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

System
layout in-
side the
control
unit
Standard equipment Additional equip-
ment
"Natural
cooling"
(only one option
per system design)
Direct
heating
circuit
Heating
circuit
with
mixer
DHW cy-
linder
Buffer
cylinder
Low loss
header
0X
1X X X
X
2X XX X
X
3XXX
4 XXX X
5XX X X
X
6 XXXX X
X
F The equipment only responds to external demand signals. All ex-
ternal sensors (e.g. room temperature sensors) and relay outputs
are disabled.
The primary pump, secondary pump and compressor start if a de-
mand is issued by an external signal (prerequisite: activation con-
ditions such as temperature limits are complied with).
Function description of systems
Note
The 230 V units must not be operated in d.
A pre-requisite for operating 230 V units in some countries is that starting cur-
rentsofupto45Aare permissible in the power grid of the country concerned
(observe other country-specific regulations, if necessary).
The sample applications are recommendations and must be checked for com-
pleteness and functionality on site. Please observe the applicable regulations
and directives for design, installation and operation.
Summary of possible system versions (cont.)
11
Preparing for installation
5592 968 GB
Installation

Heating circuit
Heat pumps require a minimum heat-
ing water throughput. Ensure that the
values specified in the relevant data-
sheet are maintained.
Accurately calculated radiator heating
systems generally have a small sys-
tem water content. With systems like
these, use a heating water buffer
cylinder with an appropriate capacity
to prevent the heat pump from being
switched on and off at frequent inter-
vals.
Heat pumps can be shut off by the
power supply utility at peak load times
depending on the power tariff. For this
reason a heating water buffer cylinder
should be installed for rapidly cooling
heating systems (radiators). The
volume of the heating water buffer
cylinder should be sufficient to pre-
ventthestoredheatfromallowingthe
building to cool down during power-
OFF periods.
Systemversions2to4donotusea
secondary pump but a separate circu-
lation pump as heating circuit pump.
We recommend the use of a heating
circuit pump with a slower throughput
than the secondary pump. Install a
heating water buffer cylinder in paral-
lel to the heating circuit to compen-
sate for the difference between these
water volumes.
Systems with large volumes, e.g.
underfloor heating systems, will not
necessarily require a heating water
buffer cylinder. In these heating sys-
tems install an overflow valve at the
underfloor heating system heating cir-
cuit distributor that is furthest away
from the heat pump. This ensures that
the minimum water circulation volume
is provided, even in closed heating
circuits.
Install a temperature limiter (acces-
sory, part no. 7151 728 or 7151 729)
in conjunction with an underfloor heat-
ing system circuit (particularly if an
instantaneous heating water heater is
installed). Install the temperature lim-
iter, for example, on the underfloor
heating circuit pump.
Heating water buffer cylinder operated in parallel
Heating water buffer cylinders provide
a hydraulic separation between the
media circulating in the heat pump
and the heating circuits. For example,
the throughput in the heat pump cir-
cuit remains constant, even if the
heating circuit throughput is reduced
by thermostatic valves.
The use of a heating water buffer
cylinder offers the following advan-
tages:
&Bridging power-OFF periods
&Constant throughput through the
heat pump
&Longer heat pump operating times
Function description of systems (cont.)
12
Preparing for installation
5592 968 GB

Systems without heating water buffer cylinder
Never install a mixer to safeguard the
minimum heating water circulation
volume.
Natural cooling function
During the summer months the tem-
perature level of the primary circuit
canbeusedtocoolthebuilding.
The natural cooling function is a
method of cooling buildings that
saves a considerable amount of
energy. All that is needed is a small
amount of electricity for the circulation
pumps to access the "cooling source"
in the ground.
During the cooling operation, the heat
pump will only be started to provide
DHW. The heat pump control system
actuates the circulation pumps, diver-
ter valves and mixers and records the
temperature via the natural cooling
extension kit.
Alternatively, this function can also be
covered by on-site components (for
an on-site wiring suggestion, see the
Vitocal 200/222/242 technical guide).
A contact humidistat monitors the dew
point.
The capability of the natural cooling
function cannot generally be com-
pared with that of air-conditioning
equipment or water chillers. Natural
cooling provides no dehumidification.
The cooling capacity depends on the
heat source temperature, which itself
is subject to seasonal fluctuations.
Experience has shown that the cool-
ing capacity is higher at the beginning
of summer than at the end. In addi-
tion, the water source temperature
curve is subject to the cooling
demand of the building. Because of
large window areas or internal
sources (lighting, electrical equip-
ment), the heat source temperature
increases more rapidly during the
course of a year than it does if less
cooling is required.
Underfloor heating systems and con-
crete core tempering are available for
cooling the building; radiator heating
systems are unsuitable for this pur-
pose. Ensure that any installed room
thermostats are able to be opened
manually or by servomotors when
using the cooling function.
Function description of systems (cont.)
13
Preparing for installation
5592 968 GB
Installation

Instantaneous heating water heater
An instantaneous heating water hea-
ter can be installed in the unit (acces-
sory, see separate installation
instructions).
Subject to the available grid, the sys-
tem may be supplied with 230 V or
400 V.
Protect the instantaneous heating
water heater via a separate connec-
tion.
The heat pump control unit regulates
this function.
Power-OFF (interruption by the power supply utility)
It is possible to have the compressor
and the instantaneous heating water
heater or just one of these shut off by
the power supply utility.
Thiscanbeintheformofa"hard"
shutdown (contactor shutdown) or a
"soft" shutdown by the heat pump
control software. For both shutdown
methods, the "power-OFF" control
unit input signal must be connected
(see page 81).
The "hard" shutdown requires an
additional control on site (see
page 81). This must not shut down the
control unit power supply.
For the "soft" shutdown, the compo-
nent that is being switched off can be
selected using the "power-OFF" para-
meter for the heat pump (see
page 137) and/or for the instanta-
neous heating water heater ("Electric
heating", see page 142).
Function description of systems (cont.)
14
Preparing for installation
5592 968 GB

Hydraulic diagram
BHeat pump interface (see from
page 16)
2Brine accessory pack
3Brine distributor for geothermal
probes/collectors
4Geothermal probes/geothermal
collectors
qQ Brine circuit pressure switch
Electrical connection
Pressure switch connection for brine circuit, qQ seepage18.
Equipment required
Pos. Description Number
2Brine accessory pack 1
3Brine distributor for geothermal probes/collectors as required
4Geothermal probes/geothermal collectors as required
qQ Brine circuit pressure switch 1
System version on the primary side
15
Preparing for installation
5592 968 GB
Installation

One heating circuit without mixer, with DHW heating and natural cooling
Note
To achieve this system version, select system design 2 at the control unit.
Hydraulic diagram
ADHW cylinder interface (see from
page 51)
BPrimary side interface (see from
page 15)
CMin. 500 mm (for hydraulic
separation)
1Heat pump
6Diaphragm expansion vessel
7Underfloor heating system tem-
perature limiter
8Plate-type heat exchanger
qP Underfloor heating circuit
qR Natural cooling extension kit
qU KM BUS distributor
qI Vitotrol 200 remote control
qO Room temperature sensor
System version 1
16
Preparing for installation
5592 968 GB

wP Extension kit for cooling circuit
with mixer
wQ Outside temperature sensor
eP Contact humidistat
eQ Circulation pump (secondary
cooling circuit pump)
eW Three-way diverter valve heating/
cooling
eE Two-way motorised ball valve
eR Frost stat
eT Circulation pump (primary cooling
circuit pump)
rQ Cooling circuit flow temperature
sensor
rW Cooling circuit mixer motor
zP Instantaneous heating water hea-
ter
System version 1 (cont.)
17
Preparing for installation
5592 968 GB
Installation

Electrical connection (400 V versions)
Connections at the main connection area X60
FControl unit power connection
(230 V)
GInstantaneous heating water hea-
ter power cable
HExternal connections at natural
cooling extension kit
KKM BUS
qQ Brine circuit pressure switch (if
thepressureswitchisnot
installed, use the jumper pro-
vided)
qE DHW circulation pump
System version 1 (cont.)
18
Preparing for installation
5592 968 GB

qR Natural cooling extension kit
qT Central fault message (230 V)
qZ Power-OFF
qI KM BUS: Vitotrol 200 remote con-
trol (with room temperature sen-
sor), see also page 77
qO Room temperature sensor (if no
remote control is installed), see
also page 77
wP KM BUS: Extension kit for cooling
circuit with mixer
wQ Outside temperature sensor
Connections to control module X80, 400 V
AFrontofcontrolmodule(withtype
plate)
BCompressor power supply
CInternal connection to control
panel
DPrimary pump connection (230 V)
ECompressor safety chain connec-
tion
FPhase monitor plug-in location
(accessories)
GStrapping plug or phase monitor
connection
HCompressor contactor
KCompressor or full wave soft star-
ter connection
LPrimary temperature sensor (for
control purposes)
MHeat pump module
NDirect connection only with
BWP 106
OConnection required as of
BWP 108
PConnection required as of
BWP 108
RFull wave soft starter (as of
BWP 108)
Information regarding other connections
The primary pump, the secondary pump, and the heating/DHW three-way valve
have already been connected in the factory.
System version 1 (cont.)
19
Preparing for installation
5592 968 GB
Installation

Components to be connected Connection descrip-
tion
Only when using an instantaneous heating water
heater:
Connect instantaneous heating water heater to main
PCB and auxiliary PCB
See separate installa-
tion instructions
Only with natural cooling:
Connect the required components to extension kit wP
and natural cooling qR extension kit
See separate installa-
tion instructions
Only when using an underfloor heating system:
Connect temperature limiter
see page 78
Only with external control (system design F):
Make connection to main PCB
See Hon page 184
System version 1 (cont.)
20
Preparing for installation
5592 968 GB