Viessmann VITOCAL 200-G Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitocal 200-G
Compact heat pump type BWP (400/230 V)
For applicability, see the last page
VITOCAL 200-G
5592 968 GB 9/2007 Please keep safe.

Please follow these safety instructions 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
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5592 968 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5592 968 GB

Installation instructions
Preparing for installation
Handling and installation............................................................................. 9
Summary of possible system versions......................................................... 10
Function description of systems .................................................................. 11
System version on the primary side............................................................. 15
System version 1 ........................................................................................ 16
System version 2 ........................................................................................ 24
System version 3 ........................................................................................ 33
System version 4 ........................................................................................ 42
System versions on the DHW side............................................................... 51
Installation sequence
Summary of electrical connections.............................................................. 54
Preparing the installation ............................................................................ 55
Installing the control module ....................................................................... 57
Installing the instantaneous heating water heater (accessories) .................. 57
Inserting the electrical cables and power supply connections ...................... 58
Checking the rotating field of the power supply connection (400 V units
only) ........................................................................................................... 59
Making the electrical connections of the cylinder loading system ................. 60
Electrical connection of the cylinder temperature sensor(s) ......................... 62
Installing the heat pump module and making the electrical connections ....... 63
Connecting the external electrical components ........................................... 67
Installing a 400 V full wave soft starter (as of BWP 108)............................... 67
Installing a 230 V full wave soft starter (all models)...................................... 68
Connecting the brine pressure switch or a jumper........................................ 70
Connections on the secondary side of the heat pump .................................. 71
Connections on the primary side of the heat pump....................................... 72
Connecting the heating circuits ................................................................... 76
Making the electrical connections to external components........................... 76
Power supply.............................................................................................. 88
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 98
Further details regarding the individual steps .............................................. 99
Troubleshooting
Control unit diagnostics .............................................................................. 113
Diagnosis ................................................................................................... 119
Index
4
Index
5592 968 GB

Control settings
Menu structure overview –Main menu ........................................................ 121
Menu structure overview –information ........................................................ 122
Menu structure overview –Programming..................................................... 123
Menu structure overview –Contractor level ................................................. 125
Control settings by contractors.................................................................... 129
Activating the technical service level ........................................................... 129
Adjusting sensor temperatures.................................................................... 130
Checking signal inputs................................................................................ 131
Manual control of relays and mixers ............................................................ 131
Control unit settings - system definition
System design............................................................................................ 134
Language ................................................................................................... 134
Power-OFF contact: 1S............................................................................... 134
Average time; outside temperature.............................................................. 134
Heating limit < T room (heating limit temperature)........................................ 135
Temperature limit for reduced temperature mode......................................... 136
Frost protection temperature....................................................................... 136
Heat pump control settings
Power-OFF compressor.............................................................................. 137
Maximum flow temperature ......................................................................... 137
Minimum return temperature ....................................................................... 137
Hysteresis T primary/min. T primary in ........................................................ 138
Minimum runtime ........................................................................................ 139
Min. compressor off .................................................................................... 139
Flow; primary/secondary pump ................................................................... 139
Optimum runtime ........................................................................................ 140
Instantaneous heating water heater control settings
E heating .................................................................................................... 142
Power-OFF; instantaneous heating water heater......................................... 142
Electric heating........................................................................................... 142
DHW with electric power ............................................................................. 143
Maximum flow temperature ......................................................................... 143
Heater rod delay ......................................................................................... 143
Electric heating threshold ........................................................................... 144
Maximum stage; electric heater................................................................... 144
Internal hydraulics control settings
Heat pump for drying buildings.................................................................... 145
Time for drying buildings ............................................................................. 145
Index (cont.)
5
Index
5592 968 GB

Flow hysteresis........................................................................................... 146
Internal pump run-on................................................................................... 146
Max. steps; three-way valve........................................................................ 146
DHW control settings
DHW cylinder temperature .......................................................................... 148
DHW program temperature ......................................................................... 148
DHW circulation pump program................................................................... 148
Operating mode.......................................................................................... 148
DHW cylinder maximum.............................................................................. 149
Hysteresis; DHW instantaneous heating water heater/hysteresis................. 149
Start optimisation........................................................................................ 151
Stop optimisation........................................................................................ 151
DHW auxiliary function................................................................................ 151
Set DHW temperature 2 .............................................................................. 151
Heat pump cylinder volume......................................................................... 151
Excess reaction .......................................................................................... 152
Maximum DHW runtime .............................................................................. 152
Maximum DHW interruption ........................................................................ 152
Heating circuit control settings
Standard temperature................................................................................. 154
Reduced temperature ................................................................................. 154
Temperature program, heating circuit .......................................................... 154
Remote control ........................................................................................... 154
Operating mode.......................................................................................... 154
Maximum flow temperature ......................................................................... 155
Minimum flow temperature .......................................................................... 155
DHW during party mode.............................................................................. 156
Excess reaction .......................................................................................... 156
Room temperature sensor........................................................................... 157
Slope; room temperature hook-up ............................................................... 157
Room temperature hook-up ........................................................................ 158
Start optimisation........................................................................................ 158
Maximum flow temperature correction......................................................... 158
Room temperature control .......................................................................... 159
Adjusting the heating curve level and slope................................................. 160
Integral room temperature controller ........................................................... 160
Flow T excess ............................................................................................. 160
Mixer runtime.............................................................................................. 161
Mixer parameters........................................................................................ 161
Screed function .......................................................................................... 162
Mixer active zone/dead zone....................................................................... 163
Index (cont.)
6
Index
5592 968 GB

Natural cooling ........................................................................................... 164
Cooling limit > T room (cooling limit temperature) ........................................ 165
Cooling curve level/slope............................................................................ 165
Natural cooling with mixer ........................................................................... 166
Active zone/dead zone natural cooling mixer............................................... 167
Cooling mixer runtime ................................................................................. 167
Cooling mixer parameters ........................................................................... 168
Buffer cylinder control settings
Buffer cylinder ............................................................................................ 169
Buffer cylinder program............................................................................... 169
Fixed temperature ...................................................................................... 169
Hysteresis temperature............................................................................... 170
Maximum temperature ................................................................................ 170
Stop optimisation........................................................................................ 171
Excess reaction .......................................................................................... 171
Components
Sensor resistance curves............................................................................ 173
Fuse........................................................................................................... 174
Connection and wiring diagrams
Overview of the PCBs and connection options............................................. 175
Main connection area.................................................................................. 176
Safety chain, 400 V units............................................................................. 178
Safety chain, 230 V units............................................................................. 179
Left part of the main PCB ............................................................................ 180
Upper and lower part of the main PCB ......................................................... 181
R.h. part of the main PCB............................................................................ 183
Parts lists.................................................................................................. 185
Commissioning/service reports
Hydraulic parameter report ......................................................................... 190
Control parameter report............................................................................. 191
Technical data for 400 V units................................................................... 195
Technical data for 230 V units
Technical data for 230 V units ..................................................................... 198
Appendix
Order to commission the Vitocal 200-G ....................................................... 200
Index (cont.)
7
Index
5592 968 GB

Certificates
Declaration of conformity ............................................................................ 201
Keyword index .......................................................................................... 202
Index (cont.)
8
Index
5592 968 GB

Transport
Do not tilt the heat pump module with
compressor by more than 30° during
transportation and installation.
Installation room requirements
&The installation room must be dry
and safe from the risk of frost.
&To prevent corrosion damage, pro-
vide the brine-side heat pump
installation with thermal insulation in
accordance with current rules as
vapour diffusion proof installation.
Installation
Wall clearances (plan view)
&To prevent structure-borne noise,
never set up the unit on wooden
ceilings in the attic.
&Observe required wall clearances
as shown in the diagram.
&Level the unit horizontally (see also
page 55).
Handling and installation
9
Preparing for installation
5592 968 GB
Installation

Top panel dimensions (plan view)
ACable entries
BSafety assembly
CPrimary flow (brine) IN
DPrimary return (brine) OUT
HR Heating return
HV Heating flow
SRL Cylinder return
SVL Cylinder flow
Summary of possible system versions
The following table provides an overview of all possible system versions.
The designs on the following pages are representative forfourtypicalheat
pump systems.
Handling and installation (cont.)
10
Preparing for installation
5592 968 GB