Viessmann VITOCAL 200-G Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-G
Type BWC 201.A06 to A17, 6 to 17 kW
Single stage heat pump with electric drive, 400 V~
Type BWC-M 201.A06 to A10, 6 to 10 kW
Single stage heat pump with electric drive, 230 V~
For applicability, see the last page
VITOCAL 200-G
5600 138 GB 5/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ National installation regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and
SVGW
Working on the system
■ Isolate the system from the power sup-
ply (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 recon-
nection.
Safety instructions
Safety instructions
5600 138 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
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 sys-
tem.
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-author-
ised 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.
Safety instructions
Safety instructions (cont.)
5600 138 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
General information on the electrical connection................................................. 7
Siting.................................................................................................................... 7
Overview of possible system schemes................................................................ 10
Primary circuit....................................................................................................... 11
DHW heating........................................................................................................ 13
System example 1, ID: 4605363_1009_01.......................................................... 18
System example 2, ID: 4605364_1009_01.......................................................... 24
Installation sequence
Siting the heat pump............................................................................................ 32
Hydraulic connections.......................................................................................... 34
Electrical connections........................................................................................... 36
Power supply........................................................................................................ 52
Connecting to terminals X3.8/X3.9....................................................................... 60
Closing the heat pump......................................................................................... 61
Checking diaphragm grommets........................................................................... 62
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 63
Further details regarding the individual steps....................................................... 64
Troubleshooting
Repairs................................................................................................................. 75
Parts lists
Parts lists.............................................................................................................. 82
Overview of the assemblies................................................................................. 83
Parts not shown.................................................................................................... 84
Casing.................................................................................................................. 84
Hydraulics............................................................................................................. 86
Heat pump module............................................................................................... 88
Electrical equipment............................................................................................. 90
Commissioning/service reports........................................................................ 96
Specification....................................................................................................... 101
Index
Index
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Appendix
Heat pump commissioning order.......................................................................... 106
Certificates
Declaration of conformity...................................................................................... 107
Keyword index.................................................................................................... 108
Index
Index (cont.)
5600 138 GB

6
The appliance is only intended to be
installed and operated in sealed unven-
ted 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 pur-
poses:
■ Central heating
■ Central cooling
■ DHW heating
The range of functions can be extended
with additional components and acces-
sories.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than central heating/cooling
or DHW heating shall be deemed inap-
propriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect 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 oper-
ate the appliance safely.
Preparing for installation
Intended use
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7
■Electrical connection of system
components (pumps, mixers, valves,
alarm facilities, contactors, function
extensions, sensors, etc.):
These connections are made inside
the heat pump control unit. Observe
information from page 39.
■Power supply:
The number of power cables from the
distribution board (meter box) to the
heat pump control unit and to the con-
trol panel depends on the system ver-
sion and tariffs used.
These connections are made inside
the heat pump control panel. Observe
information from page 52.
Siting
!Please note
Avoid damaging the appliance
during transportation.
Never put weight on top of the
appliance.
!Please note
If the compressor is at a steep
angle in the heat pump, lubricant
will enter the refrigerant circuit
and damage the appliance.
Max. tilting angle 45°.
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Ensure ambient temperatures of
0 to 35 ºC.
!Please note
Avoid risk of explosion due to
dust, gases and vapours
in the installation room.
!Please note
Observe the permissible floor
load.
See the following table, "Total
weight".
Total weight
Output stage Type BWC 201.A
(400 V~ appliance)
Type BWC-M 201.A
(230 V~ appliance)
06 113 kg 115 kg
08 117 kg 119 kg
10 129 kg 131 kg
13 135 kg —
17 148 kg —
Preparing for installation
General information on the electrical connection
5600 138 GB
Installation

8
■ To prevent structure-borne noise,
never site the appliance on ceilings
with wooden joists (e.g. in the attic).
■ Level the appliance horizontally.
If the adjustable feet are used to com-
pensate for an uneven floor (max.
10 mm), the pressure load on the feet
must be distributed evenly.
■ Observe the required floor area and
minimum room volume (to
DIN EN 378).
Type BWC 201.A,
Type BWC-M 201.A
Refrigerant volume Min. space require-
ment
06 1.2 kg 2.73 m3
08 1.45 kg 3.30 m3
10 1.7 kg 3.86 m3
13 2.2 kg 5.00 m3
17 2.9 kg 6.59 m3
■ Observe required minimum clearan-
ces:
≥ 400
≥ 1500
A
B
A■ With hydraulic module (acces-
sory, for installation above the
heat pump):
340 mm
■ Without hydraulic module:
Subject to on-site installation and
site conditions
B≥ 100 mm
Preparing for installation
Siting (cont.)
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9
Information on the use of accessories
for a heating/cooling circuit or sepa-
rate cooling circuit
NC-Box for natural cooling function
■ The NC-Box can only be used up to a
rated heating output of ≤ 16 kW. For
higher rated heating outputs, install all
the components required on site (with
correspondingly sized plate heat
exchanger) for the heating/cooling cir-
cuit or the separate cooling circuit.
Requirements for on-site connections
77
105
152
240
300
419
476
533
600
230 V
+
< 42 V
133
576
662662
727
792
888
962
Preparing for installation
Siting (cont.)
5600 138 GB
Installation

10
Install hydraulic connections on site
stress-free.
Cable lengths in the heat pump plus wall clearance:
Heat pump control unit power supply
(230 V~)
1.0 m
Compressor power supply (400 V~/230 V~) 1.0 m
Additional power cables 1.0 m
Recommended power cables:
Output stage 06 08 10 13 17
Heat pump control unit (230 V~) type BWC 201.A/BWC-M 201.A
Power cable 3 x
1.5 mm2
3 x
1.5 mm2
3 x
1.5 mm2
3 x
1.5 mm2
3 x 1.5 mm2
Power cable
with power-
OFF
5 x
1.5 mm2
5 x
1.5 mm2
5 x
1.5 mm2
5 x
1.5 mm2
5 x 1.5 mm2
Compressor type BWC 201.A (400 V~)
Power cable 5 x
2.5 mm2
5 x
2.5 mm2
5 x
2.5 mm2
5 x
2.5 mm2
5 x 2.5 mm2
Max. line
length
50 m 50 m 50 m 50 m 50 m
Compressor for type BWC-M 201.A (230 V~)
Power cable 3 x 4.0 mm23 x 4.0 mm23 x 4.0 mm2— —
Max. line
length
40 m 32 m 26 m — —
Instantaneous heating water heater (if installed) for type BWC 201.A (400 V~)
Power cable 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
Max. line
length
50 m 50 m 50 m 50 m 50 m
Instantaneous heating water heater (if installed) for type BWC-M 201.A
(230 V~)
Power cable 7 x
2.5 mm2
7 x
2.5 mm2
7 x
2.5 mm2
7 x
2.5 mm2
7 x 2.5 mm2
Max. line
length
50 m 50 m 50 m 50 m 50 m
Overview of possible system schemes
The following table provides an overview
of all possible system schemes.
Preparing for installation
Siting (cont.)
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11
Selected system schemes are explained
using system examples (see from
page 18).
Components System scheme (parameter 7000)
0 1 2 3 4 5 6 11
Heating circuit
A1 – X X – – X X –
M2 – – – X X X X –
DHW cylinder
X – X – X – X –
Heating water buffer cylinder
– 0 0 X X X X –
External heat source
00*1 0*1 0 0 0 0 –
Instantaneous heating water heater
0 0 0 0 0 0 0 –
Solar thermal system
(with Vitosolic 100/200)
0–0–0–0––
Cooling
(only natural cooling function)
A1 – 0 0 – – 0 0 –
M2 – – – 0 0 0 0 –
Sep. cooling circuit 0 0 0 0 0 0 0 –
X Components selected.
0Components can be added.
Primary circuit
Note
The circulation pumps are installed in the
heat pumps and connected at the factory
(primary pump qT, secondary pump 6,
circulation pump for cylinder heating 7,
instantaneous heating water heater 4
optional).
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5600 138 GB
Installation

12
Hydraulic installation scheme
22
27
2
--KM BUS--
--X3.8;3.9--
--230V--
P1
P1
20
21
--2/X3.8;3.9--
11
6
15 74
P
Required equipment
Pos. Description
1Heat pump
2Heat pump control unit
qT Primary pump
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Brine distributor for geothermal probes/collectors
wU Geothermal probes/collectors
Preparing for installation
Primary circuit (cont.)
5600 138 GB

13
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 39 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
X1.
X3.8
X3.9
230 V / 50 Hz
230 V; 0.15 A 21
2
DHW heating
DHW cylinder with internal indirect coil
Note
The circulation pumps are installed in the
heat pumps and connected at the factory
(primary pump qT, secondary pump 6,
circulation pump for cylinder heating 7,
instantaneous heating water heater 4
optional).
Preparing for installation
Primary circuit (cont.)
5600 138 GB
Installation

14
Hydraulic installation scheme
KW
WW
31
30
32
37
2
--F6--
--212.3--
--224.7--
--2/212.3--
--2/F7--
--2/F6--
--230 V-- --KM-BUS--
--F7--
40
--2/224.7--
11
6
15 74
Required equipment
Pos. Description
6Secondary pump
7Circulation pump for cylinder heating
eP DHW cylinder
eQ Cylinder temperature sensor, bottom (optional)
eW Cylinder temperature sensor, top
eU DHW circulation pump (optional)
rP Immersion heater (create electrical circuit on site. Can only be used as an
alternative to the external heat source for DHW reheating.)
Preparing for installation
DHW heating (cont.)
5600 138 GB

15
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 39 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
X1.
X2.N ZP
40
2
37
50 W
230 V / 50 Hz
212.3
X2.N
A
224.7
L1 L2 L3 N
F6
Low voltage
STS 31
PT500
F7
STS 32
PT500
M
1~
AOn-site contactor
DHW cylinder with cylinder loading system
Note
The circulation pumps are installed in the
heat pumps and connected at the factory
(primary pump qT, secondary pump 6,
circulation pump for cylinder heating 7,
instantaneous heating water heater 4
optional).
Preparing for installation
DHW heating (cont.)
5600 138 GB
Installation

16
Hydraulic installation scheme
KW
X
30
32
37
36 35
33 34
--2/212.3--
2
--F6--
--211.4--
--212.3--
--230V-- --KM BUS--
--2/F6-- --2/211.4--
--2/211.4--
1
15 64
7
WW
Required equipment
Pos. Designation
1Heat pump
2Heat pump control unit
6Secondary pump
7Circulation pump for cylinder heating
Preparing for installation
DHW heating (cont.)
5600 138 GB

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Pos. Designation
eP DHW cylinder
eW Cylinder temperature sensor
eE Cylinder primary pump (DHW side)
eR Plate heat exchanger
eT Flow limiter
eZ Motorised 2-way valve, normally closed
eU DHW circulation pump
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 39 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
Cylinder loading pump eE is connected
parallel to internally fitted and connected
circulation pump for cylinder heating
7.
33
230 V / 50 Hz
F6
Low voltage
STS 32
PT500
X1.
X2.N
UP
ZP
M
1~
2
37
50 W
212.3
X1.
X2.N UPSB
N
L130 W
211.4
97
7
130 W
36
M
1~
M
1~
M
1~
Note
The total output of all components con-
nected directly to the heat pump control
unit must not exceed 1000 W (e.g.
pumps, valves, message facilities, con-
tactors).
Preparing for installation
DHW heating (cont.)
5600 138 GB
Installation

18
Required parameter settings for DHW heating
Set the required parameters during com-
missioning; see from page 66.
Parameter Setting
"System definition"
■"System scheme 7000" "0" / "2" / "4" / "6" / "8" /
"10"
DHW heating:
"Time program DHW" Set time program (see op-
erating instructions)
"Time prog. DHW circ." Set time program (see op-
erating instructions)
"DHW"
■"Enable booster heaters for DHW heating 6014" "1"
■"Enable electric heaters for DHW heating 6015" "1"
"External heat source"
■"Enable external heat source for DHW heating
7B0D"
"0"
System example 1, ID: 4605363_1009_01
Selecting system scheme 2
■ 1 underfloor heating circuit without
mixer (A1)
■ DHW heating with solar backup
■ Natural cooling function at heating cir-
cuit A1
Note
This scheme is a general example with-
out shut-off valves or safety equipment.
This does not replace the need for on-
site engineering.
Preparing for installation
DHW heating (cont.)
5600 138 GB

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Hydraulic installation scheme
P1
21
20
22
27
13
2
84 82
80
1
4
3
83
91
90
A1
8
92
6
15
KW
WW
30
32
37
39
--2/212.3--
--2/F6--
42
44
45
--47/S1--
---47/R1--
41
--47/R1--
47
--230V-- -KM BUS-
43
31
--47/S2--
--47/R2--
-- --R1--
--R2--
--S1--
--S2--
12
81
85
89
49
--2/211.5--
--2/F0--
--8/145--
--2/F14--
--80/X4.1;2--
--2/X3.8;3.9--
--F6--
--F0--
--F14--
--KM BUS--
--X3.8;3.9--
--145--
--145--
--212.3--
--211.5--
--211.2--
--230V--
--145--
7
--211.3--
--211.4--
--211.1--
88
---B/137--
Pos. Designation
Heat generator
1Vitocal 200-G heat pump
2Heat pump control unit Vitotronic 200, type WO1B
3Outside temperature sensor ATS
4Instantaneous heating water heater with switching module (optional)
Preparing for installation
System example 1, ID: 4605363_1009_01 (cont.)
5600 138 GB
Installation

20
Pos. Designation
6Secondary pump
7Circulation pump for cylinder heating UPSB
8KM BUS distributor
qW Safety equipment block with safety assembly
qE Heating circuit expansion vessel
qT Primary pump
Primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Brine distributor for geothermal probes/geothermal collectors
wU Geothermal probe/geothermal collector
DHW heating
eP DHW cylinder
eW Cylinder temperature sensor STS
eU DHW circulation pump ZP
eO Cylinder loading pump in the solar heat exchanger set
DHW heating with solar backup
eQ Cylinder temperature sensor SOL (Vitosolic standard delivery)
rQ High limit safety cut-out STB (max. 95 °C) (on-site, if required)
rW Solar-Divicon
rE Solar circuit pump R1
rR Collector temperature sensor KOL (Vitosolic standard delivery)
rT Solar collector
rU Vitosolic 100, type SD1
rO Expansion vessel with solar circuit safety assembly
Natural cooling function (NC)
iP NC-Box with mixer (pre-wired)
iQ 3-way diverter valve
iW Secondary cooling circuit pump
iE Contact humidistat
iR Primary cooling circuit pump
iT Mixer motor
iI 2-way valve
iO Cooling circuit flow temperature sensor
Heating circuit without mixer A1
oP Underfloor heating circuit
oQ Vitotrol 200A remote control (accessory)
oW Overflow valve
Preparing for installation
System example 1, ID: 4605363_1009_01 (cont.)
5600 138 GB