Viessmann Vitocal 200-G Installation And Service Instructions Manual
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Viessmann Vitocal 200-G Installation And Service Instructions Manual

Compact heat pump type bwp (400/230 v)
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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
Please keep safe.
5592 968 GB
9/2007

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  • 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 Please keep safe. 5592 968 GB 9/2007...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained & the Code of Practice of relevant trade associations, Danger & all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 Instal- charge static loads. ling non-authorised compo- nents and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Handling and installation................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 ..................
  • Page 5 Index Index (cont.) Control settings Menu structure overview – Main menu ............121 Menu structure overview – information ............122 Menu structure overview – Programming............. 123 Menu structure overview – Contractor level ..........125 Control settings by contractors..............129 Activating the technical service level ............129 Adjusting sensor temperatures..............
  • Page 6 Index Index (cont.) Flow hysteresis................... 146 Internal pump run-on................... 146 Max. steps; three-way valve................ 146 DHW control settings DHW cylinder temperature ................148 DHW program temperature ................. 148 DHW circulation pump program..............148 Operating mode ..................148 DHW cylinder maximum ................149 Hysteresis;...
  • Page 7 Commissioning/service reports Hydraulic parameter report ................. 190 Control parameter report................191 Technical data for 400 V units..............195 Technical data for 230 V units Technical data for 230 V units ..............198 Appendix Order to commission the Vitocal 200-G ............200...
  • Page 8 Index Index (cont.) Certificates Declaration of conformity ................201 Keyword index ..................202...

  • Page 9: Handling And Installation

    Preparing for installation Handling and installation Transport Do not tilt the heat pump module with compressor by more than 30° during transportation and installation. Installation room requirements & The installation room must be dry and safe from the risk of frost. &...

  • Page 10: Summary Of Possible System Versions

    Preparing for installation Handling and installation (cont.) Top panel dimensions (plan view) Primary return (brine) OUT HR Heating return Cable entries Heating flow Safety assembly SRL Cylinder return Primary flow (brine) IN SVL Cylinder flow Summary of possible system versions The following table provides an overview of all possible system versions.

  • Page 11: Function Description Of Systems

    Preparing for installation Summary of possible system versions (cont.) System Standard equipment Additional equip- "Natural layout in- ment cooling" side the (only one option control per system design) unit Direct Heating DHW cy- Buffer Low loss heating circuit linder cylinder header circuit with...

  • Page 12: Heating Circuit

    Preparing for installation Function description of systems (cont.) Heating circuit Heat pumps require a minimum heat- System versions 2 to 4 do not use a ing water throughput. Ensure that the secondary pump but a separate circu- values specified in the relevant data- lation pump as heating circuit pump.

  • Page 13: Natural Cooling Function

    Preparing for installation Function description of systems (cont.) Systems without heating water buffer cylinder Never install a mixer to safeguard the minimum heating water circulation volume. Natural cooling function During the summer months the tem- The cooling capacity depends on the perature level of the primary circuit heat source temperature, which itself can be used to cool the building.

  • Page 14: Instantaneous Heating Water Heater

    Preparing for installation Function description of systems (cont.) Instantaneous heating water heater An instantaneous heating water hea- Protect the instantaneous heating ter can be installed in the unit (acces- water heater via a separate connec- sory, see separate installation tion. instructions).

  • Page 15: System Version On The Primary Side

    Preparing for installation System version on the primary side Hydraulic diagram B Heat pump interface (see from 4 Geothermal probes/geothermal page 16) collectors 2 Brine accessory pack qQ Brine circuit pressure switch 3 Brine distributor for geothermal probes/collectors Electrical connection Pressure switch connection for brine circuit, qQ see page 18.

  • Page 16: System Version 1

    Preparing for installation System version 1 One heating circuit without mixer, with DHW heating and natural cooling Note To achieve this system version, select system design 2 at the control unit. Hydraulic diagram A DHW cylinder interface (see from 7 Underfloor heating system tem- page 51) perature limiter B Primary side interface (see from...
  • Page 17 Preparing for installation System version 1 (cont.) wP Extension kit for cooling circuit eR Frost stat eT Circulation pump (primary cooling with mixer wQ Outside temperature sensor circuit pump) eP Contact humidistat rQ Cooling circuit flow temperature eQ Circulation pump (secondary sensor rW Cooling circuit mixer motor cooling circuit pump)
  • Page 18 Preparing for installation System version 1 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS qQ Brine circuit pressure switch (if (230 V) G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 19 Preparing for installation System version 1 (cont.) qR Natural cooling extension kit qO Room temperature sensor (if no qT Central fault message (230 V) remote control is installed), see qZ Power-OFF also page 77 qI KM BUS: Vitotrol 200 remote con- wP KM BUS: Extension kit for cooling trol (with room temperature sen- circuit with mixer...
  • Page 20 Preparing for installation System version 1 (cont.) Components to be connected Connection descrip- tion Only when using an instantaneous heating water See separate installa- heater: tion instructions Connect instantaneous heating water heater to main PCB and auxiliary PCB Only with natural cooling: See separate installa- Connect the required components to extension kit wP tion instructions...
  • Page 21 Preparing for installation System version 1 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit K KM BUS ter power cable (circuit breakers must be blocked) Never operate 230 V units in d.
  • Page 22 Preparing for installation System version 1 (cont.) qQ Brine circuit pressure switch (if qI KM BUS: Vitotrol 200 remote con- the pressure switch is not trol (with room temperature sen- installed, use the jumper pro- sor), see also page 77 qO Room temperature sensor (if no vided) qE DHW circulation pump...
  • Page 23 Preparing for installation System version 1 (cont.) Components to be connected Connection descrip- tion Connect capacitor to full wave soft starter see page 68 Only when using an instantaneous heating water See separate installa- heater: tion instructions Connect instantaneous heating water heater to main PCB and auxiliary PCB Only with natural cooling: See separate installa-...

  • Page 24: System Version 2

    Preparing for installation System version 1 (cont.) Pos. Description Number Cooling circuit mixer motor System 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.
  • Page 25 Preparing for installation System version 2 (cont.) Hydraulic diagram A DHW cylinder interface (see from 7 Underfloor heating system tem- page 51) perature limiter B Primary side interface (see from 8 Plate-type heat exchanger 9 Heating water buffer cylinder page 15) C Min.
  • Page 26 Preparing for installation System version 2 (cont.) qI Vitotrol 200 remote control eE Two-way motorised ball valve qO Room temperature sensor eR Frost stat wP Extension kit for cooling circuit eT Circulation pump (primary cooling with mixer circuit pump) wQ Outside temperature sensor rQ Cooling circuit flow temperature wW Heating water buffer cylinder tem- sensor...
  • Page 27 Preparing for installation System version 2 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS qQ Brine circuit pressure switch (if (230 V) G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 28 Preparing for installation System version 2 (cont.) qW Heating circuit pump, direct heat- qO Room temperature sensor (if no ing circuit remote control is installed), see qE DHW circulation pump also page 77 qR Natural cooling extension kit wP KM BUS: Extension kit for cooling qT Central fault message (230 V) circuit with mixer qZ Power-OFF...
  • Page 29 Preparing for installation System version 2 (cont.) Information regarding other connections The primary pump, the secondary pump, and the heating/DHW three-way valve have already been connected in the factory. Components to be connected Connection descrip- tion Only when using an instantaneous heating water See separate installa- heater: tion instructions...
  • Page 30 Preparing for installation System version 2 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit K KM BUS ter power cable (circuit breakers must be blocked) Never operate 230 V units in d.
  • Page 31 Preparing for installation System version 2 (cont.) qQ Brine circuit pressure switch (if qI KM BUS: Vitotrol 200 remote con- the pressure switch is not trol (with room temperature sen- installed, use the jumper pro- sor), see also page 77 qO Room temperature sensor (if no vided) qW Heating circuit pump, direct heat-...
  • Page 32 Preparing for installation System version 2 (cont.) Components to be connected Connection descrip- tion Connect capacitor to full wave soft starter see page 68 Only when using an instantaneous heating water See separate installa- heater: tion instructions Connect instantaneous heating water heater to main PCB and auxiliary PCB Only with natural cooling: See separate installa-...

  • Page 33: System Version 3

    Preparing for installation System version 2 (cont.) Pos. Description Number Frost stat Circulation pump (primary cooling circuit pump) Flow temperature sensor, mixer circuit Cooling circuit mixer motor 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.
  • Page 34 Preparing for installation System version 3 (cont.) Hydraulic diagram A DHW cylinder interface (see from C Min. 500 mm (for hydraulic page 51) separation) B Primary side interface (see from 1 Heat pump 6 Diaphragm expansion vessel page 15)
  • Page 35 Preparing for installation System version 3 (cont.) 7 Underfloor heating system tem- eW Three-way diverter valve heating/ perature limiter cooling 8 Plate-type heat exchanger eE Two-way motorised ball valve 9 Heating water buffer cylinder eR Frost stat qP Underfloor heating circuit eT Circulation pump (primary cooling qR Natural cooling extension kit circuit pump)
  • Page 36 Preparing for installation System version 3 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS qQ Brine circuit pressure switch (if (230 V) G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 37 Preparing for installation System version 3 (cont.) qR Natural cooling extension kit wP KM BUS: Extension kit for cooling qT Central fault message (230 V) circuit with mixer qZ Power-OFF wQ Outside temperature sensor qI KM BUS: Vitotrol 200 remote con- wW Heating water buffer cylinder tem- trol (with room temperature sen- perature sensor...
  • Page 38 Preparing for installation System version 3 (cont.) Information regarding other connections The primary pump, the secondary pump, and the heating/DHW three-way valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect components for heating circuit with mixer to See separate installa- extension kit tP tion instructions...
  • Page 39 Preparing for installation System version 3 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit K KM BUS ter power cable (circuit breakers must be blocked) Never operate 230 V units in d.
  • Page 40 Preparing for installation System version 3 (cont.) qQ Brine circuit pressure switch (if qO Room temperature sensor (if no the pressure switch is not remote control is installed), see installed, use the jumper pro- page 77 wP KM BUS: Extension kit for cooling vided) qE DHW circulation pump circuit with mixer...
  • Page 41 Preparing for installation System version 3 (cont.) Components to be connected Connection descrip- tion Connect capacitor to full wave soft starter see page 68 Connect components for heating circuit with mixer to See separate installa- extension kit tP tion instructions Only when using an instantaneous heating water See separate installa- heater:...

  • Page 42: System Version 4

    Preparing for installation System version 3 (cont.) Pos. Description Number Option "Natural cooling" function Vitotrans 100 plate-type heat exchanger Natural cooling extension kit Extension kit for cooling circuit with mixer Contact humidistat Three-way diverter valve heating/cooling Two-way motorised ball valve (brine circuit shut-off valve) Frost stat Circulation pump (primary cooling circuit pump) Flow temperature sensor, mixer circuit...
  • Page 43 Preparing for installation System version 4 (cont.) Hydraulic diagram A DHW cylinder interface (see from C Min. 500 mm (for hydraulic page 51) separation) B Primary side interface (see from 1 Heat pump 6 Diaphragm expansion vessel page 15)
  • Page 44 Preparing for installation System version 4 (cont.) 7 Underfloor heating system tem- eP Contact humidistat eW Three-way diverter valve heating/ perature limiter 8 Plate-type heat exchanger cooling 9 Heating water buffer cylinder eE Two-way motorised ball valve qP Underfloor heating circuit eR Frost stat qW Heating circuit pump, direct heat- eT Circulation pump (primary cooling...
  • Page 45 Preparing for installation System version 4 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS qQ Brine circuit pressure switch (if (230 V) G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 46 Preparing for installation System version 4 (cont.) qW Heating circuit pump, direct heat- qO Room temperature sensor (if no ing circuit remote control is installed), see qE DHW circulation pump also page 77 qR Natural cooling extension kit wP KM BUS: Extension kit for cooling qT Central fault message (230 V) circuit with mixer qZ Power-OFF...
  • Page 47 Preparing for installation System version 4 (cont.) Information regarding other connections The primary pump, the secondary pump, and the heating/DHW three-way valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect components for heating circuit with mixer to See separate installa- extension kit tP tion instructions...
  • Page 48 Preparing for installation System version 4 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit K KM BUS ter power cable (circuit breakers must be blocked) Never operate 230 V units in d.
  • Page 49 Preparing for installation System version 4 (cont.) qQ Brine circuit pressure switch (if qO Room temperature sensor (if no the pressure switch is not remote control is installed), see installed, use the jumper pro- also page 77 wP KM BUS: Extension kit for cooling vided) qW Heating circuit pump, direct heat- circuit with mixer...
  • Page 50 Preparing for installation System version 4 (cont.) Information regarding other connections The primary pump, the secondary pump, and the heating/DHW three-way valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect capacitor to full wave soft starter see page 68 Connect components for heating circuit with mixer to See separate installa-...

  • Page 51: System Versions On The Dhw Side

    Preparing for installation System version 4 (cont.) Pos. Description Number Instantaneous heating water heater option Option "DHW heating" see page 51 Option "Heating water buffer cylinder" Heating water buffer cylinder Heating water buffer cylinder temperature sensor Option "Natural cooling" function Vitotrans 100 plate-type heat exchanger Natural cooling extension kit Extension kit for cooling circuit with mixer...
  • Page 52 Preparing for installation System versions on the DHW side (cont.) Cylinder primary system connection A Heat pump interface (see page 16, 25, 34 or 43) Note During cylinder heating, the control unit switches DHW circulation pump qE OFF, to prevent the cylinder heating being hampered. Electrical connection Components to be connected Connection descrip-...
  • Page 53 Preparing for installation System versions on the DHW side (cont.) Equipment required Pos. Description Number Vitotrans 100 plate-type heat exchanger DHW circulation pump Cylinder primary pump Two-way valve, normally closed (on-site) Upper cylinder temperature sensor Lower cylinder temperature sensor DHW cylinder Flow limiter ("Taco setter"), on-site...

  • Page 54: Installation Sequence Summary Of Electrical Connections

    Installation sequence Summary of electrical connections The following table provides an overview of all electrical connecting areas. A Full wave soft starter, 400 or 230 C Control module with X80 connect- V version ing area B Junction box with main connec- D Main PCB with connection areas tion area X60, internal connection X5 and X16...

  • Page 55: Preparing The Installation

    Installation sequence Preparing the installation 1. Position units and perform horizon- tal alignment as described on page 9.
  • Page 56 Installation sequence Preparing the installation (cont.) A Control panel B Main PCB cover 2. Undo screws from front panel. 4. Undo the screws at the upper Pull the front panel forward at its crossbar. upper edge and lift out upwards. 5.

  • Page 57: Installing The Control Module

    Installation sequence Installing the control module A Type plate 1. Undo two pre-installed screws on 3. Tighten the screws. the underside of the control panel, but do not unscrew. 4. Fit the control panel connecting cable (7-pin) to pos. C of the con- 2.

  • Page 58: Inserting The Electrical Cables And Power Supply Connections

    Installation sequence Inserting the electrical cables and power supply connections A Inserting the external electrical cables 1. Route external electrical cables to the rear left upper edge of the unit and cut to length, leaving approx. 1800 mm of cable inside the unit. Please note Damage to the insulation of the electrical cables can...

  • Page 59: Checking The Rotating Field Of The Power Supply Connection (400 V Units Only)

    Installation sequence Inserting the electrical cables and power supply . . . (cont.) Please note With 400 V units, the wrong phase sequence can damage the equipment. The power supply connec- tion must have a clockwise rotating field in the phase sequence that is specified at the terminals.
  • Page 60 Installation sequence Checking the rotating field of the power supply . . . (cont.) 3. Switch ON the power. 4. Isolate the system from the power Remedy any faults that may be sig- supply and safeguard against re- nalled by the phase monitor (see connection.
  • Page 61 Installation sequence Making the electrical connections of the cylinder . . . (cont.) A Plug from the pack C Cylinder primary pump B Distributor (on-site) D Two-way valve (normally closed, tQ see page 53) 1. Route the connecting cable of the 3.

  • Page 62: Electrical Connection Of The Cylinder Temperature Sensor(S)

    Installation sequence Electrical connection of the cylinder temperature sensor(s) Note Subject to the DHW cylinder version, either one or two cylinder temperature sensor(s) can be connected. A Remove main PCB cover C Upper cylinder temperature sen- B Lower cylinder temperature sen- D Attach type plate here (see page 74) 1.

  • Page 63: Installing The Heat Pump Module And Making The Electrical Connections

    Installation sequence Electrical connection of the cylinder temperature . . . (cont.) 3. Secure the lead(s) with cable ties 4. Re-connect earth strap, fit main to the existing cables/leads. PCB cover and secure using four screws. Installing the heat pump module and making the electrical con- nections...
  • Page 64 Installation sequence Installing the heat pump module and making the . . . (cont.) Please note If the compressor is at a steep angle in the heat pump module, the intro- duction of lubricant into the refrigerant circuit will damage the equipment. The heat pump module must not be tilted more than 30°...
  • Page 65 Installation sequence Installing the heat pump module and making the . . . (cont.)
  • Page 66 Installation sequence Installing the heat pump module and making the . . . (cont.) Please note 8. Push the safety chain connection Putting the components of (4-pin plug with designation 1, 2, 3, 4) into pos. E at the control the heat pump module and the thermal insulation module (see page 19).

  • Page 67: Connecting The External Electrical Components

    Installation sequence Connecting the external electrical components 1. Fit strain reliefs (from pack) to top 3. Secure all cables inside the strain left of control panel (see A in illus- reliefs at the control panel. tration on page 67). Note 2.

  • Page 68: Installing A 230 V Full Wave Soft Starter (All Models)

    Installation sequence Installing a 400 V full wave soft starter (as of BWP . . . (cont.) 3. Plug cables from the left side of the full wave soft starter to pos. K of the control module (see page 19). Note The plug must click home.
  • Page 69 Installation sequence Installing a 230 V full wave soft starter (all . . . (cont.) 1. Attach the retaining bracket to the 3. Fit cables to tabs of capacitor in a base plate of the full wave soft star- diagonally offset position (like the ter with 2 sheet metal screws.

  • Page 70: Connecting The Brine Pressure Switch Or A Jumper

    Installation sequence Installing a 230 V full wave soft starter (all . . . (cont.) Danger 5. Plug connector from compressor The absence of component (6-pin plug with designation PE, N, L, S, 230, 231) to mating plug F earthing can transfer dan- gerous body currents, on the right side of the full wave should an electrical fault...

  • Page 71: Connections On The Secondary Side Of The Heat Pump

    Installation sequence Connections on the secondary side of the heat pump A Corrugated stainless steel pipe B Corrugated stainless steel pipe for secondary circuit flow for secondary circuit return...

  • Page 72: Connections On The Primary Side Of The Heat Pump

    Installation sequence Connections on the secondary side of the heat . . . (cont.) 1. Fit corrugated stainless steel pipe 3. Fit corrugated stainless steel pipe A (from pack) to front connector at (from pack) to rear connector at the bottom right in the heat pump the bottom right in the heat pump enclosure.
  • Page 73 Installation sequence Connections on the primary side of the heat . . . (cont.) Danger The absence of component earthing can transfer dangerous body cur- rents, should an electrical fault occur. Always connect the earth straps to the top panels. 1.
  • Page 74 Installation sequence Connections on the primary side of the heat . . . (cont.) 2. Insert the corrugated pipes of the connection set for the brine circuit (supplied with the heat pump) into the pipe sleeves of the heat pump. Note Do not shorten the corrugated pipes.
  • Page 75 Connections on the primary side of the heat . . . (cont.) 5. Connect corrugated pipes to on- site primary circuit. 6. Fill primary circuit with Viessmann "Tyfocor" heat transfer medium (ethylene glycol/water mixture with frost protection down to −15 °C).

  • Page 76: Connecting The Heating Circuits

    Installation sequence Connecting the heating circuits Please note With underfloor heating cir- cuits, there is a risk of building damage through the screed overheating if the control unit fails. Equip underfloor heating cir- cuits with a temperature lim- iter. 1. Thoroughly flush the heating sys- tem (particularly when connecting to an existing system) and connect the heating water flow and return in...
  • Page 77 Installation sequence Making the electrical connections to external . . . (cont.) Room temperature sensor (type Ni 500) Note Release snap fasteners to open room temperature sensor. Room temperature sensor installation instructions A Terminals in the control panel B Room temperature sensor enclo- sure Information regarding use of room temperature sensors and remote con- trols...
  • Page 78 Installation sequence Making the electrical connections to external . . . (cont.) Temperature sensor (type Pt 500) in the heating water buffer cylinder A Terminals in the control panel B Buffer cylinder sensor Connect temperature limiter to underfloor heating system When using the integral secondary circuit pump as a heating circuit pump 1.
  • Page 79 Installation sequence Making the electrical connections to external . . . (cont.) When using a separate heating circuit pump Temperature limiter installation instructions Central fault message Breaking capacity: 230 V~, 0.7 A Note This contact is not at zero volt. 230 V~ will be present if there is a fault.
  • Page 80 Installation sequence Making the electrical connections to external . . . (cont.) Extension kit for a mixer circuit and/or Vitotrol 200 remote control (via KM BUS) Note General information regarding the room temperature sensors and remote con- trols, see page 77. Connection via KM BUS data cable.
  • Page 81 Installation sequence Making the electrical connections to external . . . (cont.) A Terminals in the control panel B Natural cooling extension kit Suggestion for on-site wiring of the connections for the natural cooling function: Technical guide, Vitocal 200/222/242. Pump of the heating circuit without mixer Breaking capacity: 230 V~, 0.7 A Note The heating circuit pump with mixer is...
  • Page 82 Installation sequence Making the electrical connections to external . . . (cont.) Version 1 "Hard shutdown" of power supply for compressor and/or instantaneous heating water heater and OFF contact to control unit (see also page 14). Power-OFF with 400 V power connection (version 1) A No power-OFF in this position E Power-OFF contact for control B Control contact ripple control...
  • Page 83 Installation sequence Making the electrical connections to external . . . (cont.) Power-OFF with 230 V power connection (version 1) Instantaneous heating water heater A No power-OFF in this position E Power-OFF contact for control B Control contact ripple control unit F Terminals in the control panel receiver "power-OFF"...
  • Page 84 Installation sequence Making the electrical connections to external . . . (cont.) B Control contact ripple control E Power-OFF contact for control receiver "power-OFF" unit C Contactor F Terminals in the control panel D The air and creepage gap must G Compressor (230 V) power sup- exceed 8 mm, since the control ply connection...
  • Page 85 Installation sequence Making the electrical connections to external . . . (cont.) Over/undervoltage 15 % If the values are within the tolerance Phase asymmetry 15 % range again, the phase monitor auto- Switching delay matically re-enables the power sup- ply. The phase monitor shuts off if these tolerance ranges are exceeded.
  • Page 86 Installation sequence Making the electrical connections to external . . . (cont.) Version 1 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.
  • Page 87 Installation sequence Making the electrical connections to external . . . (cont.) Version 2 LEDs explained & LED "R" illuminates green: All voltages and the rotating field (clockwise) are healthy. & LED "Ph" flashes yellow: The relay has responded; the rotat- ing field is anti-clockwise.

  • Page 88: Power Supply

    Installation sequence Making the electrical connections to external . . . (cont.) Relay switch contacts for activat- ing signalling equipment or for blocking the heat pump: A Contact used in the safety chain (N/O) Power supply Danger Incorrectly executed electrical installations can lead to injury through the transmission of dangerous body currents and result in equipment damage.
  • Page 89 Installation sequence Power supply (cont.) The feed for the control unit and the Note instantaneous heating water heater is We recommend making the power provided on the main connecting area connection for accessories and exter- X60. The compressor feed comes nal components to the same fuse, from control module X80 (see also with at least the same phase as the...
  • Page 90 Installation sequence Power supply (cont.) The cross-section of the power supply lines must be appropriate for the con- nected load of the relevant unit. A Control unit Recommended power cable: 3 x 1,5 mm B Instantaneous heating water hea- Recommended power cable: 5 x 2.5 mm C Compressor Recommended power cable: 4 x...
  • Page 91 Installation sequence Power supply (cont.) Compressor power supply Recommended core cross-section: 1.5 mm Note The upstream fuses must have Z characteristics. A Terminals at the control module Instantaneous heating water heater power supply Max. fuse rating 16 A Recommended core cross-section: 2.5 mm The three heating elements are switched by inserting jumpers across...
  • Page 92 Installation sequence Power supply (cont.) A Common heat pump power cable C Instantaneous heating water hea- Recommended power cable: 5 x 4 Recommended power cable: 5 x B Control unit, no power-OFF per- 2.5 mm D Compressor missible Recommended power cable: 3 x Recommended power cable: 4 x 1,5 mm 1.5 mm...
  • Page 93 Installation sequence Power supply (cont.) Compressor power supply Recommended core cross-section: 1.5 mm Note The upstream fuses must have Z characteristics. A Terminals at the control module Instantaneous heating water heater power supply Max. fuse rating 16 A Recommended core cross-section: 2.5 mm The three heating elements are switched by inserting jumpers across...
  • Page 94 Installation sequence Power supply (cont.) A Control unit Recommended power cable: 3 x 1.5 mm B Instantaneous heating water hea- Recommended power cable: 7 x 2.5 mm C Compressor Recommended power cable: 3 x 4 Control unit power supply Note This supply must never be blocked.
  • Page 95 Installation sequence Power supply (cont.) Compressor power supply Recommended power cable: 3 x 4 Note The upstream fuses must have Z characteristics. A Terminals at the control module Instantaneous heating water heater power supply Each heater winding requires its own neutral conductor.
  • Page 96 Installation sequence Power supply (cont.) Adapt the cross-section of common power cable to the connected load of the instantaneous heating water heater and the compressor. The connected load of the control unit does not have to be taken into consideration. A Common heat pump power cable C Instantaneous heating water hea- Recommended power cable: 4 x...
  • Page 97 Installation sequence Power supply (cont.) Compressor power supply Recommended power cable: 3 x 4 Note The upstream fuses must have Z characteristics. A Terminals at the control module Instantaneous heating water heater power supply Each heater winding requires its own neutral conductor.

  • Page 98: Commissioning, Inspection, Maintenance Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Removing the front panel ........... •...

  • Page 99: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Removing the front panel Danger Touching 'live' components can result in the transfer of dangerous body currents. Never touch the connections inside control panel A (see page 56) and in the control module below. If the unit is live, the cover B of the electrical components (see page 56) must be fitted.
  • Page 100 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Remove the front part of the heat 3. Check the floor area, valves and all pump thermal insulation (see visible solder joints for traces of oil. page 63). Filling the primary circuit, venting it and checking its pres- sure Please note To prevent equipment damage, it is vital to prevent the compressor from...
  • Page 101 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling and venting the secondary equipment 4. Fill the heating circuit via fill & drain valve A with water; during filling, check the system pressure at pressure gauge B. Minimum system pres- 0.8 bar sure Permissible operating...
  • Page 102 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 10. Note Please note Pay attention to information con- In order to prevent equip- cerning control operation (from ment damage, check the page 129), select language if flow and return connec- necessary (see page 103, default tions of the secondary setting "German").

  • Page 103: System Configuration

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. If the pre-charge pressure of the 3. Top up with water, until the filling diaphragm expansion vessel is pressure exceeds the pre-charge lower than the static system pres- pressure of the diaphragm expan- sure, top up with sufficient nitrogen sion vessel.
  • Page 104 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If the adjacent display appears (fault messages present): Press key marked in diagram. & Press the following keys one after the other: "v", "Y", "º". & Enter the code for heating con- tractors ("SERVICE";...
  • Page 105 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Selecting a system design 1. Briefly and simultaneously press the keys shown in the diagram. Note Alternative adjustment options for the system design, see page 134. 2. Only if the code request is dis- played: Enter the code for heating contrac- tors ("SERVICE";...
  • Page 106 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Select the installed auxiliary components or functions Note 2. Select or deselect the component displayed above the keys (area C, With system designs 1 to 6, the nat- ural cooling option can also be see diagram) with "YES"/"NO".
  • Page 107 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the antifreeze concentration in the brine circuit Check the antifreeze concentration The system must be protected against frost down to −15 °C. Otherwise, and record it in the service report from page 190.
  • Page 108 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Terminate the test program with "BACK". Checking the external heating circuit pumps Note The following test program is not required for system versions without external heating circuit pump. In system versions without instantaneous heating water heaters (accessories) the heating water buffer cylinder must be heated up to at least 35 °C by the heat pump (see page 110).
  • Page 109 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the primary pump 1. Start the test program: 3. Start the compressor by pressing "ON". Menu item & "Device settings" Note & "Contractor level" The compressor will start automati- &...
  • Page 110 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking mixers, heat pump and cylinder heating Checking the mixer and heat pump 1. Start the test program: 3. Check the following temperatures and record them in the service Menu item report from page 190: &...
  • Page 111 60 °C (otherwise consult the Tech- nical Service department at Viessmann). Setting the control parameters 1. Activate the "Contractor level". 2. Check the control settings using For information regarding the the details regarding standard set- "Contractor level"...
  • Page 112 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Acknowledge all fault messages (see page 114). Note In this case, the fault messages are not notifications of equipment faults. These will have been cre- ated by the manual control of some equipment components during commissioning.
  • Page 113 Troubleshooting Control unit diagnostics Programming unit overview A Display D Operating mode selector B Rotary selector E Menu keys F Programming unit flap "Reduced room temperature" C Rotary selector "Standard room temperature" Fault messages Internal faults are captured, displayed & When the flap of the programming and saved by the device.

  • Page 114: Troubleshooting Control Unit Diagnostics

    Troubleshooting Control unit diagnostics (cont.) & Messages with lower priority will be Active faults are displayed in accor- deleted if there are messages with dance with their respective priority. higher priority (than those already stored). & In case of messages with the same priority (as those already stored), older messages will be deleted.

  • Page 115: Skipping Fault Messages

    Troubleshooting Control unit diagnostics (cont.) Scanning all stored ("historic") fault messages Menu item & "BACK" & "Information" & "Statistics" Note & "Fault history" The fault messages cannot be – Press "TIME", to display the time acknowledged in the fault history. of the fault occurrence –...
  • Page 116 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures Flow sensor Short circuit Check the sensor; replace if HC 2 required Flow sensor NC Flow sensor Lead broken Check the terminals; replace HC 2 the sensor, if required Flow sensor NC DHW sensor top Short circuit Check the sensor;...
  • Page 117 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures EXT E heater The flow temperature Check the high limit safety does not rise; the in- cut-out and the heater ele- stantaneous heating ments; replace, if required water heater may be faulty Natural cooling Faulty function...
  • Page 118 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures Safety chain Fault at one of the con- External safety chain; check nected components connected components and circuits (e.g. brine pressure or jumper) Refrigerant cir- High pressure switch, Check the flow and return cuit low pressure switch or temperature sensors, test...

  • Page 119: Diagnosis

    Troubleshooting Diagnosis Measures in case the room temperature is constantly too low Carry out the following steps to troubleshoot the problem. 1. Increase the set room temperature 5. Hydraulically balance the con- for standard operation (see operat- nected heating circuit(s). ing instructions).
  • Page 120 Troubleshooting Diagnosis (cont.) Opening the service valve When removing the sealing 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.

  • Page 121: Menu Structure Overview – Main Menu

    Control settings Menu structure overview – Main menu A see page 122 B see pages 123 and 124 C see pages 125, 126, 127 and 128...

  • Page 122: Menu Structure Overview – Information

    Control settings Menu structure overview – information Main menu > Information...

  • Page 123: Menu Structure Overview – Programming

    Control settings Menu structure overview – Programming Main menu > Equipment settings > Programming A see page 124...
  • Page 124 Control settings Menu structure overview – Programming (cont.) Main menu > Equipment settings > Programming A see page 123...

  • Page 125: Menu Structure Overview – Contractor Level

    Control settings Menu structure overview – Contractor level Main menu > Equipment settings > Technical service level A see pages 127 and 128 B see page 126...
  • Page 126 Control settings Menu structure overview – Contractor level (cont.) Main menu > Equipment settings > Technical service level A see page 125 B see pages 127 and 128...
  • Page 127 Control settings Menu structure overview – Contractor level (cont.) Main menu > Equipment settings > Technical service level A see pages 125 and 126 B see page 128...
  • Page 128 Control settings Menu structure overview – Contractor level (cont.) Main menu > Equipment settings > Technical service level A see page 125...

  • Page 129: Control Settings By Contractors

    Control settings Menu structure overview – Contractor level (cont.) B see page 127 C see pages 123 and 124 Control settings by contractors Only those settings are described on The description of the control settings the following pages that are the is structured as follows: exclusive domain of specialists oper- &...

  • Page 130: Adjusting Sensor Temperatures

    Control settings Activating the technical service level (cont.) 2. Enter code: Menu item & "Device settings" & "Access rights" & Enter code: SERVICE press each 1 x & 2 x "OK" Note Access to the technical service level is blocked if the programming unit flap is closed or the standard display key is pressed.

  • Page 131: Checking Signal Inputs

    Control settings Checking signal inputs The system can be checked using this menu. For example, in case of a fault, you can check whether the cause has been removed. This check can only be carried out with the relay switched OFF. In standard mode, all monitoring inputs are "OFF".
  • Page 132 Control settings Manual control of relays and mixers (cont.) "Relay" sub-menu Note Here, the relays can be activated at random. Some actuators may still be switched ON when this menu is called up. Please note Unintentional conflicting operating situations can be created using "manual control"...
  • Page 133 Control settings Manual control of relays and mixers (cont.) and y, then select the required & "Mixer" – Select a mixer by pressing x mixer position in % using the keys V/W. – Key c puts the mixer in its zero position.

  • Page 134: Control Unit Settings - System Definition System Design

    Control unit settings - system definition System design As well as the procedure described in Access "system configuration" (see & "Device settings" page 103), the system design can be & "Programming" modified at this point or additional & "System definition" components and/or functions selected &...

  • Page 135: Heating Limit < T Room (Heating Limit Temperature)

    Control unit settings - system definition Average time; outside temperature (cont.) Setting range 00:10 to 100:00 h Heating limit < T room (heating limit temperature) The heating limit temperature defines the value of the outside temperature below which central heating commences. The heating limit temperature is the result of the selected set room temperature less the value entered under "Heating limit <...

  • Page 136: Temperature Limit For Reduced Temperature Mode

    Control unit settings - system definition Temperature limit for reduced temperature mode The reduced temperature mode (see operating instructions) will no longer be used, if the outside temperature drops below this temperature limit. The equip- ment heats up to the temperature selected for standard operation. Operation will continue in accordance with the selected switching times, if the average outside temperature stays above this temperature limit.

  • Page 137: Maximum Flow Temperature

    Heat pump control settings Power-OFF compressor With activated power-OFF ("power-OFF: YES") the power supply utility can switch off the heat that is being generated by the heat pump. This requires that the power-OFF contact has been connected (see page 81). The heat distribution by the heating circuit pump and the circulation pump for cylinder heating are not affected by the power interruption.

  • Page 138: Hysteresis T Primary/Min. T Primary In

    Heat pump control settings Minimum return temperature (cont.) Note If the minimum return temperature has been set too low, there is more compres- sor wear due to the increase in the number of low-pressure shutdowns. If the minimum return temperature is set too high, the proportion of electrical heating increases and the degree of efficiency drops.

  • Page 139: Minimum Runtime

    Heat pump control settings Minimum runtime Setting the minimum heat pump runtime. The heat pump only switches off when this time has elapsed. This setting is designed to reach long heat pump runtimes to achieve high effi- ciency and low wear. Access Standard setting 2:00 min...

  • Page 140: Optimum Runtime

    Heat pump control settings Flow; primary/secondary pump (cont.) Access & "Device settings" & "Programming" & "Heat pump" & "Primary pump flow" "Flow sec. pump" (P/Q) Standard setting 2:00 min Setting range 00:10 to 16:40 A Heating command B Primary pump C Secondary pump D Compressor E Start delay...
  • Page 141 Heat pump control settings Optimum runtime (cont.) Access & "Device settings" & "Programming" & "Heat pump" & "Optimum runtime" (P/Q) Standard setting 2:00 h Setting range 00:20 to 24:00 A Optimum operating range B Primary temperature drop C Optimum runtime...

  • Page 142: Instantaneous Heating Water Heater Control Settings E Heating

    Instantaneous heating water heater control settings E heating The instantaneous heating water heater that is available as an accessory must be activated by this parameter, if installed. Only that way can the instantaneous heating water heater be regulated by the control unit. Access Standard setting &...

  • Page 143: Dhw With Electric Power

    Instantaneous heating water heater control settings DHW with electric power This function makes it possible to deactivate DHW heating using an integrated instantaneous heating water heater that may be installed in the unit (e.g. if the water is subsequently heated by an on-site instantaneous water heater). The instantaneous heating water heater then only affects the heating circuit.

  • Page 144: Electric Heating Threshold

    Instantaneous heating water heater control settings Electric heating threshold This setting determines, after what "value" (integral comprising the duration and level of a temperature deviation from the set control temperature) the electric heating is switched ON. Brief temperature deviations will not cause the electric heating to be switched ON.

  • Page 145: Time For Drying Buildings

    Internal hydraulics control settings Heat pump for drying buildings This setting determines whether the heat pump is used to dry the building as well as the instantaneous heating water heater. This function must be set to "NO" if the heat pump is not ready for operation because the heat pump primary circuit is not ready when building drying takes place.

  • Page 146: Flow Hysteresis

    Internal hydraulics control settings Flow hysteresis The set flow temperature of the secondary circuit is determined by the control unit in accordance with the current heat demand. The "flow hysteresis" setting defines the difference from an internally calcu- lated set flow temperature at which one of the heat generators (heat pump, instantaneous heating water heater) is switched on and off.
  • Page 147 Internal hydraulics control settings Max. steps; three-way valve (cont.) Standard setting Access Setting range do not change & "Device settings" & "Programming" & "Heat pump" & "max. step 3-w valve" (l/m)

  • Page 148: Dhw Control Settings Dhw Cylinder Temperature

    DHW control settings DHW cylinder temperature Operating instructions DHW program temperature Operating instructions DHW circulation pump program Operating instructions Operating mode Determining the DHW cylinder operating mode. Setting Function Standby Equipment frost protection Reduced The control only utilises the upper cylinder temperature sensor Standard The control utilises the upper and lower cylinder temperature sensors...

  • Page 149: Dhw Cylinder Maximum

    DHW control settings DHW cylinder maximum Setting of the maximum temperature inside the DHW cylinder. Renewed heating will be prevented after this temperature has been reached, until the temperature has dropped by at least 5 K. Danger DHW at temperatures > 60 °C will lead to scalding. At these temperatures, install anti-scalding protection on site.
  • Page 150 DHW control settings Hysteresis; DHW instantaneous heating water . . . (cont.) Note The value 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"...

  • Page 151: Start Optimisation

    DHW control settings Start optimisation Operating instructions Stop optimisation Operating instructions DHW auxiliary function Operating instructions Set DHW temperature 2 Operating instructions Heat pump cylinder volume A second (lower) cylinder temperature sensor must be installed so that the entire volume of the connected DHW cylinder can be heated in "Standard" mode.

  • Page 152: Excess Reaction

    DHW control settings 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: No heat drawn off Heat will be drawn off only in case of a critical excess, i.e.
  • Page 153 DHW control settings Maximum DHW interruption (cont.) Access Standard setting 01:30 h & "Device settings" Setting range 00:10 to & "Programming" 24:00 h & "DHW" & "Max. DHW interruption" (P/Q)

  • Page 154: Heating Circuit Control Settings Standard Temperature

    Heating circuit control settings Standard temperature Operating instructions Reduced temperature Operating instructions Temperature program, heating circuit Operating instructions Remote control If a remote control is installed, it must be activated for the relevant heating cir- cuit. Note If a remote control is used, the "Operating mode" parameter (see following page) must be set to "Remote control".

  • Page 155: Maximum Flow Temperature

    Heating circuit control settings Operating mode (cont.) Setting Function Standby Equipment frost protection Reduced Constant reduced room temperature Standard Constant standard room temperature Fixed value Operation as fixed value controller Rotary se- The operating mode is selected via the operating mode selector lector (standard setting) External...

  • Page 156: Dhw During Party Mode

    Heating circuit control settings Minimum flow temperature (cont.) Note This setting influences the natural cooling function. If the setting is too low, the dew point monitor switches the cooling function off prematurely, subject to the cooling curve (see page 155). Access &...

  • Page 157: Room Temperature Sensor

    Heating circuit control settings Excess reaction (cont.) Access & "Heating circuit 1/2" & "Device settings" & "Excess reaction" & "Programming" (l/m) & "Heating circuit" Standard setting Setting range 0 to 2 Room temperature sensor If a room temperature sensor is installed, it must be activated for the relevant heating circuit.

  • Page 158: Room Temperature Hook-Up

    Heating circuit control settings Room temperature hook-up Preconditions: Room temperature sensor installed and enabled. This setting determines when the room temperature hook-up should be enabled in addition to the weather-compensated control. Settings: No room temperature hook-up Room temperature hook-up only in reduced mode Room temperature hook-up only in standard mode Room temperature hook-up in standard and in reduced mode Access...

  • Page 159: Room Temperature Control

    Heating circuit control settings Maximum flow temperature correction (cont.) Access & "Device settings" & "Programming" & "Heating circuit" & "Heating circuit 1/2" & "Max. flow corr." (0/=) Standard setting 10.0 K Setting range 0.1 to 10.0 K A Flow temperature B Differential between set room temperature and outside tempera- ture...

  • Page 160: Adjusting The Heating Curve Level And Slope

    Heating circuit control settings Adjusting the heating curve level and slope Operating instructions Integral room temperature controller Precondition: "Room temperature control" set to "Yes". Integral proportion of the room temperature control circuit. A high value results in a rapid response. Access &...

  • Page 161: Mixer Runtime

    Heating circuit control settings Mixer runtime Note This setting is only used if parameter set "1" (free parameters) has been selected under "Mixer parameters". Setting of the time required by the servomotor of the external heating circuit mixer for a complete changeover from one operating state into another (90 degree movement).

  • Page 162: Screed Function

    Heating circuit control settings Screed function Note Observe the specifications of EN 1264-4. The report to be provided by the heat- ing contractor must contain the following heat-up details: & Heat-up data with respective flow temperatures & Actual maximum flow temperature &...

  • Page 163: Mixer Active Zone/Dead Zone

    Heating circuit control settings Screed function (cont.) Temperature/time profile 3 (to Temperature/time profile 4 ÖNORM) A Flow temperature A Flow temperature B Days B Days Access & "Heating circuit 2" & "Device settings" & "Screed function" (l/m) & "Programming" & "Heating circuit"...

  • Page 164: Natural Cooling

    Heating circuit control settings Mixer active zone/dead zone (cont.) Access & "Device settings" & "Programming" & "Heating circuit" & "Heating circuit 1/2" & "Mixer active zone" (5/%) "Mixer dead zone" (=/0) Mixer permanently closed Mixer closes (modulating) Dead zone, mixer motor at zero volt Mixer opens Mixer permanently open...

  • Page 165: Cooling Limit > T Room (Cooling Limit Temperature)

    Heating circuit control settings Cooling limit > T room (cooling limit temperature) Precondition: The natural cooling function is enabled. The cooling limit temperature defines the outside temperature, exceeding of which triggers the natural cooling function. The cooling limit temperature is the result of the selected set room temperature and the temperature entered under "cooling limit >...

  • Page 166: Natural Cooling With Mixer

    Heating circuit control settings Cooling curve level/slope (cont.) Access & "Device settings" & "Programming" & "Heating circuit" & "Heating circuit 1/2" & "Cooling curve level" ("+LEV"/"−LEV") "Heat. cooling curve" ("+SLOPE"/"−SLOPE") A Flow temperature B Outside temperature C Cooling curve D Cooling curve with a higher level (C offset) E Cooling curve with a greater slope Standard setting...

  • Page 167: Active Zone/Dead Zone Natural Cooling Mixer

    Heating circuit control settings Active zone/dead zone natural cooling mixer Note This setting is only used if parameter set "1" (free parameters) has been selected under "Cooling mixer parameters". For function description see page 163. Access & "Heating circuit 1/2" &...

  • Page 168: Cooling Mixer Parameters

    Heating circuit control settings Cooling mixer parameters Precondition: The "NC mixer" function is enabled. 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.

  • Page 169: Buffer Cylinder Control Settings Buffer Cylinder

    Buffer cylinder control settings Buffer cylinder Note This function is only available for system design 2. When selecting system designs 4 and 6, the buffer cylinder will be defined auto- matically as a system component. Should a heating water buffer cylinder be part of a system in accordance with design 2, either set it through selecting option "Yes", or via the system config- uration (see page 103) or system definition (see page 134).

  • Page 170: Hysteresis Temperature

    Buffer cylinder control settings Fixed temperature (cont.) Access & "Buffer cylinder" & "Device settings" & "Fixed temperature" (1/!) & "Programming" & "Further menu items" Standard setting 50 °C Setting range 1 to 60 °C Hysteresis temperature Note This function is only available in case of system design 2, if the option "Yes" was selected under "Buffer cylinder"...

  • Page 171: Stop Optimisation

    Buffer cylinder control settings Maximum temperature (cont.) Access & "Buffer cylinder" & "Device settings" & "Max. temperature" (1/!) & "Programming" & "Further menu items" Standard setting 60 °C Setting range 1 to 70 °C Stop optimisation Note This function is only available in case of system design 2, if the option "Yes" was selected under "Buffer cylinder"...
  • Page 172 Buffer cylinder control settings Excess reaction (cont.) Heat will be drawn off, even if the excess heat being created is not critical for the heat pump. Access & "Buffer cylinder" & "Device settings" & "Excess reaction" & "Programming" (l/m) & "Further menu items"...

  • Page 173: Sensor Resistance Curves

    Components Sensor resistance curves Room temperature sensor (Ni500) Internal sensors, cylinder tempera- ture sensor and heating water buf- fer cylinder temperature sensor (Pt500) Outside temperature sensor (Ni500)

  • Page 174: Fuse

    Components Fuse The fuse is located inside the fuse holder next to the system ON/OFF switch in the programming unit. 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.
  • Page 175 Connection and wiring diagrams Overview of the PCBs and connection options Note No physical layout is shown in any of the following connection diagrams. Main PCB Main connecting area in control Programming unit panel 400/230 V Optolink interface Control module (possibly with Sensors phase monitor, accessories) Stepper motor (internal)

  • Page 176: Main Connection Area

    Connection and wiring diagrams Main connection area X50.109 Control unit power supply con- X50.108 nection X90.109 Instantaneous heating water X90.108 heater (400 V) power supply connection...
  • Page 177 Connection and wiring diagrams Main connection area (cont.) Instantaneous heating water Safety chain, for detailed description see A on heater (230 V) power supply connection pages 178 and 179 Brine circuit pressure switch Signal from phase monitor (only Jumper for brine circuit pressure with 400 V units) switch (for detailed description Compressor contactor, for...

  • Page 178: Safety Chain, 400 V Units

    Connection and wiring diagrams Safety chain, 400 V units B Corresponds to area 5 and wQ in fig. on page 176 C From the ON/OFF switch (see page 176) D Phase monitor E Compressor protective motor switch F Optional thermal contact G Feedback, three phase power monitor to main PCB H Control high pressure...

  • Page 179: Safety Chain, 230 V Units

    Connection and wiring diagrams Safety chain, 230 V units B Corresponds to area 5 and wQ in fig. on page 176 C From the ON/OFF switch (see page 176) D Compressor protective motor switch E Full wave soft starter thermal fuse F Signal transfer to main PCB G Control high pressure H Hot gas temperature limiter...

  • Page 180: Left Part Of The Main Pcb

    Connection and wiring diagrams Left part of the main PCB Secondary return temperature to the power supply unit (see the sensor lower part of the main PCB on Cylinder primary pump (only page 181) required for cylinder loading X50. Terminals on the inner top hat system) profile rail in the control panel to X50.

  • Page 181: Upper And Lower Part Of The Main Pcb

    Connection and wiring diagrams Upper and lower part of the main PCB Programming unit Supply (L3) heating element 3 Optolink interface Power supply unit Supply (L1) heating element 1 Power supply to the power sup- Supply (L2) heating element 2 ply unit 230 V~ Central PE conductor point inside the electronics enclosure...
  • Page 182 Connection and wiring diagrams Upper and lower part of the main PCB (cont.) Heating element 3 to K8 Heating element 1 to K6 Heating element 2 to K7 X60. Main connection area for exter- nal connections on the control panel...

  • Page 183: R.h. Part Of The Main Pcb

    Connection and wiring diagrams R.h. part of the main PCB Flow temperature sensor, sec- Lower cylinder temperature sen- ondary circuit...
  • Page 184 Connection and wiring diagrams R.h. part of the main PCB (cont.) Upper cylinder temperature sen- External control connection, system design F to the auxiliary PCB Safety chain jumper (DHW alternatively with an internal SHC) jumper X60. Main connection area for exter- Stepper motor mixer heating/ nal connections on the control panel...

  • Page 185: Parts Lists

    Parts lists Parts lists When ordering spare parts: 029 Control module AS4 for Quote the part and serial no. (see BWP 110, 400 V type plate) and the item no. of the 030 Full wave soft starter, BWP 108/ required part (as per this parts list). 110, 400 V 031 Three phase monitor Obtain standard parts from your local...
  • Page 186 Parts lists Parts lists (cont.) Parts not shown 010 Touch-up paint stick, Vitosilver 008 Operating instructions 011 Touch-up spray, Vitosilver 009 Installation and service instruc- A Type plate; refrigeration module tions B Type plate, enclosure...
  • Page 187 Parts lists Parts lists (cont.)
  • Page 188 Parts lists Parts lists (cont.)
  • Page 189 Parts lists Parts lists (cont.)

  • Page 190: Commissioning/Service Reports Hydraulic Parameter Report

    Commissioning/service reports Hydraulic parameter report Setting and test values Set value Commis- sioning –15 Antifreeze concentration (brine med- °C ium) Testing the secondary pump Temperature "Secondary flow" in- creased? Temperature "Secondary return" in- creased? Temperature differential ΔT ≤ 3 K Testing the external heating circuit pumps Heating flow temperature °C...

  • Page 191: Control Parameter Report

    Commissioning/service reports Hydraulic parameter report (cont.) Setting and test values Set value Commis- sioning Heat pump cylinder heating Temperature "Secondary flow" °C increasing from: Temperature "DHW cylinder top" °C increasing from: Control parameter report Setting parameters Setting range Standard Commission- setting System definition System scheme...
  • Page 192 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting Power-OFF No/Yes Electric heating No/Yes DHW with electric No/Yes Max. flow temperature 5 to 75 °C 65 °C Heater rod delay 0:00 to 5:00 h 0:30 h 10 to 30000 K ∙...
  • Page 193 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting Excess reaction 0 to 2 Max. DHW runtime 00:10 to 24:00 h 04:00 h Max. DHW interruption 00:10 to 24:00 h 01:30 h Heating circuit Standard temperature 10 to 30 °C 20 °C Reduced temperature...
  • Page 194 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting Cooling limit > T room 2 to 20 K Cooling curve level -15 to 40 Slope, cooling curve 0.0 to 3.5 Natural cooling with No/Yes mixer Active zone natural 2 to 40 K cooling –...

  • Page 195: Technical Data For 400 V Units

    Technical data for 400 V units Technical data for 400 V units Vitocal 200-G Type BWP 106 BWP 108 BWP 110 Heat pump performance details Heat pump module Type 200/106 200/108 200/110 Rated output Refrigerating capacity Power consumption Coefficient of performance ∊...
  • Page 196 Technical data for 400 V units Technical data for 400 V units (cont.) Vitocal 200-G Type BWP 106 BWP 108 BWP 110 Starting current (compres- 25.0 14.0 20.0 sor) Starting current (compres- with stalled armature) Power consumption & Control unit <10...
  • Page 197 Technical data for 400 V units Technical data for 400 V units (cont.) Vitocal 200-G Type BWP 106 BWP 108 BWP 110 Connections Primary flow and return optional Rp ¾" or (brine) Multi-connect system DN 20 Heating flow and return...

  • Page 198: Technical Data For 230 V Units Technical Data For 230 V Units

    Technical data for 230 V units Technical data for 230 V units Vitocal 200-G Type BWP 106 BWP 108 BWP 110 Heat pump performance details Heat pump module Type 200/106 200/108 200/110 Rated output Refrigerating capacity Power consumption Coefficient of performance ∊...
  • Page 199 Technical data for 230 V units Technical data for 230 V units (cont.) Vitocal 200-G Type BWP 106 BWP 108 BWP 110 Starting current (compres- <45 <45 <45 sor) Starting current (compres- with stalled armature) Power consumption & Control unit <10...

  • Page 200: Appendix Order To Commission The Vitocal 200-G

    Appendix Order to commission the Vitocal 200-G Please send the following order, We would ask that a competent together with the enclosed system employee of yours be present during layout, by fax to your local Viessmann the commissioning. sales office.

  • Page 201: Declaration Of Conformity

    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 heating and ventilation equipment to DIN V 4701-10 specified by the EnEV [Germany].

  • Page 202: Keyword Index

    Keyword index Keyword index Adjusting sensor temperatures Central fault message ..... . Antifreeze concentration in the brine Checking mixers ......circuit Checking pumps 107, 109...
  • Page 203 Keyword index Keyword index (cont.) Control settings & Fault messages ........
  • Page 204 Keyword index Keyword index (cont.) Inspection Operating mode selector ........
  • Page 205 Keyword index Keyword index (cont.) Safety chain Tech. service level ....... .
  • Page 208 Applicability Applicable for heat pumps: Brine/water heat pump Vitocal 200-G, type BWP 106, 108 and 110 400 V and 230 V With the standard equipment from serial no: 7267 008 7 01000 ... With the heat pump module from serial no: 7278 656 6 01000 ...

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