Viessmann AC-Box Operating instructions

Installation and service instructions

for contractors

VIESMANN

AC-Box

Pre-assembled unit for implementing the natural cooling and active cooling

functions in conjunction with brine/water heat pumps up to 17 kW

For applicability, see the last page

AC-Box

5675 895 GB 2/2015 Please keep safe.

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 author-

ised 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.

Regulations to be observed

■National installation regulations

■Statutory regulations for the prevention of accidents

■Statutory regulations for the protection of the envi-

ronment

■Codes of Practice of the relevant trade associations

■All relevant safety regulations as defined by DIN, EN,

DVGW, VDE and locally applicable standards

aÖNORM, EN and ÖVE

cSEV, 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

load 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.

Wait at least 4 minutes before removing equip-

ment covers, to allow the voltage to dissipate.

■Safeguard the system against reconnection.

!Please note

Electronic assemblies can be damaged by elec-

trostatic discharge.

Prior to commencing work, touch earthed

objects such as heating or water pipes to dis-

charge static loads.

Repair work

!Please note

Repairing components that fulfil a safety func-

tion can compromise the safe operation of your

system.

Replace faulty components with genuine

Viessmann spare parts.

Auxiliary components, spare and wearing parts

!Please note

Spare and wearing parts that have not been tes-

ted together with the system can compromise its

function. Installing non-authorised components

and making non-approved modifications or con-

versions can compromise safety and may inva-

lidate our warranty.

For replacement, use only spare parts supplied

or approved by Viessmann.

Safety instructions

5675 895 GB

1. Information Symbols ................................................................................................. 4

Product information ................................................................................ 4

■Information regarding operation ......................................................... 5

2. Preparing for installation Hydraulic function diagram .................................................................... 6

Hydraulic connection with on-site pipework ........................................... 7

Hydraulic connection with AC-Box connection accessories .................. 7

Siting and transport requirements .......................................................... 8

■Transport ............................................................................................ 8

■Installation room requirements ........................................................... 8

■Minimum clearances ........................................................................... 8

3. Installation sequence Siting the AC-Box .................................................................................. 9

Hydraulic connection ............................................................................. 9

■Connection with AC-Box connection accessories .............................. 10

■Installing the contact humidistat 24 V– (accessories) ......................... 11

Electrical connection .............................................................................. 11

■Required connections ......................................................................... 11

■Additional connections ........................................................................ 12

■Overview of electrical connections ..................................................... 15

■Switching to heat pump control unit (NC / AC signal) ......................... 16

■Shutdown signal for heat pump 230 V~ .............................................. 16

■Contact humidistat 24 V– .................................................................... 18

■Additional frost stat (accessories) ....................................................... 18

■Contact humidistat signal 24 V– ......................................................... 19

Power supply ......................................................................................... 19

■Connections on plug fÖ ...................................................................... 20

Closing the AC-Box ............................................................................... 20

4. Upkeep Internal components .............................................................................. 21

5. Parts lists Overview of assemblies ......................................................................... 22

■Parts not shown .................................................................................. 23

Casing .................................................................................................... 24

Electrical equipment .............................................................................. 26

Hydraulics .............................................................................................. 28

Connection set ....................................................................................... 30

6. Connection and wiring dia-

gram

.................................................................................................................. 32

7. Specification .................................................................................................................. 33

8. Declaration of conformity .................................................................................................................. 34

9. Keyword index .................................................................................................................. 35

Index

5675 895 GB

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction 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.

Product information

Design and function

The AC-Box includes all hydraulic and electrical com-

ponents required for cooling a heating/cooling circuit

without mixer or a separate cooling circuit in conjunc-

tion with a brine/water heat pump. Subject to the cool-

ing demand, either the natural cooling or the active

cooling function starts.

In natural cooling mode, the temperature level of the

primary circuit is directly transferred to the cooling cir-

cuit. In active cooling mode, the compressor starts. As

a result, the available cooling capacity is significantly

higher compared to natural cooling.

Hydraulic connections

The heating/cooling circuit or the separate cooling cir-

cuit and the primary circuit (brine) are hydraulically

connected directly to the AC-Box. The hydraulic con-

nection between the heat pump and the AC-Box can

be made on site or via the AC-Box connection acces-

sories.

Electrical connection

The AC-Box and the heat pump are connected electri-

cally. The electrical cables and power cable required

are connected inside the AC-Box at the factory and

routed outside through the back of the appliance.

Information

Symbols

5675 895 GB

Information

Product validity

The AC-Box can be used in conjunction with the fol-

lowing heat pumps:

■Vitocal 300-G, types BW/BWC 301.A06 to A17

■Vitocal 300-G, types BW/BWC 301.B06 to B17

■Vitocal 350-G, type BW/BWC 351.A07

Information regarding operation

■In order to safeguard the transfer of the cooling

capacity at all times, we recommend connecting fan

convectors to the AC-Box.

■If cooling by means of an underfloor heating system,

a contact humidistat is required: See page 11.

Information

Product information (cont.)

5675 895 GB

Information

P R

Fig.1

Note

■Valve switching states without switching by the heat

pump.

■Component layout inside the appliance: See

page 21.

Direction of flow, 3-way diverter valve

Valve open

Valve closed

A2-way valve V1

B2-way valve V2

C2-way valve V3

D2-way valve V7

E2-way valve V5

F2-way valve V6

G3-way diverter valve V4

HHigh efficiency circulation pump M2

KHigh efficiency circulation pump M1

LPlate heat exchanger 1

MPlate heat exchanger 2

NFrost stat

OAC-Box

PContact humidistat 24 V– (accessories)

RFlow, heating/cooling circuit or separate cooling

circuit

SReturn, heating/cooling circuit or separate cool-

ing circuit

TGeothermal probe

UHeat pump

VDHW cylinder flow

WDHW cylinder return

Switching states of the integral 2-way valves and circulation pumps

Active signal V1 AV2 BV3 CV5 EV6 FV7 DM1 KM2 H

None 0 0

NC signal \ 0

AC signal \ \

Valve open

Valve closed

\ON

0OFF

Preparing for installation

Hydraulic function diagram

5675 895 GB

Installation

If the AC-Box cannot be installed immediately to the

left of the heat pump:

1. Install the AC-Box near the heat pump.

2. Connect on-site connection lines so that they are

free of load and torque stress.

Hydraulic connection with AC-Box connection accessories

The AC-Box connection accessories comprise 4 ther-

mally insulated connecting pipes, each with 1 air vent

valve and gaskets.

Fig.2

AAC-Box

BPrimary circuit connection line: AC-Box brine inlet

CPrimary circuit connection line: AC-Box brine outlet

DPrimary circuit flow: AC-Box brine outlet

EPrimary circuit return: AC-Box brine inlet

FFlow, heating/cooling circuit or separate cooling

circuit

GReturn, heating/cooling circuit or separate cooling

circuit

HSecondary circuit connection line: AC-Box heating

water outlet

KSecondary circuit connection line: AC-Box heating

water inlet

LSecondary circuit connection line: Heat pump

heating water inlet

MDHW cylinder flow

NSecondary circuit connection line: Heat pump

heating water outlet

PPrimary circuit connection line: Heat pump brine

inlet

Preparing for installation

Hydraulic connection with on-site pipework

5675 895 GB

Installation

RPrimary circuit connection line: Heat pump brine

outlet

SHeat pump

Siting and transport requirements

Transport

!Please note

Impacts, compression and tensile loads can

cause damage to the outside panels of the

appliance.

Never apply loads/weight to the top, front or

side panels of the appliance.

Installation room requirements

!Please note

Unfavourable ambient conditions can lead to

malfunction and appliance damage.

■The installation room must be dry and free

from the risk of frost.

■Ensure ambient temperatures between 0 and

35 °C.

Danger

Dust, gases and vapours can be damaging to

health and cause explosions.

Avoid dust, gases and vapours in the installation

room.

!Please note

Overloading the floor can result in damage to

the building structure.

Observe the permissible floor load. Take the

total weight of the appliance into account.

Minimum clearances

A B

200

400400

1500

Fig.3

AAC-Box

BHeat pump

Preparing for installation

Hydraulic connection with AC-Box connection… (cont.)

5675 895 GB

Installation

1. Site the AC-Box on a level surface, to the left of the

heat pump with no gap between them: See Figs. 2

and 3.

2. Level the appliance with its adjustable feet.

Hydraulic connection

To prevent corrosion damage, provide all hydraulic

pipes with thermal insulation as vapour diffusion-proof

installation (on the brine and cold water sides) in

accordance with current engineering standards.

Installation sequence

Siting the AC-Box

5675 895 GB

Installation

Connection with AC-Box connection accessories

Fig.4

Note

Thermally insulate the connections of the AC-Box and

the heat pump with vapour diffusion-proof adhesive

tape.

A to DHydraulic connection lines: See the following

table

Installation sequence

Hydraulic connection (cont.)

5675 895 GB

Installation

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