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.
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
5600 138 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.)
5600 138 GB
4
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
Index
5600 138 GB
5
Appendix
Heat pump commissioning order.......................................................................... 106
Certificates
Declaration of conformity...................................................................................... 107
Keyword index.................................................................................................... 108
Index
Index (cont.)
5600 138 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
5600 138 GB
7
■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
8
■ 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
B
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
9
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
77
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
10
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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7
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