Viessmann Vitocal 200-S Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWB(-M) 201.D04 to D16
Air/water heat pump, split version for heating operation
Type AWB(-M)-E-AC 201.D04 to D16
Air/water heat pump, split version for heating and cooling operation
For applicability, see the last page
VITOCAL 200-S
5790 931 GB 5/2017 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised contractors.
■Work on the refrigerant circuit may only be carried
out by authorised refrigeration engineers.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
Note
In addition to the control circuit there may be several
power circuits.
Danger
Contact with live components can result in
severe injuries. Some components on PCBs
remain live even after the power supply has
been switched off.
Prior to removing covers from the appliances,
wait at least 4 minutes until the voltage has
completely dropped out.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the appliance, fit-
tings or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
2. Preparing for installation Requirements for on-site connections ................................................... 8
■Indoor unit ........................................................................................... 8
■Outdoor unit ........................................................................................ 10
3. Installation sequence Installing the outdoor unit ....................................................................... 12
■Installation information ........................................................................ 12
■Installation location ............................................................................. 13
■Minimum clearances for 1 outdoor unit .............................................. 14
■Minimum clearances for heat pump cascades (max. 5 outdoor units) 15
■Transport and siting ............................................................................ 15
■Floorstanding installation .................................................................... 15
■Wall mounting ..................................................................................... 18
■Opening the wiring chamber ............................................................... 20
■Removing transport brackets .............................................................. 20
Installing the indoor unit ......................................................................... 21
■Transport ............................................................................................ 21
■Requirements for the installation room ............................................... 21
■Minimum clearances ........................................................................... 22
■Fitting the indoor unit to the wall ......................................................... 22
Connecting the refrigerant lines ............................................................. 23
■Oil lift bends ........................................................................................ 23
■Wall outlet ........................................................................................... 23
■Routing the refrigerant lines ............................................................... 24
■Insulation against noise and vibrations for line entry above ground
level .................................................................................................... 24
■Connection to the outdoor unit ........................................................... 25
■Connection to the indoor unit .............................................................. 26
Connecting the secondary circuit ........................................................... 28
Only type AWB(-M)-E-AC: Connecting the cooling circuit ..................... 29
Electrical connection .............................................................................. 29
■Preparing the electrical connections ................................................... 29
■Indoor unit: routing cables to the wiring chamber ............................... 31
■Connecting the Vitoconnect (accessories) ......................................... 32
■Indoor unit: overview of connections .................................................. 34
■Indoor unit: main PCB (230 V~ components) ..................................... 35
■Indoor unit: expansion PCB on main PCB (230 V~ components) ...... 37
■Indoor unit: luster terminals (signal and safety connections) .............. 40
■Indoor unit: controller and sensor PCB (LV connections) ................... 41
■Outdoor unit: routing cables to the wiring chamber ............................ 44
■Outdoor unit: Overview of electrical connections ............................... 45
■Connecting Modbus cable between indoor unit and outdoor unit ....... 46
Power supply ......................................................................................... 47
■Heat pump control unit power supply 230 V~ ..................................... 48
■Outdoor unit power supply .................................................................. 48
■Instantaneous heating water heater power supply ............................. 50
■Power supply with power-OFF: without on-site load disconnection ... 52
■Power supply with power-OFF: with on-site load disconnection ........ 52
■Connecting the power-OFF signal in heat pump cascades ................ 54
■Mains power supply in conjunction with on-site power consumption . 55
■Smart Grid .......................................................................................... 55
Closing the heat pump ........................................................................... 56
■Fitting the front panel of the indoor unit .............................................. 57
■Fitting the side cover for the outdoor unit ........................................... 57
Index
Index
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4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 58
5. Maintenance Overview of electrical components ........................................................ 77
Indoor unit: opening the programming unit ............................................ 77
Indoor unit: placing the control panel in its service position .................. 78
Overview of internal components: indoor unit ........................................ 79
Overview of internal components: outdoor unit ..................................... 80
■Outdoor unit, types 201.D04 to 201.D08 ............................................ 81
■Outdoor unit, types 201.D10 to 201.D16 ............................................ 82
Draining secondary side heat pump ...................................................... 83
Checking the temperature sensors ........................................................ 83
■Connection to the indoor unit .............................................................. 83
■Connection to the outdoor unit ........................................................... 83
■Indoor unit: Viessmann NTC 10 kΩ (blue marking) ............................ 84
■Indoor unit: Viessmann NTC 20 kΩ (orange marking) ........................ 85
■Indoor unit: Viessmann Pt500A (green marking) ................................ 86
■Outdoor unit: Viessmann NTC 10 kΩ (no marking) ............................ 87
Checking the fuses ................................................................................ 87
6. Indoor unit parts lists Overview of indoor unit assemblies ....................................................... 89
Indoor unit casing .................................................................................. 90
Indoor unit condenser ............................................................................ 92
Hydraulics, indoor unit type AWB(-M) .................................................... 94
Hydraulics, indoor unit type AWB(-M)-E-AC .......................................... 96
Indoor unit electrical equipment ............................................................. 98
Casing, miscellaneous ...........................................................................100
7. Parts list, outdoor unit
types AWB-M/
AWB-M-E-AC 201.D04 to
201.D08, 230 V~
Overview of assemblies, outdoor unit 230 V~ ....................................... 103
Casing, outdoor unit 230 V~ .................................................................. 104
Refrigerant circuit, outdoor unit types 201.D04 to 201.D08, 230 V~ ..... 106
Electrical equipment, outdoor unit 230 V~ .............................................108
8. Parts list, outdoor unit
230 V~, type AWB-M/
AWB-M-E-AC 201.D10 to
201.D16
Overview of assemblies, outdoor unit 230 V~ ....................................... 111
Casing, outdoor unit 230 V~ .................................................................. 112
Refrigerant circuit, outdoor unit 230 V~ ................................................. 114
Electrical equipment, outdoor unit 230 V~ ............................................. 116
9. Parts list, outdoor unit
types AWB/
AWB-E-AC 201.D10 to
201.D16, 400 V~
Overview of assemblies, outdoor unit 400 V~ ....................................... 119
Casing, outdoor unit 400 V~ .................................................................. 120
Refrigerant circuit, outdoor unit 400 V~ ................................................. 122
Electrical equipment, outdoor unit 400 V~ .............................................124
10. Commissioning/service
reports
Hydraulic parameter report .................................................................... 126
Control parameter report ....................................................................... 126
11. Specification ................................................................................................................138
12. Appendix Commissioning order .............................................................................145
Final decommissioning and disposal ..................................................... 145
13. Certificates Declaration of conformity ....................................................................... 146
14. Keyword index ................................................................................................................147
Index
Index (cont.)
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions.
Depending on the version, the appliance can only be
used for the following purposes:
■Central heating
■Central cooling
■DHW heating
Information
Disposal of packaging
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Information

7
The range of functions can be extended with additional
components and accessories.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than central heating/cooling or DHW heating shall be
deemed inappropriate.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic or
semi-domestic use, i.e. even users who have not had
any instruction are able to operate the appliance
safely.
Product information
Layout
Vitocal 200-S is a split air/water heat pump, comprising
1 indoor unit and 1 outdoor unit.
Refrigerant circuit
All components of the refrigerant circuit, including the
refrigerant circuit controller with electronic expansion
valve, are located in the outdoor unit, except for the
condenser. Subject to operating conditions, compres-
sor output is matched via inverter control.
The indoor and outdoor units are connected to each
other hydraulically via the refrigerant lines.
Hydraulics
The indoor unit is equipped with a high efficiency circu-
lation pump (secondary pump) which transports the
heated heating water into the secondary circuit. The
integral 3-way diverter valve for "central heating/DHW
heating" changes over between central heating and
DHW heating.
Central heating
The heat pump is able to supply up to 3 heating cir-
cuits: 1 heating circuit without mixer and 2 heating cir-
cuits with mixer.
Central cooling
Vitocal 200-S, type AWB-E-AC and AWB-M-E-AC can
be used for central cooling.
Central cooling results either through a heating/cooling
circuit or via a separate cooling circuit. For this, the
refrigerant circuit is reversed and heat is extracted
from the cooling circuit.
Heat pump control unit
The entire heating system is monitored and controlled
by the integral heat pump control unit Vitotronic 200,
type WO1C.
Type overview
Vitocal 200-S, type AWB-M 201.D AWB 201.D AWB-M-E-AC 201.D AWB-E-AC
201.D
Central heating X X X X
DHW heating X X X X
Central cooling — — X X
Integral instantaneous heating water
heater
— — X X
Outdoor unit power supply 230 V~ 400 V~ 230 V~ 400 V~
Information
Intended use (cont.)
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Information

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Indoor unit
880
66
50
370
+
1105 150
960
60
358
450
68
AB
80
152
224
299
374
Fig. 1
ACable entry < 42 V
BCable entry 400 V~/230 V~, > 42 V
Refrigerant line connections
Symbol Meaning Connection to the indoor unit
Type AWB/AWB-M/
AWB-E-AC/
AWB-M-E-AC
Pipe 7UNF thread
Liquid line 201.D04 to D06 6 mm ⅝
(reducer
⅝ x ⁷⁄₁₆ supplied)
201.D08 to D16 10 mm ⅝
Hot gas line 201.D04 to D06 12 mm ⅞
(reducer
⅞ x ¾ supplied)
201.D08 to D16 16 mm ⅞
Preparing for installation
Requirements for on-site connections
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Installation

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Secondary circuit connections
Symbol Meaning Connection on the indoor unit (female thread)
DHW cylinder flow (on the heating water
side)
G 1¼
+
Heating water return and DHW cylinder re-
turn
G 1¼
Heating water flow G 1¼
1. Prepare the connections on the heating water and
the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Preparing for installation
Requirements for on-site connections (cont.)
5790 931 GB
Installation

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Outdoor unit
Outdoor unit type 201.D04 to D08
1109
142
212
290
508
545
536
546
63
96
99
113
705
753
48
518
D
C
A B
BA
D
C
Fig. 2
ACable entry for indoor/outdoor unit Modbus con-
necting cable
BPower cable entry
CLiquid line
■201.D04 to D06:
UNF ⁷⁄₁₆
■201.D08:
UNF ⅝
DHot gas line
■201.D04 to D06:
UNF ¾
■201.D08:
UNF ⅞
Preparing for installation
Requirements for on-site connections (cont.)
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Installation

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Outdoor unit type 201.D10 to D16
508
545
1377
142
212
290
1109
63
96
99
113
705
536
546
48
518
BA
D
C
D
C
A B
Fig. 3
ACable entry for indoor/outdoor unit Modbus con-
necting cable
BPower cable entry
CLiquid line UNF ⅝
DHot gas line UNF ⅞
Preparing for installation
Requirements for on-site connections (cont.)
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Installation

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Installation information
Types of installation:
■Floorstanding installation with line entry above
ground level
■Floorstanding installation with line entry below
ground level
■Wall mounting
Technical guide
Floorstanding installation:
■Use supports for floorstanding installation (accesso-
ries).
■Where such supports cannot be used, install the out-
door unit freestanding on a solid base of
at least 100 mm height.
■In difficult climatic circumstances (temperatures
below zero, snow, humidity), we recommend instal-
ling the appliance on a plinth of approx. 300 mm
height.
■Take account of the weight of the outdoor unit: see
following table.
Wall mounting:
■Use the wall mounting bracket set (accessories).
■The wall must meet the structural requirements.
Siting:
■Never install with the discharge side facing the main
wind direction.
■Provide wall outlets and protective pipes for the
refrigerant lines and electrical cables without moul-
ded parts or changes of direction.
Weather influences:
■Observe wind loads when installing the unit on sites
exposed to the wind.
Where outdoor units are installed on a flat roof, con-
siderable wind loads may occur, depending on the
relevant wind load zone and height of the building.
For such installation situations we recommend hav-
ing the substructure sized by a design engineer in
accordance with DIN 1991-1-4.
■Incorporate the outdoor unit into the lightning protec-
tion system.
■Consider the heat absorbed (heating mode) and heat
emitted (cooling mode) by the appliance when
designing weatherproofing measures or an enclo-
sure.
Condensate:
■Ensure that the condensate drains off freely.
Create a permanent gravel bed under the outdoor
unit as a soakaway.
■In regions with prolonged cold seasons, provide an
electric ribbon heater (accessories) for the conden-
sate pan.
Insulation against structure-borne noise and vibra-
tions between the building and outdoor unit:
■For line entry above ground level, fit pipe bends in
the refrigerant lines for vibration compensation: see
"Connecting the refrigerant lines".
■Route cables/leads between the indoor and outdoor
units free of stress.
■Installation only on walls with a high weight per unit
area (> 250 kg/m2); in other words not on lightweight
walls, roof structures, etc.
■Anti-vibration components are included in the stand-
ard delivery of the brackets for wall mounting and
floorstanding installation. Do not use additional anti-
vibration mounts, springs, rubber mounts, etc.
Installation sequence
Installing the outdoor unit
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Installation

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Weight of outdoor units
Vitocal 200-S Type Weight in kg
230 V appliances ■AWB-M
■AWB-M-E-AC
201.D04 94
201.D06 94
201.D08 99
201.D10 136.5
201.D13 136.5
201.D16 136.5
400 V appliances ■AWB
■AWB-E-AC
201.D10 148
201.D13 148
201.D16 148
Installation location
■Select a site with good air circulation, so that the
cooled air can dissipate and be replaced by warm
air.
■Never install in the corners of rooms, in recesses or
between walls. This could result in an "air short cir-
cuit" between the air being discharged and the air
being drawn in.
!Please note
An "air short circuit" during heating mode will
result in the cooled discharged air re-entering
the unit. This can result in reduced heat pump
efficiency and defrosting problems.
Avoid "air short circuits".
!Please note
An "air short circuit" during cooling mode will
result in the heated discharged air re-entering
the unit. This can lead to high pressure faults.
Avoid "air short circuits".
■If siting the appliance in a location that is exposed to
wind, ensure that the wind cannot influence the fan
area. Strong wind can have a negative influence on
the air flow through the evaporator.
■Take the lengths of the refrigerant lines into account:
see "Connecting the refrigerant lines".
■Select an installation location where the evaporator
cannot be blocked by leaves, snow, etc.
■Select the installation location giving due considera-
tion to the physical laws concerning the propagation
and reflection of sound.
Technical guide
■Never install next to or below bedroom windows.
■Maintain a clearance of at least 3 m to pathways,
downpipes or sealed surfaces. The cooled air in the
discharge area creates a risk of ice forming when
outside temperatures are below 10 °C.
■The installation location must be easily accessible,
for example for maintenance work: see "minimum
clearances".
Installation sequence
Installing the outdoor unit (cont.)
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Installation

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Minimum clearances for 1 outdoor unit
Types 201.D04 to D08
B A
1000 a
A
B
a
100 300
1000
Fig. 4
AAir intake
BAir discharge
a■Line entry above ground level:
≥ 200 mm
■Line entry below ground level:
≥ 400 mm
Types 201.D10 to D16, 230 V~ and 400 V~
B
A
B A
100
a
300
1000
1000 a
Fig. 5
AAir intake
BAir discharge
a■Line entry above ground level:
≥ 200 mm
■Line entry below ground level:
≥ 400 mm
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation

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Minimum clearances for heat pump cascades (max. 5 outdoor units)
Facing layout without partition wall
> 500
B
> 1500
A
B
A
> 500 > 500
> 500
A
B
A
B
> 500 > 500
Fig. 6
AAir intake
BAir discharge
Facing layout with partition wall
> 500
B
400 A
B
A
> 500 > 500
400
> 500
A
B
A
B
> 500 > 500
C
Fig. 7
AAir intake
BAir discharge
Single row layout
> 500
A
400
B
A
B
A
B
> 500 > 500 > 500
A
B
> 500
A
B
> 500
Fig. 8
AAir intake
BAir discharge
Transport and siting
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never apply loads/weight to the top, front or
side panels of the appliance.
!Please note
If the compressor in the external unit is strongly
tilted, lubricant will enter the refrigerant circuit
and damage the appliance.
Max. tilting angle: 45°
Floorstanding installation
Foundations
Fit the floor supports on 2 horizontal foundation strips.
We recommend the construction of concrete founda-
tions in accordance with the following diagram. The
stated thickness of the layers represents an average
value. These values should be adjusted to suit the
local conditions. Follow the standard rules of building
engineering.
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation

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300
1100
1200
C
702
50 50
50 50
150150
D
B
B
709
120
E
D
D
C
A
B
B
E
Fig. 9
AFrost protection for foundations (compacted
crushed stone, e.g. 0 to 32/56 mm); thickness of
layer subject to local requirements and building
regulations
BFoundation strip
CGravel bed as condensate soakaway
DFixing points for floorstanding installation supports
EOnly for line entry below ground level: DN 125 KG
conduit with cover and 3 x 30° pipe bends; sealing
of line entry with end collar
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation

17
Floorstanding installation with support; line entry above ground level
3000
B
A
G
200
F
300
K
835
1100
H
702
3000
B
A
G
200
F
300
K
835
1100
H
702
C
E
D
C
D
E
Fig. 10
AGround
BPathway, patio
CPipe bends for vibration compensation in refriger-
ant lines
DPipe clips with EPDM lining
EIndoor/outdoor unit bus cable and outdoor unit
power cable
FOpenings in the base plate for free drainage of
condensate
GSupports for floorstanding installation (accesso-
ries)
HFoundation strip
KFrost protection for foundations (compacted
crushed stone, e.g. 0 to 32/56 mm); thickness of
layer subject to local requirements and building
regulations
Information regarding vibration compensation
(pipe bends
C
)
We recommend installing vibration bends, especially in
pipes < 5 m.
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation

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Floorstanding installation with support; line entry
below ground level
K
835
1100
3000
B
A
F
300
702
H
E
L
400
GC
Fig. 11
AGround
BPathway, patio
CRefrigerant lines
EIndoor/outdoor unit bus cable and outdoor unit
power cable
FOpenings in the base plate for free drainage of
condensate
GSupports for floorstanding installation (accesso-
ries)
HFoundation strip
KFrost protection for foundations (compacted
crushed stone, e.g. 0 to 32/56 mm); thickness of
layer subject to local requirements and building
regulations
LDN 125 conduit with cover and 3 x 30° pipe bends;
sealing of line entry with end collar
Installing an outdoor unit on foundations
A
B
C
D
1.
4x
4x
2.
Fig. 12
ASupports for floorstanding installation (accesso-
ries)
BGravel bed as condensate soakaway
CConcrete foundations (see technical guide)
DDN 100 KG conduit (only for line entry below
ground level)
Note
We recommend letting condensate drain away freely
(without a condensate pipe).
Wall mounting
Installation should only be performed with the bracket
set for wall mounting (accessories).
Separate installation instructions
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation

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Wall mounting with bracket set
300
G
F
B
200
A
E
D
C
300
G
F
B
200
A
E
C
D
Fig. 13
AGravel bed as condensate soakaway
BAnti-vibration mounts (standard delivery of
bracket)
CPipe bends for vibration compensation in refriger-
ant lines
DPipe clips with EPDM lining
EIndoor/outdoor unit bus cable and outdoor unit
power cable
FOpenings in the base plate for free drainage of
condensate
GBracket for wall mounting (accessories)
Information regarding vibration compensation
(pipe bends
C
)
We recommend installing vibration bends, especially in
pipes < 5 m.
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation

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Opening the wiring chamber
Opening the outdoor unit wiring chamber: Types
201.D04 to 201.D08
A
Fig. 14
AWiring chamber:
■Bus connection to the indoor unit
■Compressor power supply
Opening the outdoor unit wiring chamber: Types
201.D10 to 201.D16
A
Fig. 15
AWiring chamber:
■Bus connection to the indoor unit
■Compressor power supply
Removing transport brackets
2.
1. 2x
Fig. 16
Installation sequence
Installing the outdoor unit (cont.)
5790 931 GB
Installation