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Viessmann VITOCAL 200-G, Installation And Service Instructions Manual

The Viessmann VITOCAL 200-G is a cutting-edge heating system known for its efficiency and reliability. Take full advantage of its advanced features by downloading the comprehensive user manual, available for free on our website. With just a few clicks, you can have the detailed instructions at your fingertips to maximize the performance of your VITOCAL 200-G.

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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

55

92

968

GB

Summary of Contents for VITOCAL 200-G

Page 1: ...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 ...

Page 2: ...l legal instructions regarding the prevention of accidents all legal instructions regarding environmental protection the Code of Practice of relevant 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 fla...

Page 3: ... 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 authori...

Page 4: ...al 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 ...

Page 5: ... 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 ...

Page 6: ...uption 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 fl...

Page 7: ...ess 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...

Page 8: ...Certificates Declaration of conformity 201 Keyword index 202 Index cont 8 Index 5592 968 GB ...

Page 9: ...ide 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 Prepar...

Page 10: ...eturn 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 for four typical heat pump systems Handling and installation cont 10 Preparing for installation 5592 968 GB ...

Page 11: ... 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 rents of up to 45 A are permissible in the power grid of the country concerned observe other country specific regulations if nece...

Page 12: ...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 clos...

Page 13: ...t 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 t...

Page 14: ... just one of these shut off by the power supply utility This can be in the form of a 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 so...

Page 15: ...e switch Electrical connection Pressure switch connection for brine circuit qQ see page 18 Equipment required Pos Description Number 2 Brine accessory pack 1 3 Brine distributor for geothermal probes collectors as required 4 Geothermal probes geothermal collectors as required qQ Brine circuit pressure switch 1 System version on the primary side 15 Preparing for installation 5592 968 GB Installatio...

Page 16: ...ge 51 B Primary side interface see from page 15 C Min 500 mm for hydraulic separation 1 Heat pump 6 Diaphragm expansion vessel 7 Underfloor heating system tem perature limiter 8 Plate 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 9...

Page 17: ...ircuit 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 ...

Page 18: ...ion 230 V G Instantaneous heating water hea ter power cable H External connections at natural cooling extension kit K KM BUS qQ Brine circuit pressure switch if the pressure switch is not installed use the jumper pro vided qE DHW circulation pump System version 1 cont 18 Preparing for installation 5592 968 GB ...

Page 19: ...imary pump connection 230 V E Compressor safety chain connec tion F Phase monitor plug in location accessories G Strapping plug or phase monitor connection H Compressor contactor K Compressor or full wave soft star ter connection L Primary temperature sensor for control purposes M Heat pump module N Direct connection only with BWP 106 O Connection required as of BWP 108 P Connection required as of...

Page 20: ... 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 H on page 184 System version 1 cont 20 Preparing for installation 5592 ...

Page 21: ...ower supply G Instantaneous heating water hea ter power cable circuit breakers must be blocked H External connections at natural cooling extension kit K KM BUS System version 1 cont 21 Preparing for installation 5592 968 GB Installation 1Never operate 230 V units in d For more information see page 11 ...

Page 22: ...tside temperature sensor Connections to control module X80 230 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection E Compressor safety chain connec tion H Compressor contactor K Full wave soft starter connection L Primary temperature sensor for control purposes M Heat pump module R Full wave soft starter S Capacitor...

Page 23: ...diverter valve heating DHW 1 6 Diaphragm expansion vessel for the heating circuit 1 7 Temperature limiter only required for underfloor heating circuits 1 qP Underfloor heating circuit 1 qU KM BUS distributor 1 qI Vitotrol 200 remote control 1 qO Room temperature sensor 1 wQ Outside temperature sensor 1 zP Instantaneous heating water heater option 1 Option DHW heating see page 51 Option Natural coo...

Page 24: ...ystem version 2 One heating circuit without mixer with heating water buffer cylinder DHW heating and natural cooling Note To achieve this system version select system design 2 at the control unit System version 1 cont 24 Preparing for installation 5592 968 GB ...

Page 25: ...mp 6 Diaphragm expansion vessel 7 Underfloor heating system tem perature limiter 8 Plate type heat exchanger 9 Heating water buffer cylinder qP Underfloor heating circuit qW Heating circuit pump direct heat ing circuit qR Natural cooling extension kit qU KM BUS distributor System version 2 cont 25 Preparing for installation 5592 968 GB Installation ...

Page 26: ...linder tem perature sensor eP Contact humidistat 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 2 cont 26 Preparing for installation 5592 968 GB ...

Page 27: ...onnection 230 V G Instantaneous heating water hea ter power cable H External connections at natural cooling extension kit K KM BUS qQ Brine circuit pressure switch if the pressure switch is not installed use the jumper pro vided System version 2 cont 27 Preparing for installation 5592 968 GB Installation ...

Page 28: ...ctions to control module X80 400 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection 230 V E Compressor safety chain connec tion F Phase monitor plug in location accessories G Strapping plug or phase monitor connection H Compressor contactor K Compressor or full wave soft star ter connection L Primary temperature se...

Page 29: ... 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 separate installa tion instructions Only with external control system design F Make connection to...

Page 30: ...unit power supply G Instantaneous heating water hea ter power cable circuit breakers must be blocked H External connections at natural cooling extension kit K KM BUS System version 2 cont 30 Preparing for installation 5592 968 GB 1Never operate 230 V units in d For more information see page 11 ...

Page 31: ...perature sensor wW Heating water buffer cylinder tem perature sensor Connections to control module X80 230 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection E Compressor safety chain connec tion H Compressor contactor K Full wave soft starter connection L Primary temperature sensor for control purposes M Heat pump...

Page 32: ... and three way diverter valve heating DHW 1 6 Diaphragm expansion vessel for the heating circuit 1 7 Temperature limiter only required for underfloor heating circuits 1 qP Underfloor heating circuit 1 qW Heating circuit pump direct heating circuit 1 qU KM BUS distributor 1 qI Vitotrol 200 remote control 1 qO Room temperature sensor 1 wQ Outside temperature sensor 1 zP Instantaneous heating water h...

Page 33: ...mixer circuit 1 rW Cooling circuit mixer motor 1 System version 3 One heating circuit with mixer with heating water buffer cylinder DHW heating and natural cooling Note To achieve this system version select system design 4 at the control unit System version 2 cont 33 Preparing for installation 5592 968 GB Installation ...

Page 34: ...HW cylinder interface see from page 51 B Primary side interface see from page 15 C Min 500 mm for hydraulic separation 1 Heat pump 6 Diaphragm expansion vessel System version 3 cont 34 Preparing for installation 5592 968 GB ...

Page 35: ... temperature sensor wW Heating water buffer cylinder tem perature sensor eP Contact humidistat eW Three way diverter valve heating cooling eE Two way motorised ball valve eR Frost stat eT Circulation pump primary cooling circuit pump rP Heating circuit pump mixer circuit rQ Flow temperature sensor mixer circuit rW Three way mixer mixer motor tP Extension kit for one heating cir cuit with mixer zP ...

Page 36: ...ion 230 V G Instantaneous heating water hea ter power cable H External connections at natural cooling extension kit K KM BUS qQ Brine circuit pressure switch if the pressure switch is not installed use the jumper pro vided qE DHW circulation pump System version 3 cont 36 Preparing for installation 5592 968 GB ...

Page 37: ...l module X80 400 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection 230 V E Compressor safety chain connec tion F Phase monitor plug in location accessories G Strapping plug or phase monitor connection H Compressor contactor K Compressor or full wave soft star ter connection L Primary temperature sensor for control...

Page 38: ...ating 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 separate installa tion instructions ...

Page 39: ...ower supply G Instantaneous heating water hea ter power cable circuit breakers must be blocked H External connections at natural cooling extension kit K KM BUS System version 3 cont 39 Preparing for installation 5592 968 GB Installation 1Never operate 230 V units in d For more information see page 11 ...

Page 40: ...tem perature sensor tP Extension kit for one heating cir cuit with mixer Connections to control module X80 230 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection E Compressor safety chain connec tion H Compressor contactor K Full wave soft starter connection L Primary temperature sensor for control purposes M Heat ...

Page 41: ...onnection to main PCB See H on page 184 Equipment required Pos Description Number 1 Heat pump with integral primary pump secondary pump and three way diverter valve heating DHW 1 6 Diaphragm expansion vessel for the heating circuit 1 7 Temperature limiter only required for underfloor heating circuits 1 qP Underfloor heating circuit 1 qU KM BUS distributor 1 qI Vitotrol 200 remote control 1 qO Room...

Page 42: ...ed ball valve brine circuit shut off valve 1 eR Frost stat 1 eT Circulation pump primary cooling circuit pump 1 rQ Flow temperature sensor mixer circuit 1 rW Three way mixer mixer motor 1 System version 4 One heating circuit without mixer one heating circuit with mixer heating water buffer cylinder DHW heating and natural cooling Note To achieve this system version select system design 6 at the co...

Page 43: ...nder interface see from page 51 B Primary side interface see from page 15 C Min 500 mm for hydraulic separation 1 Heat pump 6 Diaphragm expansion vessel System version 4 cont 43 Preparing for installation 5592 968 GB Installation ...

Page 44: ...mixer wQ Outside temperature sensor wW Heating water buffer cylinder tem perature sensor eP Contact humidistat eW Three way diverter valve heating cooling eE Two way motorised ball valve eR Frost stat eT Circulation pump primary cooling circuit pump rP Heating circuit pump mixer circuit rQ Flow temperature sensor mixer circuit rW Three way mixer mixer motor tP Extension kit for one heating cir cui...

Page 45: ...onnection 230 V G Instantaneous heating water hea ter power cable H External connections at natural cooling extension kit K KM BUS qQ Brine circuit pressure switch if the pressure switch is not installed use the jumper pro vided System version 4 cont 45 Preparing for installation 5592 968 GB Installation ...

Page 46: ...g cir cuit with mixer Connections to control module X80 400 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection 230 V E Compressor safety chain connec tion F Phase monitor plug in location accessories G Strapping plug or phase monitor connection H Compressor contactor K Compressor or full wave soft star ter connecti...

Page 47: ...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 separate installa tion instructions Only w...

Page 48: ...unit power supply G Instantaneous heating water hea ter power cable circuit breakers must be blocked H External connections at natural cooling extension kit K KM BUS System version 4 cont 48 Preparing for installation 5592 968 GB 1Never operate 230 V units in d For more information see page 11 ...

Page 49: ...n kit for cooling circuit with mixer wQ Outside temperature sensor wW Heating water buffer cylinder tem perature sensor tP Extension kit for one heating cir cuit with mixer Connections to control module X80 230 V A Front of control module with type plate B Compressor power supply C Internal connection to control panel D Primary pump connection E Compressor safety chain connec tion H Compressor con...

Page 50: ...an underfloor heating system Connect temperature limiter See separate installa tion instructions Only with external control system design F Make connection to main PCB See H on page 184 Equipment required Pos Description Number 1 Heat pump with integral primary pump secondary pump and three way diverter valve heating DHW 1 6 Diaphragm expansion vessel for the heating circuit 1 7 Temperature limite...

Page 51: ...1 wP Extension kit for cooling circuit with mixer 1 eP Contact humidistat 1 eW Three way diverter valve heating cooling 1 eE Two way motorised ball valve brine circuit shut off valve 1 eR Frost stat 1 eT Circulation pump primary cooling circuit pump 1 rQ Flow temperature sensor mixer circuit 1 rW Three way mixer mixer motor 1 System versions on the DHW side Hydraulic diagrams Connection Vitocell 1...

Page 52: ...n descrip tion Connect DHW circulation pump qE to main connection area X60 see page 80 Connect upper cylinder temperature sensor tW for DHW cylinder to main PCB see page 62 Connect lower cylinder temperature sensor tE for DHW cylinder to main PCB see page 62 Only for cylinder loading system Connect cylinder primary pump tP and two way valve tQ to additional connecting area X50 see page 60 System v...

Page 53: ...n pump 1 tP Cylinder primary pump 1 tQ Two way valve normally closed on site 1 tW Upper cylinder temperature sensor 1 tE Lower cylinder temperature sensor 1 uO DHW cylinder 1 iQ Flow limiter Taco setter on site 1 System versions on the DHW side cont 53 Preparing for installation 5592 968 GB Installation ...

Page 54: ... starter 400 or 230 V version B Junction box with main connec tion area X60 internal connection area X50 and control module underneath C C Control module with X80 connect ing area D Main PCB with connection areas X5 and X16 Summary of electrical connections 54 Installation sequence 5592 968 GB ...

Page 55: ...1 Position units and perform horizon tal alignment as described on page 9 Preparing the installation 55 Installation sequence 5592 968 GB Installation ...

Page 56: ...t out upwards 3 Lift both top panels forward and up and release their respective earth strap 4 Undo the screws at the upper crossbar 5 Remove the control unit retainer and hook it into the r h front edge of the equipment i e into the ser vice position Preparing the installation cont 56 Installation sequence 5592 968 GB ...

Page 57: ...he two addi tional holes 3 Tighten the screws 4 Fit the control panel connecting cable 7 pin to pos C of the con trol module see page 19 Note The plug must click home Installing the instantaneous heating water heater accessories If the instantaneous heating water heater accessory is used it is advisable to install it at this stage of the installation procedure Installation instructions instantaneo...

Page 58: ...cal cables can result in short circuits Route cables so that they cannot touch very hot vibrating or sharp edged components Secure cables with cable ties Route cables to control panel through one of the available cable entries A In doing this separate the LV cables from those carrying mains voltage and tie up both types of cable separately Inserting the electrical cables and power supply connectio...

Page 59: ...on to the terminals marked L1 N and PE at pos B of the control module see page 22 Checking the rotating field of the power supply connection 400 V units only Please note With 400 V units the wrong phase sequence can damage the equipment The power supply connection must have a clockwise rotating field in the phase sequence that is specified at the terminals With phase monitor installation 1 Fit pha...

Page 60: ...ply connection and correct if necessary 3 Isolate the system from the power supply and safeguard against re connection 4 Fit strapping plug from pack to pos G of the control module see page 19 Making the electrical connections of the cylinder loading sys tem Note This connection must only be made if a cylinder loading system is used for DHW heating Using a directly heated cylinder requires no addi...

Page 61: ...le and the two way valve in accordance with the illustration with the 3 pin plug with the contact designation PE 7 8 in the pack 3 Undo the four screws and lift out the control panel upwards 4 Fit the connecting cable in front position to mating plugs on top hat rail marked PE 7 and 8 con necting area X50 5 Re insert the control panel and secure with the four screws Making the electrical connectio...

Page 62: ...or D Attach type plate here see page 74 1 Remove main PCB cover by undoing four screws and discon necting the earth strap 2 Connect sensor cable s to term inal strip X5 at top right on main PCB as shown in illustration When only one cylinder tempera ture sensor is used connect the lead across X5 1 and X5 2 Electrical connection of the cylinder temperature sensor s 62 Installation sequence 5592 968...

Page 63: ...es leads 4 Re connect earth strap fit main PCB cover and secure using four screws Installing the heat pump module and making the electrical con nections Electrical connection of the cylinder temperature cont 63 Installation sequence 5592 968 GB Installation ...

Page 64: ...ulation into the groove of the recess in the lower part of the thermal insula tion 4 Check the floor area valves and all visible solder joints of the heat pump for traces of oil Note Traces of oil indicate a leaking refrigerant circuit Ask a refrigera tion engineer to check the heat pump 5 Lead the thermal insulation A of the primary inlets and outlets through the openings in the top part of the t...

Page 65: ...Installing the heat pump module and making the cont 65 Installation sequence 5592 968 GB Installation ...

Page 66: ... 3 4 into pos E at the control module see page 19 Push the primary pump connec tion 3 pin plug with designation PE 5 6 into pos D at the con trol module see page 19 Note The plugs must click home 9 Push the primary temperature sensor connection 2 pin LV see illustration on page 65 into the mating plug dangling from the control panel 10 Please note Damage to the insulation of the electrical cables ...

Page 67: ...the heat pump module must already be installed The heat pump module cannot be installed after the full wave soft starter has been installed A Strain relief installation positions 1 Danger The absence of component earthing can transfer dan gerous body currents should an electrical fault occur It is important to connect the earth strap from the cross bar to the full wave soft star ter Attach full wa...

Page 68: ... a 230 V full wave soft starter all models Note In accordance with the previously described installation procedure the heat pump module must already be installed The heat pump module cannot be installed after the full wave soft starter has been installed Installing a 400 V full wave soft starter as of BWP cont 68 Installation sequence 5592 968 GB ...

Page 69: ...parately packed capacitor with washer A and serrated lock washer B to base plate of full wave soft starter 3 Fit cables to tabs of capacitor in a diagonally offset position like the capacitor that is already installed Installing a 230 V full wave soft starter all cont 69 Installation sequence 5592 968 GB Installation ...

Page 70: ...hown in illustra tion 5 Plug connector from compressor 6 pin plug with designation PE N L S 230 231 to mating plug F on the right side of the full wave soft starter Note The plug must click home 6 Plug cable E of the full wave soft starter to pos K of control module see page 22 Note The plug must click home Connecting the brine pressure switch or a jumper The brine pressure switch is con nected ac...

Page 71: ...d stainless steel pipe for secondary circuit flow B Corrugated stainless steel pipe for secondary circuit return Connections on the secondary side of the heat pump 71 Installation sequence 5592 968 GB Installation ...

Page 72: ...be resistant to the Tyfocor heat trans fer medium never use galvanised pipes To ensure the perfect operation of the brine circuit route pipes so that air pockets cannot form and that complete venting is ensured Equip brine circuit with diaphragm expansion vessel and safety valve as described in DIN 4757 The diaphragm expansion vessel must be approved in accordance with DIN 4807 The diaphragms and ...

Page 73: ...an transfer dangerous body cur rents should an electrical fault occur Always connect the earth straps to the top panels 1 Fit the rear top panel Connections on the primary side of the heat cont 73 Installation sequence 5592 968 GB Installation ...

Page 74: ...nnector at the shortened end of the corrugated pipe Then secure the corrugated pipes using the clamps provided and con nect to the on site brine circuit installation see page 15 Installation information brine circuit connection set 3 Fit the front top panel 4 Affix type plate to main PCB cover for position see illustration on page 62 Connections on the primary side of the heat cont 74 Installation...

Page 75: ...5 C Please note To prevent the brine circuit pump from being destroyed primary circuit pump never exceed a glycol concentra tion in the heat transfer med ium of 30 not even for short periods i e during fill ing Also never use the pump for filling the system air pock ets in conjunction with the glycol water mixture can destroy the pump Connections on the primary side of the heat cont 75 Installatio...

Page 76: ...2 Carry out a leak tightness test Operating pressure 3 bar Max test pressure 4 bar Making the electrical connections to external components Note The unit s external electrical connec tions are located together on the con trol panel in the top r h area of the unit see X60 on B in illustration on page 54 Sensor connections With the exception of the outside tem perature sensor we recommend the use of...

Page 77: ... tem perature sensor for this heating circuit must be connected to the remote con trol If 2 remote controls have been connected connection X60 29 X60 30 on the control panel will be disabled Both the remote control units and the room temperature sensors must be acti vated independently see control settings pages 154 and 157 Outside temperature sensor type Ni 500 A Terminals in the control panel B ...

Page 78: ...g the integral secondary circuit pump as a heating circuit pump 1 Unplug connector or built in sec ondary circuit pump A from X16 of main PCB B see page 54 2 Plug connector of built in second ary circuit pump into socket on tem perature limiter C 3 Plug connector of temperature lim iter to X16 on main PCB Making the electrical connections to external cont 78 Installation sequence 5592 968 GB ...

Page 79: ...ressure switch brine circuit Note If no brine circuit pressure switch is connected always connect the jumper in the pack downstream of the power supply Always check the rotating field prior to inserting the jumper A Terminals in the control panel B Brine pressure switch C Jumper The contact must be able to switch at least 230 V and 0 7 A Note Only use components in the safety chain that do not aut...

Page 80: ...the extension kit If several subscribers are to be connected to the KM BUS we recom mend the use of a KM BUS distributor accessory Cores are interchangeable Extension kit installation instructions DHW circulation pump A Terminals in the control panel B DHW circulation pump Breaking capacity 230 V 0 7 A Natural cooling extension kit The control unit provides a control signal with which the natural ...

Page 81: ...ut mixer Breaking capacity 230 V 0 7 A Note The heating circuit pump with mixer is connected to the extension kit for one heating circuit with mixer Power OFF connection 400 230 V The signal from the power OFF contact has the following effects Notification to control unit via junction box terminal strip X60 Shutting down the supply voltage hard shutdown of the respective operat ing component Makin...

Page 82: ...position B Control contact ripple control receiver power OFF C Contactor part no 7814 681 D The air and creepage gap must exceed 8 mm since the control input is a low voltage input E Power OFF contact for control unit F Terminals in the control panel G Compressor or instantaneous heating water heater 400 V power supply connection Making the electrical connections to external cont 82 Installation s...

Page 83: ... no 7814 681 D The air and creepage gap must exceed 8 mm since the control input is a low voltage input E Power OFF contact for control unit F Terminals in the control panel G Instantaneous heating water heater 230 V power supply con nection Compressor A No power OFF in this position Making the electrical connections to external cont 83 Installation sequence 5592 968 GB Installation ...

Page 84: ...e control unit i e the control internal relay is not actuated A No power OFF in this position B Control contact ripple control receiver power OFF C Terminals in the control panel D The air and creepage gap must exceed 8 mm since the control input is a low voltage input Phase monitors only with 400 V units accessory The phase monitor available as an accessory can be used to monitor the compressor p...

Page 85: ... monitor shuts off if these tolerance ranges are exceeded If the values are within the tolerance range again the phase monitor auto matically re enables the power sup ply Making the electrical connections to external cont 85 Installation sequence 5592 968 GB Installation ...

Page 86: ...U LEDs explained LED Rel illuminates green All voltages and the rotating field clockwise are healthy LED Ph illuminates red The relay has responded the rotat ing field is anti clockwise All LED s off One or several phases have dropped out LED U illuminates red Incorrect voltage on one several phase s LED Asy illuminates red Incorrect voltage on one several phase s Making the electrical connections...

Page 87: ...hes yellow The relay has responded the rotat ing field is anti clockwise All LED s off One or several phases have dropped out LED U flashes yellow Undervoltage on one several phase s LED U illuminates yellow Overvoltage on one several phase s LED Asy illuminates yellow Incorrect voltage on one several phase s Making the electrical connections to external cont 87 Installation sequence 5592 968 GB I...

Page 88: ...n isolator requirements if necessary If a main isolator is set it must isolate the power circuit with at least 3 mm contact separation If no main isolator is set all non earthed cables must be isolated by the upstream cable protection switch with at least 3 mm contact separation General information regarding the power supply The power supply is separated into 3 areas Control unit feed electronics ...

Page 89: ... cur rents should an electrical fault occur The equipment and the pipework must be connected to the earth bonding of the house in question Please note Only for 400 V units An incorrect phase sequence can cause damage to the unit The power supply to the compressor must have a clockwise rotating field in the phase sequence that is specified at the terminals In negotiations with your power sup ply ut...

Page 90: ...ommended power cable 3 x 1 5 mm2 B Instantaneous heating water hea ter Recommended power cable 5 x 2 5 mm2 C Compressor Recommended power cable 4 x 1 5 mm2 Control unit power supply A Terminals in the control panel Note This supply must never be blocked Max fuse rating 16 A Power supply cont 90 Installation sequence 5592 968 GB ...

Page 91: ...ust be connected to N Power supply 400 V one tariff One common power cable with a large cross section up to the vicinity of the heat pump The common power cable cannot be blocked Selective blocking of the indivi dual power cables must take place downstream of the sub distribution which means additional sub distribution costs Adapt the cross section of common power cable to the connected load of th...

Page 92: ...m2 C Instantaneous heating water hea ter Recommended power cable 5 x 2 5 mm2 D Compressor Recommended power cable 4 x 1 5 mm2 E Sub distribution on the heat pump itself Control unit power supply A Terminals in the control panel Note This supply must never be blocked Max protection 16 A Power supply cont 92 Installation sequence 5592 968 GB ...

Page 93: ...section 2 5 mm2 The three heating elements are switched by inserting jumpers across X60 8 X60 9 and X60 10 in star for mation and must be connected to N 230 V power supply various tariffs Three separate power cables Selective power OFF for compressor and instantaneous heating water heater possible The cross section of the power supply lines must be appropriate for the con nected load of the releva...

Page 94: ...ing water hea ter Recommended power cable 7 x 2 5 mm2 C Compressor Recommended power cable 3 x 4 mm2 Control unit power supply A Terminals in the control panel Note This supply must never be blocked Max protection 16 A Power supply cont 94 Installation sequence 5592 968 GB ...

Page 95: ...t for marking the neutral conductors in accordance with VDE 0100 part 430 Danger Incomplete phase shutdowns can lead to the transfer of dan gerous body currents should an electrical fault occur The circuit breakers must be mechanically blocked together The use of individual circuit breakers is not accepta ble Power supply 230 V one tariff One common power cable with a large cross section up to the...

Page 96: ...ecommended power cable 4 x 10 mm2 B Control unit no power OFF per missible Recommended power cable 3 x 1 5 mm2 C Instantaneous heating water hea ter Recommended power cable 7 x 2 5 mm2 D Compressor Recommended power cable 3 x 4 mm2 E Sub distribution on the heat pump itself Control unit power supply A Terminals in the control panel Note This supply must never be blocked Max protection 16 A Power s...

Page 97: ...es its own neutral conductor Never bridge the neutral conductor without increasing the cross section Blue flexible tubing has been provided with the unit for marking the neutral conductors in accordance with VDE 0100 part 430 Danger Incomplete phase shutdowns can lead to the transfer of dan gerous body currents should an electrical fault occur The circuit breakers must be mechanically blocked toge...

Page 98: ...connections on the heating water and DHW sides for leaks 10 Checking the safety valve function 11 Checking the external connections at the control panel for tightness and correct terminal allocation 12 Switching ON the main MCB 13 System configuration 103 14 Checking the antifreeze concentration in the brine circuit 107 15 Checking the sensor connections 107 16 Checking the secondary pump 107 17 C...

Page 99: ...vent equipment damage Work on the refrigeration circuit must only be carried out by a qualified refrigeration engineer For work in connection with commis sioning inspection and maintenance remove the front panel and place the control unit into its service position see page 56 Observe the operating instruc tions when commissioning the equipment Maintaining service reports Enter measurements taken d...

Page 100: ...ircuit has not been filled For this pull the plug in connector from the compressor see page 65 1 Only for commissioning Flush the primary circuit 2 Only for commissioning Fill the primary circuit with heat transfer medium Tyfocor 15 C and vent the circuit 3 Check the primary circuit pressure The pressure should be approx 2 bar 4 Check the pre charge pressure of the diaphragm expansion vessel and a...

Page 101: ... valve A with water during filling check the system pressure at pressure gauge B Minimum system pres sure 0 8 bar Permissible operating pressure 3 bar 5 Close fill drain valve A 6 Open a suitable air vent valve in the heating circuit 7 Switch ON the power 8 Setting the operating mode selec tor D on page 113 to 9 9 Start the equipment at the system ON OFF switch see page 174 Further details regardi...

Page 102: ...ck the seating of the seal rings Replace all seal rings that may have slipped Let the commissioning program run until the equipment is fully vented For this observe the sys tem pressure should that drop below 0 8 bar top up with water 12 Close the air vent valve 13 Terminate the commissioning pro gram with key BACK 14 Only for commissioning Fit the front part of the heat pump thermal insulation se...

Page 103: ...tem the filling pres sure must be approx 0 2 bar higher than the static pressure Max operating pressure 3 5 bar 4 During commissioning mark this value on the pressure gauge as minimum filling pressure System configuration Enable the system design used see from page 16 and any optional compo nents and functions at the control unit Only required outside German speaking countries Setting the display ...

Page 104: ...or heating con tractors SERVICE for details see page 129 Press 5 Select language Select area marked A in dia gram using y Press Select the required language using y Confirm language selection using O Press O and n several times to return to main menu Further details regarding the individual steps cont 104 Commissioning inspection maintenance 5592 968 GB ...

Page 105: ...page 134 2 Only if the code request is dis played Enter the code for heating contrac tors SERVICE for details see page 129 3 Select the required system design 2 4 or 6 with Note The selected system design is shown in the display area marked A Further details regarding the individual steps cont 105 Commissioning inspection maintenance 5592 968 GB Service ...

Page 106: ... component by pressing the key again The selected components are listed in the display area marked B In the example for system design 2 area A the Buffer cylinder function area B has already been selected the natural cooling function however has not area C Pressing CONTINUE in the example shown will lead to the nat ural cooling function being excluded from the system design 3 Confirm your choice b...

Page 107: ...u item Device settings Contractor level Commissioning Secondary pump Note The time elapsed since the start of the test program is shown in the top r h corner of the display Further more the status of all components that are part of the test procedure is displayed 2 Observe the temperatures at the Secondary flow and the Sec ondary return The temperatures must rise Otherwise check the instantaneous ...

Page 108: ... the status of all components that are part of the test procedure is displayed 2 Determine the temperature differ ential between the heating flow and return of the respective heating cir cuit using a contact thermometer 3 Determine and enter the actual values and test conditions in accor dance with the commissioning ser vice report from page 190 4 The heating flow temperature must reach the temper...

Page 109: ...ary circuit Check the pump connections Change the pump stage If required use a larger pump 3 Start the compressor by pressing ON Note The compressor will start automati cally after expiry of 250 s test 4 Determine the temperature differ ential ΔT between the primary inlet display Primary in and outlet no display use contact thermo meter Set values ΔT 3 to 5 K at 35 C for Secondary flow and 10 C fo...

Page 110: ...sted Check the electrical mixer con nections see page 183 Replace the mixer if required The temperature at Secondary flow must rise observe a rise up to approx 30 C Otherwise Check the primary pump Check the electrical connec tions of the components con cerned Check the casing temperature of the heat pump compressor see page 111 The spread between the second ary flow and the secondary return must ...

Page 111: ...sor casing temperature 1 Start the heat pump and let it run for at least 10 min see page 110 point 1 and 2 2 Measure the temperature of the compressor casing exterior while it is in operation Ice must not form on the outside of the compressor and the housing must not become warmer than 60 C otherwise consult the Tech nical Service department at Viessmann Setting the control parameters 1 Activate t...

Page 112: ...he fault messages are not notifications of equipment faults These will have been cre ated by the manual control of some equipment components during commissioning Further details regarding the individual steps cont 112 Commissioning inspection maintenance 5592 968 GB ...

Page 113: ... If there are active faults The red LED to the left of the Opto link interface flashes C in fig on page 174 Note If a Vitotrol 200 remote control is connected its red fault indicator also flashes When the flap of the programming unit is closed the fault symbol U flashes on the display A maximum of eight faults can be stored If more faults than that have occurred the control unit acts as fol lows C...

Page 114: ...ed as soon as their cause has been removed Following acknowl edgement the control unit checks whether the fault has been remedied If this is not the case the fault is re displayed as not acknowledged Acknowledged faults remain in the list until the control unit has recog nised that the cause of the fault has been removed Press OK to acknowledge the highlighted fault message Press ALL to acknowledg...

Page 115: ... The sensor resistance curves required for testing the sensors are on page 173 Fault messages Cause Measures System fault Control unit processor faulty Replace programming unit 10 Outside tempera ture sensor Short circuit Check the sensor replace if required 18 Outside tempera ture sensor Lead broken Check the terminals replace the sensor if required 20 Sec flow sensor Short circuit Check the sens...

Page 116: ...ensor Lead broken Check the terminals replace the sensor if required 69 Secondary return sensor A6 Secondary pump Secondary pump faulty Check the secondary pump see page 107 replace the pump if required A8 Pump HC 1 No DHW circulation Check the external heating circuit pump see page 108 replace the pump if required A9 Heat pump Heat pump Check the heat pump the primary pump and the sec ondary pump...

Page 117: ...ections and re place the programming unit if required BA KM BUS mixer HC 2 Communication fault mixer HC 2 Check the extension kit con nections start the extension kit BB KM BUS NC mixer Communication fault natural cooling mixer BC KM BUS RC HC 1 Fault KM BUS remote control heating circuit 1 Check connections and cables leads BD KM BUS RC HC 2 Fault KM BUS remote control heating circuit 2 C1 Power ...

Page 118: ...s minimum level Check the brine circuit for throughput D3 Safety chain Fault at one of the con nected components External safety chain check connected components and circuits e g brine pressure or jumper D5 DHW SHC Break in jumper X 6 5 X 6 6 Check any possibly con nected switching contact or bridge connection on the power PCB D7 E heater K6 Heating element con nected to K6 faulty Check heating el...

Page 119: ...see page 142 No display in the display field of the programming unit Carry out the following steps to troubleshoot the problem 1 Switch the system ON OFF switch ON see page 174 2 Check the fuse replace it if required see page 174 3 Check whether there is voltage at the power feed to the control unit electronics provide power if required 4 Check the plug in and threaded connections 5 Replace the po...

Page 120: ...ealing cap A counterhold the hexagon C with a spanner Closing the service valve Use a new copper seal B When refitting the sealing cap A counterhold the hexagon C with a spanner Required torque 11 Nm Diagnosis cont 120 Troubleshooting 5592 968 GB ...

Page 121: ...A see page 122 B see pages 123 and 124 C see pages 125 126 127 and 128 Menu structure overview Main menu 121 Control settings 5592 968 GB Service ...

Page 122: ...Main menu Information Menu structure overview information 122 Control settings 5592 968 GB ...

Page 123: ...Main menu Equipment settings Programming A see page 124 Menu structure overview Programming 123 Control settings 5592 968 GB Service ...

Page 124: ...Main menu Equipment settings Programming A see page 123 Menu structure overview Programming cont 124 Control settings 5592 968 GB ...

Page 125: ...Main menu Equipment settings Technical service level A see pages 127 and 128 B see page 126 Menu structure overview Contractor level 125 Control settings 5592 968 GB Service ...

Page 126: ...Main menu Equipment settings Technical service level A see page 125 B see pages 127 and 128 Menu structure overview Contractor level cont 126 Control settings 5592 968 GB ...

Page 127: ...Main menu Equipment settings Technical service level A see pages 125 and 126 B see page 128 Menu structure overview Contractor level cont 127 Control settings 5592 968 GB Service ...

Page 128: ...Main menu Equipment settings Technical service level A see page 125 Menu structure overview Contractor level cont 128 Control settings 5592 968 GB ...

Page 129: ...rranty The description of the control settings is structured as follows Descriptions of the Technical ser vice level menu see also pages 125 to 128 are listed on pages 129 to 132 This section has the header head line Control settings The settings in the Programming menu see also pages 123 and 124 are described on pages 134 to 171 The header includes the descrip tions of the individual sub menus Sy...

Page 130: ...are to be made at the technical service level Adjusting sensor temperatures Sensor deviations caused by differing line resistances can be compensated for using this function Data is saved even during power failures Menu item Device settings Contractor level Adjust sensor temp Enter current temperature measure ment for each sensor Pressing RESET reverses the adjustment entered for the high lighted ...

Page 131: ...cility can be used to switch the relays and mixers gen eric term actuators for starting or testing individual components All control functions are disabled as long as the Manual control menu or one of its sub menus is called up All actuators are manually controlled for as long as the programming unit flap is open Upon leaving the Manual control menu e g by closing the programming unit flap all act...

Page 132: ...starter may be damaged After switching the compressor off wait for at least 10 minutes before switching it on again Menu item Device settings Contractor level Manual control Relay The RESET key switches all relays OFF that are currently switched ON Select a relay by pressing x and y then switch the relay with the keys ON and OFF OK Mixer sub menu The motors for the internal and external mixers max...

Page 133: ...a mixer by pressing x and y then select the required mixer position in using the keys V W Key c puts the mixer in its zero position OK Manual control of relays and mixers cont 133 Control settings 5592 968 GB Service ...

Page 134: ...setting determines whether the power OFF contact acts as N O YES or N C NO contact Access Device settings Programming System definition Power OFF contact 1S YES NO Standard setting NO Setting range YES NO Average time outside temperature This parameter determines the filtering of the outside temperature by a time constant of 22 hours standard setting This compensates for short term tem perature fl...

Page 135: ...ered under Heating limit T room is 4 0 K Central heating commences if the average outside temperature drops below 16 C heating limit temperature If the outside temperature exceeds 18 C central heating is adjusted because of the specified hysteresis of 2 K A Set room temperature B Outside temperature C Selected value Heating limit T room D Heating OFF E Heating ON Access Device settings Programming...

Page 136: ...temperature The equipment enters reduced mode to protect itself against frost as soon as the average outside temperature drops below this value This will be implemen ted independent of the setting of the operating mode selector The OFF point of the frost protection is set 2 K higher than the ON point A Outside temperature B Frost protection temperature can be selected C Frost protection OFF point ...

Page 137: ...on the instantaneous heating water hea ter is determined separately see page 142 Access Device settings Programming Heat pump Power OFF YES NO Standard setting YES Setting range YES NO Maximum flow temperature Setting the maximum heat pump flow temperature Access Device settings Programming Heat pump Max flow temp 1 Standard setting 60 C Setting range 25 to 60 C Minimum return temperature Not the ...

Page 138: ...ndard setting 5 C Setting range 1 to 40 C Hysteresis T primary min T primary in This setting determines the control range for starting and stopping the heat pump The shutdown point of the heat pump is determined by the minimum brine entry temperature Min T primary in A Brine inlet temperature B Min T primary in C Hysteresis T brine D Heat pump ON E Heat pump OFF Access Device settings Programming ...

Page 139: ... be restarted This protects the heat pump from overload conditions 3 starts per hour are the maxi mum Access Device settings Programming Heat pump Min compressor off P Q Standard setting 10 00 min Setting range 00 20 to 30 00 min Flow primary secondary pump When the compressor starts the following conditions must already be met The primary pump must already be running to enable the primary circuit...

Page 140: ...at pump Primary pump flow or Flow sec pump P Q Standard setting 2 00 min Setting range 00 10 to 16 40 min Optimum runtime Setting the optimum heat pump runtime Excessive runtimes subject to the pri mary circuit layout can lead to the geothermal probe icing up which reduces the efficiency COP Flow primary secondary pump cont 140 Heat pump control settings 5592 968 GB ...

Page 141: ...imary temperature drop C Optimum runtime Access Device settings Programming Heat pump Optimum runtime P Q Standard setting 2 00 h Setting range 00 20 to 24 00 h Optimum runtime cont 141 Heat pump control settings 5592 968 GB Service ...

Page 142: ...instantaneous heating water heater using a special control unit set ting YES This requires that the power OFF contact has been connected see page 81 If the power supply utility is not to have this facility select NO Access Device settings Programming Electric heater Power OFF YES NO Standard setting YES Setting range YES NO Electric heating This setting enables or disables the boosting of the heat...

Page 143: ... range YES NO Maximum flow temperature This determines the maximum flow temperature provided by the instantaneous heating water heater Access Device settings Programming Electric heater Max flow temp 1 Standard setting 65 C Setting range 5 to 75 C Heater rod delay Adjustment of the time during which the electric heating is not switched ON after changing the operating mode reduced standard Access D...

Page 144: ...egral comprising the duration and level of a tempera ture deviation Access Device settings Programming Electric heater E heating threshold P Q Standard setting 300 K min Setting range 10 to 30000 K min Maximum stage electric heater This setting determines with what output stage 1 2 or 3 see from page 195 DHW and heating water will be boosted Access Device settings Programming Electric heater Max s...

Page 145: ... setting the heat pump will not start Heating will be implemented in accordance with the settings for set temperature and switching times for standard and reduced mode see operating instruc tions The 0 setting switches this function OFF The remaining days for drying buildings will be shown on the display when the programming unit flap is closed Note If the Screed function see page 162 has been act...

Page 146: ...e heat pump or the instantaneous heating water heater has been stopped Access Device settings Programming Internal hydraulics Int pump run on P Q Standard setting 02 00 min Setting range 00 10 to 05 00 min Max steps three way valve Subject to the type of the three way valve the number of step pulses varies that the motor requires to drive the valve from one end stop to the opposite one This parame...

Page 147: ...ess Device settings Programming Heat pump max step 3 w valve l m Standard setting 320 Setting range do not change Max steps three way valve cont 147 Internal hydraulics control settings 5592 968 GB Service ...

Page 148: ...er cylinder temperature sensors Fixed value Operation as fixed value controller with a selected set tempera ture 2 for the DHW Rotary se lector The settings of the operating mode selector the programmed switching times and the settings of the remote control are taken into account standard setting External no function Switching times Only the settings made in conjunction with the programmed switchi...

Page 149: ...evice settings Programming DHW DHW cylinder maximum T U Standard setting 60 C Setting range 20 to 80 C Hysteresis DHW instantaneous heating water heater hysteresis These settings determine the deviation from the set DHW cylinder temperature DHW cylinder temp at which the cylinder heating is switched on and off by the heat pump Hysteresis If an instantaneous heating water heater is also installed t...

Page 150: ...selected for Hysteresis should be higher than the expected temperature drop due to heat losses in a single night approx 5 K A lower value for Hysteresis DHW E heating increases the proportion of electrical DHW heating i e the sys tem efficiency drops Access Device settings Programming DHW Hysteresis or Hysteresis DHW E heating 5 Standard setting Setting range Hysteresis 7 0 K 1 0 to 10 0 K Hystere...

Page 151: ...ted DHW cylinder can be heated in Standard mode This cylinder temperature sensor must be activated in the control unit using this parameter Note If the cylinder temperature sensor 2 is disabled then the control unit will only regulate the cylinder temperature sensor 1 in the operating modes Upper and Standard Access Device settings Programming DHW Vol cylinder for HP YES NO Standard setting YES Se...

Page 152: ... DHW runtime This value determines the time during which the DHW cylinder will be heated However this only applies in case of a simultaneous heat demand from the heating circuit Should the heating circuit not require any heat then the DHW cylinder will be heated beyond this time until the selected DHW cylinder tem perature has been reached see operating instructions Access Device settings Programm...

Page 153: ...Access Device settings Programming DHW Max DHW interruption P Q Standard setting 01 30 h Setting range 00 10 to 24 00 h Maximum DHW interruption cont 153 DHW control settings 5592 968 GB Service ...

Page 154: ...ndicator will flash on the remote control The remote control must also be programmed for the corresponding heating cir cuit For more information on the use of room temperature sensors and remote controls see page 77 Access Device settings Programming Heating circuit Heating circuit 1 2 Remote control YES NO Standard setting NO Setting range YES NO Operating mode You can set a fixed operating mode ...

Page 155: ... activated beforehand see page 154 Access Device settings Programming Heating circuit Heating circuit 1 2 Operating mode Maximum flow temperature Limiting the heating circuit flow temperature to a maximum value The lowest available value represents the setting of the temperature at min flow temp see following section Access Device settings Programming Heating circuit Heating circuit 1 2 Max flow t...

Page 156: ...ating instructions Access Device settings Programming Heating circuit Heating circuit 1 2 DHW during party YES NO Standard setting YES Setting range YES NO Excess reaction Coordination of the heat drawn off in the secondary circuit when the heat pump produces an excess of heat or the heat drawn by the secondary circuit is sud denly choked off Settings 0 No heat drawn off 1 Heat will be drawn off o...

Page 157: ...t Heating circuit 1 2 Room temperature sensor YES NO Standard setting NO Setting range YES NO Slope room temperature hook up The slope for room temperature hook up can be selected subject to a room temperature sensor being installed and enabled and room temperature hook up being enabled see page 158 The higher the selected value the greater the influence of the room tempera ture Access Device sett...

Page 158: ...d mode 3 Room temperature hook up in standard and in reduced mode Access Device settings Programming Heating circuit Heating circuit 1 2 Room temp hook up l m Standard setting 0 Setting range 0 to 3 Start optimisation Operating instructions Maximum flow temperature correction Preconditions Room temperature sensor installed and enabled Setting the maximum value by which the flow temperature can be ...

Page 159: ...ure control A room temperature dependent control is possible subject to a room tempera ture sensor being installed and enabled This function must be enabled for this Note If Yes is selected for room control the level and slope of the heating curve can no longer be adjusted weather compensated control unit parameters Access Device settings Programming Heating circuit Heating circuit 1 2 Room temper...

Page 160: ... room temperature con troller Standard setting 100 Setting range 5 to 1000 Flow T excess If a mixer circuit is connected system designs 3 4 5 and 6 the temperature increase of the secondary circuit is adjusted with regard to the mixer circuit using this function Access Device settings Programming Heating circuit Heating circuit 2 Flow T excess 1 Standard setting 0 0 K Setting range 10 to 40 0 K Ad...

Page 161: ...uit 2 Mixer runtime 0 Standard setting 0 10 min Setting range 0 05 to 4 15 min Mixer parameters At setting 0 the heat pump control unit utilises the function of the KM BUS mixer the mixer only receives the required flow temperature At the setting 1 the mixer parameters of the heat pump control unit e g Mixer runtime are used to determine the mixer position Settings 0 KM BUS mixer 1 Available param...

Page 162: ... time profile 0 is selected The temperature time profiles 5 to 15 regulate to the maximum flow tempera ture Only one time program can be enabled even if two heating circuits are con nected Four different temperature time profiles are available for screed drying Note If Building drying time has been activated see page 145 no intervention must occur here The settings under time for drying buildings ...

Page 163: ...rameters has been selected under Mixer parameters The dead zone C determines the fluctuation range around the set flow tem perature in which the mixer does not react is at zero volts As soon as the flow temperature leaves this zone above or below the mixer motor starts to cycle with a certain pulse modulation mixer active zone B and D Outside the active zone the mixer will be permanently closed A ...

Page 164: ...g Setting range Mixer active zone 4 0 K 2 0 to 40 0 K Mixer dead zone 1 0 K 0 5 to 3 0 K Natural cooling If all on site components for the natural cooling function are installed the sys tem definition must be extended to be able to use that function This setting can also be effected via the system configuration see page 103 Access Device settings Programming Heating circuit Heating circuit 1 2 Nat...

Page 165: ...f 1 K A Set room temperature B Cooling limit temperature C Selected value Cooling limit T room D Average outside temperature E Cooling function ON F Cooling function OFF Access Device settings Programming Heating circuit Heating circuit 1 2 Cooling limit T room 5 Standard setting 4 0 K Setting range 2 0 to 20 0 K Cooling curve level slope Precondition The natural cooling function is enabled A spec...

Page 166: ...o 3 5 Natural cooling with mixer If a mixer has been used for the natural cooling function and is actuated via the KM BUS this setting must be set to Yes This enables the simultaneous fault monitoring If the mixer is not controlled via the KM BUS but via on site control equipment see Vitocal 200 222 242 technical guide this setting must be set to No Access Device settings Programming Heating circu...

Page 167: ...runtime Note This setting is only used if parameter set 1 free parameters has been selected under Cooling mixer parameters Setting of the time required by the servomotor of the cooling mixer for a com plete changeover from one operating state into another 90 degree movement Runtimes that are too short can lead to the cooling mixer Cycling Access Device settings Programming Heating circuit Heating ...

Page 168: ...At the setting 1 the mixer parameters of the heat pump control unit e g Mixer runtime are used to determine the mixer position Settings 0 KM BUS mixer 1 Available parameters Access Device settings Programming Heating circuit Heating circuit 1 2 Cooling mixer parameters l m Standard setting 0 Setting range 0 1 Cooling mixer parameters 168 Heating circuit control settings 5592 968 GB ...

Page 169: ...nge YES NO Buffer cylinder program Note This function is only available in case of system design 2 if the option Yes was selected under Buffer cylinder see page 169 Operating instructions Fixed temperature Note This function is only available in case of system design 2 if the option Yes was selected under Buffer cylinder see page 169 The temperature cannot be set higher than that selected under Ma...

Page 170: ...hich the cylinder heating is switched on and off A Set temperature B Start hysteresis C Cylinder heating OFF D Cylinder heating ON Access Device settings Programming Further menu items Buffer cylinder Hysteresis temp 1 Standard setting 5 K Setting range 2 to 20 K Maximum temperature Note This function is only available in case of system design 2 if the option Yes was selected under Buffer cylinder...

Page 171: ...tems Buffer cylinder Stop optimisation YES NO Standard setting YES Setting range YES NO Excess reaction Note This function is only available in case of system design 2 if the option Yes was selected under Buffer cylinder see page 169 Coordination of the heat drawn off in the secondary circuit when the heat pump produces an excess of heat or the heat drawn by the secondary circuit is sud denly chok...

Page 172: ...t being created is not critical for the heat pump Access Device settings Programming Further menu items Buffer cylinder Excess reaction l m Standard setting 2 Setting range 0 to 2 Excess reaction cont 172 Buffer cylinder control settings 5592 968 GB ...

Page 173: ...ure sensor Ni500 Outside temperature sensor Ni500 Internal sensors cylinder tempera ture sensor and heating water buf fer cylinder temperature sensor Pt500 Sensor resistance curves 173 Components 5592 968 GB Service ...

Page 174: ...reen LED Fuse 6 3 A slow 250 V max power loss 2 5 W Danger Touching live components can result in the transfer of danger ous body currents Before working on the equip ment always ensure that the power circuit is also at zero volt Removing the fuse from the programming unit does not switch the power circuit to zero volt Fuse 174 Components 5592 968 GB ...

Page 175: ... L Primary pump M Auxiliary PCB O Secondary pump S Safety chain T Main connecting area in control panel 400 230 V U Control module possibly with phase monitor accessories V Full wave soft starter tP Cylinder primary pump zP Instantaneous heating water heater accessory X60 Main connection area for exter nal connections on the control panel Overview of the PCBs and connection options 175 Connection ...

Page 176: ...109 B X50 108 C X90 109 D X90 108 1 Control unit power supply con nection 2 Instantaneous heating water heater 400 V power supply connection Main connection area 176 Connection and wiring diagrams 5592 968 GB ...

Page 177: ...parate RCD circuits qI Signal from refrigerant circuit qO Safety chain for detailed description see A on pages 178 and 179 wP Signal from phase monitor only with 400 V units wQ Compressor contactor for detailed description see B on pages 178 and 179 wW Primary pump wE optional wR Neutral conductor instanta neous heating water heater with separate RCD circuits HDE To instantaneous heating water hea...

Page 178: ...witch F Optional thermal contact G Feedback three phase power monitor to main PCB H Control high pressure K Hot gas temperature limiter L Safety low pressure M Feedback refrigerant circuit safety chain to main PCB N Compressor relay PCB O Brine pressure limiter jumper P Compressor contactor on control module Safety chain 400 V units 178 Connection and wiring diagrams 5592 968 GB ...

Page 179: ...Full wave soft starter thermal fuse F Signal transfer to main PCB G Control high pressure H Hot gas temperature limiter K Safety low pressure L Feedback refrigerant circuit safety chain to main PCB M Compressor relay PCB N Brine pressure limiter jumper O Compressor contactor on control module Safety chain 230 V units 179 Connection and wiring diagrams 5592 968 GB Service ...

Page 180: ...stem D Secondary pump only required for cylinder loading system E to the power supply unit see the lower part of the main PCB on page 181 X50 Terminals on the inner top hat profile rail in the control panel X60 Main connection area for exter nal connections on the control panel Left part of the main PCB 180 Connection and wiring diagrams 5592 968 GB ...

Page 181: ...ply L2 heating element 2 1 E Supply L3 heating element 3 1 F Power supply unit G Power supply to the power sup ply unit 230 V Upper and lower part of the main PCB 181 Connection and wiring diagrams 5592 968 GB Service 1Central PE conductor point inside the electronics enclosure ...

Page 182: ...3 to K8 K Heating element 2 to K7 L Heating element 1 to K6 X60 Main connection area for exter nal connections on the control panel Upper and lower part of the main PCB cont 182 Connection and wiring diagrams 5592 968 GB ...

Page 183: ...A Flow temperature sensor sec ondary circuit B Lower cylinder temperature sen sor R h part of the main PCB 183 Connection and wiring diagrams 5592 968 GB Service ...

Page 184: ...F Stepper motor mixer heating DHW G Flow temperature sensor pri mary circuit H External control connection system design F K Safety chain jumper DHW SHC X60 Main connection area for exter nal connections on the control panel R h part of the main PCB cont 184 Connection and wiring diagrams 5592 968 GB ...

Page 185: ...27 Control module AS2 for BWP 106 400 V 028 Control module AS3 for BWP 108 400 V 029 Control module AS4 for BWP 110 400 V 030 Full wave soft starter BWP 108 110 400 V 031 Three phase monitor 032 Three phase current monitor strapping plug 400 V 033 Logo 034 Side panel left 035 Side panel right 036 Front panel 037 Top panel back 038 Front top panel 039 Top brace 040 Mounting panel 041 Fixing element...

Page 186: ...ing instructions 009 Installation and service instruc tions 010 Touch up paint stick Vitosilver 011 Touch up spray Vitosilver A Type plate refrigeration module B Type plate enclosure Parts lists cont 186 Parts lists 5592 968 GB ...

Page 187: ...Parts lists cont 187 Parts lists 5592 968 GB Service ...

Page 188: ...Parts lists cont 188 Parts lists 5592 968 GB ...

Page 189: ...Parts lists cont 189 Parts lists 5592 968 GB Service ...

Page 190: ...ion pump stage Overflow valve setting Testing the primary pump Primary in temperature C Primary outlet temperature C Temperature differential ΔT at Secondary flow 35 C and Primary in 10 C K 3 to 5 or Secondary flow 35 C and Primary in 0 C K 2 to 4 The pump enclosure of the primary cool ing circuit pump heats up No Testing the mixer heat pump and cylinder heating Checked under the following conditi...

Page 191: ...e 30 to 30 K 30 K Frost protection tem perature 15 to 15 C 1 C Heat pump Power OFF No Yes Yes Max flow temperature 25 to 60 C 60 C Min return tempera ture 1 to 40 C 5 C Hysteresis T brine 1 to 20 K 5 K Min T primary in 10 to 20 C 4 C Min runtime 2 00 to 30 00 min 2 00 minutes Min compressor off 00 20 to 30 00 min 10 00 min utes Primary pump flow 00 10 to 16 40 min 2 00 minutes Secondary pump flow ...

Page 192: ...o 05 00 min 02 00 min utes Max steps three way valve 30000 to 30000 320 DHW DHW cylinder tem perature 10 to 70 C 50 C DHW program tem perature Seven day program OFF DHW circulation pump program Seven day program OFF Operating mode 0 to 6 1 4 DHW cylinder max 20 to 80 C 60 C Hysteresis DHW elec tric heating 2 to 30 K 10 K Hysteresis 1 to 10 K 7 K Start optimisation No Yes Yes Stop optimisation No Y...

Page 193: ...ion No Yes No Max flow correction 0 1 to 10 0 K 10 0 K Room temperature control No Yes No Heating curve level 15 to 40 K 0 K Heating curve slope 0 0 to 3 5 0 6 Integral room tempera ture controller 5 to 1000 100 Flow T excess 10 to 40 K 0 K Mixer runtime 0 05 to 4 15 min 0 10 minutes Mixer parameters 0 1 0 Screed function 0 to 15 0 passive Mixer active zone 2 to 40 K 4 K Mixer dead zone 0 5 to 3 K...

Page 194: ... K 1 K Cooling mixer runtime 0 05 to 4 15 min 0 10 minutes Cooling mixer para meters 0 1 0 DHW buffer cylinder Buffer cylinder No Yes No Buffer cylinder pro gram Seven day program OFF Fixed temperature 1 to 60 C 50 C Temperature hyster esis 2 to 20 K 5 K Max temperature 1 to 70 C 60 C Stop optimisation No Yes Yes Excess reaction 0 to 2 1 2 Control parameter report cont 194 Commissioning service re...

Page 195: ...external pressure drop mbar 400 480 380 Max inlet temperature C 25 25 25 Min inlet temperature C 5 5 5 Heating water secondary Content heat pump litres 1 6 1 8 2 0 Content total litres 7 0 7 2 7 4 Min throughput 2 l h 800 800 800 Max external pressure drop mbar 450 450 450 Max flow temperature C 60 60 60 Electrical values Rated voltage heat pump 3 N PE 400 V 50 Hz Rated voltage instanta neous heat...

Page 196: ...ill volume kg 1 05 1 20 1 35 Compressor Type Hermetically sealed scroll compressor Dimensions Total length mm 716 716 716 Total width mm 600 600 600 Total height mm 1113 1113 1113 Weights Total weight kg 120 130 135 Weight standard device kg 70 70 70 Weight heat pump kg 50 60 65 Permissible operating pressure Brine circuit primary bar 4 0 4 0 4 0 Heating water circuit sec ondary bar 3 0 3 0 3 0 DH...

Page 197: ...EV Germany heating mode without instanta neous heating water heater Rated output kW 6 1 7 7 9 7 Coefficient of performance N at 0 C 35 C 4 3 4 3 4 3 Correction factor 0 C 1 087 1 087 1 087 Factor Δt 7 K 0 995 0 987 0 956 Heating energy expendi ture value at 0 C 35 C 0 215 0 217 0 221 DHW energy expenditure value at 0 C 35 C 0 256 0 257 0 262 Technical data for 400 V units cont 197 Technical data f...

Page 198: ...Max external pressure drop mbar 400 480 380 Max inlet temperature C 25 25 25 Min inlet temperature C 5 5 5 Heating water secondary Content heat pump litres 1 6 1 8 2 0 Content total litres 7 0 7 2 7 4 Min throughput 2 l h 800 800 800 Max external pressure drop mbar 450 450 450 Max flow temperature C 60 60 60 Electrical values Rated voltage heat pump 1 N PE 230 V 50 Hz Rated voltage instanta neous ...

Page 199: ...ength mm 716 716 716 Total width mm 600 600 600 Total height mm 1113 1113 1113 Weights Total weight kg 120 130 135 Weight standard device kg 70 70 70 Weight heat pump kg 50 60 65 Permissible operating pressure Brine circuit primary bar 4 0 4 0 4 0 Heating water circuit sec ondary bar 3 0 3 0 3 0 DHW cylinder DHW side bar 10 0 10 0 10 0 Connections Primary flow and return brine optional Rp or Multi...

Page 200: ... together with the enclosed system layout by fax to your local Viessmann sales office We would ask that a competent employee of yours be present during the commissioning Order to commission the Vitocal 200 G 200 Appendix 5592 968 GB ...

Page 201: ... Directives this product is designated with _ 89 336 EEC 98 37 EC 97 23 EC 2006 95 EC Details according to the Pressure Equipment Directive 97 23 EC Category I module A The product characteristics determined as system values for the product Vitocal 200 G as part of EC type testing according to the Efficiency Direc tive see specification table can be utilised to assess the energy consumption of hea...

Page 202: ...ump 110 Checking the internal pumps 107 109 Checking the pressure 100 101 102 Checking the primary pump 109 Checking the pumps 108 Checking the refrigeration circuit for leaks 99 Checking the secondary pump 107 Checking the system pressure 100 101 102 Commissioning 99 200 Commissioning order 200 Components 173 Connection and wiring diagrams 175 Connection extension natural cooling 80 Connections B...

Page 203: ...58 67 76 Equipment required 15 23 32 41 50 53 Extension kit 80 Extension Heating circuit 80 Natural cooling 80 F Fault messages 113 Fault messages acknowledging 114 scanning 114 skipping 115 Fault message display 115 Faults 113 Filling and venting the heating water side of the system 101 Frost stat 80 Full wave soft starter 67 68 Function description 11 Fuse 174 H Heat pump start delay 139 Heating...

Page 204: ... 139 Minimum heat pump runtime 139 Mixer parameters 161 N Natural cooling 13 80 164 O Operating mode selector 113 Operating mode DHW cylinder 148 Heating circuit 154 Outside temperature sensor 77 P Parts lists 185 Phase monitors 84 Power contact 81 Power shut off 81 Power supply 58 88 Power supply connection rotating field 59 Power supply utility 12 Power OFF 14 81 88 Pressure switch brine circuit...

Page 205: ...ce position 56 Setting parameters for system component 103 Slope Cooling curve 165 Heating curve 160 Room temperature hook up 157 Specification 195 198 Start optimisation 151 158 Stop optimisation 151 171 System configuration 103 System design 134 System layout 16 24 33 42 System versions 10 T Tech service level 129 Transport 9 Troubleshooting 113 W Wall clearances 9 Keyword index cont 205 Keyword...

Page 206: ...206 5592 968 GB ...

Page 207: ...207 5592 968 GB ...

Page 208: ... 7278 658 6 01000 200 110 230 V 7282 751 6 01000 200 106 400 V 7282 752 6 01000 200 108 400 V 7282 753 6 01000 200 110 400 V 208 Printed on environmentally friendly chlorine free bleached paper 5592 968 GB Subject to technical modifications Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF...

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