Viessmann Vitocal 200-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWB 201.B04 to B13
Air/water heat pump, split version for heating operation
Type AWB-AC 201.B04 to B13
Air/water heat pump, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 200-S
5604 692 GB 10/2011 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
5604 692 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.)
5604 692 GB

4
Installation instructions
Preparing for installation
Application............................................................................................................ 6
Requirements for on-site connections.................................................................. 7
Overview of possible system schemes................................................................ 9
Designations in the system examples.................................................................. 11
System example 1, ID: 4605169_1103_04.......................................................... 11
System example 2, ID: 4605170_1103_04.......................................................... 19
Installation sequence
Installing the external unit..................................................................................... 27
Installing the internal unit...................................................................................... 32
Connecting the refrigerant lines........................................................................... 35
Connecting a secondary circuit............................................................................ 41
Connecting a cooling circuit if required................................................................ 42
Electrical connection............................................................................................ 42
Power supply........................................................................................................ 60
Closing the heat pump......................................................................................... 66
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 68
Further details regarding the individual steps....................................................... 70
Troubleshooting
Repairs................................................................................................................. 88
Parts lists, internal unit
Internal unit parts lists.......................................................................................... 99
Overview of assemblies, internal unit................................................................... 100
Internal unit parts not shown................................................................................ 101
Casing, internal unit.............................................................................................. 101
Electrical equipment, internal unit........................................................................ 103
Hydraulics, internal unit, type AWB...................................................................... 105
Hydraulics, internal unit, type AWB-AC................................................................ 107
External unit parts lists
External unit parts lists......................................................................................... 109
External unit type AWB/AWB-AC 201.B04........................................................... 109
External unit type AWB/AWB-AC 201.B07........................................................... 111
Overview of assemblies, external unit, type AWB/AWB-AC 201.B10, B13.......... 113
Casing, external unit, type AWB/AWB-AC 201.B10, B13.................................... 114
Index
Index
5604 692 GB

5
Electrical equipment, external unit, type AWB/AWB-AC 201.B10, B13............... 116
Hydraulics, external unit, type AWB/AWB-AC 201.B10, B13............................... 118
Commissioning/service reports
Hydraulic parameters report................................................................................. 120
Control parameters report.................................................................................... 120
Specification....................................................................................................... 125
Appendix
Heat pump commissioning order.......................................................................... 130
Certificates
Declaration of conformity...................................................................................... 131
Keyword index.................................................................................................... 132
Index
Index (cont.)
5604 692 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 considered inappropriate.
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
5604 692 GB

7
Internal unit
905
58
40
360
+
1105 150
AB
/
960
50
360
450
A B
75
147
219
294
369
41
Preparing for installation
Requirements for on-site connections
5604 692 GB
Installation

8
Symbol Meaning Connection
Refrigerant lines from/to the
external unit:
Type
AWB/
AWB-AC
Pipe 7UNF thread
■ Hot gas line 201.B04 12 mm ⅞
Reducer
⅞ x ¾
201.B07
201.B10
201.B13
16 mm
16 mm
16 mm
⅞
⅞
⅞
■ Liquid line 201.B04 6 mm ⅝
Reducer
⅝ x ⁷⁄₁₆
201.B07
201.B10
201.B13
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
A Cable entry <42 V —
B Cable entry 400 V~/230 V~,
>42 V
—
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/leads:
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 for on-site connections (cont.)
5604 692 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.B04 201.B07 201.B10 201.B13
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 for on-site connections (cont.)
5604 692 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 Selected component.
0Component can be added.
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5604 692 GB

11
--230V-- -KM BUS-
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
2
2
[H
F
[YF
F
--2/F14--
--2/211.2--
-2/145-
A1
--2/X3.8;3.9--
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
System example 1, ID: 4605169_1103_04
Selecting system scheme 6
■ Internal unit of the heat pump
type AWB 201.B without instantane-
ous heating water heater or
type AWB-AC 201.B 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 general example with-
out shut-off valves or safety equipment.
This does not replace the need for local
engineering.
Preparing for installation
Designations in the system examples
5604 692 GB
Installation

12
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--
A1 M2
27 28
13
12
15
-2/X3.3;3.4-
--X3.3;3.4--
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5604 692 GB

13
Pos. Description
Heat source
1 Internal unit, heat pump Vitocal 200-S
2 Heat pump control unit Vitotronic 200, type WO1B
3 Outside temperature sensor ATS
4 Instantaneous heating water heater with control module
(only for Vitocal 200-S, type AWB-AC)
5 3-way diverter valve for "Heating/DHW"
6 Secondary pump
8 KM BUS distributor
q W Safety assembly
q E Heating circuit expansion vessel
q T Flow switch
Primary circuit
w U Liquid line
w I Hot gas line
w O External unit of the heat pump Vitocal 200-S
DHW heating
e P DHW cylinder (dual mode)
e Q Cylinder temperature sensor STS
e U DHW circulation pump ZP
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5604 692 GB
Installation

14
Pos. Description
External heat source
q R High limit safety cut-out for switching off the secondary pump
t P External heat source, e.g. oil/gas boiler
t Q External heat source demand (connection to heat pump control unit)
t W Circulation pump for cylinder heating UPSB
t E Boiler water temperature sensor KTS (for connection to the heat pump
control unit):
■ As contact temperature sensor
or
■ As immersion temperature sensor
t R Mixer motor, directly controlled
t T High limit safety cut-out STB 70°C (for switching off the external heat
source)
z P Heating water buffer cylinder
z Q Buffer temperature sensor PTS
z W System flow temperature sensor
Heating circuit with mixer M2 (KM BUS)
u P Underfloor heating circuit
u Q Vitotrol 200A remote control
u E Flow temperature sensor
u R Temperature limiter to limit the maximum temperature of underfloor heating
systems
■ As immersion thermostat
or
■ As contact thermostat
u Z Heating circuit pump
u U 3-way mixer, heating circuit
Mixer motor of 3-way mixer
q - T Mixer extension kit
Heating circuit without mixer A1
o P Radiator heating circuit
o Q Vitotrol 200A remote control
o Z Heating circuit pump
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 45 and the separate
service instructions for the heat pump
control unit.
For information regarding the power sup-
ply, see page 60.
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5604 692 GB

15
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
X2.N
X1.
222.4
222.3
X3.1
51
222.2
X2.N
X1. 54
222.1
OPEN
CLOSED
L3
N
L2
L1
4
3 / N / PE
400 V, 50 Hz
High limit safety cut-out
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
2
1H1
2
1H2
NTC
136
X2.N
211.3
224.4
2
130W
130W
50W
100W
100W
L
N
55
High limit safety cut-out
20
X3.4
X3.3
15
HK M2
M
1~
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
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5604 692 GB
Installation

16
Note
The instantaneous heating water heater
4, the 3-way diverter valve 5 and the
secondary pump 6 are already instal-
led and fully wired.
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.
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5604 692 GB

17
External unit connections
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.)
5604 692 GB
Installation

18
Required parameter settings
Parameter Setting
"System definition"
■"System scheme 7000" "6"
"Compressor"
■"Output compressor stage 5030" Type AWB/AWB-AC
■ 201.B04: "4"
■ 201.B07: "7"
■ 201.B10: "10"
■ 201.B13: "13"
"Ext. 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
wizard on page 80 and page 81.
Preparing for installation
System example 1, ID: 4605169_1103_04 (cont.)
5604 692 GB

19
Selecting system scheme 6
■ Internal unit of heat pump
type AWB-AC 201.B 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
■ Cooling, heating circuit M2/HC2 via
active cooling function
Note
This scheme is a general example with-
out shut-off valves or safety equipment.
This does not replace the need for local
engineering.
Preparing for installation
System example 2, ID: 4605170_1103_04
5604 692 GB
Installation

20
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--
A1 M2
27 28
--2/X3.8;3.9--
--
18
13
12
15
--2/X3.3;3.4--
-----
--X3.3;3.4--
Note
In cooling mode, safeguard the minimum flow rate in the secondary circuit. Open
valves on the heating circuit distributor or install an overflow valve.
Preparing for installation
System example 2, ID: 4605170_1103_04 (cont.)
5604 692 GB