Viessmann VITOTRONIC 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitotronic 200
Type WO1A
Heat pump control unit
For applicability, see the last page
VITOTRONIC 200
5692 861 GB 8/2010 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
designed for qualified personnel.
■ 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 requirements
■ All legal instructions regarding the pre-
vention of accidents,
■ All legal instructions regarding envi-
ronmental protection,
■ The Code of Practice of 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 and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator.
Note
In addition to the control circuit, there
may be several power circuits.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions
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Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original 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 orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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Introduction
Scope of functions................................................................................................ 9
Setting levels........................................................................................................ 9
Programming unit................................................................................................. 10
Function description
Heat pump stage 2............................................................................................... 12
Heat pump cascade............................................................................................. 12
Externally switched functions............................................................................... 17
Power-OFF........................................................................................................... 19
Booster heaters.................................................................................................... 19
DHW heating........................................................................................................ 21
Heating water buffer cylinder/low loss header...................................................... 25
Heating circuits/cooling circuit.............................................................................. 26
Cooling functions.................................................................................................. 30
Swimming pool heating........................................................................................ 31
Troubleshooting
Messages............................................................................................................. 33
Diagnosis (service scans).................................................................................... 68
Testing outputs (actuator test).............................................................................. 93
Function check..................................................................................................... 94
LON subscriber check.......................................................................................... 95
No display in programming unit............................................................................ 96
Control unit settings
Coding level 1 in service menu............................................................................ 97
Parameter group system definition
Parameter group system definition....................................................................... 98
7000 System scheme !..................................................................................... 98
7003 Temperature differential for calculating the heating limit !....................... 100
7004 Temperature differential for calculating the cooling limit !....................... 100
7008 Swimming pool !...................................................................................... 101
7010 External extension !................................................................................. 101
700A Cascade control !.................................................................................... 102
5735 Number of lag heat pumps in cascade !.................................................. 102
700B Output lag heat pump !............................................................................ 103
700C Use of heat pump in cascade !............................................................... 103
7011 System components for external changeover !....................................... 104
7012 Operating status for external changeover !............................................. 106
7013 Duration of external changeover !........................................................... 107
7014 Effect of external demand on heat pump/heating circuits !...................... 108
Index
Index
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7015 Effect of ext. blocking on heat pump/heating circuits !............................ 108
7017 Vitocom 100 !........................................................................................... 109
701A Effect of external blocking on pumps/compressor !................................ 109
701B Common flow temperature sensor system !............................................ 111
Parameter group compressor
Parameter group compressor............................................................................... 112
5000 Enable compressor !................................................................................ 112
5010 Evaporator temperature for defrost end !............................................ 112
5030 Output compressor stage 1 !................................................................... 112
Parameter group compressor 2
Parameter group compressor 2............................................................................ 113
5100 Enable compressor !................................................................................ 113
5130 Output compressor stage 2 !................................................................... 113
Parameter group external heat source
Parameter group external heat source................................................................. 114
7B00 Enable external heat source !................................................................. 114
7B01 Priority ext. heat source/instant. heating water heater !.......................... 114
7B02 Dual mode temperature external heat source !....................................... 114
7B0D Enable external heat source for DHW heating !..................................... 115
Parameter group DHW
Parameter group DHW......................................................................................... 116
6000 Set DHW temperature................................................................................. 116
6005 Min. DHW temperature !.......................................................................... 116
6006 Max. DHW temperature !......................................................................... 116
6007 Hysteresis DHW temperature heat pump !.............................................. 117
6008 Hysteresis DHW temperature instant. heating water heater !................. 118
6009 Start optimisation for DHW heating............................................................. 118
600A Stop optimisation for DHW heating............................................................. 118
600C Set DHW temperature 2............................................................................. 119
600E Temperature sensor at bottom of DHW cylinder......................................... 119
6014 Enable booster heaters for DHW heating !.............................................. 120
6015 Enable electric heaters for DHW heating !.............................................. 120
6016 Priority DHW heating with combi cylinder !.............................................. 120
6017 Start attempts for DHW after high pressure shutdown !.......................... 121
6020 Operating mode cylinder primary pump !................................................ 121
Parameter group solar
Parameter group solar.......................................................................................... 123
Index
Index
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7A00 Type solar control unit !........................................................................... 123
7A01 Max. collector temperature !.................................................................... 123
7A02 Start hysteresis solar circuit pump !........................................................ 123
7A03 Stop hysteresis solar circuit pump !........................................................ 124
7A07 Flow rate solar circuit for calculating solar yield !.................................... 124
7A09 Display message incorrect circulation !................................................... 124
Parameter group electric booster heater
Parameter group electric heater........................................................................... 125
7900 Enable instantaneous heating water heater !.......................................... 125
7902 Enable instant. heating water heater for central heating !....................... 125
7907 Max. output instantaneous heating water heater !................................... 126
790A Output for instant. heating water heater at power-OFF !......................... 126
790B Dual mode temp. instant. heating water heater !.................................... 126
Parameter group internal hydraulics
Parameter group internal hydraulics.................................................................... 128
7300 Heat pump for drying a building !............................................................. 128
7303 Time program for screed drying !............................................................ 128
730C Flow temperature for external demand !................................................. 130
730D Enable three-way diverter valve heating/DHW !..................................... 131
7320 Operating mode primary pump !......................................................... 131
7340 Operating mode secondary pump !......................................................... 132
Parameter group buffer cylinder
Parameter group buffer cylinder........................................................................... 133
7200 Enable buffer cylinder/ low loss header !................................................. 133
7202 Temp. in operating status fixed value for buffer cyl !............................... 133
7203 Hysteresis temperature heating buffer cylinder !..................................... 133
7204 Max. temperature buffer cylinder !........................................................... 134
7208 Temp. limit op. status fixed value for buffer cylinder !............................. 135
Parameter group heating circuits/cooling circuit
Parameter group heating circuits/cooling circuit................................................... 136
2000 Standard room temperature........................................................................ 136
2001 Reduced room temperature........................................................................ 136
2003 Remote control !...................................................................................... 136
2006 Heating curve level...................................................................................... 137
2007 Heating curve slope..................................................................................... 137
200A Influence room temperature hook-up !.................................................... 138
200B Room temperature hook-up !.................................................................. 138
200E Max. flow temperature heating circuit !................................................... 139
Index
Index
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2022 Room temperature in party mode................................................................ 139
Parameter group cooling
Parameter group cooling...................................................................................... 140
7100 Cooling function !..................................................................................... 140
7101 Cooling circuit !........................................................................................ 140
7102 Set room temperature separate cooling circuit............................................ 141
7103 Min. flow temperature cooling !................................................................ 141
7104 Influence room temperature hook-up cooling circuit !.............................. 141
7110 Cooling curve level !................................................................................ 142
7111 Cooling curve slope !............................................................................... 142
71FE Enable active cooling mode........................................................................ 142
Parameter group time
Parameter group time........................................................................................... 143
7C00 to 7C06 Automatic changeover summertime - wintertime !.................... 143
Parameter group communication
Parameter group communication......................................................................... 144
5707 Heat pump number in cascade (LON) !................................................... 144
7710 Enable LON communication module !..................................................... 144
7777 LON subscriber number !........................................................................ 144
7779 LON fault manager !................................................................................ 145
7797 Outside temperature !.............................................................................. 145
7798 LON system number !.............................................................................. 146
779C Interval for data transfer via LON !.......................................................... 146
77FF Time via LON !........................................................................................ 146
Parameter group operation
Parameter group operation.................................................................................. 148
8800 Lock out controls !................................................................................... 148
PCBs and connection options
Overview of the PCBs.......................................................................................... 149
Information regarding the electrical connections.................................................. 150
Main and extension PCB...................................................................................... 150
Cross connect PCB.............................................................................................. 165
Luster terminals (only Vitocal 222-G/242-G)........................................................ 168
Luster terminals (only Vitocal 200-S)................................................................... 170
Controller and sensor PCB................................................................................... 172
AVI PCB (only Vitocal 200-S)............................................................................... 176
NC PCB................................................................................................................ 177
EEV PCB.............................................................................................................. 178
Index
Index
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Pressure sensors................................................................................................. 180
Certificates
Declaration of conformity...................................................................................... 181
Keyword index.................................................................................................... 182
Index
Index (cont.)
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These service instructions include infor-
mation regarding the heat pump control
unit Vitotronic 200 , type WO1A for
Viessmann heat pumps:
■ Function description
■ Control parameters for matching the
heat pump to the different require-
ments and operating conditions
■ Diagnosis options for heating system
and refrigerant circuit
■ Troubleshooting measures
■ Overview of electrical connections
For system examples see the
installation and service instruc-
tions for the heat pump in ques-
tion and "Heat pump system
examples".
The functions and control characteristics
of the heat pump control unit are
matched to the relevant heat pump by
means of the coding card. As a conse-
quence, the entire scope of functions as
described here is not available for every
heat pump type.
In addition, the selected system scheme
and the auxiliary equipment have a
major influence on the available func-
tions in the heat pump control unit.
Type or system-specific details are only
highlighted in those places where they
have a direct effect on the characteristics
of the heat pump or the heating system.
The following symbols are used to iden-
tify the different heat pump types:
Brine/water heat pumps
Air/water heat pumps
Air/water heat pumps, split version
Setting levels
To avoid incorrect operation of the heat
pump or other system components, the
control parameters and fault messages
are available at different setting levels.
System user
Operation takes place in the standard
menu and in the extended menu and is
suitable for individuals that have been
trained in the operation of the heating
system by a heating contractor.
Introduction
Scope of functions
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■ The general operating functions are
found in the standard menu. These
include the selection of the set room
temperature or the selection of the
operating program.
■ The extended menu offers further
functions, such as the setting of time
programs, for example. To call up the
extended menu press .
For functions at the "System
user" setting level, see the oper-
ating instructions.
Contractor
Additional functions and the parameters
of Coding level 1 are available under this
setting level. These are identified by the
symbol !.
Note
The "Contractor" setting level includes
the functions of the "System user" level.
Programming unit
DHW
Solar energy
Information
Select with
40°C
Heating/cooling
Flow temperature
i
(
Note
The programming unit can also be set into a wall mounting base (accessory) near
the heat pump.
One step back in the menu or can-
cel a setting that has been started.
Cursor keys for scrolling through
the menu or for setting values.
OK Confirm selection or save a setting
just made.
Call up help text in connection with
the selected menu point.
Introduction
Setting levels (cont.)
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Activate extended menu
Introduction
Programming unit (cont.)
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Some heat pumps can be extended by
means of a second heat pump stage.
This relates to a separate heat pump,
which is controlled by heat pump
stage 1. Stage 2 has no heat pump con-
trol unit, but is equipped with its own sep-
arately controlled refrigerant circuit.
The heat pump control unit starts heat
pump stage 2 if the heating output
required is greater than that delivered by
heat pump stage 1.
For optimised starting and stopping of
heat pump stage 2, the heating outputs
of the two compressors must be known.
Parameter Setting
Compressor 1:
■"Enable compressor 5000" "1"
■"Output compressor stage 1 5030" Value corresponding to the
rated heating output of heat
pump stage 2, see type
plate.
Compressor 2:
■"Enable compressor 5100" "1"
■"Output compressor stage 2 5130" Value corresponding to the
rated heating output of heat
pump stage 2, see type
plate.
Heat pump cascade
A heat pump cascade consists of a lead
appliance and lag heat pumps:
■ Up to 3 lag heat pumps connected via
a KM-BUS in conjunction with the
external extension H1.
■ Up to 4 lag heat pumps when connec-
ted via LON.
Each lag heat pump has a heat pump
control unit. Both lead appliance and lag
heat pumps can have 2 stages.
The lead appliance regulates the heat
pump operation within the cascade.
Cascade via external extension H1
The lead appliance calls for the lag heat
pumps via the switching outputs of exter-
nal extension H1.
Function description
Heat pump stage 2
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Electrical connection diagram
aVG
1
2
3
sA
L
N
A
C
B
sK
sÖ
?
L
N
?
230V
230V
X3.13 X3.12
D
X3.13 X3.12
H
K
X3.11
X3.10
E
223.1
L
N
?
230V
X3.13 X3.12
F
G
L
?
N
L1
?
N
fÖ
N L1
L
aVG
223.2
223.1
223.2
223.1
223.2
2
1
AHeat pump 1 (lead appliance)
BKM BUS
CExternal extension H1
DFloating contact "external demand"
E1st lag heat pump
Connection to the contact for "exter-
nal demand"
FFloating contact "external demand"
Function description
Heat pump cascade (cont.)
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G2nd lag heat pump
Connection to the contact for "exter-
nal demand"
HFloating contact "external demand"
K3rd lag heat pump
LCentral fault message input, lag
heat pump
Open contact X3.10 / X3.11 triggers
a message
Subject to the system equipment level,
the parameter "Use of heat pumps in
cascade 700C" at the lead appliance
can be used to set all the lag heat pumps
to be used for central heating/cooling
and/or for DHW heating.
The changeover between central heat-
ing/cooling and DHW heating is effected
by a central 3-way diverter valve that is
controlled by the lead appliance. If the
lag heat pumps also use 3-way diverter
valves to change over, then the corre-
sponding switching outputs at their heat
pump control units must be connected to
the central diverter valve in parallel.
Lag heat pump faults are reported to the
lead appliance ("E2 Lag heat pump").
Parameter Setting
Lead appliance Lag heat pump
"System scheme 7000" "0" to "10" "11"
"External extension 7010" "1" "0"
"Cascade control 700A" "1" "0"
"Number of lag heat pumps in
cascade 5735"
"1" to "3" —
"Output lag heat pump 700B" "0" to "255" —
"Use of heat pump in cascade
700C"
"0" to "3" —
"Flow temperature for external
demand 730C"
—"0" to "700"
(≙ 0 to 70 °C)
"Enable three-way diverter
valve heating/DHW 730D"
"1" "1"
Function description
Heat pump cascade (cont.)
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Cascade via LON
The following communication modules
(accessories) must be fitted in the heat
pump control units:
■ LON communication module for the
cascade in the lead appliance
■ LON communication module in lag
heat pumps
Subject to the system equipment level,
all heat pumps within a LON cascade
can be enabled separately for different
functions by means of parameter "Use
of heat pumps in cascade 700C":
■ Central heating/cooling
■ DHW heating
■ Swimming pool heating
■ Solar DHW heating
(only possible in conjunction with inte-
gral solar control function)
Several functions can be active simulta-
neously.
Central heating/cooling
Lead appliance and lag heat pumps are
connected hydraulically in parallel, with
each branch having its own circulation
pump.
DHW heating
Connection versions for lead appliance
and lag heat pumps:
■ Parallel to the flow to the DHW cylin-
der:
Each lag heat pump has its own circu-
lation pump for cylinder heating, which
is switched on by the lag heat pump
when there is a demand from the lead
appliance.
■ Via the 3-way diverter valve for "cen-
tral heating/DHW heating" in each
pump, parallel to the flow to the DHW
cylinder:
The changeover takes place subject to
the demand from the lead appliance to
the lag heat pump in question.
■ Parallel to a common flow secondary
circuit:
The changeover is carried out by a
central 3-way diverter valve for "cen-
tral heating/DHW heating". This is
controlled via the heat pump control
unit of the lead appliance.
Integrating a heat pump control unit into LON
Example of a heat pump cascade and Vitocom
A
LON
B
LON LON
C
LON
AHeat pump control unit lead appli-
ance
BHeat pump control unit lag heat
pump
Function description
Heat pump cascade (cont.)
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CVitocom
A B C
"System scheme 7000" "0"up to "10" "11" —
"Cascade control 700A" "2" "0" —
"Number of lag heat pumps in cas-
cade 5735"
"1" to "4" — —
"Heat pump number in cascade
(LON) 5707"
—"1" to "4" —
LON communication module instal-
led
"Enable LON communication
module 7710"
"1" "1" —
"LON system number 7798" "1" to "5" "1" to "5" —
"LON subscriber number 7777"
Each number can only be allocated
once.
"1" to "99" "1" to "99" 1 to 99
"LON fault manager 7779"
Only one control unit per system
may be programmed as the fault
manager.
"0" or "1" "0" or "1" Device is
always the
fault man-
ager
"Time via LON 77FF" "2" "1" Device
receives the
time
"Outside temperature via LON
7797"
"2" "1" —
"Interval for data transfer via LON
779C"
"20" "20" —
"Output lag heat pump 700B" "0" to "255" — —
"Use of heat pump in cascade
700C"
"0" to "31" "0" to "31" —
"Flow temperature for external
demand 730C"
—"0" to "700"
0 to 70 °C
—
"Enable three-way diverter valve
heating/DHW 730D"
"0"/"1" "0"/"1" —
Function description
Heat pump cascade (cont.)
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■ External demand/external mixer
OPEN or control function
■ External changeover of the operating
status
■ External blocking/external mixer
CLOSED or control function
Various contacts are available for these
functions:
■ Floating contacts in heat pump control
units with cross connect PCB (see
page 165):
–X3.12, X3.13 for external demand/
external mixer OPEN or control
function and/or external switching
of the operating status.
–X3.2, X3.14 for external blocking/
external mixer CLOSED or control
function.
■ Via KM BUS, e.g. in conjunction with
external extension H1 (accessory).
Note
The signal "External blocking" has pri-
ority over the signal "External
demand".
External demand/external mixer OPEN or control function
The heat pump is requested or blocked
by closing the floating contact and the
heating circuit mixers are moved to
OPEN or into control mode.
The following parameters influence the
function:
■"Effect of external demand on heat
pump/heating circuits 7014"
Specifies the characteristics of the
heat pump and heating circuit mixers.
■"Flow temperature for external
demand 730C"
Specifies the set flow temperature at
which the secondary circuit should be
regulated under external demand.
Note
In conjunction with external exten-
sion H1, an analogue voltage signal
applied to connector aVF can be used to
specify a set flow temperature.
For this, the voltage range 0 to 10 V cor-
responds to a temperature range of 0 to
100 °C (delivered condition).
The heat pump control uses the higher
value.
Only heat pump contractors certified by
Viessmann may change this.
Function description
Externally switched functions
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External changeover of the operating status
Closing the floating contact changes the
operating status.
The following parameters influence the
function:
■"System components for external
changeover 7011"
Specifies the system components on
which the changeover should act.
■"Operating status for external
changeover 7012"
Specifies the operating status to be
changed over to.
■"Duration of external changeover
7013"
Specifies the minimum duration for the
changeover after deleting the signal
External blocking/external mixer CLOSED or control function
Closing the floating contact blocks the
heat pump and the heating circuit mixers
can be moved to CLOSED or control
mode.
The following parameters influence the
function:
■"Effect of ext. blocking on heat
pump/heating circuits 7015"
Specifies the characteristics of the
heat pump and heating circuit mixers.
■"Effect of external blocking on
pumps/compressor 701A"
Specifies which operating compo-
nents should be blocked in the secon-
dary circuit, e.g. pumps or compres-
sors.
Function description
Externally switched functions (cont.)
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Frequently, economy tariffs for electricity
include an agreement that the electrical
supply for compressors and instantane-
ous heating water heaters can be sus-
pended by the power supply utility sev-
eral times each day. The heat pump con-
trol unit receives the power-OFF signal
via a floating contact.
To safeguard the remaining functions of
the heating system during the power-
OFF period, the power supply of the heat
pump control unit is not be switched
off.
Booster heaters
External heat source
The heat pump control unit enables dual
mode operation of the heat pump
together with an external heat source,
e.g. an oil boiler ("Enable external heat
source 7B00").
The external heat source is hydraulically
connected in such a way that the heat
pump can also be used as a return tem-
perature raising facility for the boiler.
System separation is provided either
with a low loss header or a heating water
buffer cylinder.
For optimum heat pump operation, the
external heat source must be integrated
via a mixer into the system flow. Directly
controlling this mixer via the heat pump
control unit achieves a rapid response.
Central heating
If the long term average of the outside
temperature lies below the "Dual mode
temperature external heat source
7B02", the heat pump control unit
switches the external heat source on. In
the case of heat demand from the con-
sumers (e.g. for frost protection or if the
heat pump is faulty), the external heat
source is also switched on above the
dual mode temperature.
DHW heating
See chapter "DHW heating with booster
heater".
Safety functions
The heat pump control unit does not
contain any safety functions for the
external heat source.
Function description
Power-OFF
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Connect two high limit safety cut-outs
(switching threshold respectively 70 °C)
for protection against excessively high
heat pump flow and return temperatures:
■ High limit safety cut-out for switching
off the external heat source
and
■ High limit safety cut-out for switching
off the secondary pumps
Instantaneous heating water heater
An electric instantaneous heating water
heater can be integrated in the secon-
dary circuit flow as an auxiliary heat
source.
Subject to the type of heat pump, the
instantaneous heating water heater can
be part of the standard delivery, an
accessory, or need to be supplied on
site.
Installation instructions, instanta-
neous heating water heater
The instantaneous heating water heater
can be enabled separately for central
heating and DHW reheating. For central
heating with an instantaneous heating
water heater, the long term average out-
side temperature must be below the
"Dual mode temp. instant. heating
water heater 790B".
Subject to the heat demand, the heat
pump control unit switches on stages 1,
2 or 3 of the instantaneous heating water
heater ("Max. output instantaneous
heating water heater 7907"). As soon
as the max. flow temperature for the sec-
ondary circuit "Max. flow temperature
heating circuit 200E" is reached, the
heat pump control unit stops the instan-
taneous heating water heater.
To limit the total power consumption, the
heat pump control unit stops the instan-
taneous heating water heater for a few
seconds directly before the compressor
starts. Each stage is subsequently star-
ted individually one after the other in
intervals of 10 s.
If the instantaneous heating water heater
is on and the differential between flow
and return temperatures in the secon-
dary circuit does not rise by at least 1 K
within 24 h, the heat pump control unit
displays the fault message "AB
Instant.htg wtr heater".
Function description
Booster heaters (cont.)
5692 861 GB