Viessmann Vitocal 200-S Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitocal 200-S
Type AWB(-M)/AWB(-M)-E 201.D
Air/water heat pump, split version for heating operation
Type AWB(-M)-E-AC 201.D
Air/water heat pump, split version for heating and cooling operation
VITOCAL 200-S
6150113 GB 5/2023 Please keep safe.

2
Please follow these safety instruc-
tions closely to prevent accidents
and material 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for authorised contractors.
■Work on the refrigerant circuit may only
be carried out by authorised refrigera-
tion 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 to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions
Safety instructions
6150113

3
Safety instructions for working on the system
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 PCBs remain live
even after the power supply has
been switched off.
Prior to removing covers from the
appliances, wait at least 4 minutes
until the voltage has completely
dropped out.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
appliance, fittings or pipework.
Danger
Risk of fire: Electrostatic discharge
can cause sparks which may be
ignited by escaping, flammable
refrigerant (R32).
Before beginning work, touch
earthed objects, such as heating or
water pipes, to discharge any static.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Work on the refrigerant circuit
Refrigerants are air displacing, colour-
less, odourless gases.
■R32 forms flammable mixtures with air.
■R410A is not flammable.
Danger
Direct contact with liquid and gas-
eous refrigerant can cause serious
damage to health.
■Avoid direct contact with liquid and
gaseous refrigerant.
■Wear personal protective equip-
ment when handling liquid and
gaseous refrigerant.
Danger
Unregulated escape of refrigerant in
enclosed spaces can lead to
breathing difficulties and suffoca-
tion.
■Never breathe in refrigerant
vapours.
■Ensure adequate ventilation in
enclosed spaces.
Perform the following measures before
beginning work on the refrigerant circuit:
■Check the refrigerant circuit for leaks.
■Ensure very good ventilation especially
in the floor area and sustain this for the
duration of the work.
Safety instructions
Safety instructions (cont.)
6150113

4
■Inform all persons in the vicinity of the
system about the type of work to be
carried out.
■Secure the area surrounding the work
area.
Further measures before starting work
on the refrigerant circuit with flammable
refrigerants (R32):
■Remove all flammable materials and
ignition sources from the immediate
vicinity of the heat pump.
■Before, during and after the work,
check the surrounding area for escap-
ing refrigerant using a suitable refriger-
ant detector.
This refrigerant detector must not gen-
erate any sparks and must be suitably
sealed.
■A CO2 or powder extinguisher must be
to hand in the following cases:
–Refrigerant is being topped up.
–Soldering or welding work is being
carried out.
■Display signs prohibiting smoking.
Danger
Damage to the refrigerant circuit
can cause refrigerant to enter the
hydraulic system. This can cause
serious damage to health.
After completion of the work, pro-
fessionally vent the hydraulic sys-
tem on the primary and secondary
sides.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
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 func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions for operating the system
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Safety instructions
Safety instructions (cont.)
6150113

5
1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■System examples ............................................................................... 9
■Maintenance parts and spare parts .................................................... 9
2. Preparing for installation Requirements for on-site connections ................................................... 10
■Indoor unit ........................................................................................... 10
■Outdoor unit ........................................................................................ 11
3. Installation sequence Installing the outdoor unit ....................................................................... 13
■Transport ............................................................................................ 13
■Installation information ........................................................................ 13
■Installation location ............................................................................. 15
■Minimum clearances for 1 outdoor unit .............................................. 16
■Minimum clearances for heat pump cascade (max. 5 outdoor units) . 17
■Floorstanding installation .................................................................... 17
■Wall mounting ..................................................................................... 22
■Opening the wiring chamber ............................................................... 25
■Removing the transport brackets ........................................................ 25
Installing the indoor unit ......................................................................... 26
■Transport ............................................................................................ 26
■Requirements for the installation room ............................................... 26
■Minimum clearances ........................................................................... 27
■Fitting the indoor unit to the wall ......................................................... 27
Connecting the refrigerant lines ............................................................. 28
■Oil lift bends ........................................................................................ 28
■Wall outlet ........................................................................................... 29
■Line lengths ........................................................................................ 29
■Sound-resistant and anti-vibration mounts ......................................... 30
■Outdoor unit: Connecting the refrigerant lines .................................... 33
■Indoor unit: Connecting the refrigerant lines ....................................... 34
Connecting the secondary circuit ........................................................... 35
Only type AWB(-M)-E-AC: Connecting the cooling circuit ..................... 36
■Contact humidistat .............................................................................. 36
Electrical connection .............................................................................. 36
■Preparing the electrical connections ................................................... 36
■Indoor unit: Routing cables to the wiring chamber ............................. 38
■Connecting the Vitoconnect (accessories) ......................................... 39
■Indoor unit: Electrical terminal areas .................................................. 41
■Indoor unit: Main PCB (230 V~ components) ..................................... 42
■Indoor unit: Expansion PCB on main PCB (230 V~ components) ...... 45
■Indoor unit: Luster terminals (signal and safety connections) ............ 48
■Indoor unit: Controller and sensor PCB (LV connections) .................. 49
■Outdoor unit: Routing cables to the wiring chamber ........................... 52
■Outdoor unit: Electrical terminal area ................................................. 53
■Connecting the Modbus cable between the indoor and outdoor unit . 54
Power supply ......................................................................................... 55
■Heat pump control unit power supply 230 V~ ..................................... 56
■Instantaneous heating water heater power supply ............................. 56
■Outdoor unit: Power supply ................................................................ 58
■Power supply with power-OFF: Without on-site load disconnection ... 60
■Power supply with power-OFF: With on-site load disconnection ........ 60
■Connecting the power-OFF signal in heat pump cascades ................ 61
■Mains power supply in conjunction with self-consumption ................. 62
■Smart Grid .......................................................................................... 62
Closing the heat pump ........................................................................... 64
■Indoor unit: Fitting the front panel ....................................................... 64
Index
Index
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6
■Outdoor unit: Fitting the side cover ..................................................... 64
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 65
5. Maintenance Overview of electrical components ........................................................ 87
Indoor unit: Opening the programming unit ........................................... 87
Indoor unit: Placing the control unit panel in its service position ........... 88
Indoor unit: Overview of internal components ....................................... 89
Outdoor unit: Overview of internal components ..................................... 89
■Outdoor unit with 1 fan ....................................................................... 90
■Outdoor unit with 2 fans ...................................................................... 91
Draining secondary side heat pump ...................................................... 92
Checking the temperature sensors ........................................................ 92
■Connection to the indoor unit .............................................................. 92
■Connection to the outdoor unit ........................................................... 92
■Indoor unit: Viessmann NTC 10 kΩ (blue marking) ............................ 93
■Indoor unit: Viessmann NTC 20 kΩ (orange marking) ........................ 94
■Indoor unit: Viessmann Pt500A (green marking) ................................ 95
■Outdoor unit: Viessmann NTC 10 kΩ (no marking) ............................ 96
Checking the fuses ................................................................................ 96
6. Commissioning/service
reports
Hydraulic parameter report .................................................................... 98
Control parameter report ....................................................................... 98
7. Specification ................................................................................................................ 110
8. Appendix Commissioning order ............................................................................. 118
Final decommissioning and disposal ..................................................... 118
9. Certificates Declaration of conformity ....................................................................... 119
10. Keyword index ................................................................................................................120
Index
Index (cont.)
6150113

7
Please dispose of packaging waste in line with statu-
tory regulations.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of personal injury
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions.
Depending on the version, the appliance can only be
used for the following purposes:
■Central heating
■Central cooling
■DHW heating
Information
Disposal of packaging
6150113
Information

8
The range of functions can be extended with additional
components and accessories.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than central heating/cooling or DHW heating shall be
deemed inappropriate.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic or
semi-domestic use, i.e. even users who have not had
any instruction are able to operate the appliance
safely.
Product information
Layout
Vitocal 200-S is a split air/water heat pump, comprising
1 indoor unit and 1 outdoor unit.
Refrigerant circuit
All components of the refrigerant circuit, including the
refrigerant circuit controller with electronic expansion
valve, are located in the outdoor unit, except for the
condenser. Subject to operating conditions, compres-
sor output is matched via inverter control.
For room cooling, the refrigerant circuit is reversed
(only types with designation "-AC").
The indoor and outdoor units are connected to each
other hydraulically via the refrigerant lines.
Hydraulics
The high efficiency circulation pump (secondary pump)
installed in the indoor unit pumps the heating water
into the secondary circuit. The integral 3-way diverter
valve for "central heating/DHW heating" changes over
between central heating and DHW heating.
System without buffer cylinder
■Room heating
The heat pump heats 1 heating/cooling circuit with-
out mixer.
■Room cooling
The heat pump cools through 1 heating/cooling cir-
cuit without mixer or through 1 separate cooling cir-
cuit.
System with heating water buffer cylinder
■Central heating
The heat pump heats up to 3 heating/cooling circuits:
1 heating/cooling circuit without mixer and 2 heating/
cooling circuits with mixer
■Central cooling
The heat pump can only cool either through one of
the max. 3 heating/cooling circuits or through a sepa-
rate cooling circuit.
The heating water buffer cylinder is bypassed
hydraulically by a bypass circuit.
System with heating water/coolant buffer cylinder
■Central heating
The heat pump can heat up to 3 heating/cooling cir-
cuits: 1 heating/cooling circuit without mixer and
2 heating/cooling circuits with mixer
■Central cooling
The heat pump can cool through up to 3 heating/
cooling circuits. Central cooling via a separate cool-
ing circuit is not possible.
Heat pump control unit
The entire heating system is monitored and controlled
by heat pump control unit Vitotronic 200, type WO1C.
The heat pump control unit is integrated into the indoor
unit. The indoor and outdoor units communicate via
Modbus.
Information
Intended use (cont.)
6150113
Information

9
Type overview
Type Instantaneous heating
water heater
Room cooling Rated voltage
Indoor unit Outdoor unit
AWB 201.D – – 230 V~ 400 V~
AWB-M 201.D – – 230 V~ 230 V~
AWB-E 201.D X –230 V~ 400 V~
AWB-M-E 201.D X –230 V~ 230 V~
AWB-E-AC 201.D X X 230 V~ 400 V~
AWB-M-E-AC 201.D X X 230 V~ 230 V~
System examples
Available system examples: See
www.viessmann-schemes.com.
Maintenance parts and spare parts
Maintenance parts and spare parts can be identified and ordered directly online.
Viessmann Partnershop
Login:
https://shop.viessmann.com/
Viessmann spare part app
www.viessmann.com/etapp
Information
Product information (cont.)
6150113
Information

10
Indoor unit
880
66
50
370
1105 150
960
60
358
450
68
FG
80
152
224
299
374
EDCBA
Fig. 1
AHot gas line: See following table.
BLiquid line: See following table.
CDHW cylinder flow (heating water side) G 1¼
(female thread)
DHeating water return and DHW cylinder return
G 1¼ (female thread)
EHeating water flow G 1¼ (female thread)
FCable entry for extra low voltage (ELV) leads
< 42 V
GCable entry for power cables 400 V~/230 V~,
> 42 V
Refrigerant line connections
Meaning Connection to the indoor unit
Types Pipe 7UNF thread
Liquid line 201.D04 to D06 6 mm ⅝
(reducer
⅝ x ⁷⁄₁₆ supplied)
201.D08 to D16 10 mm ⅝
Hot gas line 201.D04 to D06 12 mm ⅞
(reducer
⅞ x ¾ supplied)
201.D08 to D16 16 mm ⅞
Preparing for installation
Requirements for on-site connections
6150113
Installation