...

Page 15: ...nt of parameters and the code see from page 30 2 Raise the return temperature for this change parameter HEA see page 31 As the units are reverse controlled select a value approx 5 C lower than the required flow temperature Adjusting the throughput in the hydraulic circuit The pump rate of the internal pump of the hydraulic circuit can be adjusted to ensure the required minimum throughput This is m...

Page 16: ...tting starting from the available delivery pressure the required water throughput will be achieved see the following exam ple 4 If necessary change the pump set ting see section Adjusting the pump rate on page 17 5 Check the pressure again Example Further details regarding the individual steps cont 16 Commissioning inspection maintenance 5692 695 GB ...

Page 17: ... intersection B and D with the pump curves for stage 1 and 3 lie outside the range of the required flow rate The point of intersection C with the pump curve for stage 2 lies within the range of the required flow rate Therefore set the pump to stage 2 Adjusting the pump rate Danger Touching live components can result in the transfer of dangerous body currents Isolate the unit from the power supply ...

Page 18: ...e the test is started 1 Determine the low pressure with the pressure gauge attached to the inlet side of the service valve see Fig on page 6 2 Using the temperature scale of the pressure gauge determine the saturation temperature of the inlet side Tse that corresponds to this pressure 3 Place a contact thermometer at the outlet connector of the evaporator and determine the effective tem perature T...

Page 19: ...mentation of the work in the service report from page 39 Checking the water side of the evaporator for contamination The temperature differential between the flow and the return temperature at the plate type heat exchanger must be 5 to 8 K The plate type heat exchanger may be contaminated at temperature differentials 8 K In this event separate the heat exchanger hydraulically and clean it chemical...

Page 20: ...ecord the determined value in the service report from page 39 Checking the compressor Check the compressor for smooth running noise development and ensure it is fixed correctly Record the implementation of the work in the service report from page 39 Checking the oil sump heater Record the implementation of the work in the service report from page 39 Checking the compressor power consumption Check ...

Page 21: ...service report from page 39 Checking the protective motor switch Record the implementation of the work in the service report from page 39 Checking the thermostat Record the work carried out in the ser vice report on page 39 Checking the cables Record the work carried out in the ser vice report on page 39 Checking the temperature sensors Record the work carried out in the ser vice report on page 39...

Page 22: ...Checking the relays Record the implementation of the work in the service report from page 39 Further details regarding the individual steps cont 22 Commissioning inspection maintenance 5692 695 GB ...

Page 23: ...mode indication E Key for operating mode selection F Key for switching the unit ON and OFF see page 14 for deleting messages see page 24 or for scrolling down through the menu G Display H ON OFF indicator defrost K ON OFF indicator electric hea ter 2 Indication of the operating states through the LED at the programming unit LED LED indicator Operating condition Compressor 1 Flashes Active delay ON...

Page 24: ...the return temperature Scanning messages Press the following keys 1 CD simultaneously and briefly 2 s the dis play shows SET 2 D until the display shows Err 3 CD simultaneously and briefly the display shows the first message Note If there is no message the display shows 4 D to display any other mes sages that may be cur rent 5 CD simultaneously and for at least 5 s to reach the next higher menu le...

Page 25: ...an the water filter and in crease the heating water throughput if required E02 Low pres sure fault automatic reset up to twice per hour Inadequate throughput in side the hydraulic circuit Clean the water filter in crease the water through put if required Air heat exchanger con taminated Clean the air heat exchan ger Filter dryer blocked Replace the filter dryer E05 Frost protec tion auto matic res...

Page 26: ... the filter dryer Ice on the suction line The preselected super heating is incorrect Increase the superheating setting Check refrigerant level Increased noise development Lines vibrating Check line retainers if in stalled Thermostatic expansion valve hisses Top up refrigerant Check filter dryer Compressor noisy Check compressor mounts Compressor bearing worn replace compressor Low oil level inside...

Page 27: ...motor winding for continuity Compressor seized Replace compressor Low pressure switch is tripped and switches the unit off Refrigerant leak Identify and repair leak Inadequate refrigerant fill ing Top up refrigerant Low pressure switch faulty Replace low pressure switch High pressure switch is tripped and switches the unit off High pressure switch Replace high pressure switch Gases in the refriger...

Page 28: ...A Continued see page 29 Menu structure overview 28 Control settings 5692 695 GB ...

Page 29: ...A Continued see page 28 B Code 177 Menu structure overview cont 29 Control settings 5692 695 GB ...

Page 30: ...rameter group is dis played 3 Press C and D simulta neously for less than 2 s The next lower menu level will be shown 4 With C or D scroll up or down through the menu until the required parameter is displayed 5 To change the parameter increase or reduce the value with C or D or change the option from ON to OFF or vice versa 6 To save the change and to exit the menu level press C and D simultaneous...

Page 31: ...ntry is saved and the next higher menu level is dis played 5 To return to the standard display return temperature repeat step 4 Selecting the set value for heating mode HEA Press the following keys 1 CD simultaneously and briefly 2 s the display shows SET 2 CD simultaneously and briefly the display shows Coo 3 D the display shows HEA 4 CD simultaneously and briefly the display shows the current se...

Page 32: ...values Press the following keys 1 CD simultaneously and briefly 2 s the dis play shows SET 2 D to display tP 3 CD simultaneously and briefly the display shows T01 4 CD simultaneously and briefly the display shows the temperature at the return tempera ture sensor ST1 5 CD simultaneously and at least for 5 s the display shows T01 6 D to display T02 7 CD simultaneously and briefly the display shows t...

Page 33: ...simultaneously and at least for 5 s the display shows T03 again 12 To return to the standard display return temperature repeat step 11 several times Scanning sensor values cont 33 Control settings 5692 695 GB ...

Page 34: ...e differential pressure regulator ensures that a volume of water that is adequate for the compressor opera tion is available in the hydraulic cir cuit This prevents damage to the heat exchanger e g as a result of a circu lation pump failure or through icing up of the hydraulic circuit Differential pressure regulator 34 Components 5692 695 GB ...

Page 35: ... switch 5 Service valve low pressure side 6 Plate type heat exchanger 7 Differential pressure switch 8 Air vent valve 9 Circulation pump hydraulic circuit qP Diaphragm expansion vessel qQ Pressure gauge qW Safety valve qE Fill drain valve qR Expansion valve qT Filter qZ Air heat exchanger with fan Unit for cooling mode 35 Refrigerant circuits 5692 695 GB ...

Page 36: ...de 4 Compressor 5 Low pressure switch 6 Service valve low pressure side 7 Differential pressure switch 8 Air vent valve 9 Circulation pump hydraulic circuit qP Diaphragm expansion vessel qQ Pressure gauge qW Safety valve qE Fill drain valve qR Plate type heat exchanger qT Liquid collector qZ Filter qU Expansion valve qI Air heat exchanger with fan Unit for heating and cooling mode 36 Refrigerant c...

Page 37: ...25 A 021 Fuse 10 A 022 Fuse 4 A 023 Fuse holder 32 A single pole 024 Fuse holder 32 A three pole 025 Electric heater 35 W 041 Installation instructions 042 Service instructions 044 Touch up paint stick Vitosilver 045 Touch up spray Vitosilver Parts list fan convectors type V202H to V209H When ordering spare parts Quote the part and serial no see type plate and the item no of the required part as p...

Page 38: ...hree way valve 040 Operating instructions 041 Installation instructions Parts list duct mounted devices type DC205H to DC210H When ordering spare parts Quote the part and serial no see type plate and the item no of the required part as per this parts list Obtain standard parts from your local supplier Parts 001 Capacitor 003 Fan complete 008 Temperature sensor 009 Fan 040 Operating instructions 04...

Page 39: ...ssor condition Noise emissions test Compressor current Start up Operation Hot gas temperature C Suction gas temperature C High pressure bar Low pressure bar Oil sump heater Refrigerant circuit Soundness Thermal insulation High pressure switch Low pressure switch Expansion valve Control unit and electrical equipment Contactors Protective motor switch Thermostat Cables Temperature sensors Relay Othe...

Page 40: ...Assembly Tested Re placed Cleane d Comments Antifreeze concentration hydraulic circuit Water filter Tested by Date Test report cont 40 Commissioning service reports 5692 695 GB ...

Page 41: ...4 7 14 7 Starting current only compres sor A 76 76 Max power consumption 1 kW 4 6 4 6 Power consumption oil sump heater W 70 70 Power consumption secondary heat exchanger heater W 35 35 Refrigerant circuit Process medium R 407 C Fill volume kg 2 0 2 0 Compressor Type Scroll Surface area W x H primary heat exchanger mm 640 x 810 640 x 810 Fan No 1 1 Air flow rate m3 h 2800 2800 Speed rpm 800 800 ma...

Page 42: ...h mm 400 400 Total width mm 1182 1182 Total height mm 905 905 Weight kg 110 110 Permissible operating pres sure bar 3 0 3 0 Hydraulic Flow connection R 1 1 Return connection R 1 1 Diaphragm expansion vessel ca pacity l 2 2 Specification cont 42 Specification 5692 695 GB ...

Page 43: ... EN 60 204 1 EN 61 000 6 4 In accordance with the following Directives this product is designated with _ 89 336 EC 2006 95 EC 97 23 EC Details as per Pressure Equipment Directive Category II module A1 and category III module B and C1 Test station no 1115 PASCAL arl Allendorf 20 February 2007 Viessmann Werke GmbH Co KG pp Manfred Sommer Declaration of conformity 43 Certificates 5692 695 GB ...

Page 44: ...3 24 25 Frost protection 10 H Heating curve 15 I Inspection 9 L Leak soundness testing 9 Load drawing 14 M Main fuse MCB 9 Maintenance 9 Messages 23 24 25 Minimum circulation volume 15 Minimum throughput 15 P Parts lists 37 38 Pressure gauge 10 15 Process medium 10 Programming unit 14 23 Pump curve 16 Pump rate 16 17 R Repair work 9 Room thermostat 23 S Set value Cooling mode 32 Heating mode 31 Sy...

Page 45: ...45 5692 695 GB ...

Page 46: ...46 5692 695 GB ...

Page 47: ...47 5692 695 GB ...

Page 48: ...n environmentally friendly chlorine free bleached paper 5692 695 GB Subject to technical modifications Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com ...

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