Viessmann VITOCAL 200-G Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-G
Type BWC 201.A06 to A17, 6 to 17 kW
Brine/water heat pump with electric drive, 400 V~
Type BWC-M 201.A06 to A10, 6 to 10 kW
Brine/water heat pump with electric drive, 230 V~
For applicability, see the last page
VITOCAL 200-G
5546 220 GB 6/2014 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
5546 220 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.)
5546 220 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Requirements for on-site connections.................................................................. 7
Requirements for siting........................................................................................ 8
Installation sequence
Siting the heat pump............................................................................................ 11
Making the hydraulic connections........................................................................ 14
Electrical connections........................................................................................... 16
Power supply........................................................................................................ 33
Make connections at terminals X3.8/X3.9............................................................ 44
Closing the heat pump......................................................................................... 45
Check the diaphragm grommets.......................................................................... 46
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 47
Further details regarding the individual steps....................................................... 48
Troubleshooting
Repairs................................................................................................................. 62
Parts lists, type BWC 201.A (400 V appliances)
Overview of the assemblies................................................................................. 71
Parts not shown.................................................................................................... 72
Casing.................................................................................................................. 72
Electrical equipment............................................................................................. 75
Heat pump module............................................................................................... 78
Hydraulics............................................................................................................. 81
Parts lists, type BWC-M 201.A (230 V appliances)
Overview of the assemblies................................................................................. 84
Parts not shown.................................................................................................... 85
Casing.................................................................................................................. 85
Electrical equipment............................................................................................. 88
Heat pump module............................................................................................... 90
Hydraulics............................................................................................................. 92
Commissioning/service reports
Hydraulic parameters report................................................................................. 94
Control parameters report.................................................................................... 95
Index
Index
5546 220 GB

5
Specification....................................................................................................... 104
Appendix
Commissioning order........................................................................................... 109
Certificates
Declaration of conformity...................................................................................... 110
Keyword index.................................................................................................... 111
Index
Index (cont.)
5546 220 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
5546 220 GB

7
77
105
152
240
300
419
476
533
600
230 V
+
< 42 V
133
576
662662
727
792
888
962
Heating flow
DHW cylinder flow
Secondary circuit return (heating return and DHW cylinder return)
+
Primary circuit return (heat pump brine outlet)
Primary circuit flow (heat pump brine inlet)
Install hydraulic connections on site
stress-free.
Preparing for installation
Requirements for on-site connections
5546 220 GB
Installation

8
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 connecting cables 1.0 m
Recommended power cables
Power cable 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. cable length 50 m 50 m 50 m 50 m 50 m
Compressor type BWC-M 201.A (230 V~)
Power cable 3 x
4.0 mm2
3 x
4.0 mm2
3 x
4.0 mm2
— —
Max. cable length 40 m 32 m 26 m — —
Instantaneous heating water heater (if installed) 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. cable length 50 m 50 m 50 m 50 m 50 m
Instantaneous heating water heater (if installed) 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. cable length 50 m 50 m 50 m 50 m 50 m
Requirements for 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°.
Preparing for installation
Requirements for on-site connections (cont.)
5546 220 GB

9
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Ensure ambient temperatures
between 0 and 35 °C.
!Please note
Avoid risks of explosion due to
dust, gases and vapours.
Avoid dust, gases and vapours in
the installation room.
!Please note
Observe the permissible floor
load.
■ Align the appliance horizon-
tally.
If the adjustable feet are used
to compensate for an uneven
floor (max. 10 mm), the pres-
sure load on the feet must be
distributed evenly.
■ The total weight must be con-
sidered (see table).
Total weight
Type Weight in kg
BWC (400 V appliances)
201.A06 113
201.A08 117
201.A10 129
201.A13 135
201.A17 148
BWC-M (230 V appliances)
201.A06 115
201.A08 119
201.A10 131
To prevent the transmission of structure-
borne noise, never site the appliance on
ceilings with wooden joists, e.g. in the
attic.
Minimum room volume (to EN 378)
Type BWC/BWC-M Refrigerant charge in
kg
Minimum room vol-
ume in m3
201.A06 1.20 2.73
201.A08 1.45 3.30
201.A10 1.70 3.86
201.A13 2.20 5.00
201.A17 2.90 6.59
Preparing for installation
Requirements for siting (cont.)
5546 220 GB
Installation

10
Minimum clearances
≥ 400
≥ 1500
A
B
ADimension subject to on-site instal-
lation and site conditions
B≥ 100 mm
Preparing for installation
Requirements for siting (cont.)
5546 220 GB

11
Removing the transport brackets and levelling the heat pump
4x
4x
1.
2.
Installation sequence
Siting the heat pump
5546 220 GB
Installation

12
1. !Please note
Operating the appliance with-
out first removing the trans-
port brackets may cause
vibrations and excessive
noise.
Remove the transport brack-
ets.
2. Position and level the heat pump hor-
izontally as described on page 8.
Installation sequence
Siting the heat pump (cont.)
5546 220 GB

13
Removing the top panel
1.
Installation sequence
Siting the heat pump (cont.)
5546 220 GB
Installation

14
For arrangement of hydraulic connec-
tions, see page 7.
Connecting the primary circuit
!Please note
The components used must be
resistant to the heat transfer
medium.
Never use zinc-plated/galvan-
ised pipes.
1. Equip the primary circuit with an
expansion vessel and safety valve (to
DIN 4757).
Note
■ The expansion vessel must be
approved to DIN 4807. The dia-
phragms of expansion vessel and
safety valve must be suitable for
the heat transfer medium.
■ The discharge and drain pipes
should terminate in a container.
This container must be able to hold
the maximum possible expansion
volume of the heat transfer
medium.
2. Ensure adequate thermal and anti-
vibration insulation of all pipes routed
through walls.
3. Connect primary pipes to heat
pump.
!Please note
Avoid appliance damage.
Connect on-site primary lines
to the heat pump so they are
free of load and torque
stresses.
!Please note
Make tight hydraulic connec-
tions on the primary side.
With hose outlets, ensure the
diaphragm grommets are
seated correctly. Seal hose
outlets with sealing tape if
necessary.
4. Insulate pipes inside the building to
provide protection from heat and
vapour diffusion.
5. Charge the primary circuit with
Viessmann heat transfer medium
and vent.
Note
Ensure frost protection down to
–19 °C.
Viessmann heat transfer medium is a
ready-mixed ethylene glycol-based
medium. It contains inhibitors for cor-
rosion protection. The heat transfer
medium can be used at temperatures
down to –19 °C.
Installation sequence
Making the hydraulic connections
5546 220 GB

15
Note
For diaphragm grommets, see
page 46.
Connecting the secondary circuit
1. Equip the secondary circuit on site
with an expansion vessel and safety
assembly (to DIN 4757).
Fit the safety assembly to the on-site
line in the heating water return.
2. Connect the secondary lines to the
heat pump (7 ≥ 28 mm).
!Please note
Avoid appliance damage.
Connect on-site secondary
lines to the heat pump so they
are free of load and torque
stresses.
!Please note
Make tight hydraulic connec-
tions on the secondary side.
With hose outlets, ensure the
diaphragm grommets are
seated correctly. Seal hose
outlets with sealing tape if
necessary.
3. Fill and vent secondary circuit.
4. Thermally insulate pipes inside the
building.
Note
■ For diaphragm grommets, see
page 46.
■ In underfloor heating circuits, install a
temperature limiter on site to restrict
the maximum temperature of the
underfloor heating system.
■ Ensure the minimum flow rate, e.g. by
means of an overflow valve (see
"Specification" on page 104).
Installation sequence
Making the hydraulic connections (cont.)
5546 220 GB
Installation

16
Installing the programming unit
2x
3.
2.
1.
Installation sequence
Electrical connections
5546 220 GB

17
6x
[XÖ
X
7.
8.
4.
6.
9.
11.
10.
5.
Routing cables to the wiring chamber
Danger
Damaged cable insulation can
cause injury and damage to the
appliance.
Route cables so that they cannot
touch very hot, vibrating or sharp-
edged components.
Danger
Incorrect wiring can lead to seri-
ous injury from electrical current
and result in appliance damage.
Observe the following points
when making an electrical con-
nection:
Installation sequence
Electrical connections (cont.)
5546 220 GB
Installation

18
■ Route LV cables < 42 V separately
from cables > 42 V/230 V~/400 V~.
■ Strip the insulation from the cables as
close to the terminals as possible, and
bundle tightly to the corresponding ter-
minals.
■ Secure cables with cable ties.
■ If 2 components are connected to the
same terminal, press both cores
together in a single wire ferrule.
This ensures that, in the event of a fault
(e.g. when detaching a wire), the wires
cannot drift into the adjacent voltage
area.
When routing the on-site connecting
cables, observe the location of the cable
entries leading into the appliance
through the back panel (see page 7).
< 42 V
230 V
1. Route LV leads through the "< 42 V"
aperture to the heat pump control unit
wiring chamber and apply strain relief
using the cable ties provided.
2. Route 230 V~ leads and power
cables for the compressor through
the "230 V~" aperture to the heat
pump control unit wiring chamber and
apply strain relief using the cable ties
provided. For power supply, see from
page 33.
Installation sequence
Electrical connections (cont.)
5546 220 GB

19
Note
Route LV leads and 230 V~ cables as
far apart as possible.
Overview of the electrical connections in the heat pump control
unit
A
X3F1
X2X1
X31
X25
X24
aVG
F0 F4
F6
F7
F20
F14
F16
F8
F27
F11
F13
F26
F3
sXF sXS
sYAsYS
sVA
J4
J3
B
C
D
ALuster terminals: See page 28.
F1 Fuse 6.3 A (slow)
BMain PCB: See page 20.
F3 Fuse 6.3 A (slow)
CExpansion PCB on main PCB: See
page 25.
DController and sensor PCB: See
page 30.
Installation sequence
Electrical connections (cont.)
5546 220 GB
Installation

20
Main PCB
Information regarding connection
values
■ The specified output is the recommen-
ded connected load.
■ The total output of all components con-
nected directly to the heat pump con-
trol unit (e.g. pumps, valves, message
facilities, contactors) must not exceed
1000 W.
If the total output is ≤ 1000 W, the indi-
vidual rating of a component (e.g.
pump, valve, message facility, contac-
tor) can be greater than specified.
However, the breaking capacity of the
corresponding relay must not be
exceeded.
■ The specified current indicates the
max. switching current of the switching
contact. Observe total current 5 A.
■ Safety LV is unsuitable for controlling
external heat generators.
Set the required parameters during com-
missioning: See from page 51.
Installation sequence
Electrical connections (cont.)
5546 220 GB