Viessmann Vitocal 200-S Installation And Service Instructions Manual
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Viessmann Vitocal 200-S Installation And Service Instructions Manual

Air/water heat pump, split version for heating and cooling operation
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VIESMANN
Installation and service
instructions
for contractors
Vitocal 200-S
Type AWB 201.A04 to A13
Air/water heat pump, split version for heating operation
Type AWB-AC 201.A04 to A13
Air/water heat pump, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 200-S
Please keep safe.
5601 429 GB
3/2011

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Summary of Contents for Viessmann Vitocal 200-S

  • Page 1 VIESMANN Installation and service instructions for contractors Vitocal 200-S Type AWB 201.A04 to A13 Air/water heat pump, split version for heating operation Type AWB-AC 201.A04 to A13 Air/water heat pump, split version for heating and cooling opera- tion For applicability, see the last page VITOCAL 200-S Please keep safe.
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ The Code of Practice of relevant trade associations Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, VDE and risk of injury.
  • Page 3 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...

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Application......................Requirements of on-site connections..............Overview of possible system schemes..............Designations in the system examples..............11 System example 1, ID: 4605169_1103_04............12 System example 2, ID: 4605170_1103_04............18 Installation sequence Installing the external unit..................25 Installing the internal unit..................
  • Page 5 Index Index (cont.) Hydraulics, external unit, type AWB/AWB-AC 201.A10, A13....... 112 Commissioning/service reports Hydraulic parameters report................. 114 Control parameters report..................114 Specification....................... 119 Appendix Heat pump commissioning order................124 Certificates Declaration of conformity..................125 Keyword index....................126...

  • Page 6: Preparing For Installation

    Application The heat pumps Vitocal 200-S, Note type AWB and AWB-AC can be used for Vitocal 200-S is intended exclusively for the following purposes: domestic use, i.e. even people who have ■ Central heating via a heating system not had any instruction are able to oper- ■...

  • Page 7: Requirements Of On-Site Connections

    Preparing for installation Requirements of on-site connections Internal unit 230 V~ 400 V~ < 42 V > 42 V...
  • Page 8 Preparing for installation Requirements of on-site connections (cont.) Symbol Explanation Connection Refrigerant lines from/to the Type Pipe 7 UNF thread external unit: AWB/ AWB-AC ⅞ ■ Hot gas line 201.A04 12 mm Reducer ¾ x ⅞ ⅞ 201.A07 16 mm ⅞...

  • Page 9: Overview Of Possible System Schemes

    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, 201.A04 201.A07 201.A10 201.A13 AWB-AC External unit (compressor) 230 V~ Cable cross-section 3 x 2.5 mm 3 x 2.5 mm...
  • Page 10 Preparing for installation Overview of possible system schemes (cont.) Components System scheme (parameter 7000) Heating circuit A1/HC1 – – – M2/HC2 – – – DHW cylinder – – – Heating water buffer cylinder – External heat source – Cooling A1/HC1 M2/HC2 Sep.

  • Page 11: Designations In The System Examples

    Preparing for installation Designations in the system examples -2/145- --2/F14-- --2/F14-- --2/X3.8;3.9-- --2/211.2-- --2/212.3-- -2/211.4- --2/F8-- --A/137--...

  • Page 12: System Example 1, Id: 4605169_1103_04

    Preparing for installation System example 1, ID: 4605169_1103_04 Setting system scheme 6 ■ DHW heating ■ Internal unit of the heat pump ■ External heat source type AWB 201.A without instantane- ■ Heating water buffer cylinder ous heating water heater or type AWB-AC 201.A with instantane- Note ous heating water heater...
  • Page 13 3-way diverter valve for "Heating/DHW" Secondary pump KM BUS distributor Heating circuit expansion vessel Primary circuit Liquid line Hot gas line External unit of the heat pump Vitocal 200-S DHW heating DHW cylinder (dual mode) Cylinder temperature sensor STS DHW circulation pump ZP...
  • Page 14 Preparing for installation System example 1, ID: 4605169_1103_04 (cont.) Pos. Description External heat source High limit safety cut-out for switching off the secondary pump External heat source, e.g. oil/gas boiler Demand of external heat source (connection to heat pump control unit) Circulation pump for cylinder heating UPSB Boiler water temperature sensor KTS (for connection to the heat pump control unit):...
  • Page 15 Preparing for installation System example 1, ID: 4605169_1103_04 (cont.) 70 °C 130W 211.2 X2.N 212.3 X2.N 100W 212.2 HK A1 X2.N 100W 224.7 UPSB X2.N 222.3 X3.1 222.4 70 °C X2.N 222.2 OPEN X2.N CLOSE 222.1 KM BUS distributor HK A1 HK M2 HK M2 230 V/ 50 Hz...
  • Page 16 230 V/ 50 Hz 400 V 43 V 3 / N / PE 400 V/ 50 Hz 10 / 13 kW 1 / N / PE Note 230 V/ 50 Hz Instantaneous heating water heater only for Vitocal 200-S, type AWB-AC. 12 V...
  • Page 17 Preparing for installation System example 1, ID: 4605169_1103_04 (cont.) Required parameter settings Parameter Setting "System definition" ■ "System scheme 7000" "6" "Compressor" ■ "Output compressor stage 5030" Type AWB/AWB-AC ■ 201.A04: "4" ■ 201.A07: "7" ■ 201.A10: "10" ■ 201.A13: "13" "External heat source"...

  • Page 18: System Example 2, Id: 4605170_1103_04

    Preparing for installation System example 2, ID: 4605170_1103_04 Setting system scheme 6 ■ Heating water buffer cylinder ■ Internal unit of heat pump type ■ Cooling, heating circuit M2/HC2 via AWB-AC 201.A with instantaneous "active cooling" function heating water heater ■...
  • Page 19 System example 2, ID: 4605170_1103_04 (cont.) Pos. Description Heat source Internal unit, heat pump, Vitocal 200-S, type AWB-AC Heat pump control unit Vitotronic 200, type WO1B Outside temperature sensor ATS Instantaneous heating water heater with control module 3-way diverter valve for "Heating/DHW"...
  • Page 20 Preparing for installation System example 2, ID: 4605170_1103_04 (cont.) Pos. Description Heating water buffer cylinder Buffer temperature sensor System flow temperature sensor Heating circuit with mixer M2 (KM BUS) Underfloor heating circuit/cooling circuit Vitotrol 200A remote control Flow temperature sensor Temperature limiter to limit the maximum temperature of underfloor heating systems ■...
  • Page 21 Preparing for installation System example 2, ID: 4605170_1103_04 (cont.) 70 °C 130W 211.2 X2.N 212.3 X2.N 100W 212.2 HK A1 X2.N 100W 224.7 UPSB X2.N 222.3 X3.1 222.4 70 °C X2.N 222.2 OPEN X2.N CLOSE 222.1 KM BUS distributor HK A1 HK M2 HK M2 230 V/ 50 Hz...
  • Page 22 Preparing for installation System example 2, ID: 4605170_1103_04 (cont.) 211.5 X2.N X3.8 X3.9 PT500 PT500 PT500 PT500 Ni500...
  • Page 23 Preparing for installation System example 2, ID: 4605170_1103_04 (cont.) Power supplies for the internal unit Connections for the external unit and instantaneous heating water heater 4 kW Power supply to heat pump control unit F1 6.3 AH (slow) 1 / N / PE 230 V/ 50 Hz 1 / N / PE 230 V / 50 Hz...
  • Page 24 Preparing for installation System example 2, ID: 4605170_1103_04 (cont.) Required parameter settings Parameter Setting "System definition" ■ "System scheme 7000" "6" "Compressor" ■ "Output compressor stage 5030" Type AWB/AWB-AC ■ 201.A04: "4" ■ 201.A07: "7" ■ 201.A10: "10" ■ 201.A13: "13" "External heat source"...

  • Page 25: Installation Sequence

    Installation sequence Installing the external unit Please note Type AWB/AWB- Max. tilting angle Avoid damaging the appliance during transportation. 201.A04 45° Never put weight on top of the 201.A07 45° appliance. 201.A10 30° 201.A13 30° Please note If the compressor in the external unit is steeply angled, lubricant will enter the refrigerant circuit and damage the appliance.
  • Page 26 Installation sequence Installing the external unit (cont.) ■ The heat emitted by the external unit Weights of the external units must be considered when installing Type AWB/AWB- Weight in kg weather proofing measures. ■ To prevent water collecting around the 201.A04 unit, a drainage surface must be instal- 201.A07...
  • Page 27 Installation sequence Installing the external unit (cont.) A Air intake B Air discharge Type AWB/AWB- Dimensions in mm ≥ 100 ≥ 100 ≥ 300 ≥ 1000 201.A04 ≥ 100 ≥ 100 ≥ 300 ≥ 1000 201.A07 ≥ 100 ≥ 200 ≥...

  • Page 28: Installing The Internal Unit

    Installation sequence Installing the external unit (cont.) Wall mounting Installation must be completed with the Note bracket set for wall mounting (acces- Wind loads must be considered when sory). installing the unit on external walls or roofs. Separate installation instructions Installing the internal unit Please note Avoid damaging the appliance...
  • Page 29 Installation sequence Installing the internal unit (cont.) Minimum clearances 400 V~ <42 V >42 V 230 V~...
  • Page 30 Installation sequence Installing the internal unit (cont.) Fitting the internal unit to the wall...

  • Page 31: Connecting The Refrigerant Lines

    Installation sequence Connecting the refrigerant lines ■ The external unit is pre-filled with – In heating mode, if the internal unit refrigerant R410A. is installed higher than the external ■ Install oil lift bends (see illustration) unit. into the vertical lines in the following –...
  • Page 32 Installation sequence Connecting the refrigerant lines (cont.) Example type AWB/AWB-AC 201.A04 C Liquid line D Hot gas line Please note 3. Swage the pipe ends. Contamination (such as metal swarf) or moisture must not 4. Secure the pipes. enter the copper pipes. Therefore, hold the pipe open- ings down or plug them.
  • Page 33 Installation sequence Connecting the refrigerant lines (cont.) Tighten the nuts with the following torques: Type Line Connection to Torque in Nm AWB/ external unit AWB-AC ⁷⁄₁₆ UNF 201.A04 Liquid line 7 6 mm 14–18 Hot gas line 7 12 mm ¾...
  • Page 34 Installation sequence Connecting the refrigerant lines (cont.) Please note 2. Swage the pipe ends of the refriger- Contamination (such as metal ant lines. swarf) or moisture must not enter the copper pipes. Note Therefore, hold the pipe open- If solder fittings are used, solder the ings down or plug them.

  • Page 35: Connecting A Secondary Circuit

    Installation sequence Connecting a secondary circuit Refrigerant lines from/to the exter- nal unit Symbol Explanation Connection DHW cylinder flow (heating water side) G 1¼ Heating water return and DHW cylinder G 1¼ return Heating water flow G 1¼ 1. Equip the secondary circuit on site 2.

  • Page 36: Connecting A Cooling Circuit If Required

    Installation sequence Connecting a secondary circuit (cont.) 4. Thermally insulate pipes inside the Note building. ■ In underfloor heating circuits, install a temperature limiter to limit the maxi- 5. Connect the drain hose to the safety mum temperature for underfloor heat- valve.
  • Page 37 Installation sequence Electrical connections (cont.) ■ Route LV leads < 42 V and Please note cables > 42 V/230 V~/400 V~ The BUS connecting lead for the separately. internal/external unit (12 V or ■ Strip the insulation from the 43 V) is, in accordance with cables as close to the terminals safety requirements, not a low as possible, and bundle tightly...
  • Page 38 Installation sequence Electrical connections (cont.) < 4 > 4 < 4 > 4 A Type AWB/AWB-AC 201.A10 and B Type AWB/AWB-AC 201.A04 and 201.A13: 201.A07: BUS connecting lead 12 V: Routing BUS connecting lead 43 V: Routing in the voltage range 230 V~ (con- in the voltage range 230 V~ (con- nection, see page 53) nection, see page 53)
  • Page 39 Installation sequence Electrical connections (cont.) Overview of connections: Internal unit Note ■ Route 230 V~ cables and LV cables separately and bundle them tightly together at the terminals. This ensures that, in case of failure, for example when detaching a wire, the wires can- not drift into the adjacent voltage area.
  • Page 40 Installation sequence Electrical connections (cont.) F101 P203 COM 43V P202 12V COM...
  • Page 41 Installation sequence Electrical connections (cont.) A AVI PCB (see page 51) D Controller and sensor PCB (see F101 Fuse 1.0A (slow) page 50) B Control module and power supply E Main PCB (see page 41) for instantaneous heating water F3 Fuse 6.3 A (slow) heater F Extension PCB on main PCB (see C Luster terminals (see page 48)
  • Page 42 Installation sequence Electrical connections (cont.) Plug sYS Terminals Function Explanation 212.2 Heating circuit pump for ■ This pump is installed in addition to the heating circuit without mixer secondary pump if a heating water buf- (A1) fer cylinder is connected. ■...
  • Page 43 Installation sequence Electrical connections (cont.) Heating circuit without mixer A1/ Connection Circulation pump C A to control unit ■ Without heating water buffer cylin- 211.2 Secondary pump ■ With heating water buffer cylinder 212.2 Heating circuit pump A1/ Connecting the temperature limiter, part no.
  • Page 44 Installation sequence Electrical connections (cont.) Extension PCB on main PCB Information regarding the connection Set the required parameters during com- values missioning; see from page 74. ■ The output given is the recommended connected load. ■ The total output of all components con- nected directly to the heat pump con- trol unit (e.g.
  • Page 45 Installation sequence Electrical connections (cont.) Plug sXS Terminals Function Explanation 222.3 Switching external heat Zero volt contact 222.4 source with two high limit safety cut-outs (max. 70 °C) Note to protect the heat pump and ■ The switching contact is a zero volt to stop the secondary pump N/O contact that is closed when a heat demand is issued.
  • Page 46 Installation sequence Electrical connections (cont.) C Connection on the external heat High limit safety cut-out for heat pump in conjunction with an external source at terminals for external heat source demand D High limit safety cut-out (max. 70 °C) as heat pump protection X3.1 K1 Relay;...
  • Page 47 Installation sequence Electrical connections (cont.) Immersion heater (400 V~) 224.7 X2.N A Immersion heater, power supply B Terminals of the heat pump control 3/N/PE 400 V/50 Hz unit Immersion heater (230 V~, on site) 224.7 X2.N A Immersion heater, power supply B Terminals of the heat pump control 1/N/PE 230 V/50 Hz unit...
  • Page 48 Installation sequence Electrical connections (cont.) Luster terminals Set the required parameters during com- missioning; see from page 74. Message and safety connections Terminals Function Explanation Fuse, heat pump control 6.3 A (slow) unit X3.1 Phase switched Via control unit ON/OFF switch Note Observe the total load (1000 W) of all con- nected components.
  • Page 49 Installation sequence Electrical connections (cont.) Terminals Function Explanation X3.8 ■ Type AWB-AC: Floating contact required: X3.9 Contact humidistat and/ ■ Closed: Safety chain has continuity or frost stat, cooling ■ Open: Safety chain interrupted; heat pump shut down Jumper ■ Breaking capacity 230 V~, 0.15 A ■...
  • Page 50 Installation sequence Electrical connections (cont.) Terminals Function Explanation 211.2 Secondary pump Connection values ■ Max. output: 130 W ■ Voltage: 230 V~ ■ Max. switching current: 4(2) A Connected at the factory. ■ In systems without a heating water buf- fer cylinder, no other heating circuit pump is required (see terminal 212.2) ■...
  • Page 51 Installation sequence Electrical connections (cont.) Plug Sensor Type Cylinder temperature sensor, bottom; connect on site Pt 500 (X6.1/X6.3) (PTC) Flow temperature sensor, system (with sensor well, Pt 500 downstream of heating water buffer cylinder); connect on (PTC) site Flow temperature sensor, cooling circuit (direct heating Ni 500 circuit A1/HC1 or separate cooling circuit);...
  • Page 52 Installation sequence Electrical connections (cont.) Note ■ Only one BUS connection should be connected. ■ Do not interchange the BUS connec- tion wires between the internal and external units. ■ Route the BUS connecting cable in the 230 V~ voltage area. Overview of connections: External unit Opening the external unit wiring chamber Type AWB/AWB-AC...
  • Page 53 Installation sequence Electrical connections (cont.) Connecting internal and external units Type AWB/AWB-AC 201.A04 201.A07 201.A10 and A13 C N L ? C2 C1 ? N L 12V COM COM 43V 12V COM COM 43V 12V COM COM 43V A Wiring chamber, external unit (see Note page 52) Route BUS connecting lead for internal/...

  • Page 54: Power Supply

    Installation sequence Power supply Isolators for non-earthed conductors Danger ■ The mains isolator (if installed) must An absence of component earth- simultaneously isolate all non-earthed ing in the system can lead to seri- conductors from the power supply with ous injury from electrical current a minimum contact separation of 3 mm if an electrical fault occurs.
  • Page 55 Installation sequence Power supply (cont.) ■ The heat pump control unit/PCB must be supplied without power-OFF; tariffs that are subject to possible shut- down must not be used here ■ Protect the power supply to the heat pump control unit with max. 16 A ■...
  • Page 56 Installation sequence Power supply (cont.) Power supply, external unit (230 V~) Type AWB/AWB-AC 201.A04 201.A07 201.A10 and A13 C N L ? C2 C1 ? N L ? N L1 ? N L1 A Wiring chamber, external unit (see page 52) B Power supply 230 V/50 Hz Type AWB/AWB-AC 201.A04...
  • Page 57 Installation sequence Power supply (cont.) Connecting power cable for instantaneous heating water heater (only type AWB-AC) Internal unit ■ Recommended power cable: Phase asymmetrical 400 V~: 3/N/PE 5 x 2.5 mm 400 V/50 Hz Phase asymmetrical 230 V~: 7 x 2.5 mm ■...
  • Page 58 Installation sequence Power supply (cont.) Parameter "Output for instant. heating Note water heater at power-OFF 790A" Observe the technical connection determines whether and at what stage requirements of the relevant power sup- an instantaneous heating water heater (if ply utility. installed) remains operational during power-OFF.
  • Page 59 Installation sequence Power supply (cont.) Power-OFF with on-site load disconnection The power-OFF signal is connected to Note the on-site contactor of the economy tar- Observe the technical connection iff power supply and in the heat pump requirements of the relevant power sup- control unit.

  • Page 60: Closing The Heat Pump

    Installation sequence Closing the heat pump Please note Danger Seal the appliance so it is sound- An absence of component earth- proof and diffusion-proof. ing in the system can lead to seri- On the pipe and hose outlets, ous injury from electrical current ensure the thermal insulation has if an electrical fault occurs.
  • Page 61 Installation sequence Closing the heat pump (cont.) Fitting the side cover for the external unit In reverse order to "Opening the external unit wiring chamber", page 52.

  • Page 62: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Opening the heat pump..........64 • 2. Writing reports..............64 •...

  • Page 63: Commissioning Steps

    Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • 18. Commissioning the system........... 74 • 19. Ticking the heat pump type on the type plate of the internal unit (according to external unit type plate) •...

  • Page 64: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Opening the heat pump Danger Please note Touching 'live' components can Wait at least 30 min between the result in severe injury due to elec- installation and commissioning of tric shock. the appliance to prevent equip- ■...

  • Page 65: Evacuating The Refrigerant Lines And Internal Unit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Evacuating the refrigerant lines and internal unit Please note Please note Commissioning is weather- Before evacuating the refrigerant dependent. lines and the internal unit, check In the event of high relative all connections for tightness with humidity (e.g.
  • Page 66 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Example type AWB/AWB-AC 201.A04 A Internal unit H Pressure gauge set B External unit K Connection hose between pressure C Hot gas line gauge set and vacuum pump L Vacuum pump D Fill valve M Connection hose between pressure E Service valve (Schrader valve)
  • Page 67 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Make all connections, as shown 5. Close the valve on the pressure above. gauge set to the vacuum pump. Stop the vacuum pump and wait Please note approx. 5 min. There is a leak if the Filler valve D must remain indication on the vacuum gauge rises.

  • Page 68: Filling Refrigerant Lines And The Internal Unit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling refrigerant lines and the internal unit Note Please note ■ The external unit is pre-filled with Topping up the system with refrigerant R410A refrigerant or evacuating the ■ No topping up is required for line refrigerant can result in appliance lengths up to 12 m damage.

  • Page 69: Checking The Refrigerant Circuit For Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Top up the required amount of refrig- 7. Enter the amount of refrigerant top- erant (see following table). ped up on the type plate and in the operator's log. Please note Refrigerant must not be Information for systems with a fill-...

  • Page 70: Filling And Venting On The Secondary Side

    16.8 °dH (3.0 mol/m ), e.g. with the observe the VDI 2035 [or local regula- small softening system for heating tions]. water (see the Viessmann Vitoset pricelist). 1. Open any non-return valves installed on site. 2. Check the pre-charge pressure of the expansion vessel and adjust if required (see page 72).
  • Page 71 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 8. To prevent damage to electrical com- ponents, connect an on-site hose to the secondary circuit air vent valve Open secondary circuit air vent valve 9. Move 3-way diverter valve C by its handle into its centre position.

  • Page 72: Checking Expansion Vessel And Heating Circuit Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking expansion vessel and heating circuit pressure Check the pre-charge pressure of the Note expansion vessel at test nipple A and Also check the pre-charge pressure at the on-site expansion vessel. recharge, if required.

  • Page 73: Checking That The External Unit Condensate Pan Enables Condensate To Drain Away Freely 12. Checking The Free Running Of The Fan In The External Unit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the free running of the fan in the external unit Danger 1. ■ Type AWB/AWB-AC 201.A04: Starting the fan with the external First remove the top cover, then the unit open can lead to severe inju- front panel.

  • Page 74: Checking The Thermal Insulation On The Swaged Connections 15. Checking The Electrical Connections Of The External Unit For Firm Seating

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the electrical connections of the external unit for firm seating Danger Wait at least 4 min, until the Contact with 'live' components capacitors have discharged, can result in severe injuries. before starting work on the exter- Capacitors remain 'live' after the nal unit.
  • Page 75 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning with the commissioning assistant The commissioning assistant guides you Switch on the ON/OFF switch on the automatically through all the menus heat pump control unit. where settings have to be made. For ■...
  • Page 76 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Language Date Time Date / Time Start commissioning? Parameter group Parameter Coding select level 1 Sensor values Temperature sensors display Signal inputs Signal inputs display Actuator test Actuator test carry out Function check Function Function...
  • Page 77 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Disabling the service menu 3. Select parameter group: "System definition" The service menu remains active until it 4. Select parameter: "System scheme is disabled with "Terminate service?", 7000" or if no operation takes place for 30 5.
  • Page 78 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pumps and other components Pump/component Parameter Setting Heating circuit pump "System definition" Ó ■ With heating circuit A1/ HC1 (for heating circuit "System scheme 7000" without mixer) ■ With heating circuit M2/ HC2 (for heating circuit with mixer) DHW circulation pump...
  • Page 79 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pump/component Parameter Setting Remote control (e.g. "Heating circuit 1" Ó "1" Vitotrol 200A) "Remote control 2003" Note Set code at the Vitotrol 200A "Heating circuit 2" Ó to assign heating circuits: "Remote control 3003"...
  • Page 80 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) External functions Parameter Setting External changeover in oper- "System definition" Ó "0" to "10" ating status of various system "System components for components external changeover 7011" "System definition" Ó "0" to "3" "Operating status for external changeover 7012"...
  • Page 81 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instantaneous heating water heater Parameters for Setting instantaneous heating water heater "Electr booster heater" Ó "1" "Enable instantaneous heating water heater 7900" "Electr booster heater", if applicable Ó "1" "Enable instant. heating water heater for cen- tral heating 7902"...
  • Page 82 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the system function (e.g. actuators, temperatures, heat meter if applicable) Please note If the heat pump is exposed to temperatures below –15 °C, e.g. during storage or transport, the high limit safety cut-out of the instantaneous heating water heater may respond.

  • Page 83: Troubleshooting

    Troubleshooting Repairs Opening the programming unit 2. 2x...
  • Page 84 Troubleshooting Repairs (cont.) Removing cover from programming unit if necessary...
  • Page 85 Troubleshooting Repairs (cont.) Placing the control panel in its service position...
  • Page 86 Troubleshooting Repairs (cont.) Removing the separating plate...
  • Page 87 Troubleshooting Repairs (cont.) Overview of internal components: Internal unit...
  • Page 88 Troubleshooting Repairs (cont.) A Pressure gauge H Liquid gas temperature sensor (IRT) B Pressure sensor (ITC) for determin- K Secondary circuit return tempera- ing the condensation temperature of ture sensor L Secondary circuit flow temperature the condenser C Condenser sensor D Expansion vessel M 3-way diverter valve for "Heating/ E Secondary circuit temperature sen-...
  • Page 89 Troubleshooting Repairs (cont.) External unit, type AWB/AWB-AC 201.A04 A Fan F Electronic expansion valve (EEV) B Heat exchanger (evaporator) G Temperature sensor, compressor C Temperature sensor, air intake, head (CTT) evaporator (OAT) H Liquid separator D Temperature sensor, evaporator K Temperature sensor, refrigerant (OMT) inlet, evaporator (OCT) E 4-way diverter valve...
  • Page 90 Troubleshooting Repairs (cont.) External unit, type AWB/AWB-AC 201.A07 A Fan F Electronic expansion valve (EEV) B Heat exchanger (evaporator) G Temperature sensor, compressor C Temperature sensor, air intake, head (CTT) evaporator (OAT) H Liquid separator D Temperature sensor, evaporator K Temperature sensor, refrigerant (OMT) inlet, evaporator (OCT) E 4-way diverter valve...
  • Page 91 Troubleshooting Repairs (cont.) External unit, type AWB/AWB-AC 201.A10 and 201.A13 A Fan G Temperature sensor, compressor B Heat exchanger (evaporator) head (CTT) C Temperature sensor, air intake, H Liquid separator evaporator (OAT) K Temperature sensor, refrigerant D Temperature sensor, evaporator inlet, evaporator (OCT) (OMT) L Compressor...
  • Page 92 Troubleshooting Repairs (cont.) Draining secondary side heat pump 1. Close the on-site boiler drain & fill 2. Drain the heat pump at the secondary valve. circuit fill & drain valve (see chapter "Overview of internal components: Internal unit"). Checking the sensors Sensor Captur- Installed loca-...
  • Page 93 Troubleshooting Repairs (cont.) Temperature sensors, type Ni 500 Temperature sensors, type Pt 500 140 180 Temperature in °C -40 -20 Temperature in °C Temperature sensors NTC 10 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C...
  • Page 94 Troubleshooting Repairs (cont.) Temperature sensors NTC 50 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C Checking fuses For fuse locations, see from page 39: ■ Fuse F1 is located on the mains ter- minal of the heat pump control unit.

  • Page 95: Parts Lists, Internal Unit

    Parts lists, internal unit Parts lists, internal unit Ordering individual parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local dealer. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list)

  • Page 96: Overview Of The Assemblies, Internal Unit

    Parts lists, internal unit Overview of the assemblies, internal unit A Type plate C Assembly, electrical equipment B Assembly, casing E Assembly, hydraulics...

  • Page 97: Parts Not Shown, Internal Unit

    Parts not shown, internal unit 0004 Touch-up paint stick, Vitowhite 0008 Vitotronic 200, type WO1B serv- 0005 Spray paint, Vitowhite ice instructions 0006 Vitocal 200-S installation and 0009 Adaptor service instructions 0007 Vitotronic 200, type WO1B oper- ating instructions Casing, internal unit...
  • Page 98 Parts lists, internal unit Casing, internal unit (cont.) 0005 0009 0010 0004 0002 0006 0011 0007 0012 0003 0008 0001 0008...

  • Page 99: Electrical Equipment, Internal Unit

    Parts lists, internal unit Electrical equipment, internal unit 0001 Programming unit Parts not shown 0002 Controller and sensor PCB with 0003 PCB with connection adaptor cover (CU401) (SA136-A10) 0005 Main PCB with cover (MB761) 0004 PCB with connection adaptor, 0006 Extension PCB with cover ON/OFF switch (SA137-A10) (SA135) 0012 Connecting cable, instantaneous...

  • Page 100: Hydraulics, Internal Unit

    Parts lists, internal unit Electrical equipment, internal unit (cont.) 0026 0024 0025 0008 0025 0013 0011 0002 0007 0009 0005 0010 0006 0033 0035 0034 0019 0018 0021 0020 0036 0001 Hydraulics, internal unit 0001 Hot gas line 0004 Connecting cable, condenser - 0002 Liquid line circulation pump 0003 Connecting cable, condenser -...
  • Page 101 Parts lists, internal unit Hydraulics, internal unit (cont.) 0007 Connecting cable DN 28 0025 Air vent valve G⅜ 0008 Hose, heating water return/DHW 0026 Pressure gauge cylinder return 0027 Expansion vessel 0009 Hose, heating water flow 0028 Instantaneous heating water 0010 Connection hose, heating water heater 9 kW return...
  • Page 102 Parts lists, internal unit Hydraulics, internal unit (cont.) 0014 0042 0015 0025 0010 0017 0003 0016 0034 0028 0034 0006 0027 0043 0043 0007 0032 0034 0026 0021 0037 0039 0043 0034 0004 0001 0036 0039 0002 0011 0022 0043 0022 0013 0023...

  • Page 103: Parts Lists, External Unit

    Parts lists, external unit Parts lists, external unit Ordering individual parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local dealer. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) External unit, type AWB/AWB-AC 201.A04...
  • Page 104 Parts lists, external unit External unit, type AWB/AWB-AC 201.A04 (cont.) 0024 0022 0026 0010 0021 0020 0031 0028 0023 0027 0009 0014 0006 0005 0004 0030 0025 0002 0008 0019 0015 0017 0016 0001 0003 0032 0018 0013 0029 0007 0011 0012...

  • Page 105: External Unit, Type Awb/Awb-Ac 201.A07

    Parts lists, external unit External unit, type AWB/AWB-AC 201.A07 0001 Air discharge grille 0025 Coil EEV 0002 Side panel, left 0026 Heat exchanger (evaporator) 0003 M8 nut 0027 Protective grille 0004 Axial fan 0028 Retainer, temperature sensor 0005 4-way diverter valve, complete 0029 Transformer 0006 4-way diverter valve 0030 Partition...
  • Page 106 Parts lists, external unit External unit, type AWB/AWB-AC 201.A07 (cont.) 0033 0032 0031 0036 0027 0036 0028 0030 0026 0035 0029 0034 0004 0007 0006 0038 0003 0012 0022 0020 0021 0025 0005 0013 0024 0037 0023 0014 0011 0017 0015 0016 0001...

  • Page 107: Overview Of The Assemblies, External Unit, Type Awb/Awb-Ac 201.A10, A13

    Parts lists, external unit Overview of the assemblies, external unit, type AWB/AWB-AC 201.A10, A13 A Type plate C Electrical equipment assembly B Casing assembly D Hydraulic assembly...

  • Page 108: Casing, External Unit, Type Awb/Awb-Ac 201.A10, A13

    Parts lists, external unit Casing, external unit, type AWB/AWB-AC 201.A10, A13 0001 Top panel 0013 Transport handle, left 0002 Side panel, right 0014 Motor support 0003 Cover, power supply 0015 Air inlet ring 0004 Front panel, left 0016 Transport handle, right 0005 Front panel, right 0017 ODU control unit 0006 Air discharge grille...
  • Page 109 Parts lists, external unit Casing, external unit, type AWB/AWB-AC 201.A10,… (cont.) 0012 0001 0019 0018 0013 0014 0009 0021 0010 0015 0011 0004 0008 0006 0020 0021 0010 0003 0015 0017 0016 0006 0007 0002 0016 0005...

  • Page 110: Electrical Equipment, External Unit, Type Awb/Awb-Ac 201.A10, A13

    Parts lists, external unit Electrical equipment, external unit, type AWB/AWB-AC 201.A10, A13 0001 Main PCB 0016 Wiring harness, compressor 0002 Driver PCB 0017 Wiring harness complete, com- 0003 Capacitor PCB pressor 0004 PCB, mains filter 0018 Temperature sensor NTC 10 kΩ 0005 Coils (OCT) 0006 Terminal...
  • Page 111 Parts lists, external unit Electrical equipment, external unit, type… (cont.) 0002 0004 0003 0006 0005 0011 0009 0012 0010 0001 0013 0007 0008...

  • Page 112: Hydraulics, External Unit, Type Awb/Awb-Ac 201.A10, A13

    Parts lists, external unit Hydraulics, external unit, type AWB/AWB-AC 201.A10, A13 0001 Compressor 0009 Compressor thermal insulation 0002 EEV pipework, complete 0010 Temperature sensor NTC 50 kΩ 0003 4-way diverter valve pipework, (CTT) complete 0011 Shut-off valve, liquid line 0004 Liquid separator 0012 Compressor power supply cover 0005 High pressure switch 0006 Shut-off valve...
  • Page 113 Parts lists, external unit Hydraulics, external unit, type AWB/AWB-AC… (cont.) 0002 0005 0008 0004 0010 0007 0006 0003 0009 0001 0011 0012...

  • Page 114: Commissioning/Service Reports

    Commissioning/service reports Hydraulic parameters report Setting and test values Set value Commission- Testing the external heating circuit pumps Circulation pump type Circulation pump stage Overflow valve setting Primary circuit commissioning Temperature, air intake °C Temperature, air discharge °C Temperature differential ΔT: Secondary circuit flow temperature = 3 to 5 35 °C at air intake temperature ≤...
  • Page 115 Commissioning/service reports Control parameters report (cont.) Parameter Code Delivered condi- Commis- tion sioning System definition System scheme 7000 Language 7001 German Temperature differential for calculating 7003 40 (≙ 4 K) the heating limit Temperature differential for calculating 7004 40 (≙ 4 K) the cooling limit External extension 7010...
  • Page 116 Commissioning/service reports Control parameters report (cont.) Parameter Code Delivered condi- Commis- tion sioning Set DHW temperature 6000 500 (≙ 50 °C) Min. DHW temperature 6005 100 (≙ 10 °C) Max. DHW temperature 6006 600 (≙ 60 °C) Hysteresis DHW temperature heat pump 6007 70 (≙...
  • Page 117 Commissioning/service reports Control parameters report (cont.) Parameter Code Delivered condi- Commis- tion sioning Heating water buffer cylinder Enable buffer cylinder/low loss header 7200 Temp. in operating status fixed value for 7202 500 (≙ 50 °C) buffer cyl Hysteresis temperature heating buffer 7203 50 (≙...
  • Page 118 Commissioning/service reports Control parameters report (cont.) Parameter Code Delivered condi- Commis- tion sioning Cooling curve slope 7111 12 (≙1.2) Time Automatic changeover summertime - 7C00 wintertime Start summertime - month 7C01 Start summertime - week 7C02 Start summertime - day 7C03 Start wintertime - month 7C04...

  • Page 119: Specification

    Specification Specification Vitocal 200-S Type AWB/AWB-AC 201.A04 201.A07 201.A10 201.A13 Heating output data at 100 % to EN 14511 (A2/W35 °C, spread 5 K) Rated heating output 10.6 Compressor frequency Fan speed Power consumption 0.91 1.73 2.20 3.25 Coefficient of perform- 3.30...
  • Page 120 Specification Specification (cont.) Type AWB/AWB-AC 201.A04 201.A07 201.A10 201.A13 Air intake tempera- ture Cooling mode (type AWB-AC) ■ Min. °C ■ Max. °C Heating mode (type AWB, AWB-AC) ■ Min. °C –15 –15 –15 –15 ■ Max. °C Heating water at 10 K spread Content (excl.
  • Page 121 Specification Specification (cont.) Type AWB/AWB-AC 201.A04 201.A07 201.A10 201.A13 Electrical values Internal unit Heat pump control unit/PCB ■ Rated voltage, con- 1/N/PE 230 V/50 Hz trol unit/PCB ■ Fuse protection, 1xB16A power supply ■ Fuse, internal 6.3A (slow)/250 V Instantaneous heat- ing water heater Only for type AWB-AC ■...
  • Page 122 Specification Specification (cont.) Type AWB/AWB-AC 201.A04 201.A07 201.A10 201.A13 Refrigerant circuit Refrigerant R410A R410A R410A R410A Fill volume 2.15 2.95 2.95 Top-up amount for line lengths >12 m to ≤30 m Compressor (hermeti- Type Rotating Rotating Scroll Scroll cally sealed) piston piston Permiss.
  • Page 123 Specification Specification (cont.) Type AWB/AWB-AC 201.A04 201.A07 201.A10 201.A13 Connections Heating water flow 1¼ 1¼ 1¼ 1¼ Heating water return 1¼ 1¼ 1¼ 1¼ and DHW cylinder return DHW cylinder flow 1¼ 1¼ 1¼ 1¼ Condensate line 16 x 1 16 x 1 16 x 1 16 x 1...

  • Page 124: Appendix

    Installation completed in full up to refrigerant circuit All windows and external doors sealed Components for cooling mode fully installed (optional) Preferred appointment: Date Time Date Time All work ordered from Viessmann will be charged to me/us in accordance with the current Viessmann pricelist. Place/date Signature...

  • Page 125: Certificates

    Declaration of conformity We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole respon- sible body that the product Vitocal 200-S, type AWB and type AWB-AC incl. the Vitotronic 200, type WO1B complies with the following standards: DIN 8901 DIN EN 61 000-3-11;...

  • Page 126: Keyword Index

    Keyword index Keyword index Checking for leaks Acoustic reflection......25 ■ Refrigerant circuit......69 Air circulation........25 Checking solder joints......69 Air short circuit........25 Checking swaged connections..69 Area cooling system......36 Checking the electrical connections of Assembly........95, 103 the external unit.........74 Assembly, casing Checking the fan........73 ■...
  • Page 127 Keyword index Keyword index (cont.) Curve Enable ■ NTC temperature sensors..93, 94 ■ Electric booster heater....81 ■ Temperature sensor, type Ni 500...93 ■ Instantaneous heating water heater 81 ■ Temperature sensor, type Pt 500...93 Enable electric booster heater...81 Curves of the sensors......92 Evacuating a refrigerant circuit..65 Cylinder primary pump....50, 78 Evacuating refrigerant lines....65...
  • Page 128 Keyword index Keyword index (cont.) Height differential of internal unit/exter- Fan.........89, 90, 91 nal unit..........31 Filler valve High pressure fault......25 ■ External unit......68, 69 Hot gas line Filling ■ External unit........33 ■ Refrigerant circuit......68 ■ Internal unit........34 Filling a refrigerant circuit....68 Hydraulic installation scheme..12, 18 Filling capacity Hydraulic parameters.......114...
  • Page 129 Keyword index Keyword index (cont.) Internal unit ■ Cable lengths........8 Oil lift bends........31 ■ Closing..........60 ON/OFF switch........75 ■ Dimensions.......7, 122 On-site connections......7 ■ Electrical connection.......39 On-site load disconnection...57, 59 ■ Electrical values......121 Opening the heat pump.....64 ■ Installation........28 Opening the programming unit..83 ■...
  • Page 130 Keyword index Keyword index (cont.) Parameter settings Power-OFF......9, 56, 57 ■ For changing over operating status Power-OFF signal......57, 59 externally........80 Power supply ■ For circulation pump for DHW reheat- ■ Compressor........52 ing...........78 ■ External unit........56 ■ For cylinder primary pump....78 ■...
  • Page 131 Keyword index Keyword index (cont.) Return, DHW cylinder......123 System schemes......12, 18 Return, DHW cylinder/heating water..35 System schemes, overview....9 Room height........28 Room temperature sensor....92 Room volume........28 Temperature limiter......42 Rubber buffer........27 Temperature sensor ■ Air intake, evaporator (OAT)89, 90, 91 ■ Compressor head (CTT)..89, 90, 91 Safety connections......48 ■...
  • Page 132 Serial No.: 7424689 7424690 7424691 7424692 7454115 7454116 7454117 7454118 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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