Viessmann Vitocal 100-A Series Assembly And Servicing Instructions
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Viessmann Vitocal 100-A Series Assembly And Servicing Instructions

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  • Page 1 6020930...
  • Page 2 This manual has been drawn up for informative purposes. The company disclaims any liability for the results of any design or any installation based on the explanations and on the technical specifications provided in this manual. Even the partial reproduction of the texts and figures in this manual is prohibited under any form.

  • Page 3: Table Of Contents

    CONTENTS PURPOSE AND CONTENTS OF THE MANUAL ......................5 HOW TO KEEP THE MANUAL ............................5 GRAPHIC SYMBOLS USED IN THE MANUAL ........................ 5 NORMATIVE REFERENCES ............................... 6 PERMITTED USE ................................... 6 GENERAL SAFETY GUIDELINES ............................6 WORKERS’ HEALTH AND SAFETY ..........................7 PERSONAL PROTECTIVE EQUIPMENT ...........................
  • Page 4 10.1 ..................................33 ESIDUAL RISKS TECHNICAL DATA ................................40 11.1 TECHNICAL SHEET ................................40 11.2 UNIT AND AUXILIARY ELECTRICAL DATA ....................... 43 OPERATING LIMITS ................................43 12.1 EVAPORATOR WATER FLOW RATE ..........................43 12.2 COLD WATER PRODUCTION (SUMMER MODE) ......................44 12.3 HOT WATER PRODUCTION (WINTER MODE) ......................

  • Page 5: Purpose And Contents Of The Manual

    The manual of the Vitocal 100-A units contains all the necessary information for optimal use of the equipment under safe conditions for the operator. 1 PURPOSE AND CONTENTS OF THE MANUAL This manual provides basic information as to the selection, installation, operation and maintenance of the Vitocal 100-A unit.

  • Page 6: Normative References

    2 NORMATIVE REFERENCES Vitocal 100-A units have been designed in compliance with the following directives and harmonized standards on the safety of machinery:  EC directives, 2014/35/UE, 2014/30/UE, 2011/65/UE, 2012/19/UE, 2014/68/UE  Standard UNI EN 12735-1  Standard IEC EN 60335-1, IEC EN 60335-2-40 ...

  • Page 7: Workers' Health And Safety

    Do not spray or pour water directly on the unit. Do not dispose of, abandon or leave within reach of children packaging materials (cardboard, staples, plastic bags, etc.) as they may represent a hazard. Any routine or extraordinary maintenance operation must be carried out with the machine stopped and disconnected.

  • Page 8: Personal Protective Equipment

    For any operation on the heat pump system: Wear the appropriate PPE (specifically gloves and goggles). Make sure that the workplace is well ventilated. Do not work in closed environments or ditches with little air circulation. Do not operate on the refrigerant in the vicinity of hot parts or naked flames. Do not release the refrigerant into the environment and pay special attention to accidental leakage from pipes and/or fittings even after having emptied the plant.

  • Page 9: Refrigerant Safety Data Sheet

    4.4 REFRIGERANT SAFETY DATA SHEET Name: R32. HAZARDS IDENTIFICATION Main hazards: Asphyxiation. Specific hazards: Quick evaporation could cause it to freeze. FIRST AID MEASURES General information: Do not administer to people who are unconscious. Inhalation: Immediately remove to fresh air. Use oxygen or artificial respiration as required.

  • Page 10: Specific R32 Gas Warnings

    Hygienic measures: No smoking. PHYSICAL AND CHEMICAL PROPERTIES Colour: Colourless. Odour: Ethereal. Hard to perceive at low concentrations. Boiling point: -51.7°C at atm. press. Flash point: 648 °C. Relative gas density (air =1) 1.8. Relative liquid density 1.1. (water =1) Solubility in water: 280000 mg/l.

  • Page 11: R32 Gas Charge

    4.6 R32 GAS CHARGE The procedures described below may only be performed by skilled technicians or qualified personnel: - ensure the R32 is not contaminated by any other types of refrigerant; - keep the gas cylinder in an upright position when charging; - ground the refrigerant circuit - apply the appropriate label on the unit after charging;...

  • Page 12: Lifting And Handling

    CAUTION: The units are designed for outdoor installation. The outside temperature must never exceed 46°C. Beyond this value, the unit is no longer covered by the current regulations in the field of safety of pressure equipment. CAUTION: The installation place must be without any fire risks. Therefore all the necessary measures should be adopted in order to prevent the risk of fire at the installation place.

  • Page 13: Positioning And Minimum Technical Clearances

    5.3 POSITIONING AND MINIMUM TECHNICAL CLEARANCES All models of the Vitocal 100-A range are designed and constructed for outdoor installations. It is advisable to create an adequately sized support base for the unit. The units transmit a small amount of vibrations to the ground: it is nonetheless advisable to apply vibration dampers between the base frame and support surface.
  • Page 14 Lmin In the event of side-by-side units, the minimum Lmin distance between them is 1 m. Covering with canopies or placing near plants or walls should be avoided to prevent air recirculation. In the event of winds stronger than 2.2 m/s the use of wind barriers is recommended.

  • Page 15: Dimensions

    5.4 DIMENSIONS 5.4.1 Model Vitocal 100-A 06 / 08 IN/OUT: 1”M G E: power supply input 5.4.2 Model Vitocal 100-A 10 / 12 IN/OUT: 1”M G E: power supply input 6020930...

  • Page 16: Model Vitocal 100-A 14 / 16

    5.4.3 Model Vitocal 100-A 14 / 16 IN/OUT: 1”M G E: power supply input 5.5 ACCESSING THE INNER PARTS 5.5.1 Mod. Vitocal 100-A 06 / 08 DETAIL A SCALE 1 : 3 DETAIL B SCALE 1 : 4 Interlocking tab 6020930...

  • Page 17: Mod. Vitocal 100-A 10 / 12

    1) Remove the cover 2) Undo the screws (number 2; 3; 4) of the sheet metal cover of the user interface and the screw (number 1) of the side panel to separate the front sheet metal from the side panel (Detail A). 3) Undo in sequence the screws (number 5;...

  • Page 18: Mod. Vitocal 100-A 14 / 16

    5.5.3 Mod. Vitocal 100-A 14 / 16 DETAIL A SCALE 1 : 1 DETAIL B SCALE 1 : 2 1) Remove the cover by undoing the screws (number 1; 2; 3; 4; 5; 6; 7; 8;9). 2) Undo the screws (number 10; 11) of the front sheet and then push the panel downwards to remove the tabs (Detail A);...

  • Page 19: Features Of The Circuit Water

    All of the units leave the company supplied with flow switch (installed in factory). If the flow switch is altered or removed or if the water filter and dirt separator are missing from the unit, the guarantee will be void. Refer to the wiring diagram attached to the unit to connect the flow switch.

  • Page 20: Handbook

    5.6.3 Handbook If you need more information about the possible configurations, there is a handbook which is a technical notebook including a series of system diagrams that have been highlighted regarding the installation configuration of our high efficiency heat pumps. The Handbook is also intended to show the symbiosis potential with some of our elements found in the catalogue.

  • Page 21: Service Sleeves

    When it is required to top up the circuit or to adapt the glycol level, please use the service valve. Unscrew and remove the cap from the service valve and Ring nut connect a 14 or 12 mm pipe (inside Cap with gasket diameter - check the valve model installed on your unit), connected to the...

  • Page 22: Vitocal 100-A 06 / 08

    FUNCTIONAL DIAGRAMS 5.6.9 Vitocal 100-A 06 / 08 CODE NUM. DESCRIPTION CODE NUM. DESCRIPTION COMPRESSOR H/CS UTILITY WATER OUTLET CO/EV CONDENSER (IN CHILLER MODE) H/CR UTILITY WATER INLET EV/CO EVAPORATOR (IN CHILLER MODE) PEHTC HIGH PRESSURE TRANSDUCER ELECTRONIC EXPANSION VALVE PEDTR LOW PRESSURE TRANSDUCER YISV...

  • Page 23: Vitocal 100-A 14 / 16

    Vitocal 100-A 10 / 12 CODE NUM. DESCRIPTION CODE NUM. DESCRIPTION COMPRESSOR H/CS UTILITY WATER OUTLET CO/EV CONDENSER (IN CHILLER MODE) H/CR UTILITY WATER INLET EV/CO EVAPORATOR (IN CHILLER MODE) PEHTC HIGH PRESSURE TRANSDUCER ELECTRONIC EXPANSION VALVE PEDTR LOW PRESSURE TRANSDUCER YISV 4-WAY CYCLE REVERSING VALVE OUTDOOR AIR TEMPERATURE PROBE...
  • Page 24 5.6.10 Vitocal 100-A 14 / 16 CODE NUM. DESCRIPTION CODE NUM. DESCRIPTION COMPRESSOR H/CS UTILITY WATER OUTLET CO/EV CONDENSER (IN CHILLER MODE) H/CR UTILITY WATER INLET EV/CO EVAPORATOR (IN CHILLER MODE) PEHTC HIGH PRESSURE TRANSDUCER ELECTRONIC EXPANSION VALVE PEDTR LOW PRESSURE TRANSDUCER YISV 4-WAY CYCLE REVERSING VALVE OUTDOOR AIR TEMPERATURE PROBE...

  • Page 25: Electrical Connections

    5.7 ELECTRICAL CONNECTIONS Check that the power supply matches the unit’s electric nominal data (voltage, phases, frequency) displayed on the rating plate on the unit’s side panel. The electric power connections must be made in accordance to the wiring diagram enclosed with the unit and in conformity with national and international standards (providing general circuit breaker, residual current devices for each line, proper earthing of the plant, etc.).

  • Page 26: Power Supply Terminal Block

    plate of the cable glands. When the work is finished, close all of the removed covers applying the screws and gaskets (if included). 5.7.2 Power supply terminal block The electrical wiring to the terminal blocks has to be done only by qualified personnel. The electrical wiring has to be done only by qualified personnel.

  • Page 27: User Terminal Block

    Changeover contact, single phase X-14.1/X- Double set-point valve output (VDS1) voltage 230Vac, 50Hz, 5A resistive, 14.2 1A inductive. Summer/winter mode change input from remote (to activate the function, see the relevant paragraph in the Voltage-free digital input 16.1/X16.2 MCO manual) Remote on/off input Voltage-free digital input 15.1/X15.2...

  • Page 28: Control Logics

    14/16 kW 14/16 kW 3ph 5.7.4 Control logics For the control logics, see the manual cod. MCO01110L8500. 5.7.5 Fuses Details on the type and nominal specifications of the fuses are set out on the machine’s data plate, as well as on the fuses. 6 STARTUP Before start-up: ...

  • Page 29: Switching On The Unit

     Check that the electrical connections have been made according to standards in force, including earthing.  Voltage must match that on the unit’s rating plate.  Make sure that the electric voltage is within the tolerance limits (±5%).  Check that the electric heaters of the compressors are properly powered. ...

  • Page 30: Shutdowns For Long Periods

    We recommend keeping track of the interventions carried out on the unit so as to make any troubleshooting easier. In case of failure or malfunctioning:  check the type of alarm triggered to report it to the assistance centre;  contact an authorised assistance centre; ...

  • Page 31: Cleaning The Finned Coil

    possible. Verify the mandatory nature and the documentation required in regulation n.517/2014 and its subsequent amendments or repeals. As the manufacturer, we recommend that the following service plan is maintained (if necessary, carried out by a specialist company). Non-compliance can have a negative effect on error-free operation and the expected product service life of the heat pump.

  • Page 32: Extraordinary Maintenance

    aluminium fins. Do not strike the coil with the water hose. Apply your thumb at the end of the hose to increase the pressure of the water jet instead of using specific nozzles which could damage the coil. CAUTION: Do not clean the coil using high-pressure cleaners so as not to apply excessive pressure which could cause irreparable damage.

  • Page 33: Residual Risks

    The user is responsible for the proper disposal of this product, according to national regulations in the country of destination of the appliance. For more information you should contact the Installation Company or local competent authority. An incorrect decommissioning of the appliance may create serious environmental damage and endanger people’s safety.
  • Page 34 Every person working on the refrigerant circuit must be able to produce a certificate of competence issued by an ■ organisation with industry accreditation. This certificate confirms their competence in the safe handling of refrigerants by means of a standard industry procedure. Servicing work may only carried out in accordance with the manufacturer's specifications.
  • Page 35 Measure Completed Notes Checking the refrigeration system Any replacement electrical components must be suitable for the ■ application and must correspond to the manufacturer’s specifi- cation. Only replace faulty components with genuine spare parts. Carry out all component replacements in accordance with ■...
  • Page 36 Measure Completed Notes Repairs on sealed enclosures When carrying out work on sealed components, fully isolate the ■ appliance from the power supply, also before removing sealed covers. If a power supply is absolutely necessary during the work: Posi- ■ tion a continuously operating refrigerant detector in the most critical locations, to provide warning of any potentially danger- ous situation.
  • Page 37 Measure Completed Notes Leak detection The following leak detection processes are suitable for systems with flammable refrigerants: Leak detection with electronic refrigerant detectors: Electronic refrigerant detectors may not have the required sensi- ■ tivity or may need to be calibrated to the relevant range. Carry out the calibration in refrigerant-free surroundings.
  • Page 38 short as possible to minimise the amount of refrigerant contained in them. – Cylinders shall be kept upright. – Ensure that the refrigeration system is earthed prior to charging the system with refrigerant. – Label the system when charging is complete (if not already). –...
  • Page 39 Recovering the refrigerant and compressor oil Recovery When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely. When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge are available.

  • Page 40: Technical Data

    11 TECHNICAL DATA 11.1 TECHNICAL SHEET Vitocal 100-A Unit of TECHNICAL SPECIFICATIONS AWO-M-AC AWO-M-AC AWO-M-AC AWO-M-AC measurement 101.A06 101.A08 101.A10 101.A12 Cooling capacity (1) 3.20 / 5.02 / 3.80 / 6.08 / 4.66 / 7.53 / 4.55 / 8.51 / 5.52* 6.69* 8.28*...
  • Page 41 Maximum input power with antifreeze Maximum input current with antifreeze 15.6 17.6 20.7 22.7 A - Length 1047 1047 B - Depth Dimensions and C - Height weights Shipping weight Operating weight Performance referring to the following conditions, according to standard 14511:2018: (1) Cooling: outdoor air temperature 35°C;...
  • Page 42 Vitocal-100A Unit of TECHNICAL SPECIFICATIONS measurement AWO-M-AC 101.A14 AWO-AC 101.A14 AWO-M-AC 101.A16 AWO-AC 101.A16 Cooling capacity (1) 6.87 / 11.48 / 12.05* 6.87 / 11.48 / 12.05* 5.99 / 13.80 / 14.49* 5.99 / 13.80 / 14.49* min/nom/max Input power (1) 3.53 3.53 4.38...

  • Page 43: Unit And Auxiliary Electrical Data

    Maximum input power with antifreeze kit Maximum input current with 29.2 31.0 10.3 antifreeze kit A - Length 1044 1044 1044 1044 B - Depth Dimensions and C - Height 1409 1409 1409 1409 weights Shipping weight Operating weight Performance referring to the following conditions, according to standard 14511:2018: (1) Cooling: outdoor air temperature 35°C;...

  • Page 44: Cold Water Production (Summer Mode)

    Model Minimum water flow to be assured in chiller mode 0.15 0.17 0.23 0.25 0.34 0.34 (condition (1) technical sheet) [l/s] Maximum water flow to be assured in chiller mode 0.40 0.46 0.60 0.68 0.92 0.92 (condition (1) technical sheet) [l/s] Minimum flow switch 0.117 0.117...
  • Page 45 Operating limits Water chiller mode Room temperature Minimum -10°C Maximum +46°C Outlet water temperature Minimum +5°C Maximum +25°C Heat pump mode Room temperature Minimum -20°C Maximum +30°C Outlet water temperature Minimum +25°C Maximum +60°C Heat pump mode for domestic hot water Room temperature with water at maximum 39°C Minimum -20°C Maximum +40°C...
  • Page 46 CHILLER MODE Cooling DOMESTIC HOT WATER MODE DHW mode 6020930...

  • Page 47: User Interface - Controller

    13 USER INTERFACE - CONTROLLER The unit includes a display placed underneath a hinged polycarbonate transparent door with a protection rating of IP67. The interface has a part with variable text and a series of icons identifying operation of the unit as shown in the table below.

  • Page 48: Menu

    Grants access to the parameter setting menu and allows you to set the summer, winter and sanitary setpoint. UP key. In the parameter setting mode, it allows you to move to a higher menu or to increase the parameter value when in “edit” mode. DOWN key.
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This manual is also suitable for:

Vitocal 100-a 06/08Vitocal 100-a 10/12Vitocal 100-a 14/16Awo-m-ac 101.a06Awo-m-ac 101.a08Awo-m-ac 101.a10 ... Show all

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