Viessmann Vitocal 200-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWB 201.B04 to B13, C10, C13
Air source heat pump, split version for heating operation
Type AWB-AC 201.B04 to B13, C10, C13
Air source heat pump, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 200-S
5546 727 GB 7/2014 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 inten-
ded for qualified 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 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 regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the 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, SWKI and
SVGW
Working on the system
■ Isolate the system from the power sup-
ply (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 the
PCBs will remain 'live' even
after the power supply has
been switched off.
Prior to removing equipment
covers, wait at least 4 min. to
allow the voltage to dissipate.
■ Safeguard the system against recon-
nection.
Safety instructions
Safety instructions
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!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
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.
Defective components must be
replaced with genuine
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 spare
parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Requirements regarding on-site connections....................................................... 7
Installation sequence
Installing the external unit..................................................................................... 10
Installing the internal unit...................................................................................... 16
Connecting the refrigerant lines........................................................................... 19
Connecting the secondary circuit......................................................................... 26
Connecting a cooling circuit if required................................................................ 27
Electrical connection............................................................................................ 27
Power supply........................................................................................................ 49
Closing the heat pump......................................................................................... 58
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 60
Further details regarding the individual steps....................................................... 62
Troubleshooting
Repairs................................................................................................................. 84
Parts lists, internal unit
Ordering parts...................................................................................................... 97
Overview of assemblies, internal unit................................................................... 98
Parts not shown, internal unit............................................................................... 99
Casing, internal unit.............................................................................................. 99
Electrical equipment, internal unit........................................................................ 101
Hydraulics, internal unit, type AWB...................................................................... 103
Hydraulics, internal unit, type AWB-AC................................................................ 105
Parts lists, external unit 230 V~, type AWB/AWB-AC 201.B04
Ordering parts...................................................................................................... 107
External unit 230 V~............................................................................................. 107
Parts lists, external unit 230 V~, type AWB/AWB-AC 201.B07
Ordering parts...................................................................................................... 110
External unit 230 V~............................................................................................. 110
Parts lists, external unit 230 V~, type AWB/AWB-AC 201.B10, B13
Ordering parts...................................................................................................... 113
Index
Index
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Overview of assemblies 230 V~........................................................................... 114
Casing, external unit 230 V~................................................................................ 115
Electrical equipment, external unit 230 V~........................................................... 117
Hydraulics, external unit 230 V~.......................................................................... 119
Parts lists, external unit 400 V~, type AWB/AWB-AC 201.C10, C13
Ordering parts...................................................................................................... 121
Overview of assemblies 400 V~........................................................................... 122
Casing, external unit 400 V~................................................................................ 123
Electrical equipment, external unit 400 V~........................................................... 125
Hydraulics, external unit 400 V~.......................................................................... 127
Commissioning/service reports
Hydraulic parameter report................................................................................... 129
Control parameters report.................................................................................... 129
Specification....................................................................................................... 140
Appendix
Commissioning order........................................................................................... 148
Declaration of conformity.................................................................................. 149
Keyword index.................................................................................................... 150
Index
Index (cont.)
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions.
Depending on the version, the appliance
can only be used for the following pur-
poses:
■ Central heating
■ Central cooling
■ DHW heating
The range of functions can be extended
with additional components and acces-
sories.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than central heating/cooling
or DHW heating shall be deemed inap-
propriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function.
Note
The appliance is intended exclusively for
domestic use, i.e. even users who have
not had any instruction are able to oper-
ate the appliance safely.
Preparing for installation
Intended use
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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 regarding on-site connections
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Installation

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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
201.C10
201.C13
16 mm
16 mm
16 mm
16 mm
16 mm
⅞
⅞
⅞
⅞
⅞
■ Liquid line 201.B04 6 mm ⅝
Reducer
⅝ x ⁷⁄₁₆
201.B07
201.B10
201.B13
201.C10
201.C13
10 mm
10 mm
10 mm
10 mm
10 mm
⅝
⅝
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
ACable entry < 42 V —
BCable entry 400 V~/230 V~,
> 42 V
—
1. Prepare the connections on the heat-
ing water and the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Preparing for installation
Requirements regarding on-site connections (cont.)
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Cable lengths in 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~/400 V~) – 1.5 m
Other connecting cables:
■ 230 V~, e.g. for circulation pumps 2.0 m –
■ < 42 V, e.g. for sensors 2.0 m –
Internal/external unit connecting cable:
■ 12 V BUS 2.5 m 1.5 m
■ 43 V BUS 2.5 m 1.5 m
Recommended power cables
Type AWB, AWB-AC 201.B04 to B13, C10, C13
Heat pump control unit (internal unit) 230 V~
Cable cross-section
■ Without power-OFF 3 x 1.5 mm2
■ With power-OFF 5 x 1.5 mm2
Instantaneous heating water heater
Cable cross-section
■ 400 V~ 5 x 2.5 mm2
■ 230 V~ 7 x 2.5 mm2
Max. cable length 25 m
Type AWB, AWB-AC 201.B04 201.B07 201.B10 201.B13
External unit 230 V~ (compres-
sor)
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 20 m 20 m
or or
Cable cross-section – – 3 x 4.0 mm23 x 6.0 mm2
Max. cable length – – 32 m 30 m
Type AWB, AWB-AC 201.C10 201.C13
External unit 400 V~ (compressor)
Cable cross-section 5 x 2.5 mm25 x 2.5 mm2
Max. cable length 30 m 30 m
Preparing for installation
Requirements regarding 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 instal-
lation (accessories).
■ Where such supports cannot be used,
install the external unit freestanding on
a solid base of at least 100 mm height.
■ In difficult climatic circumstances
(temperatures below zero, snow,
humidity) install the appliance on a
plinth of approx. 300 mm height.
■ Take into account the weight of the
external unit: See the following table.
Wall mounting:
■ Use the wall mounting bracket set
(accessories).
■ The wall must meet the structural
requirements.
Positioning:
■ Never install with the discharge side
facing the main wind direction.
■ Provide wall ducts and protective
pipes for the refrigerant lines and elec-
trical cables without moulded parts
and change of direction.
Weather influences:
■ Observe wind loads when installing
the unit on sites exposed to the wind.
■ Incorporate the external unit into the
lightning protection system.
■ Consider the heat emitted by the unit
when planning your weatherproofing
or an enclosure.
Condensate:
■ Ensure the condensate can drain
freely, and create a permanent gravel
bed below the external unit as a soak-
away.
■ In regions with prolonged cold sea-
sons (such as Sweden for example),
provide an electric ribbon heater
(accessory) for the condensate pan.
Insulation against structure-borne
noise and vibrations between build-
ing and external unit:
■ When line entry is above ground level,
fit pipe bends in the refrigerant lines for
vibration compensation: See "Con-
necting refrigerant lines".
■ Route electrical cables/leads between
the internal and external units free of
stress.
■ Installation only on walls with high
weight per area (> 250 kg/m2), in other
words not on lightweight walls, roof
structures etc.
■ For floorstanding installation, only use
the rubber mounts supplied.
■ For wall mounting, only use the anti-
vibration mounts from the bracket set.
■ Never use additional anti-vibration
mounts, springs, rubber mounts, etc.
Installation sequence
Installing the external unit
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Weight of external units
Type
AWB/AWB-AC
Weight in kg
201.B04 43
201.B07 66
201.B10 113
201.B13 113
201.C10 113
201.C13 113
Installation site
■ Select a site with good air circulation,
so that the cooled air can dissipate and
be replaced by warm air.
■ Avoid direct insolation.
■ When siting the unit where it is
exposed to wind, ensure that the wind
cannot influence the fan area. Strong
wind can have a negative influence on
the evaporator ventilation.
■ Take into account the lengths of the
refrigerant lines: See "Connecting
refrigerant lines".
■ Select the installation site so that the
evaporator cannot be blocked by
leaves, snow etc.
■ Select the installation site giving due
consideration to the physical laws con-
cerning the propagation and reflection
of sound.
Technical guide "Heat pump
principles"
■ Never install in interior corners, in
recesses or between walls. This could
result in an "air short circuit" between
the air being discharged and the air
being drawn in.
!Please note
An "air short circuit" during
heating operation will result in
the cooled discharged air re-
entering the unit. This can
result in reduced heat pump
efficiency and defrosting prob-
lems.
Avoid "air short circuits".
!Please note
An "air short circuit" during
cooling operation will result in
the heated discharged air re-
entering the unit. This can lead
to high pressure faults.
Avoid "air short circuits".
■ Never install next to or below bedroom
windows.
Installation sequence
Installing the external unit (cont.)
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Installation

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■ Never install closer than 3 m to path-
ways, downpipes or sealed surfaces.
The cooled air in the discharge area
creates a risk of ice forming when out-
side temperatures are below 10 °C.
■ The installation site must be easily
accessible, for example for mainte-
nance work: See "Minimum clearan-
ces".
Minimum clearances
A
B
b
d
ac
Example type AWB/AWB-AC 201.B04
AAir intake BAir discharge
Type AWB/
AWB-AC
Dimensions in mm
a b c d
Cable entry
above
ground
level
below
ground
level
201.B04 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
201.B07 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
201.B10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
201.B13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
Installation sequence
Installing the external unit (cont.)
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Type AWB/
AWB-AC
Dimensions in mm
a b c d
Cable entry
above
ground
level
below
ground
level
201.C10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
201.C13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
Minimum clearances for heat pump cascade (max. 5 external
units)
> 500
A
400
B
A
B
A
B
> 500 > 500 > 500 > 500
AAir intake BAir discharge
> 500
B
400 A
B
A
> 500 > 500
400
> 500
A
B
A
B
> 500 > 500
C
AAir intake
BAir discharge
CPartition
Installation sequence
Installing the external unit (cont.)
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Installation

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> 500
B
> 1500
A
B
A
> 500 > 500
> 500
A
B
A
B
> 500 > 500
AAir intake BAir discharge
Transport and installation
!Please note
Avoid damaging the appliance
during transport.
Never put weight on top 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.
Note the max. tilting angle of
45°.
Installation sequence
Installing the external unit (cont.)
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Floor mounting
2.
1.
4x
4x
A
B
C
E
D
ASupport for floorstanding installation
(accessories)
Installation sequence
Installing the external unit (cont.)
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Installation

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BGravel bed as condensate soak-
away
CConcrete foundations (see technical
guide)
DDrainage pipe DN 100 (only with
entries below ground level)
ERubber mounts (supplied)
Note
We recommend letting condensate drain
away freely (without condensate pipe).
Wall mounting
Installation must only be performed with
the bracket set suitable for wall mounting
(accessory).
Separate installation instructions
Installing the internal unit
!Please note
Avoid damaging the appliance
during transportation.
Never put weight on top of the
appliance.
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Ensure ambient temperatures
between 0 and 35 °C.
!Please note
Avoid risks of explosion due to
dust, gases and vapours.
Avoid dust, gases and vapours in
the installation room.
Minimum room volume (to EN 378):
Type AWB/AWB-
AC
Minimum room
volume in m3
201.B04 2.7
201.B07 4.8
201.B10 6.7
201.B13 6.7
201.C10 6.7
201.C13 6.7
Installation sequence
Installing the external unit (cont.)
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Minimum clearances
100
1000
100
A B
ACable entry <42 V
BCable entry 400 V~/230 V~, >42 V
Installation sequence
Installing the internal unit (cont.)
5546 727 GB
Installation

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Fitting the internal unit to the wall
2.
2x
3.
5.
1.
4.
Installation sequence
Installing the internal unit (cont.)
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■ The external unit is pre-charged with
refrigerant R410A.
■ In the following cases, fit oil lift bends
in the rising pipe:
– In heating mode, if the internal unit
is installed higher than the external
unit: See diagram below.
– In cooling mode, if the internal unit is
installed lower than the external unit.
Routing the refrigerant lines
Type AWB/AWB-AC 201.B04 201.B07 201.B10
201.C10
201.B13
201.C13
Refrigerant lines
Min. line length 3 m 3 m 3 m 3 m
Max. line length 20 m 30 m 30 m 30 m
Max. height differential, internal
unit – external unit
10 m 15 m 15 m 15 m
Note
No topping up is required for line lengths
between 3 and 12 m.
internal unit above external unit
5000
5000
A
B
D
E
C
D
Heating mode
AInternal unit
BHot gas line
CLiquid line
DExternal unit
EOil lift bends
Installation sequence
Connecting the refrigerant lines
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Installation

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Internal unit below external unit or at same level
CA B
D
Heating mode
AInternal unit
BHot gas line
CLiquid line
DExternal unit
Installation sequence
Connecting the refrigerant lines (cont.)
5546 727 GB