Viessmann Vitocal 200-S Kurzanleitung

Installation and service

instructions

for contractors

VIESMANN

Vitocal 200-S

Type AWB 201.B04 to B13, C10, C13

Air source heat pump, split version for heating operation

Type AWB-AC 201.B04 to B13, C10, C13

Air source heat pump, split version for heating and cooling opera-

tion

For applicability, see the last page

VITOCAL 200-S

5546 727 GB 7/2014 Please keep safe.

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

5546 727 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.)

5546 727 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...................................................................................... 16

Connecting the refrigerant lines........................................................................... 19

Connecting the secondary circuit......................................................................... 26

Connecting a cooling circuit if required................................................................ 27

Electrical connection............................................................................................ 27

Power supply........................................................................................................ 49

Closing the heat pump......................................................................................... 58

Service instructions

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 60

Further details regarding the individual steps....................................................... 62

Troubleshooting

Repairs................................................................................................................. 84

Parts lists, internal unit

Ordering parts...................................................................................................... 97

Overview of assemblies, internal unit................................................................... 98

Parts not shown, internal unit............................................................................... 99

Casing, internal unit.............................................................................................. 99

Electrical equipment, internal unit........................................................................ 101

Hydraulics, internal unit, type AWB...................................................................... 103

Hydraulics, internal unit, type AWB-AC................................................................ 105

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

Ordering parts...................................................................................................... 107

External unit 230 V~............................................................................................. 107

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

Ordering parts...................................................................................................... 110

External unit 230 V~............................................................................................. 110

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

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

Index

5546 727 GB

Overview of assemblies 230 V~........................................................................... 114

Casing, external unit 230 V~................................................................................ 115

Electrical equipment, external unit 230 V~........................................................... 117

Hydraulics, external unit 230 V~.......................................................................... 119

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

Ordering parts...................................................................................................... 121

Overview of assemblies 400 V~........................................................................... 122

Casing, external unit 400 V~................................................................................ 123

Electrical equipment, external unit 400 V~........................................................... 125

Hydraulics, external unit 400 V~.......................................................................... 127

Commissioning/service reports

Hydraulic parameter report................................................................................... 129

Control parameters report.................................................................................... 129

Specification....................................................................................................... 140

Appendix

Commissioning order........................................................................................... 148

Declaration of conformity.................................................................................. 149

Keyword index.................................................................................................... 150

Index

Index (cont.)

5546 727 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

5546 727 GB

Internal unit

905

360

1105 150

960

360

450

A B

147

219

294

369

Preparing for installation

Requirements regarding on-site connections

5546 727 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.)

5546 727 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~ (compres-

sor)

Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 4.0 mm2

Max. cable length 29 m 25 m 20 m 20 m

or or

Cable cross-section – – 3 x 4.0 mm23 x 6.0 mm2

Max. cable length – – 32 m 30 m

Type AWB, AWB-AC 201.C10 201.C13

External unit 400 V~ (compressor)

Cable cross-section 5 x 2.5 mm25 x 2.5 mm2

Max. cable length 30 m 30 m

Preparing for installation

Requirements regarding on-site connections (cont.)

5546 727 GB

Installation

Installation information

Types of installation:

■ Floorstanding installation with line

entry above ground level

■ Floorstanding installation with line

entry below ground level

■ Wall mounting

Technical guide

Floorstanding installation:

■ Use supports for floorstanding instal-

lation (accessories).

■ Where such supports cannot be used,

install the external unit freestanding on

a solid base of at least 100 mm height.

■ In difficult climatic circumstances

(temperatures below zero, snow,

humidity) install the appliance on a

plinth of approx. 300 mm height.

■ Take into account the weight of the

external unit: See the following table.

Wall mounting:

■ Use the wall mounting bracket set

(accessories).

■ The wall must meet the structural

requirements.

Positioning:

■ Never install with the discharge side

facing the main wind direction.

■ Provide wall ducts and protective

pipes for the refrigerant lines and elec-

trical cables without moulded parts

and change of direction.

Weather influences:

■ Observe wind loads when installing

the unit on sites exposed to the wind.

■ Incorporate the external unit into the

lightning protection system.

■ Consider the heat emitted by the unit

when planning your weatherproofing

or an enclosure.

Condensate:

■ Ensure the condensate can drain

freely, and create a permanent gravel

bed below the external unit as a soak-

away.

■ In regions with prolonged cold sea-

sons (such as Sweden for example),

provide an electric ribbon heater

(accessory) for the condensate pan.

Insulation against structure-borne

noise and vibrations between build-

ing and external unit:

■ When line entry is above ground level,

fit pipe bends in the refrigerant lines for

vibration compensation: See "Con-

necting refrigerant lines".

■ Route electrical cables/leads between

the internal and external units free of

stress.

■ Installation only on walls with high

weight per area (> 250 kg/m2), in other

words not on lightweight walls, roof

structures etc.

■ For floorstanding installation, only use

the rubber mounts supplied.

■ For wall mounting, only use the anti-

vibration mounts from the bracket set.

■ Never use additional anti-vibration

mounts, springs, rubber mounts, etc.

Installation sequence

Installing the external unit

5546 727 GB

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