Viessmann Vitocal 200-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWB 201.A04 to A13
Air/water heat pump, split version for heating operation
Type AWB-AC 201.A04 to A13
Air/water heat pump, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 200-S
5601 429 GB 3/2011 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 contractors.
■ Work on the refrigerant circuit must
only be carried out by qualified and
authorised refrigeration engineers
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer
Regulations
Observe the following when working on
this system:
■ National installation requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental 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.
Danger
Contact with 'live' components
can lead to severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Before removing covers from
appliances, wait at least 4
minutes for the power to dissi-
pate.
■ Safeguard the system against unau-
thorised reconnection
Safety instructions
Safety instructions
5601 429 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
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.)
5601 429 GB

4
Installation instructions
Preparing for installation
Application............................................................................................................ 6
Requirements of on-site connections................................................................... 7
Overview of possible system schemes................................................................ 9
Designations in the system examples.................................................................. 11
System example 1, ID: 4605169_1103_04.......................................................... 12
System example 2, ID: 4605170_1103_04.......................................................... 18
Installation sequence
Installing the external unit..................................................................................... 25
Installing the internal unit...................................................................................... 28
Connecting the refrigerant lines........................................................................... 31
Connecting a secondary circuit............................................................................ 35
Connecting a cooling circuit if required................................................................ 36
Electrical connections........................................................................................... 36
Power supply........................................................................................................ 54
Closing the heat pump......................................................................................... 60
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 62
Further details regarding the individual steps....................................................... 64
Troubleshooting
Repairs................................................................................................................. 83
Parts lists, internal unit
Parts lists, internal unit......................................................................................... 95
Overview of the assemblies, internal unit............................................................. 96
Parts not shown, internal unit............................................................................... 97
Casing, internal unit.............................................................................................. 97
Electrical equipment, internal unit........................................................................ 99
Hydraulics, internal unit........................................................................................ 100
Parts lists, external unit
Parts lists, external unit........................................................................................ 103
External unit, type AWB/AWB-AC 201.A04.......................................................... 103
External unit, type AWB/AWB-AC 201.A07.......................................................... 105
Overview of the assemblies, external unit, type AWB/AWB-AC 201.A10, A13.... 107
Casing, external unit, type AWB/AWB-AC 201.A10, A13.................................... 108
Electrical equipment, external unit, type AWB/AWB-AC 201.A10, A13............... 110
Index
Index
5601 429 GB

5
Hydraulics, external unit, type AWB/AWB-AC 201.A10, A13............................... 112
Commissioning/service reports
Hydraulic parameters report................................................................................. 114
Control parameters report.................................................................................... 114
Specification....................................................................................................... 119
Appendix
Heat pump commissioning order.......................................................................... 124
Certificates
Declaration of conformity...................................................................................... 125
Keyword index.................................................................................................... 126
Index
Index (cont.)
5601 429 GB

6
The heat pumps Vitocal 200-S,
type AWB and AWB-AC can be used for
the following purposes:
■ Central heating via a heating system
■ Central cooling (only type AWB-AC)
via a heating system
■ DHW heating
Any use that differs from or goes beyond
this is not in accordance with require-
ments.
Note
Vitocal 200-S is intended exclusively for
domestic use, i.e. even people who have
not had any instruction are able to oper-
ate the appliance safely.
Preparing for installation
Application
5601 429 GB

7
Internal unit
850
114
105
116
360
+
230 V~
400 V~
< 42 V > 42 V
1160
A
150
75
147
219
294
369
450
41
Preparing for installation
Requirements of on-site connections
5601 429 GB
Installation

8
Symbol Explanation Connection
Refrigerant lines from/to the
external unit:
Type
AWB/
AWB-AC
Pipe 7UNF thread
■ Hot gas line 201.A04 12 mm ⅞
Reducer
¾ x ⅞
201.A07
201.A10
201.A13
16 mm
16 mm
16 mm
⅞
⅞
⅞
■ Liquid line 201.A04 6 mm ⅝
Reducer
⁷⁄₁₆ x ⅝
201.A07
201.A10
201.A13
10 mm
10 mm
10 mm
⅝
⅝
⅝
DHW cylinder flow (heating
water side)
G 1¼
+
Heating water return and
DHW cylinder return
G 1¼
Heating water flow G 1¼
ADrain & fill valve —
Safety valve (supplied) —
1. Preparing connections on the heating
water and the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Note
The internal/external unit BUS con-
necting cable can be routed along the
refrigerant line and fixed to it.
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:
Preparing for installation
Requirements of on-site connections (cont.)
5601 429 GB

9
Cables Internal unit External unit
12 V BUS 1.5 m 1.5 m
43 V BUS 1.5 m 1.5 m
Recommended power cables
Vitocal 200-S, type AWB,
AWB-AC
201.A04 201.A07 201.A10 201.A13
External unit (compressor)
230 V~
Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 4.0 mm2
Max. cable length 29 m 25 m 16 m 20 m
or or
Cable cross-section – – 3 x 4.0 mm23 x 6.0 mm2
Max. cable length – – 26 m 30 m
Heat pump control unit (inter-
nal unit) 230 V~
Cable cross-section
■ Without power-OFF 3 x 1.5 mm23 x 1.5 mm23 x 1.5 mm23 x 1.5 mm2
■ With power-OFF 5 x 1.5 mm25 x 1.5 mm25 x 1.5 mm25 x 1.5 mm2
Instantaneous heating water
heater
Cable cross-section
■ 400 V~ 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
■ 230 V~ 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.
Preparing for installation
Requirements of on-site connections (cont.)
5601 429 GB
Installation

10
Components System scheme (parameter 7000)
0 1 2 3 4 5 6
Heating circuit
A1/HC1 – X X – – X X
M2/HC2 – – – 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
Cooling
A1/HC1 0 0 0 0
M2/HC2 0 0 0 0
Sep. cooling circuit 0 0 0 0 0 0 0
X Components selected
0Components can be added
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5601 429 GB

11
--A/137--
--2/212.3--
--230V-- -KM BUS-
KW
WW
--2/F6--
--2/F14--
--2/211.2--
--2/F0--
-2/211.4-
--94/20--
--
--2/F8--
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
-2/145-
A1
--2/X3.8;3.9--
2
1
qE
qW
6
4
3
7
5
eU
eQ
eP
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
2
[H
F
[YF
F
Preparing for installation
Designations in the system examples
5601 429 GB
Installation

12
Setting system scheme 6
■ Internal unit of the heat pump
type AWB 201.A without instantane-
ous heating water heater or
type AWB-AC 201.A with instantane-
ous heating water heater
■ 1 radiator heating circuit without mixer
A1/HC1
■ 1 underfloor heating circuit with mixer
M2/HC2
■ DHW heating
■ External heat source
■ Heating water buffer cylinder
Note
This scheme is a basic example without
shut-off devices or safety equipment.
This does not replace the need for local
engineering.
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
30
2
--2/212.3--
--2/F13--
--2/F0--
--2/F20--
--2/F6--
--2/222.1;2--
--2/F4--
--2/212.2--
--2/224.7--
-2/222.4--51-
--212.3--
--222.1;2--
--224.7--
--212.2--
--222.4--
--F6--
--F20--
--F0--
--F13--
--F4--
-2/211.2--14-
4
5
6
--105/52--
--74/20--
-105/20--76-
--105/2--
--KM BUS--
--211.2--
--230V--
--52--
--2--
-KM BUS-
--20--
-230V-
105
8
--145-- --145--
--145--
-8/145- -8/145-
--145--
13
A1 M2
27 28
Preparing for installation
System example 1, ID: 4605169_1103_04
5601 429 GB

13
Pos. Description
Heat source
1Internal unit, heat pump Vitocal 200-S
2Heat pump control unit Vitotronic 200, type WO1B
3Outside temperature sensor ATS
4Instantaneous heating water heater with control module
(only for Vitocal 200-S, type AWB-AC)
53-way diverter valve for "Heating/DHW"
6Secondary pump
8KM BUS distributor
qE Heating circuit expansion vessel
Primary circuit
wU Liquid line
wI Hot gas line
wO External unit of the heat pump Vitocal 200-S
DHW heating
eP DHW cylinder (dual mode)
eQ Cylinder temperature sensor STS
eU DHW circulation pump ZP
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5601 429 GB
Installation

14
Pos. Description
External heat source
qR High limit safety cut-out for switching off the secondary pump
tP External heat source, e.g. oil/gas boiler
tQ Demand of external heat source (connection to heat pump control unit)
tW Circulation pump for cylinder heating UPSB
tE Boiler water temperature sensor KTS (for connection to the heat pump
control unit):
■ As contact temperature sensor
or
■ As immersion temperature sensor
tR Mixer motor, directly controlled
tT High limit safety cut-out STB 70 °C (to switch off the external heat
source)
zP Heating water buffer cylinder
zQ Buffer temperature sensor PTS
zW System flow temperature sensor
Heating circuit with mixer M2 (KM BUS)
uP Underfloor heating circuit
uQ Vitotrol 200A remote control
uE Flow temperature sensor
uR Temperature limiter to limit the maximum temperature of underfloor heating
systems
■ As immersion thermostat
or
■ As contact thermostat
uZ Heating circuit pump
uU 3-way mixer, heating circuit
Mixer motor in 3-way mixer
q-T Mixer extension kit
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 39 and the separate
service instructions for the heat pump
control unit.
For information regarding the power sup-
ply, see page 54.
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5601 429 GB

15
230 V/ 50 Hz
2
211.2
X2.N
X1. UP 6
212.3
X2.N
X1.
212.2
X2.N
X1. HK A1 96
ZP 37
224.7
X2.N
X1. UPSB 52
70 °C
X2.N
X1.
70 °C
222.4
222.3
X3.1
51
222.2
X2.N
X1. 54
222.1
OPEN
CLOSE
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
2
1
HK A1
HK M2
91
71
Low voltage
1 / N / PE
1
2H1
1
2H2
NTC
2
130W
50W
100W
100W
L
N
55
STB
20
HK M2
KM BUS distributor
M
1~
M
1~
M
1~
M
1~
M
1~
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
1
3
2
Note
The instantaneous heating water heater
4, the 3-way diverter valve 5 and the
secondary pump 6 are already instal-
led and electrically connected.
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5601 429 GB
Installation

16
2
Low voltage
F6
STS 31
PT500
F4
PTS 61
KTS
PT500
PT500
53
F20
F0
VTS 62
ATS
PT500
Ni500
3
F13
Power supplies for the internal unit
and instantaneous heating water
heater
N1
1 / N / PE
230 V/ 50 Hz
N1
N1
L1
4
L1
L1
3 / N / PE
400 V/ 50 Hz
N
L2
4
L3
L1
230 V
400 V
Instantaneous heating water heater power supply
Power supply to heat pump control unit
2
1 / N / PE
230 V / 50 Hz
F1 6.3 AH (slow)
L1
N
X40
L1
N
Note
Instantaneous heating water heater only
for Vitocal 200-S, type AWB-AC.
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
COM
12 V
2
L1
N1 / N / PE
230 V/ 50 Hz
NL
L
N
C1
C2
10 / 13 kW
< 42 V
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5601 429 GB

17
Required parameter settings
Parameter Setting
"System definition"
■"System scheme 7000" "6"
"Compressor"
■"Output compressor stage 5030" Type AWB/AWB-AC
■ 201.A04: "4"
■ 201.A07: "7"
■ 201.A10: "10"
■ 201.A13: "13"
"External heat source"
■"Enable external heat source 7B00" "1"
■"Enable external heat source for DHW heating
7B0D"
"1"
DHW heating:
"Time program DHW heating" Set time program (see oper-
ating instructions)
"Time program DHW circulation"
(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"
"1"
Remote controls (accessories):
"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 74 and page 76.
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5601 429 GB
Installation

18
Setting system scheme 6
■ Internal unit of heat pump type
AWB-AC 201.A with instantaneous
heating water heater
■ 1 radiator heating circuit without mixer
A1/HC1
■ 1 underfloor heating circuit with mixer
M2/HC2
■ DHW heating
■ External heat source
■ Heating water buffer cylinder
■ Cooling, heating circuit M2/HC2 via
"active cooling" function
Note
This scheme is a basic example without
shut-off devices or safety equipment.
This does not replace the need for local
engineering.
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
30
2
--2/212.3--
--2/F13--
--2/F0--
--2/F20--
--2/F6--
--2/222.1;2--
--2/F4--
--2/212.2--
--2/224.7--
-2/222.4--51-
--212.3--
--222.1;2--
--224.7--
--212.2--
--222.4--
--F6--
--F20--
--F0--
--F13--
--F4--
-2/211.2--6-
4
5
6
--105/52--
--74/20--
-105/20--76-
--105/2--
--KM BUS--
--211.2--
--230V--
--2/211.5--
89
89
--2/211.5-----
--211.5--
-2/X3.8;3.9-
83
--52--
--2--
-KM BUS-
--20--
-230V-
105
8
--145-- --145--
--145--
--145--
-8/145- -8/145-
--
--X3.8;3.9--
13
A1 M2
27 28
Preparing for installation
System example 2, ID: 4605170_1103_04
5601 429 GB

19
Pos. Description
Heat source
1Internal unit, heat pump, Vitocal 200-S, type AWB-AC
2Heat pump control unit Vitotronic 200, type WO1B
3Outside temperature sensor ATS
4Instantaneous heating water heater with control module
53-way diverter valve for "Heating/DHW"
6Secondary pump
8KM BUS distributor
qE Heating circuit expansion vessel
Primary circuit
wU Hot gas line
wI Liquid gas line
wO External unit, heat pump Vitocal 200-S
DHW heating
eP DHW cylinder (with internal indirect coil)
eQ Cylinder temperature sensor STS
eU DHW circulation pump ZP
External heat source
qR High limit safety cut-out for switching off the secondary pump
tP External heat source, e.g. oil/gas boiler
tQ Demand of external heat source (connection to heat pump control unit)
tW Circulation pump for cylinder heating UPSB
tE Boiler water temperature sensor KTS (for connection to the heat pump
control unit):
■ As contact temperature sensor
or
■ As immersion temperature sensor
tR Mixer motor directly controlled
tT High limit safety cut-out STB 70 °C (to switch off the external heat
source)
Preparing for installation
System example 2, ID: 4605170_1103_04 (cont.)
5601 429 GB
Installation

20
Pos. Description
zP Heating water buffer cylinder
zQ Buffer temperature sensor
zW System flow temperature sensor
Heating circuit with mixer M2 (KM BUS)
uP Underfloor heating circuit/cooling circuit
uQ Vitotrol 200A remote control
uE Flow temperature sensor
uR Temperature limiter to limit the maximum temperature of underfloor heating
systems
■ As immersion thermostat
or
■ As contact thermostat
uZ Heating circuit pump
uU 3-way mixer, heating circuit
Mixer motor in 3-way mixer
q-T Extension kit, heating circuit with mixer
"Active cooling" function AC
iE Contact humidistat 230 V
iO 3-way diverter valve for "heating/cooling"
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 39 and the separate
service instructions for the heat pump
control unit.
For information regarding the power sup-
ply, see page 54.
Preparing for installation
System example 2, ID: 4605170_1103_04 (cont.)
5601 429 GB