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
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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