Viessmann VITOCAL 200-G Guida rapida

Installation and service

instructions

for contractors

VIESMANN

Vitocal 200-G

Type BWC 201.A06 to A17, 6 to 17 kW

Single stage heat pump with electric drive, 400 V~

Type BWC-M 201.A06 to A10, 6 to 10 kW

Single stage heat pump with electric drive, 230 V~

For applicability, see the last page

VITOCAL 200-G

5600 138 GB 5/2013 Please keep safe.

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

5600 138 GB

!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.)

5600 138 GB

Installation instructions

Preparing for installation

Intended use......................................................................................................... 6

General information on the electrical connection................................................. 7

Siting.................................................................................................................... 7

Overview of possible system schemes................................................................ 10

Primary circuit....................................................................................................... 11

DHW heating........................................................................................................ 13

System example 1, ID: 4605363_1009_01.......................................................... 18

System example 2, ID: 4605364_1009_01.......................................................... 24

Installation sequence

Siting the heat pump............................................................................................ 32

Hydraulic connections.......................................................................................... 34

Electrical connections........................................................................................... 36

Power supply........................................................................................................ 52

Connecting to terminals X3.8/X3.9....................................................................... 60

Closing the heat pump......................................................................................... 61

Checking diaphragm grommets........................................................................... 62

Service instructions

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 63

Further details regarding the individual steps....................................................... 64

Troubleshooting

Repairs................................................................................................................. 75

Parts lists

Parts lists.............................................................................................................. 82

Overview of the assemblies................................................................................. 83

Parts not shown.................................................................................................... 84

Casing.................................................................................................................. 84

Hydraulics............................................................................................................. 86

Heat pump module............................................................................................... 88

Electrical equipment............................................................................................. 90

Commissioning/service reports........................................................................ 96

Specification....................................................................................................... 101

Index

5600 138 GB

Appendix

Heat pump commissioning order.......................................................................... 106

Certificates

Declaration of conformity...................................................................................... 107

Keyword index.................................................................................................... 108

Index

Index (cont.)

5600 138 GB

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

5600 138 GB

■Electrical connection of system

components (pumps, mixers, valves,

alarm facilities, contactors, function

extensions, sensors, etc.):

These connections are made inside

the heat pump control unit. Observe

information from page 39.

■Power supply:

The number of power cables from the

distribution board (meter box) to the

heat pump control unit and to the con-

trol panel depends on the system ver-

sion and tariffs used.

These connections are made inside

the heat pump control panel. Observe

information from page 52.

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°.

Installation room requirements

!Please note

The installation room must be dry

and free from the risk of frost.

Ensure ambient temperatures of

0 to 35 ºC.

!Please note

Avoid risk of explosion due to

dust, gases and vapours

in the installation room.

!Please note

Observe the permissible floor

load.

See the following table, "Total

weight".

Total weight

Output stage Type BWC 201.A

(400 V~ appliance)

Type BWC-M 201.A

(230 V~ appliance)

06 113 kg 115 kg

08 117 kg 119 kg

10 129 kg 131 kg

13 135 kg —

17 148 kg —

Preparing for installation

General information on the electrical connection

5600 138 GB

Installation

■ To prevent structure-borne noise,

never site the appliance on ceilings

with wooden joists (e.g. in the attic).

■ Level the appliance horizontally.

If the adjustable feet are used to com-

pensate for an uneven floor (max.

10 mm), the pressure load on the feet

must be distributed evenly.

■ Observe the required floor area and

minimum room volume (to

DIN EN 378).

Type BWC 201.A,

Type BWC-M 201.A

Refrigerant volume Min. space require-

ment

06 1.2 kg 2.73 m3

08 1.45 kg 3.30 m3

10 1.7 kg 3.86 m3

13 2.2 kg 5.00 m3

17 2.9 kg 6.59 m3

■ Observe required minimum clearan-

ces:

≥ 400

≥ 1500

A■ With hydraulic module (acces-

sory, for installation above the

heat pump):

340 mm

■ Without hydraulic module:

Subject to on-site installation and

site conditions

B≥ 100 mm

Preparing for installation

Siting (cont.)

5600 138 GB

Information on the use of accessories

for a heating/cooling circuit or sepa-

rate cooling circuit

NC-Box for natural cooling function

■ The NC-Box can only be used up to a

rated heating output of ≤ 16 kW. For

higher rated heating outputs, install all

the components required on site (with

correspondingly sized plate heat

exchanger) for the heating/cooling cir-

cuit or the separate cooling circuit.

Requirements for on-site connections

105

152

240

300

419

476

533

600

230 V

< 42 V

133

576

662662

727

792

888

962

Preparing for installation

Siting (cont.)

5600 138 GB

Installation

Install hydraulic connections on site

stress-free.

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 power cables 1.0 m

Recommended power cables:

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. line

length

50 m 50 m 50 m 50 m 50 m

Compressor for type BWC-M 201.A (230 V~)

Power cable 3 x 4.0 mm23 x 4.0 mm23 x 4.0 mm2— —

Max. line

length

40 m 32 m 26 m — —

Instantaneous heating water heater (if installed) for type BWC 201.A (400 V~)

Power cable 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2

Max. line

length

50 m 50 m 50 m 50 m 50 m

Instantaneous heating water heater (if installed) for 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. line

length

50 m 50 m 50 m 50 m 50 m

Overview of possible system schemes

The following table provides an overview

of all possible system schemes.

Preparing for installation

Siting (cont.)

5600 138 GB

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