Viessmann Vitocal 200-S Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWS, 4 to 13 kW
Air/water heat pump, split version for heating operation
Type AWS-AC, 4 to 13 kW
Air/water heat pump, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 200-S
5724 152 GB 5/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ National installation requirements
■ All legal instructions regarding the pre-
vention of accidents,
■ All legal instructions regarding envi-
ronmental protection,
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator.
Note
In addition to the control circuit, there
may be several power circuits.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions
5724 152 GB

3
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5724 152 GB

4
Installation instructions
Preparing for installation
Requirements of on-site connections................................................................... 6
Overview of possible system schemes................................................................ 8
System example 1, ID: 4605169_1005_01.......................................................... 9
System example 2, ID: 4605170_1005_01.......................................................... 16
Installation sequence
Installing the external unit..................................................................................... 25
Installing the internal unit...................................................................................... 30
Connecting the refrigerant lines........................................................................... 32
Connecting the secondary circuit......................................................................... 36
Connecting a cooling circuit if required................................................................ 37
Electrical connection............................................................................................ 38
Power supply........................................................................................................ 58
Closing the heat pump......................................................................................... 64
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 66
Further details regarding the individual steps....................................................... 68
Troubleshooting
Steps if the room temperature is too low.............................................................. 85
Repairs................................................................................................................. 86
Parts lists
Parts list, internal unit........................................................................................... 97
Parts list, external unit, type AWS/AWS-AC 104.................................................. 101
Parts list, external unit, type AWS/AWS-AC 107.................................................. 102
Parts list, external unit, type AWS/AWS-AC 110/113........................................... 104
Commissioning/service reports
Hydraulic parameters report................................................................................. 108
Control parameters report.................................................................................... 108
Specification....................................................................................................... 113
Appendix
Heat pump commissioning order.......................................................................... 118
Index
Index
5724 152 GB

5
Certificates
Declaration of conformity...................................................................................... 119
Keyword index.................................................................................................... 120
Index
Index (cont.)
5724 152 GB

6
■ Install hydraulic connections on site
stress-free.
■ Observe DIN VDE 0100.
Internal unit
850
450
114
105
116
360
+
230 V~
400 V~
<42 V >42 V
1160
Preparing for installation
Requirements of on-site connections
5724 152 GB

7
Symbol Explanation Connection
Refrigerant lines from/to the
external unit:
■ Hot gas line ■ 4 kW: 7 12 mm
■ 7 kW: 7 16 mm
■10 kW: 7 16 mm
■13 kW: 7 16 mm
■ Liquid gas line ■ 4 kW: 7 6 mm
■ 7 kW: 7 10 mm
■10 kW: 7 10 mm
■13 kW: 7 10 mm
DHW cylinder flow (heating
water side)
G 1¼
+
Heating water return and DHW
cylinder return
G 1¼
Heating water flow G 1¼
Safety valve —
1. Prepare the connections on the heat-
ing water and the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Note
You can route the BUS cable along-
side and can be secured to the refrig-
erant line.
Cable lengths inside the internal/external unit plus wall clearance:
Cables Internal unit External unit
Power cables:
Heat pump control unit (230 V~) 2.0 m —
Compressor (230 V~) — 1.5 m
Additional connecting cables:
230 V~, e.g. for pumps 2.0 m —
< 42 V, e.g. for sensors 2.0 m —
Connecting cables between the internal/external units:
12 V BUS 1.0 m 1.5 m
43 V BUS 1.5 m 1.5 m
Preparing for installation
Requirements of on-site connections (cont.)
5724 152 GB
Installation

8
Recommended power cables:
Rated heating output 4 kW 7 kW 10 kW 13 kW
External unit (compressor)
230 V~
Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 4.0 mm23 x 6.0 mm2
Max. cable length 25 m 25 m 25 m 30 m
Heat pump control unit
(internal unit)
230 V~
3 x 1.5 mm23 x 1.5 mm23 x 1.5 mm23 x 1.5 mm2
Instantaneous heating
water heater 9 kW (if instal-
led, internal unit)
Cable cross-section
■ 400 V~ (phase symmetri-
cal/asymmetrical)
5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
■ 230 V~ (phase asymmet-
rical)
7 x 2.5 mm27 x 2.5 mm27 x 2.5 mm27 x 2.5 mm2
Max. cable length 25 m 25 m 25 m 25 m
Overview of possible system schemes
The following table provides an overview
of all possible system schemes ("Sys-
tem scheme").
Preparing for installation
Requirements of on-site connections (cont.)
5724 152 GB

9
Components System scheme (parameter 7000)
0 1 2 3 4 5 6
Heating circuit
A1 – X X – – X X
M2 – – – X X X X
DHW cylinder
X – X – X – X
Heating water buffer cylinder
– 0 0 X X X X
External heat source
– 0*1 0*1 0 0 0 0
Solar thermal system
0–0–0–0
Cooling
A1 0 0 0 0
M2 0 0 0 0
Sep. cooling circuit 0 0 0 0 0 0 0
X Selected component.
0The component can be added.
System example 1, ID: 4605169_1005_01
Setting system scheme 6
■ Internal unit of heat pump type AWS
with or without instantaneous heating
water heater
■ 1 radiator heating circuit without mixer
(A1)
■ 1 underfloor heating circuit with mixer
(M2)
■ DHW heating
■ External heat source
■ Heating water buffer cylinder
Note
This scheme is a basic example without
shut-off valves or safety equipment. This
does not replace the local technical engi-
neering task.
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5724 152 GB
Installation

10
Hydraulic installation scheme
KW
WW
60
61
71
70
73
74
76
77
91
90
96
1
29
14
55
3
62
54
52
50
53
37
31
32
30
2
--2/212.3--
--2/F13--
--2/F0--
--2/F20--
--2/F6--
--2/F7--
--2/222.1;2--
--2/F4--
--2/212.2--
--2/224.7--
-2/222.4-
--212.3--
--222.1;2--
--224.7--
--212.2--
--222.4--
--F6--
--F7--
--F20--
--F0--
--F13--
--F4--
-2/211.2-
4
5
6
--105/52--
--105/20--
--105/20--
--105/2--
--KM-BUS--
--211.2--
--230V--
--52--
--2--
-KM-BUS-
--20--
-230V-
105
8
--145-- --145--
--145--
-8/145- -8/145-
--145--
Pos. Description
Heat source
1Internal unit of the heat pump
2Heat pump control unit
3Outside temperature sensor
4Instantaneous heating water heater with control module
53-way diverter valve "Heating/DHW"
6Secondary pump
8KM BUS distributor
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB

11
Pos. Description
Primary circuit
wO External unit of the heat pump
DHW heating
eP DHW cylinder
eQ Cylinder temperature sensor, top
eW Cylinder temperature sensor, bottom
eU DHW circulation pump
External heat source
qR High limit safety cut-out for switching off the secondary pump (on-site)
tP External heat source, e.g. oil boiler
tQ External heat source demand (connection to external heat source)
tW Circulation pump for cylinder reheating
tE Boiler water temperature sensor (connection to heat pump control unit)
tR Directly controlled mixer motor
tT High limit safety cut-out 70 °C for shutting down the external heat source
(on site)
Heating water buffer cylinder
zP Heating water buffer cylinder
zQ Buffer cylinder temperature sensor
zW System flow temperature sensor
Heating circuit with mixer (M2)
uP Underfloor heating circuit with extension kit for one heating circuit with
mixer
uQ Vitotrol 200A remote control
uE Flow temperature sensor
uR Temperature limiter as maximum limiter for underfloor heating systems
uZ Heating circuit pump
uU Mixer motor - 3-way mixer
q¢T Extension kit for one heating circuit with mixer
Heating circuit without mixer (A1)
oP Radiator heating circuit
oQ Vitotrol 200A remote control
oZ Heating circuit pump
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 41 onwards and the
separate service instructions for the heat
pump control unit.
For information regarding the power sup-
ply, see page 58.
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB
Installation

12
230 V/ 50 Hz
2
211.2
X2.N
X1. UP 6
211.4
X2.N
X1.
212.3
X2.N
X1.
212.2
X2.N
X1. HK A1 96
ZP 37
5
224.7
X2.N
X1. UPSB 52
UV
70°C
X2.N
X1.
70°C
222.4
222.3
X3.1
51
222.2
X2.N
X1. 54
222.1
OPEN
CLOSED
L3
N
L2
L1
137
4
3 / N / PE
400 V, 50 Hz
STB 55
STB 14
1
2
145
8
145
145
145
145
40
145
52
21
2
N
L
UP M2
77
73
M
1~
74
76
M2
VTS M2
20
230 V/ 50 Hz
105
1
2
HK A1
HK M2
91
71
Low voltage
1 / N / PE
1
2H1
1
2H2
NTC
136
X2.N
211.3
224.4
2
130W
130W
50W
100W
100W
L
N
M
1~
M
1~
M
1~
M
1~
M
1~
M
1~
1
3
2
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB

13
With instantaneous heating water heater connection 4 for 230 V~
230 V/ 50 Hz
2
211.2
X2.N
X1. UP 6
211.4
X2.N
X1.
212.3
X2.N
X1.
212.2
X2.N
X1. HK A1 96
ZP 37
5
224.7
X2.N
X1. UPSB 52
UV
70°C
X2.N
X1.
70°C
222.4
222.3
X3.1
51
222.2
X2.N
X1. 54
222.1
OPEN
CLOSED
L1
N
L1
L1
137
4
230 V
STB 55
STB 14
1
2
145
8
145
145
145
145
40
145
52
21
2
N
L
UP M2
77
73
M
1~
74
76
M2
VTS M2
20
230 V/ 50 Hz
105
1
2
HK A1
HK M2
91
71
Low voltage
1 / N / PE
1
2H1
1
2H2
NTC
136
X2.N
211.3
224.4
16A
N
N
2
130W
130W
50W
100W
100W
L
N
M
1~
M
1~
M
1~
M
1~
M
1~
M
1~
1
3
2
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB
Installation

14
2
Low voltage
F6
STS 31
F7
STS
PT500
PT500
32
F4
PTS 61
KTS
PT500
PT500
53
F20
F0
VTS 62
ATS
PT500
Ni500
3
F13
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB

15
Connections for the external unit
C N L
29
4 kW
COM
43 V
> 42 V
2
L1
N
1 / N / PE
230 V/ 50 Hz
COM
29
7 kW
COM
43 V
> 42 V
2
L1
N1 / N / PE
230 V/ 50 Hz
Li No Lo
Ni
29
10 kW / 13 kW
COM
12 V
Low voltage
2
L1
N1 / N / PE
230 V/ 50 Hz
NL
L
N
C1
C2
Connections for the internal unit
L1
N
2
L1
N
1 / N / PE
230 V/ 50 Hz
L3 L3 3 / PE
400 V/ 50 Hz
L2 L2
L1 L1
PE
Phase symmetrical
L3 L3
3 / N / PE
400 V/ 50 Hz
L2 L2
L1 L1
PE
Phase asymmetrical
N1
N3
N2 N
X40
4
4
L3 L1
1 / N / PE
230 V/ 50 Hz
L2 L1
L1 L1
PE
Phase asymmetrical
N1
N3
N2 N
4
N
N
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB
Installation

16
Required parameters
Parameter Setting
"System definition"
■"System scheme 7000" "6"
"External heat source"
■"Enable external heat source 7B00" "1"
■"Enable external heat source for DHW heating
7B0D"
"1"
DHW heating:
"Time program DHW" Set time program (see oper-
ating instructions)
"Time prog. DHW circ."
(if a DHW circulation pump is installed)
Set time program (see oper-
ating instructions)
"DHW"
■"Enable booster heaters for DHW heating 6014" "1"
■"Enable electric heaters for DHW heating 6015" "1"
Instantaneous heating water heater (if installed):
"Electr booster heater"
■"Enable instantaneous heating water heater
7900"
"1"
■"Enable instant. heating water heater for central
heating 7902"
"0"
Remote controls (if installed):
"Heating circuit 1"
■"Remote control 2003" "1"
"Heating circuit 2"
■"Remote control 3003" "1"
To call up "Coding level 1" for setting
the parameters, see the commissioning
assistant on page 78 and page 80.
System example 2, ID: 4605170_1005_01
Setting system scheme 6
■ Internal unit of heat pump
type AWS-AC with instantaneous
heating water heater
■ 1 radiator heating circuit without mixer
(A1)
■ 1 underfloor heating circuit with mixer
(M2)
■ DHW heating
■ External heat source
■ Heating water buffer cylinder
■ Cooling on heating circuit M2 (on-site)
with active cooling function
Preparing for installation
System example 1, ID: 4605169_1005_01 (cont.)
5724 152 GB

17
Note
This scheme is a basic example without
shut-off valves or safety equipment. This
does not replace the local technical engi-
neering task.
Hydraulic installation scheme
KW
WW
60
61
71
70
73
74
76
77
91
90
96
1
29
14
55
3
62
54
52
50
53
37
31
32
30
2
--2/212.3--
--2/F13--
--2/F0--
--2/F20--
--2/F6--
--2/F7--
--2/222.1;2--
--2/F4--
--2/212.2--
--2/224.7--
-2/222.4-
--212.3--
--222.1;2--
--224.7--
--212.2--
--222.4--
--F6--
--F7--
--F20--
--F0--
--F13--
--F4--
-2/211.2-
4
5
6
--105/52--
--105/20--
--105/20--
--105/2--
--KM-BUS--
--211.2--
--230V--
--2/211.5;X3.1--
89
89
--2/211.5;X3.1--
-211.5;X3.1-
-2/215.3-
83
--52--
--2--
-KM-BUS-
--20--
-230V-
105
8
--145-- --145--
--145--
--145--
-8/145- -8/145-
--
--215.3--
Pos. Description
Heat source
1Internal unit of the heat pump
2Heat pump control unit
Preparing for installation
System example 2, ID: 4605170_1005_01 (cont.)
5724 152 GB
Installation

18
Pos. Description
3Outside temperature sensor
4Instantaneous heating water heater with control module
53-way diverter valve "Heating/DHW"
6Secondary pump
8KM BUS distributor
Primary circuit
wO External unit of the heat pump
DHW heating
eP DHW cylinder
eQ Cylinder temperature sensor, top
eW Cylinder temperature sensor, bottom
eU DHW circulation pump
External heat source
qR High limit safety cut-out for switching off the secondary pump (on-site)
tP External heat source, e.g. oil boiler
tQ External heat source demand (connection to external heat source)
tW Circulation pump for cylinder reheating
tE Boiler water temperature sensor (connection to heat pump control unit)
tR Directly controlled mixer motor
tT High limit safety cut-out 70 °C for shutting down the external heat source
(on site)
Heating water buffer cylinder
zP Heating water buffer cylinder
zQ Buffer cylinder temperature sensor
zW System flow temperature sensor
Heating circuit with mixer (M2)
uP Underfloor heating circuit with extension kit for one heating circuit with
mixer
uQ Vitotrol 200A remote control
uE Flow temperature sensor
uR Temperature limiter as maximum limiter for underfloor heating systems
uZ Heating circuit pump
uU Mixer motor - 3-way mixer
q¢T Extension kit for one heating circuit with mixer
Cooling on heating circuit M2 (on-site) with active cooling (AC) func-
tion
iE Contact humidistat
iO 3-way diverter valve "Heating/cooling"
Preparing for installation
System example 2, ID: 4605170_1005_01 (cont.)
5724 152 GB

19
Pos. Description
Heating circuit without mixer (A1)
oP Radiator heating circuit
oQ Vitotrol 200A remote control
oZ Heating circuit pump
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 41 onwards and the
separate service instructions for the heat
pump control unit.
For information regarding the power sup-
ply, see page 58.
Preparing for installation
System example 2, ID: 4605170_1005_01 (cont.)
5724 152 GB
Installation

20
230 V/ 50 Hz
2
211.2
X2.N
X1. UP 6
211.4
X2.N
X1.
212.3
X2.N
X1.
212.2
X2.N
X1. HK A1 96
ZP 37
5
224.7
X2.N
X1. UPSB 52
UV
70°C
X2.N
X1.
70°C
222.4
222.3
X3.1
51
222.2
X2.N
X1. 54
222.1
OPEN
CLOSED
L3
N
L2
L1
137
4
3 / N / PE
400 V, 50 Hz
STB 55
STB 14
1
2
145
8
145
145
145
145
40
145
52
21
2
N
L
UP M2
77
73
M
1~
74
76
M2
VTS M2
20
230 V/ 50 Hz
105
1
2
HK A1
HK M2
91
71
Low voltage
1 / N / PE
1
2H1
1
2H2
NTC
136
X2.N
211.3
224.4
2
130W
130W
50W
100W
100W
L
N
M
1~
M
1~
M
1~
M
1~
M
1~
M
1~
1
3
2
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
Preparing for installation
System example 2, ID: 4605170_1005_01 (cont.)
5724 152 GB