Viessmann Vitocal 200-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWB 201.B04 to B13
Air source heat pump, split version for heating operation
Type AWB-AC 201.B04 to B13
Air source heat pump, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 200-S
5623 611 GB 10/2012 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
5623 611 GB

3
!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.)
5623 611 GB

4
Installation instructions
Preparing for installation
Application............................................................................................................ 6
Requirements regarding on-site connections....................................................... 7
Overview of possible system schemes................................................................ 9
Markings in the system examples........................................................................ 11
System example 1, ID: 4605169_1202_05.......................................................... 11
System example 2, ID: 4605170_1202_05.......................................................... 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........................................................................................................ 64
Closing the heat pump......................................................................................... 71
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 73
Further details regarding the individual steps....................................................... 75
Troubleshooting
Repairs................................................................................................................. 95
Parts lists, internal unit
Parts lists, internal unit......................................................................................... 107
Overview of assemblies, internal unit................................................................... 108
Parts not shown, internal unit............................................................................... 109
Casing, internal unit.............................................................................................. 109
Electrical equipment, internal unit........................................................................ 111
Hydraulics, internal unit, type AWB...................................................................... 113
Hydraulics, internal unit, type AWB-AC................................................................ 115
Parts lists, external unit
Parts lists, external unit........................................................................................ 117
External unit type AWB/AWB-AC 201.B04........................................................... 117
External unit type AWB/AWB-AC 201.B07........................................................... 119
Overview of assemblies, external unit, type AWB/AWB-AC 201.B10, B13.......... 121
Casing, external unit, type AWB/AWB-AC 201.B10, B13.................................... 122
Index
Index
5623 611 GB

5
Electrical equipment, external unit, type AWB/AWB-AC 201.B10, B13............... 124
Hydraulics, external unit, type AWB/AWB-AC 201.B10, B13............................... 126
Commissioning/service reports
Hydraulic parameter report................................................................................... 128
Control parameters report.................................................................................... 128
Specification....................................................................................................... 136
Appendix
Heat pump commissioning order.......................................................................... 142
Declaration of conformity.................................................................................. 143
Keyword index.................................................................................................... 144
Index
Index (cont.)
5623 611 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
5623 611 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 regarding on-site connections
5623 611 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
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.
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~) – 1.5 m
Other connecting cables:
230 V~, e.g. for 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
Preparing for installation
Requirements regarding on-site connections (cont.)
5623 611 GB

9
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 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
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 regarding on-site connections (cont.)
5623 611 GB
Installation

10
System schemes
Component System scheme
0 1 2 3 4 5 6 11
Heating circuit
A1/HC1 — X X — — X X —
M2/HC2 — — — X X X X —
DHW cylinder
X — X — X — X —
Immersion heater
0—0—0—0—
Heating water buffer cylinder
— 0 0 X X X X —
External heat source
00*1 0*1 0 0 0 0 —
Instantaneous heating water heater (type AWB-AC only)
X X X X X X X —
Swimming pool
— 0 0 0 0 0 0 —
Cooling (only type AWB-AC)
A1/HC1 — 0 0 — — 0 0 —
M2/HC2 — — — 0 0 0 0 —
SKK 0 0 0 0 0 0 0 —
Electricity meter 1-phase/3-phase
0 0 0 0 0 0 0 0
Vitovent
0 0 0 0 0 0 0 0
X Component selected.
0Component may be added.
*1 Only in conjunction with a heating water buffer cylinder.
Preparing for installation
Overview of possible system schemes (cont.)
5623 611 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_1202_05
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
Markings in the system examples
5623 611 GB
Installation

12
Hydraulic installation scheme
CW
DHW
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--51-
4
5
6
--105/52--
--74/20--
-105/20--76-
--105/2--
--KM BUS--
--211.2--
--230 V--
--52--
--2--
-KM BUS-
--20--
-230 V-
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--
-2/211.4--5-
56
Preparing for installation
System example 1, ID: 4605169_1202_05 (cont.)
5623 611 GB

13
Pos. Designation
Heat source
1Internal unit of heat pump Vitocal 200-S, type AWB 201.B or
type AWB-AC 201.B
2Heat pump control unit Vitotronic 200, type WO1C
3Outside temperature sensor ATS
4Instantaneous heating water heater with switching module
(only for Vitocal 200-S, type AWB-AC)
53-way diverter valve for "Central heating/DHW heating"
6Secondary pump
8KM BUS distributor
qW Safety assembly
qE Heating circuit expansion vessel
qT Flow switch
Primary circuit
wU Hot gas line
wI Liquid line
wO External unit of the Vitocal 200-S heat pump
DHW heating
eP DHW cylinder (dual mode)
eQ Cylinder temperature sensor
eU DHW circulation pump ZP
External heat source
qR High limit safety cut-out STB 70 °C (on-site provision, for switching off the
external heat source and the secondary pump)
tP Oil/gas boiler
tQ External heat source demand (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 (on-site provision, for switching off the
external heat source and the secondary pump)
tZ High limit safety cut-out STB 70 °C (on-site provision, for changing over the
3-way diverter valve for "Central heating/DHW heating" to "Central heat-
ing")
zW Flow temperature sensor, system VTS
Preparing for installation
System example 1, ID: 4605169_1202_05 (cont.)
5623 611 GB
Installation

14
Pos. Designation
zP Heating water buffer cylinder
zQ Buffer temperature sensor
Heating circuit with mixer M2 (KM BUS)
uP Underfloor heating circuit/cooling circuit
uQ Vitotrol remote control
uE Flow temperature sensor
uR Temperature limiter to restrict 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 of 3-way mixer
q-T Mixer extension kit
Heating circuit without mixer A1
oP Radiator heating circuit
oQ Vitotrol 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 46 and the separate
service instructions for the heat pump
control unit.
For information regarding the power sup-
ply, see page 64.
Preparing for installation
System example 1, ID: 4605169_1202_05 (cont.)
5623 611 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
CLOSE
L3
N
L2
L1
4
3/N/PE
400 V, 50 Hz
STBs
55
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
1
2
1
136
X2.N
211.3
224.4
2
130 W
130 W
50 W
100 W
100 W
L
N
55 STBs
20
X3.4
X3.3
15
HK M2
NTC 10 kΩ
STB 56
14
14
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_1202_05 (cont.)
5623 611 GB
Installation

16
Note
Instantaneous heating water heater 4
(only type AWB-AC), 3-way diverter
valve 5 and secondary pump 6 are
already installed and electrically connec-
ted.
2
Low voltage
F6
STS 31
F4
PTS 61
KTS 53
F20
F0
VTS 62
ATS 3
F13
NTC 10 kΩ
NTC 10 kΩ
NTC 10 kΩ
NTC 10 kΩ
NTC 10 kΩ
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
Heat pump control unit power supply
2
1/N/PE
230 V/50 Hz
F1 6.3AH (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_1202_05 (cont.)
5623 611 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
Required parameter settings
To call up "Coding level 1" for setting
the parameters, see the commissioning
assistant on page 85 and page 87.
Preparing for installation
System example 1, ID: 4605169_1202_05 (cont.)
5623 611 GB
Installation

18
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"
"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 op-
erating instructions)
"Time program DHW circulation"
(if a DHW circulation pump is installed)
Set time program (see op-
erating 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"
"0"
■"Time prog elec heater" Set time program (see op-
erating instructions)
Remote controls (accessories):
"Heating circuit 1"
■"Remote control 2003" "1"
"Heating circuit 2"
■"Remote control 3003" "1"
Preparing for installation
System example 1, ID: 4605169_1202_05 (cont.)
5623 611 GB

19
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_1202_05
5623 611 GB
Installation

20
Hydraulic installation scheme
CW
DHW
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--51-
4
5
6
--105/52--
--74/20--
-105/20--76-
--105/2--
--KM BUS--
--211.2--
--230 V--
--2/211.5--
89
89
-2/211.5-
--211.5--
-2/X3.8;3.9-
83
--52--
--2--
-KM BUS-
--20--
-230 V-
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
--X3.3;3.4--
15
-2/X3.3;3.4-
-2/211.4--5-
56
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_1202_05 (cont.)
5623 611 GB