Viessmann VITOCAL 200-G Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitocal 200-G
Type
Type BWC 201.B06 to B17, 400 V~
Type BWC-M 201.B06 to B10, 230 V~
Heat pump with electric drive
■Brine/water heat pump: 5.7 to 17.4 kW
■With conversion kit to water/water heat pump: 7.5 to 22.6 kW
VITOCAL 200-G
6152043 GB 3/2020 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for authorised contractors.
■Work on the refrigerant circuit may only
be carried out by authorised refrigera-
tion 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 to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions
Safety instructions
6152043

3
Safety instructions for working on the system
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 PCBs remain live
even after the power supply has
been switched off.
Prior to removing covers from the
appliances, wait at least 4 minutes
until the voltage has completely
dropped out.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
appliance, fittings or pipework.
Danger
Risk of fire: Electrostatic discharge
can cause sparks which may be
ignited by escaping, flammable
refrigerant (R32).
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Work on the refrigerant circuit
Refrigerants are air displacing, colour-
less, odourless gases.
■R32 forms flammable mixtures with air.
■R410A is not flammable.
Danger
Direct contact with liquid and gas-
eous refrigerant can cause serious
damage to health.
■Avoid direct contact with liquid and
gaseous refrigerant.
■Wear personal protective equip-
ment when handling liquid and
gaseous refrigerant.
Danger
Unregulated escape of refrigerant in
enclosed spaces can lead to
breathing difficulties and suffoca-
tion.
■Never breathe in refrigerant
vapours.
■Ensure adequate ventilation in
enclosed spaces.
Perform the following measures before
beginning work on the refrigerant circuit:
■Check the refrigerant circuit for leaks.
■Ensure very good ventilation especially
in the floor area and sustain this for the
duration of the work.
Safety instructions
Safety instructions (cont.)
6152043

4
■Inform all persons in the vicinity of the
system about the type of work to be
carried out.
■Secure the area surrounding the work
area.
Further measures before starting work
on the refrigerant circuit with flammable
refrigerants (R32):
■Remove all flammable materials and
ignition sources from the immediate
vicinity of the heat pump.
■Before, during and after the work,
check the surrounding area for escap-
ing refrigerant using a suitable refriger-
ant detector.
This refrigerant detector must not gen-
erate any sparks and must be suitably
sealed.
■A CO2 or powder extinguisher must be
to hand in the following cases:
–Refrigerant is being topped up.
–When soldering or welding work is
being carried out.
■Display signs prohibiting smoking.
Danger
Damage to the refrigerant circuit
can cause refrigerant to enter the
hydraulic system. This can cause
serious damage to health.
After completion of the work, pro-
fessionally vent the hydraulic sys-
tem on the primary and secondary
sides.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
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 func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions for operating the system
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Safety instructions
Safety instructions (cont.)
6152043

5
1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■System examples ............................................................................... 8
■Spare parts lists .................................................................................. 9
2. Preparing for installation Requirements concerning on-site connections ...................................... 10
Siting and transport requirements .......................................................... 10
■Transport ............................................................................................ 10
■Installation room requirements ........................................................... 11
3. Installation sequence Siting the heat pump .............................................................................. 13
■Removing the front panel ................................................................... 13
■Removing the heat pump module ....................................................... 14
■Transporting the heat pump module ................................................... 17
■Installing the heat pump module ......................................................... 17
■Levelling the heat pump ..................................................................... 18
Hydraulic connections ............................................................................ 18
■Connecting the primary/secondary circuits ......................................... 18
■Connecting the cooling circuit ............................................................. 20
Electrical connection .............................................................................. 20
■Preparing the electrical connections ................................................... 20
■Opening the wiring chamber ............................................................... 22
■Installing the programming unit .......................................................... 23
■Routing the cables to the wiring chamber .......................................... 25
■Connecting the Vitoconnect (accessories) ......................................... 27
■Overview of electrical connections ..................................................... 28
■Main PCB (230 V~ function components) .......................................... 29
■Expansion PCB on main PCB (230 V~ components) ......................... 31
■Luster terminals (message and safety connections) .......................... 34
■Controller and sensor PCB (extra low voltage (ELV) connections) .... 36
■Connecting a temperature limiter to restrict the maximum tempera-
ture of underfloor heating circuit ......................................................... 37
■Swimming pool heating ...................................................................... 40
Power supply ......................................................................................... 41
■Heat pump control unit power supply 230 V~ ..................................... 42
■Compressor power supply 230 V~ ..................................................... 42
■Compressor power supply 400 V~ ..................................................... 43
■Instantaneous heating water heater power supply 230 V~ ................. 43
■Instantaneous heating water heater power supply 400 V~ ................. 43
■Power supply with power-OFF, 400 V appliances: Without on-site
load disconnect ................................................................................... 44
■Power supply with power-OFF, 230 V appliances: Without on-site
load disconnect ................................................................................... 44
■Power supply with power-OFF, 400 V appliances: With on-site load
disconnect .......................................................................................... 45
■Power supply with power-OFF, 230 V appliances: With on-site load
disconnect .......................................................................................... 46
■Mains power supply in conjunction with on-site power consumption . 48
■Smart Grid .......................................................................................... 48
Make connections at terminals X3.8/X3.9 ............................................. 50
Closing the heat pump ........................................................................... 50
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 51
5. Maintenance Opening the casing door ........................................................................ 69
Overview of electrical components ........................................................ 69
■400 V appliances ................................................................................ 69
Index
Index
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6
■230 V appliances ................................................................................ 70
Overview of internal components .......................................................... 71
Draining heat pump on the secondary side ........................................... 71
Checking the temperature sensors ........................................................ 72
■Viessmann NTC 10 kΩ (blue marking) ............................................... 73
■Viessmann Pt500A (green marking) ................................................... 74
■NTC 10 kΩ (no marking) ..................................................................... 75
Checking the fuses ................................................................................ 75
Appliance is too noisy ............................................................................ 76
6. Commissioning/service
reports
Hydraulic parameters report .................................................................. 77
Control parameter report ....................................................................... 77
7. Specification Specification for brine/water heat pumps ............................................... 88
Specification for water/water heat pumps .............................................. 93
8. Appendix Commissioning order ............................................................................. 95
9. Declaration of Conformity Declaration of conformity ....................................................................... 96
10. Keyword index ................................................................................................................ 97
Index
Index (cont.)
6152043

7
Please dispose of packaging waste in line with statu-
tory regulations.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
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.
or
■Acoustic signal
■Fit new component.
or
■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.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions.
Depending on the version, the appliance can only be
used for the following purposes:
■Central heating
■Central cooling
■DHW heating
The range of functions can be extended with additional
components and accessories.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than central heating/cooling or DHW heating shall be
deemed inappropriate.
Information
Disposal of packaging
6152043
Information

8
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic or
semi-domestic use, i.e. even users who have not had
any instruction are able to operate the appliance
safely.
Product information
Structure
The Vitocal 200-G is a heat pump with brine/water
heat pump module for room heating, room cooling and
DHW heating in mono mode or mono energetic sys-
tems. The heat pump module can be removed for
transporting the appliance.
To back up the heat pump module an instantaneous
heating water heater has been installed as a further
heat source. This can be activated when there is a
high heat demand.
Refrigerant circuit
The refrigerant circuit has an electronic expansion
valve with an independent control circuit (refrigerant
circuit controller).
Hydraulics
The heat pump is equipped with high efficiency circula-
tion pumps for the primary and secondary circuits. The
integral 3-way diverter valve for "central heating/DHW
heating" changes over between central heating and
DHW heating.
Conversion to a water/water heat pump
Using the conversion kit (accessories), the brine/water
heat pump can be converted into a water/water heat
pump. A separate well circuit provides the primary cir-
cuit with heating energy via a separating heat
exchanger (accessories). The components of the well
circuit and primary circuit are controlled by the heat
pump control unit.
Room heating
The heat pump can supply up to 3 heating circuits,
1 heating circuit without mixer and 2 heating circuits
with mixer.
The mixer extension kit (accessories) is required to
control the mixer for the 2nd heating circuits with mixer
(M3/HC3).
Room cooling
Rooms can be cooled either via 1 heating/cooling cir-
cuit or 1 separate cooling circuit. Hydraulic accessories
are required for this, e.g. NC-Box with mixer.
Heat pump control unit
The entire system is monitored and controlled by the
integral Vitotronic 200 heat pump control unit,
type WO1C.
System examples
Available system examples: See www.viessmann-
schemes.com.
Information
Intended use (cont.)
6152043
Information

9
Spare parts lists
Information about spare parts can be found at
www.viessmann.com/etapp or in the Viessmann
spare part app.
Information
Product information (cont.)
6152043
Information

10
< 42 V
230 V~/
400 V~
120
210
300
390
36
600
A B C D E
888
975
980
1081
1255
680
480
F
A
BCD
E
Fig. 1
APrimary circuit flow (heat pump brine inlet), con-
nection Cu 28 x 1.5 mm
BPrimary circuit return (heat pump brine outlet),
connection Cu 28 x 1.5 mm
CSecondary circuit flow (DHW cylinder), connection
Cu 28 x 1.5 mm
DSecondary circuit flow (heating circuits), connec-
tion Cu 28 x 1.5 mm
ESecondary circuit return (heating circuits DHW cyl-
inder), connection Cu 28 x 1.5 mm
FRear top panel, pivoted open
Siting and transport requirements
Transport
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never put weight on the top, front or side panels
of the appliance.
!Please note
Tilting the compressor at a steep angle inside
the heat pump can result in appliance damage.
Max. tilting angle: 45° for a very short time
For handling purposes, the heat pump module can be
removed: See page 14.
Preparing for installation
Requirements concerning on-site connections
6152043
Installation

11
Installation room requirements
!Please note
Unfavourable ambient conditions can lead to
malfunctions and appliance damage.
The installation room must be dry and free from
the risk of frost:
■Ensure ambient temperatures between 0 and
35 °C.
■Max. 70 % relative humidity (corresponds to
an absolute humidity of approx. 25 g water
vapour/kg dry air)
Danger
Dust, gases and vapours can be damaging to
health and trigger 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.
Total weight
Type BWC Weight in kg
Heat pump Heat pump mod-
ule
201.B06 145 74
201.B08 148 77
201.B10 152 81
201.B13 158 87
201.B17 165 94
Type BWC-M Weight in kg
Heat pump Heat pump mod-
ule
201.B06 145 74
201.B08 148 77
201.B10 152 81
To prevent the transmission of structure-borne noise,
never site the appliance above ceilings with wooden
joists, e.g. in the attic.
Minimum room volume (to EN 378):
Type BWC Refrigerant
charge in kg
Minimum room
volume in m3
201.B06 1.40 3.2
201.B08 1.95 4.5
201.B10 2.40 5.5
201.B13 2.15 4.9
201.B17 2.60 5.9
Type BWC-M Refrigerant
charge in kg
Minimum room
volume in m3
201.B06 1.40 3.2
201.B08 1.95 4.5
201.B10 2.40 5.5
Minimum clearances for 1 heat pump
400
1000
200
Fig. 2
Other minimum distances may apply in con-
nection with accessories, e.g. with hydraulic
connection sets and/or NC-Box.
Installation instructions for the relevant accesso-
ries
Observe engineering information.
Brine/water heat pump technical guide
Preparing for installation
Siting and transport requirements (cont.)
6152043
Installation

12
Minimum clearances for heat pump cascades (max. 5 heat pumps)
1000
200 200 200 200 400200
1000 1000 1000 1000
Fig. 3
If the hydraulic connection sets available as
accessories are used, other minimum distan-
ces may apply.
Installation instructions for the relevant hydraulic
connection set
Observe engineering information.
Brine/water heat pump technical guide
Preparing for installation
Siting and transport requirements (cont.)
6152043
Installation

13
Removing the front panel
3.
2.
1.
4.
Fig. 4
Installation sequence
Siting the heat pump
6152043
Installation

14
Removing the heat pump module
2. 5x
3.
1.
Fig. 5
Installation sequence
Siting the heat pump (cont.)
6152043
Installation

15
4.
Fig. 6
Installation sequence
Siting the heat pump (cont.)
6152043
Installation

16
7.
5.
6.
Fig. 7
8.
Fig. 8
Installation sequence
Siting the heat pump (cont.)
6152043
Installation

17
9.
Fig. 9
Transporting the heat pump module
The heat pump module has been removed.
1. Insert both brackets of the transport aid at the front
and rear of the heat pump module: See Fig. 8 on
page 16.
2. The heat pump module must be carried by at least
2 people.
Installing the heat pump module
Refit the heat pump module in reverse order to the
removal sequence: See individual steps from page 14.
Installation sequence
Siting the heat pump (cont.)
6152043
Installation

18
Levelling the heat pump
1. 4x
Fig. 10
Hydraulic connections
Connecting the primary/secondary circuits
■The pipes of the primary circuit/secondary circuit
connection set are located in the EPP box, which is
positioned on top of the appliance on delivery.
■With the primary circuit/secondary circuit connection
set, the on-site hydraulic lines can be connected at
the top of the heat pump.
Note
The following connection versions are possible with
the hydraulic connection sets available as accessories:
■Connection of the primary lines to the right or left
■Connection of all hydraulic lines at the back
Note
We recommend fitting shut-off devices to the connec-
tion set on site. This will allow the primary and secon-
dary circuit to be shut off for maintenance work.
Installation sequence
Siting the heat pump (cont.)
6152043
Installation

19
Fitting the primary/secondary circuit connection set (standard delivery)
B
C
D
A
2.
5x
1.
5x
+
E
Fig. 11
APrimary circuit flow (heat pump brine inlet), con-
nection Cu 28 x 1.5 mm
BPrimary circuit return (heat pump brine outlet),
connection Cu 28 x 1.5 mm
CSecondary circuit flow (DHW cylinder), connection
Cu 28 x 1.5 mm
DSecondary circuit flow (heating circuits), connec-
tion Cu 28 x 1.5 mm
ESecondary circuit return (heating circuits DHW cyl-
inder), connection Cu 28 x 1.5 mm
Connecting the primary circuit
!Please note
The heat transfer medium can cause corrosion
damage to on-site lines and components.
The components and lines used must be resist-
ant to the heat transfer medium. Never use zinc-
plated/galvanised pipes.
1. Equip the primary circuit with an expansion vessel
and safety valve, in accordance with DIN 4757.
Note
■The expansion vessel must be approved to
DIN 4807. The diaphragms of the expansion ves-
sel and safety valve must be suitable for the heat
transfer medium.
■The blow down and drain pipes should exit into 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 insula-
tion where pipes penetrate walls.
Installation sequence
Hydraulic connections (cont.)
6152043
Installation

20
3. Connect the primary lines to the pipes of the
hydraulic connection set: See diagram in chapter
"Fitting the primary circuit/secondary circuit con-
nection set".
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Connect on-site lines so that they are free of
load and torque stress.
4. Insulate pipes inside the building to prevent heat
and vapour diffusion.
5. Fill the primary circuit with Viessmann heat transfer
medium and vent.
Note
Ensure frost protection down to at least –15 °C.
Viessmann heat transfer medium is a ready-mixed
ethylene glycol-based medium. It contains inhibi-
tors for corrosion protection. The heat transfer
medium can be used at temperatures down to
–16 °C.
Connecting the secondary circuit
1. Equip the secondary circuit on site with an expan-
sion vessel and safety assembly in accordance
with DIN 4757.
Install the safety equipment block with safety
assembly (enclosed in EPP box) on the on-site line
in the secondary circuit return.
Note
The expansion vessel must be approved to
EN 13831.
2. Connect the secondary lines to the pipes of the
hydraulic connection set: See diagram in chapter
"Fitting the primary circuit/secondary circuit con-
nection set".
!Please note
Mechanically loaded hydraulic connections
lead to leaks, vibrations and appliance dam-
age.
Connect on-site lines so that they are free of
load and torque stress.
3. Thermally insulate lines inside the building.
Note
■For underfloor heating circuits, install a temperature
limiter to restrict the maximum temperature in the
underfloor heating system: See chapter "Connecting
a temperature limiter to restrict the maximum tem-
perature of underfloor heating".
■Ensure the minimum flow rate, e.g. with an overflow
valve: See chapter "Specification".
Connecting the cooling circuit
An NC-Box (accessories) is required for cooling mode.
Connect the heating/cooling circuit or separate cooling
circuit to the NC-Box.
Installation instructions "NC-Box"
Electrical connection
Preparing the electrical connections
Cables
■For cable lengths and cable cross-sections, see the
following tables.
■For accessories:
Cables with the required number of cores for exter-
nal connections.
Prepare an on-site distribution box.
Danger
Damaged wiring insulation wiring can lead to
serious injury from electrical current and result in
appliance damage.
Route cables so that they cannot touch very hot,
vibrating or sharp-edged components.
Installation sequence
Hydraulic connections (cont.)
6152043
Installation