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

5782 176 GB 2/2013 Please keep safe.

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

5782 176 GB

!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.)

5782 176 GB

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...................................................................................... 14

Connecting the refrigerant lines........................................................................... 17

Connecting a secondary circuit............................................................................ 23

Connecting a cooling circuit if required................................................................ 24

Electrical connections........................................................................................... 24

Power supply........................................................................................................ 46

Closing the heat pump......................................................................................... 54

Service instructions

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 56

Further details regarding the individual steps....................................................... 58

Troubleshooting

Repairs................................................................................................................. 79

Parts lists, internal unit

Parts lists, internal unit......................................................................................... 91

Overview of assemblies, internal unit................................................................... 92

Parts not shown, internal unit............................................................................... 93

Casing, internal unit.............................................................................................. 93

Electrical equipment, internal unit........................................................................ 95

Hydraulics, internal unit, type AWB...................................................................... 97

Hydraulics, internal unit, type AWB-AC................................................................ 99

Parts lists for external unit 230 V~, type AWB/AWB-AC 201.B04

Ordering individual parts...................................................................................... 101

External unit......................................................................................................... 101

Parts lists for external unit 230 V~, type AWB/AWB-AC 201.B07

Ordering individual parts...................................................................................... 103

External unit......................................................................................................... 103

Parts lists for external unit 230 V~, type AWB/AWB-AC 201.B10, B13

Ordering individual parts...................................................................................... 105

Index

5782 176 GB

Overview of the assemblies................................................................................. 106

External unit casing.............................................................................................. 107

Electrical equipment, external unit....................................................................... 109

Hydraulics, external unit....................................................................................... 111

Parts lists for external unit 400 V~, type AWB/AWB-AC 201.C10, C13

Ordering individual parts...................................................................................... 113

Overview of the assemblies................................................................................. 114

External unit casing.............................................................................................. 115

Electrical equipment, external unit....................................................................... 117

Hydraulics, external unit....................................................................................... 119

Commissioning/service reports

Hydraulic parameter report................................................................................... 121

Control parameters report.................................................................................... 121

Specification....................................................................................................... 129

Appendix

Commissioning order........................................................................................... 137

Declaration of conformity.................................................................................. 138

Keyword index.................................................................................................... 139

Index

Index (cont.)

5782 176 GB

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

5782 176 GB

Internal unit

905

360

1105 150

960

360

450

A B

147

219

294

369

Preparing for installation

Requirements regarding on-site connections

5782 176 GB

Installation

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

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

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.)

5782 176 GB

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~ (compressor)

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.)

5782 176 GB

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 requirements

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 in a location

exposed to wind, ensure that the wind

does not affect the fan area. This could

result in an "air short circuit" between

the air being discharged and the air

being drawn in. Strong wind can have

a negative influence on the evaporator

ventilation.

!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".

■ Take the lengths of the refrigerant

lines into account (see "Connecting

refrigerant lines").

■ Select the installation site so that the

evaporator cannot be blocked by

leaves, snow etc.

■ Select the installation site with due

consideration of the physical laws of

sound dissipation and reflection.

Technical guide "Heat pump

principles"

■ Never site in corners, recesses or

between walls.

■ Never install next to or below bedroom

windows.

■ 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 fall below 10 °C.

■ The installation site should be easily

accessible, for example for mainte-

nance work (see "Minimum clearan-

ces").

Installation sequence

Installing the external unit

5782 176 GB

Types of installation

■ Floorstanding installation with cable

entry above ground level

■ Floorstanding installation with cable

entry below ground level

■ Wall mounting

Technical guide

Installation information

■ Floorstanding installation:

Use supports (accessories) for floor-

standing installation.

Where such supports cannot be used,

install the external unit freestanding on

a solid base of at least 100 mm height

(provide on site).

In difficult climatic circumstances

(temperatures below zero, snow,

humidity) install the appliance on a

plinth of approx. 300 mm height.

Take account of the weight of the

external unit (see following table).

■ Wall mounting:

Use the wall mounting bracket set

(accessories).

The wall must meet the structural

requirements.

■ Never install with the discharge side

facing the main wind direction.

■ Observe wind loads when installing

the unit on sites exposed to wind.

■ Provide wall ducts and protective

pipes for the refrigerant lines and elec-

trical cables without moulded parts

and change of direction.

■ Incorporate the external unit into the

lightning protection system.

■ Consider the heat emitted by the unit

when planning your weatherproofing

or an enclosure.

■ 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 (e.g. in Germany), provide an

electric supplementary heating facility

(accessories) for the condensate pan.

■ For insulating against structure-borne

noise and vibrations between the

building and the external unit, consider

the following measures:

– When cable entry is above ground

level, fit pipe bends in the refrigerant

lines for vibration compensation

(see "Connecting 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.

– When installing the unit on the floor,

use only the rubber mounts sup-

plied; for wall mounting use the anti-

vibration mounts supplied with the

wall mounting bracket set; never use

additional anti-vibration mounts,

springs, rubber buffers etc.

Weight of external units

Type

AWB/AWB-AC

Weight in kg

201.B04 43

201.B07 66

201.B10 110

201.B13 110

Installation sequence

Installing the external unit (cont.)

5782 176 GB

Installation

Type

AWB/AWB-AC

Weight in kg

201.C10 113

201.C13 113

Minimum clearances

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

201.C10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000

201.C13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000

Installation sequence

Installing the external unit (cont.)

5782 176 GB

Floor mounting

ASupport for floorstanding installation

(accessory)

Installation sequence

Installing the external unit (cont.)

5782 176 GB

Installation

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.

Safeguard ambient temperatures

between 0 and 35 °C.

!Please note

Avoid the risk of explosion due to

dust, gases and vapours

in the installation room.

Minimum room volume (to EN 378):

Type AWB/AWB-

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.)

5782 176 GB

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.)

5782 176 GB

Installation

Fitting the internal unit to the wall

Installation sequence

Installing the internal unit (cont.)

5782 176 GB

■ The external unit is pre-filled with

refrigerant R 410A.

■ In the following cases, fit oil lift bends

in the vertical pipe (see diagram

below):

– In heating mode, if the internal unit

is installed higher than the external

unit.

– In cooling mode, if the internal unit is

installed lower than the external unit.

Routing 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.

5000

Example type AWB/AWB-AC 201.B07

AInternal unit

BExternal unit

CLiquid line

DHot gas line

EOil lift bends

, Flow direction in heating mode

, Flow direction in cooling mode

Installation sequence

Connecting the refrigerant lines

5782 176 GB

Installation

Sound and vibration isolation when cable entry is above ground

level

Note

Route connecting cables and refrigerant

lines separately.

APipe bends as vibration compensa-

tors

BPipe clips with EPDM lining

CCable entry, e.g. drainage pipe with

thermal insulation

DElectrical cables/leads, internal/

external unit

Installation sequence

Connecting the refrigerant lines (cont.)

5782 176 GB

Connection to the external unit

1. Type AWB/AWB-AC 201.B04 and

201.B07:

Remove the side cover; see

page 43.

Example type AWB/AWB-AC 201.B04

CLiquid line DHot gas line

Installation sequence

Connecting the refrigerant lines (cont.)

5782 176 GB

Installation

2. !Please note

Contamination (e.g. metal

swarf) or moisture must not

enter the copper pipes.

Therefore, hold the pipe open-

ings down or plug them.

Remove the nuts from connections

C (liquid line) and D (hot gas line)

of the refrigerant lines.

Type AWB/AWB-AC 201.B04:

Slide the nuts onto the refrigerant

lines prepared on site.

Type AWB/AWB-AC 201.B07 to

B13, C10, C13:

Replace nuts with the supplied union

nuts (internal unit) (⅝ UNF for liquid

line, ⅞ UNF for hot gas line).

3. Flare the pipe ends.

4. Secure the pipes.

Tighten the nuts with the following torque:

Type

AWB/

AWB-AC

Line Connection to

external unit

Torque in Nm

201.B04 Liquid line 7 6 mm ⁷⁄₁₆ UNF 14–18

Hot gas line 7 12 mm ¾ UNF 50–62

201.B07 Liquid line 7 10 mm ⅝ UNF 33–42