Viessmann 7424689 Installation And Service Instructions Manual Download Page 72

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Checking expansion vessel and heating circuit pressure

Check the pre-charge pressure of the
expansion vessel at test nipple

and

recharge, if required.
Pre-charge pressure: 0.75 to 0.95 bar

Note
Also check the pre-charge pressure at
the on-site expansion vessel.

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5601 429 GB

Summary of Contents for 7424689

Page 1: ...al 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 5601 429 GB 3 2011 Please keep safe ...

Page 2: ...working on this system National installation requirements Legal instructions regarding the pre vention of accidents Legal instructions regarding environ mental protection The Code of Practice of relevant trade associations All current safety regulations as defined by DIN EN DVGW VDE and all locally applicable standards a ÖNORM EN and ÖVE c SEV SUVA SVTI and SWKI Working on the system Isolate the s...

Page 3: ...eplace faulty components only with original 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 ori...

Page 4: ...ons Commissioning inspection maintenance Steps commissioning inspection and maintenance 62 Further details regarding the individual steps 64 Troubleshooting Repairs 83 Parts lists internal unit Parts lists internal unit 95 Overview of the assemblies internal unit 96 Parts not shown internal unit 97 Casing internal unit 97 Electrical equipment internal unit 99 Hydraulics internal unit 100 Parts lis...

Page 5: ... 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 Index Index cont 5601 429 GB ...

Page 6: ...ing only type AWB AC via a heating system DHW heating Any use that differs from or goes beyond this is not in accordance with require ments 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 5601 429 GB ...

Page 7: ...7 Internal unit 850 114 105 116 360 230 V 400 V 42 V 42 V 1160 A 150 75 147 219 294 369 450 41 Preparing for installation Requirements of on site connections 5601 429 GB Installation ...

Page 8: ... Preparing connections on the heating water and the DHW side Flush the heating system 2 Prepare the electrical connections Note The internal external unit BUS con necting cable can be routed along the refrigerant line and fixed to it Cable lengths inside 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 ...

Page 9: ...ump control unit inter nal unit 230 V Cable cross section Without power OFF 3 x 1 5 mm2 3 x 1 5 mm2 3 x 1 5 mm2 3 x 1 5 mm2 With power OFF 5 x 1 5 mm2 5 x 1 5 mm2 5 x 1 5 mm2 5 x 1 5 mm2 Instantaneous heating water heater Cable cross section 400 V 5 x 2 5 mm2 5 x 2 5 mm2 5 x 2 5 mm2 5 x 2 5 mm2 230 V 7 x 2 5 mm2 7 x 2 5 mm2 7 x 2 5 mm2 7 x 2 5 mm2 Max cable length 25 m 25 m 25 m 25 m Overview of p...

Page 10: ...g water buffer cylinder 0 0 X X X X External heat source 0 1 0 1 0 0 0 0 Cooling A1 HC1 0 0 0 0 M2 HC2 0 0 0 0 Sep cooling circuit 0 0 0 0 0 0 0 X Components selected 0 Components can be added 1 Only in conjunction with a heating water buffer cylinder Preparing for installation Overview of possible system schemes cont 5601 429 GB ...

Page 11: ...11 2 2 F0 2 211 4 94 20 2 F8 F6 F0 F8 F14 212 3 211 2 211 4 2 X3 8 3 9 2 145 A1 2 X3 8 3 9 2 1 qE qW 6 4 3 7 5 eU eQ eP oR iE oE oP oQ oW oE 2 F14 oE oE 2 H F YF F Preparing for installation Designations in the system examples 5601 429 GB Installation ...

Page 12: ... is a basic example without shut off devices or safety equipment This does not replace the need for local engineering Hydraulic installation scheme KW WW 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 14 4 5 6 105 52 74 20 105 20 76 105 2 KM BUS ...

Page 13: ...tocal 200 S type AWB AC 5 3 way diverter valve for Heating DHW 6 Secondary pump 8 KM BUS distributor qE Heating circuit expansion vessel Primary circuit wU Liquid line wI Hot gas line wO External unit of the heat pump Vitocal 200 S DHW heating eP DHW cylinder dual mode eQ Cylinder temperature sensor STS eU DHW circulation pump ZP Preparing for installation System example 1 ID 4605169_1103_04 cont ...

Page 14: ...ensor Heating circuit with mixer M2 KM BUS uP Underfloor heating circuit uQ Vitotrol 200A remote control uE Flow temperature sensor uR Temperature limiter to limit 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 in 3 way mixer q T Mixer extension kit Heating circuit without mix...

Page 15: ... 76 M2 VTS M2 20 230 V 50 Hz 105 2 1 HK A1 HK M2 91 71 Low voltage 1 N PE 1 2 H1 1 2 H2 NTC 2 130W 50W 100W 100W L N 55 STB 20 HK M2 KM BUS distributor 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 Note The instantaneous heating water heater 4 the 3 way diverter valve 5 and the secondary pump 6 are already instal led and electrically connected Preparing for installation System example 1 ID...

Page 16: ...er heater power supply Power supply to heat pump control unit 2 1 N PE 230 V 50 Hz F1 6 3 AH slow L1 N X40 L1 N Note Instantaneous heating water heater only for Vitocal 200 S type AWB AC Connections for the external unit 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 N 1 N PE 230 V 50 Hz Li No Lo Ni 29 COM 12 V 2 L1 N 1 N PE 230 V 50 Hz N L L N C1 C2 10 13 kW ...

Page 17: ...alled Set time program see oper ating 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 1 Remote controls accessories Heating circuit 1 Remote control 2003 1 He...

Page 18: ...hut off devices or safety equipment This does not replace the need for local engineering Hydraulic installation scheme KW WW 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 4 5 6 105 52 74 20 105 20 76 105 2 KM BUS 211 2 230V 2 211 5 89 89 2 211...

Page 19: ...direct coil eQ Cylinder temperature sensor STS eU DHW circulation pump ZP External heat source qR High limit safety cut out for switching off the secondary pump tP External heat source e g oil gas boiler tQ Demand of external heat source 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 ...

Page 20: ...ating circuit Mixer motor in 3 way mixer q T Extension kit heating circuit with mixer Active cooling function AC iE Contact humidistat 230 V iO 3 way diverter valve for heating cooling Heating circuit without mixer A1 oP Radiator heating circuit oQ Vitotrol 200A remote control oZ Heating circuit pump Electrical installation scheme For an overview of the electrical connec tions and more information...

Page 21: ... 76 M2 VTS M2 20 230 V 50 Hz 105 2 1 HK A1 HK M2 91 71 Low voltage 1 N PE 1 2 H1 1 2 H2 NTC 2 130W 50W 100W 100W L N 55 STB 20 HK M2 KM BUS distributor 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 Note The instantaneous heating water heater 4 the 3 way diverter valve 5 and the secondary pump 6 are already instal led and electrically connected Preparing for installation System example 2 ID...

Page 22: ...211 5 X2 N X1 89 89 X1 X3 8 X3 9 83 M 1 M 1 2 Low voltage F6 STS 31 PT500 F4 PTS 61 KTS PT500 PT500 53 F20 F0 VTS 62 ATS PT500 Ni500 3 F13 Preparing for installation System example 2 ID 4605170_1103_04 cont 5601 429 GB ...

Page 23: ...upply Power supply to heat pump control unit 2 1 N PE 230 V 50 Hz F1 6 3 AH slow L1 N X40 L1 N Connections for the external unit 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 N 1 N PE 230 V 50 Hz Li No Lo Ni 29 COM 12 V 2 L1 N 1 N PE 230 V 50 Hz N L L N C1 C2 10 13 kW 42 V Preparing for installation System example 2 ID 4605170_1103_04 cont 5601 429 GB Install...

Page 24: ...m see oper ating 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 1 Cooling Cooling function 7100 3 Cooling circuit 7101 2 Remote controls if installed Heating...

Page 25: ...r free condensate drainage For installation in difficult climatic con ditions temperatures below zero snow humidity we recommend installing the unit on a plinth with a height of approx 300 mm Take account of the weight of the external unit see following table When installing the unit where it is exposed to wind ensure that the wind cannot influence the fan area This might result in an air short ci...

Page 26: ...ensate pan This ensures the reliable flow of condensate Position the external unit no closer than 3 m from pathways or terraces The cooled air in the discharge area creates a risk of ice forming when out side temperatures are below 10 C Easy accessibility for maintenance work see the clearances in the follow ing diagram Weights of the external units Type AWB AWB AC Weight in kg 201 A04 43 201 A07 ...

Page 27: ...7 100 100 300 1000 201 A10 100 200 300 1000 201 A13 100 200 300 1000 Positioning 4x 2 3 1 4x 4x A Example type A04 A Supplied rubber buffer Note We recommend letting condensate drain away freely without condensate drain pipe Installation sequence Installing the external unit cont 5601 429 GB Installation ...

Page 28: ...ing transportation Never put weight on top of the appliance Installation room requirements Please note The installation room must be dry and free from the risk of frost Ensure ambient temperatures of 0 to 35 ºC Please note Avoid dust gases and vapours due to a risk of explosion in the installation room Minimum room volume to DIN EN 378 Type AWB AWB AC Minimum room volume in m3 201 A04 2 7 201 A07 ...

Page 29: ...29 Minimum clearances 100 1000 100 230 V 42 V 42 V 400 V Installation sequence Installing the internal unit cont 5601 429 GB Installation ...

Page 30: ...30 Fitting the internal unit to the wall 2 2x 4 3 5 1 Installation sequence Installing the internal unit cont 5601 429 GB ...

Page 31: ...AC 201 A04 201 A07 201 A10 201 A13 Max line length of refrigerant lines 20 m 30 m 30 m 30 m Max height differential of internal unit external unit 10 m 15 m 15 m 15 m B 5000 A 5000 C D E Example type AWB AWB AC 201 A07 A Internal unit B External unit C Liquid line D Hot gas line E Oil lift bends Flow direction for heating mode Flow direction for cooling mode Connection to the external unit 1 Type ...

Page 32: ...em Remove the nuts from connections C liquid line and D hot gas line of the refrigerant lines Type AWB AWB AC 201 A04 Slide the nuts onto the refrigerant lines prepared on site Type AWB AWB AC 201 A07 201 A10 201 A13 Replace nuts with union nuts sup plied internal unit UNF for liquid line UNF for hot gas line 3 Swage the pipe ends 4 Secure the pipes Installation sequence Connecting the refrigerant...

Page 33: ...62 201 A07 Liquid line 7 10 mm UNF 33 42 Hot gas line 7 16 mm UNF 63 77 201 A10 Liquid line 7 10 mm UNF 33 42 Hot gas line 7 16 mm UNF 63 77 201 A13 Liquid line 7 10 mm UNF 33 42 Hot gas line 7 16 mm UNF 63 77 Connection to the internal unit 2 1 3 2x D C D C D C C Liquid line D Hot gas line Installation sequence Connecting the refrigerant lines cont 5601 429 GB Installation ...

Page 34: ...erant lines from the external unit 2 Swage the pipe ends of the refriger ant lines Note If solder fittings are used solder the fittings using an inert gas 3 Fit refrigerant lines and insulate them to provide protection from heat and vapour diffusion Tighten the nuts with the following torques Type AWB AWB AC Line Connection to internal unit Torque in Nm 201 A04 Liquid line 7 6 mm UNF with reducer ...

Page 35: ...n accordance with DIN 4757 integral expansion vessel see page 72 Fit the safety assembly to the on site line in the heating water return 2 Connect secondary lines to the heat pump Please note To prevent equipment dam age connect on site secondary lines to the heat pump so that they are free of load and tor que stresses Make tight hydraulic connec tions on the secondary side 3 Fill and vent seconda...

Page 36: ...e contact humidistat Electrical connection 230 V 0 5 A Installation inside the room to be cooled at the cooling water flow remove thermal insulation if required If several rooms with different relative humidity are part of the cooling circuit fit and connect several contact humidi stats in series Switching contacts as N C contacts Electrical connections Routing electrical cables to the wiring cham...

Page 37: ...an not drift into the adjacent voltage area Please note The BUS connecting lead for the internal external unit 12 V or 43 V is in accordance with safety requirements not a low voltage cable The BUS connecting lead must be routed together with the 230 V cables Note To ensure that the control panel can be placed in the service position see page 85 all connections on the con trol panel see page 39 mu...

Page 38: ... 201 A13 BUS connecting lead 12 V Routing in the voltage range 230 V con nection see page 53 B Type AWB AWB AC 201 A04 and 201 A07 BUS connecting lead 43 V Routing in the voltage range 230 V con nection see page 53 Installation sequence Electrical connections cont 5601 429 GB ...

Page 39: ... that in case of failure for example when detaching a wire the wires can not drift into the adjacent voltage area Strip the insulation as close to the ter minals as possible If two components are connected to the same terminal press both wires together into a single wire ferrule Installation sequence Electrical connections cont 5601 429 GB Installation ...

Page 40: ...40 B E F D A C P202 12V COM P203 COM 43V F101 222 224 G F14 F4 aVG X31 F21 F16 F6 F0 F7 F13 F18 F20 211 212 Installation sequence Electrical connections cont 5601 429 GB ...

Page 41: ...utput 1000 W the indi vidual rating of a component e g pump valve message facility contac tor can be greater than specified However never exceed the breaking capacity of the corresponding relay The stated current indicates the max switching current of the switching con tact observe the total current of 5 A Safety LV is unsuitable for controlling external heat sources Set the required parameters du...

Page 42: ...es see the following chapter Connection values Output 100 W Voltage 230 V Max switching current 4 2 A Connect on site 212 3 DHW circulation pump Connection values Output 50 W Voltage 230 V Max switching current 4 2 A Connect on site Connecting a temperature limiter as a maximum temperature limiter for under floor heating Connecting a general temperature limiter B M 1 C B X2 N A X1 Connecting the t...

Page 43: ...ating water buffer cylinder 212 2 Heating circuit pump A1 HC1 Connecting the temperature limiter part no 7151 728 7151 729 B to mixer extension kit M 1 C B A sÖ sÖ A Connect plug sÖ to mixer extension kit B Temperature limiter C Heating circuit pump for heating cir cuit with mixer Installation sequence Electrical connections cont 5601 429 GB Installation ...

Page 44: ...tated current indicates the max switching current of the switching con tact observe the total current of 5 A Controls for external heat source and central fault message are unsuitable for safety LV Set the required parameters during com missioning see from page 74 Function components 230 V Plug sXS Terminals Function Explanation 222 1 Mixer motor control for external heat source Signal mixer CLOSE...

Page 45: ...ute low voltage via this con tact that requires an on site relay The boiler water temperature sensor in the external heat source plug F20 must capture the average temperature of the external heat source Connection values contact loads Voltage 230 V Max switching current 4 2 A Connect the high limit safety cut out on site In series to the secondary pump ter minal 211 2 on the main PCB In series to ...

Page 46: ...D High limit safety cut out max 70 C as heat pump protection K1 Relay sizing in accordance with the external heat source observe safety instructions Plug sXF Terminals Function Explanation 224 7 Circulation pump for DHW reheating or Connection values Max output 100 W Voltage 230 V Max switching current 4 2 A Connect on site EHE immersion heater con trol for connection see the following diagram Ins...

Page 47: ...N PE 400 V 50 Hz B Terminals of the heat pump control unit Immersion heater 230 V on site 224 7 X2 N N L1 L1 L1 B A N N A Immersion heater power supply 1 N PE 230 V 50 Hz B Terminals of the heat pump control unit Installation sequence Electrical connections cont 5601 429 GB Installation ...

Page 48: ...ect on site remove jumper when con necting Note No parameters need to be set The compressor is forced off as soon as the contact opens The supply voltage to the relevant com ponents subject to power supply utility is switched off by the power OFF contact signal For the instantaneous heating water heater the stages to be switched off can be selected parameter Output for instant heating water heater...

Page 49: ...ed heat pump shut down Breaking capacity 230 V 0 15 A Connect on site Connected in series if both safety com ponents are installed Insert jumper if no safety compo nents are installed X40 L1 Heat pump control unit power supply Phase L1 X40 Earth conductor connection X40 N Neutral conduc tor connection Connected to 230 V power supply on site Installation sequence Electrical connections cont 5601 42...

Page 50: ...Voltage 230 V Max switching current 4 2 A 3 way diverter valve connected at the fac tory connect the cylinder primary pump in parallel on site In conjunction with the pri mary store system Cylinder primary pump M 2 way shut off valve Controller and sensor PCB Set the required parameters during com missioning see from page 74 Note Plug F11 F17 Nothing must be connected to plug F11 and F17 on site S...

Page 51: ...external heat source connect on site Pt 500 PTC aVG KM BUS Connection of components on site cores interchangea ble If several of the following appliances are connected use KM BUS distributor accessory Extension kit for one heating circuit with mixer M2 HC2 Vitotrol 200A remote control assign the heating cir cuits at the remote control External extension H1 Vitocom 100 communication interface X31 C...

Page 52: ...0 V voltage area Overview of connections External unit Opening the external unit wiring chamber Type AWB AWB AC 201 A04 201 A07 201 A10 and A13 A A A A Wiring chamber BUS connection to the internal unit Note Do not interchange the BUS con nection wires between the internal and external units Compressor power supply Installation sequence Electrical connections cont 5601 429 GB ...

Page 53: ... 43V A B C A Wiring chamber external unit see page 52 B BUS connecting lead between the external and internal units Recommended cable 3 x 1 5 mm2 The cores are not interchangeable C AVI PCB in the internal unit see page 41 Note Route BUS connecting lead for internal external unit in the voltage range 230 V Installation sequence Electrical connections cont 5601 429 GB Installation ...

Page 54: ...earth ing in the system can lead to seri ous injury from electrical current if an electrical fault occurs Connect the appliance and pipe work to the equipotential bonding of the house in question Danger Incorrect core allocation can cause severe injury and damage the appliance Never interchange cores L and N In negotiations with your power supply utility different supply tariffs for the main power...

Page 55: ...se as the heat pump control unit we recom mend using the same fuse MCB Connection to the same fuse MCB provides additional safety when the power is switched off Observe the power consumption of the connected consumers Heat pump control unit power supply 230 V X40 A N L1 N L1 F1 T6 3 AH 1 N PE 230 V 50 Hz Note This supply must never be blocked Max fuse rating 16 A Standard tariff no optional econom...

Page 56: ...le 3 x 2 5 mm2 3 x 2 5 mm2 3 x 2 5 mm2 max 16 m 3 x 4 0 mm2 max 20 m or 3 x 4 0 mm2 max 26 m 3 x 6 0 mm2 max 30 m Fuse protection B20A B20A B25A B32A Economy tariff and power OFF can be used No parameters need to be set when using economy tariff with power OFF The compressor is shut down during the power OFF period During power OFF the diagnostic functions for the external unit are not supported N...

Page 57: ...t see page 39 B Jumpers Recommended power cable Phase asymmetrical 400 V 5 x 2 5 mm2 Phase asymmetrical 230 V 7 x 2 5 mm2 Fuse rating max 16 A Economy tariff and power OFF can be used Power supply with power OFF Power OFF without on site load disconnection The power OFF signal is connected directly to the heat pump control unit The compressor is forced off when power OFF is enabled Installation se...

Page 58: ...3 4 4 3 3 N 3 N 4 K kWh kWh 5 3 400 V 7 230 V X40 E Diagram excluding fuses and RCD A Heat pump control unit internal unit luster terminals see page 39 B Instantaneous heating water heater if installed C Heat pump compressor external unit D Heat pump control unit power sup ply see page 55 E High tariff meter F Backup fuse ripple control receiver G Ripple control receiver contact open power OFF ena...

Page 59: ... C B E H 3 3 4 4 3 3 N 3 N G K 4 kWh kWh 3 L D 7 5 400 V 230 V X3 7 X3 6 A X40 F Diagram excluding fuses and RCD A Heat pump control unit internal unit luster terminals see page 39 B Instantaneous heating water heater if installed C Heat pump compressor external unit D Heat pump control unit power sup ply see page 55 E High tariff meter F Backup fuse ripple control receiver G Ripple control receiv...

Page 60: ...ger An absence of component earth ing in the system can lead to seri ous injury from electrical current if an electrical fault occurs Attach earth conductor to front panel and side panel Fitting the front panel of the internal unit 2 1 2x 3 Note Ensure that the locking screws are tight ened before operating Installation sequence Closing the heat pump 5601 429 GB ...

Page 61: ...61 Fitting the side cover for the external unit In reverse order to Opening the external unit wiring chamber page 52 Installation sequence Closing the heat pump cont 5601 429 GB Installation ...

Page 62: ...for leaks 69 8 Filling and venting on the secondary side 70 9 Checking expansion vessel and heating circuit pressure 72 10 Checking electrical connections of the internal unit for firm seating 11 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 73 13 Cleaning the heat exchanger evaporator in the exte...

Page 63: ...rding to external unit type plate 20 Checking the heat pump for unusual noises e g operating noise of fan compressor and pump venting again if required 21 Checking the system function e g actuators temperatures heat meter if applicable 82 22 Instructing the system user 82 Commissioning inspection maintenance Steps commissioning inspection and cont 5601 429 GB Service ...

Page 64: ...y due to electric shock and component damage in the event of an electrical fault All earth connectors must be reconnected Please note Wait at least 30 min between the installation and commissioning of the appliance to prevent equip ment damage Work on the refrigerant circuit may only be carried out by certi fied personnel in accordance with EC Directives 842 2006 and 303 2008 1 Remove front panel ...

Page 65: ... skin damage Wear safety goggles and protec tive gloves when working on the refrigerant circuit Please note Before evacuating the refrigerant lines and the internal unit check all connections for tightness with leak detecting spray Keep the valves on the external unit shut and fill the system with nitrogen through the service valve The test pressure is the max permissible operating pres sure Commi...

Page 66: ...ll hose between pressure gauge set and external unit H Pressure gauge set K Connection hose between pressure gauge set and vacuum pump L Vacuum pump M Connection hose between pressure gauge set and vacuum gauge N Valve for vacuum gauge O Vacuum gauge Please note Never subject the vacuum gauge to positive pressure 1 Close all valves at the pressure gauge set Commissioning inspection maintenance Fur...

Page 67: ...the vacuum gauge Leave the vacuum pump running until almost 0 bar is indicated on the vac uum gauge at least 30 min Note The vacuum pump runtime will depend on the ambient conditions 5 Close the valve on the pressure gauge set to the vacuum pump Stop the vacuum pump and wait approx 5 min There is a leak if the indication on the vacuum gauge rises Remove the leak and repeat the proc ess 6 Close all...

Page 68: ...Wear safety goggles and protec tive gloves when working on the refrigerant circuit Please note Topping up the system with refrigerant or evacuating the refrigerant can result in appliance damage Flush the secondary side of the plate heat exchanger of the inter nal unit with water or drain it com pletely Please note With all connections counterhold with a second open ended spanner Line lengths up t...

Page 69: ...ry Refrigerant fill volume per metre of line length for line lengths from 12 m to 30 m Type AWB AWB AC R410A in g m 201 A04 20 201 A07 60 201 A10 60 201 A13 60 Checking the refrigerant circuit for leaks Danger R410A is a non poisonous gas that displaces air Uncontrolled escape of refrigerant R410A in enclosed spaces can result in dif ficulties in breathing and suffoca tion Ensure adequate ventilat...

Page 70: ...water with a hardness above 16 8 dH 3 0 mol m3 e g with the small softening system for heating water see the Viessmann Vitoset pricelist A 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 3 Fill flush and vent the secondary cir cuit via an on site connection 4 Check the system pressure at pres sure gauge A and...

Page 71: ...dary circuit air vent valve B Open secondary circuit air vent valve B 9 Move 3 way diverter valve C by its handle into its centre position 10 Close secondary circuit air vent valve B Commissioning inspection maintenance Further details regarding the individual steps cont 5601 429 GB Service ...

Page 72: ...ressure of the expansion vessel at test nipple A and recharge if required Pre charge pressure 0 75 to 0 95 bar Note Also check the pre charge pressure at the on site expansion vessel Commissioning inspection maintenance Further details regarding the individual steps cont 5601 429 GB ...

Page 73: ... unit from the power supply and safeguard against reconnection Be aware that the fan may run on Cleaning with compressed air 1 Open the casing of the external unit Please note The sharp edges of the heat exchanger can cause inju ries Avoid contact with the heat exchanger 2 Please note Excessive air pressure from the front and sides can result in the deformation of the alu minium fins of the heat e...

Page 74: ...cking refrigerant circuit for leaks The following sequence must be fol lowed 1 Switch ON external unit voltage 2 Wait 2 min 3 Switch ON internal unit voltage 4 Start internal unit at the ON OFF switch Note If the internal unit is switched ON before the external unit or the waiting time is shorter than 2 min the fault message 0A Fault external unit appears Service instructions for Vitotronic 200 he...

Page 75: ...rranty Switch on the ON OFF switch on the heat pump control unit The prompt Start commission ing appears automatically on first commissioning Note The commissioning assistant can also be started manually To do this when you switch on the heat pump control unit progress bar visible hold down When the unit is commissioned the display is in German Sprache Cesky CZ Deutsch DE Dansk English DK GB Wähle...

Page 76: ...nal inputs Actuator test Commissioning terminated Control mode OK OK OK OK OK OK OK OK OK OK OK NO YES OK Function check Coding level 1 Date set Time set Commissioning without the commissioning assistant Enabling the service menu The service menu can be enabled from any menu Press OK å simultaneously for approx 4 s Commissioning inspection maintenance Further details regarding the individual steps...

Page 77: ... 6 Alternatively if the service menu was already enabled Extended menu 1 å 2 Service 3 Select Coding level 1 4 Select parameter group System definition 5 Select parameter System scheme 6 Confirm parameter code 7000 7 Set system scheme 6 Required parameters for the heat pump Output compressor stage 5030 The heating output of the heat pump subject to type must be selected during commissioning Type A...

Page 78: ... heat source Ó Enable external heat source 7B00 1 External heat source Ó Enable external heat source for DHW heating 7B0D 1 In conjunction with the primary store system Cylinder primary pump 2 way motorised valve System definition Ó System scheme 7000 With DHW heating Extension kit mixer for heating circuit M2 HC2 System definition Ó System scheme 7000 With heating circuit M2 HC2 Note Set rotary s...

Page 79: ...External extension 7010 1 Note For parameters for external hook up see the following table External functions External functions Parameter Setting External demand Internal hydraulics if applicable Ó Flow temperature for external demand 730C Set flow temperature for external demand External starting of the com pressor mixer in control mode or OPEN System definition Ó Effect of external demand on he...

Page 80: ... of external block ing on pumps compressor 701A 0 to 31 External blocking of the com pressor mixer in control mode or CLOSED System definition Ó Effect of ext blocking on heat pump heating circuits 7015 0 to 8 System definition Ó Effect of external block ing on pumps compressor 701A 0 to 31 Type AWB AC Cooling function Cooling function parameters Setting Cooling Ó Cooling 7100 3 Cooling Ó Cooling ...

Page 81: ...W 3 for 9 kW DHW if applicable Ó Enable electric heaters for DHW heating 6015 1 External heat source External heat source parameters Setting External heat source Ó Enable external heat source 7B00 1 With circulation pump for DHW reheating External heat source Ó Enable booster heaters for DHW heating 6014 1 Immersion heater Immersion heater parameters Setting DHW Ó Enable electric heaters for DHW h...

Page 82: ...taneous heating water heater may respond Heat the high limit safety cut out above 20 C e g with a blow dryer and press reset button A of the high limit safety cut out A Instructing the system user The system installer must hand the oper ating instructions to the system user and instruct him her in the operation of the system Commissioning inspection maintenance Further details regarding the indivi...

Page 83: ...83 Opening the programming unit 1 3 2 2x Troubleshooting Repairs 5601 429 GB Service ...

Page 84: ...84 Removing cover from programming unit if necessary 5 4 4x Troubleshooting Repairs cont 5601 429 GB ...

Page 85: ...85 Placing the control panel in its service position 4x 2 3 1 Troubleshooting Repairs cont 5601 429 GB Service ...

Page 86: ...86 Removing the separating plate 1 2 Troubleshooting Repairs cont 5601 429 GB ...

Page 87: ...87 Overview of internal components Internal unit D P O A B C M G L F E N K H H Troubleshooting Repairs cont 5601 429 GB Service ...

Page 88: ...ture sensor IRT K Secondary circuit return tempera ture sensor L Secondary circuit flow temperature sensor M 3 way diverter valve for Heating DHW N Secondary pump O Secondary circuit drain fill valve P Safety valve 3 bar Overview of internal components External unit Danger Contact with live components can result in severe injuries Capacitors remain live after the power supply has been switched OFF...

Page 89: ...ture sensor air intake evaporator OAT D Temperature sensor evaporator OMT E 4 way diverter valve F Electronic expansion valve EEV G Temperature sensor compressor head CTT H Liquid separator K Temperature sensor refrigerant inlet evaporator OCT L Compressor Troubleshooting Repairs cont 5601 429 GB Service ...

Page 90: ...perature sensor air intake evaporator OAT D Temperature sensor evaporator OMT E 4 way diverter valve F Electronic expansion valve EEV G Temperature sensor compressor head CTT H Liquid separator K Temperature sensor refrigerant inlet evaporator OCT L Compressor Troubleshooting Repairs cont 5601 429 GB ...

Page 91: ...ensor air intake evaporator OAT D Temperature sensor evaporator OMT E 4 way diverter valve F Electronic expansion valve EEV G Temperature sensor compressor head CTT H Liquid separator K Temperature sensor refrigerant inlet evaporator OCT L Compressor M High pressure switch pHi Troubleshooting Repairs cont 5601 429 GB Service ...

Page 92: ...r F4 Cylinder temperature sensor top F6 and bottom F7 Flow temperature sensor system F13 Boiler water temperature sensor external heat source F20 Pt 500 Temperature sensor compres sor head CTT NTC 50 kΩ External unit see page 88 Refrigerant circuit control observe label on the exter nal unit Flow temperature sensor secon dary circuit upstream of instanta neous heating water heater LWT Liquid gas t...

Page 93: ...00 20 40 60 640 Temperature sensors type Pt 500 460 20 540 100 Resistance in Temperature in C 60 140 180 620 700 780 860 20 Temperature sensors NTC 10 kΩ 0 1 1 10 100 1000 Resistance in kΩ 30 20 10 0 10 20 30 40 50 60 70 80 90 100 Temperature in C Troubleshooting Repairs cont 5601 429 GB Service ...

Page 94: ...rol unit Fuse F3 is located on the main PCB Fuse F101 is located on the AVI PCB Fuse F1 and F3 T 6 3AH 250 V Max power loss 2 5 W Fuse F101 T 1 0AL Max power loss 2 5 W Danger Touching live components can result in severe injury due to elec tric shock Before working on the appliance always ensure that the main power circuit is also isolated Removing this fuse does not isolate the main power circui...

Page 95: ...red Serial no see type plate A Assembly from this parts list Position number of the individual part within the assembly from this parts list Standard parts are available from your local dealer Parts lists internal unit Parts lists internal unit 5601 429 GB Service ...

Page 96: ...96 A B C E A Type plate B Assembly casing C Assembly electrical equipment E Assembly hydraulics Parts lists internal unit Overview of the assemblies internal unit 5601 429 GB ...

Page 97: ...e WO1B serv ice instructions 0009 Adaptor Casing internal unit 0001 Front panel 0002 Casing frame 0003 Bottom panel front 0004 Cover 0005 Mounting plate expansion vessel condenser 0006 Separating plate 0007 Bottom panel back 0008 Viessmann logo 0009 Diaphragm grommet DG36 0010 Diaphragm grommet 0011 Control panel 0012 Screws Parts lists internal unit Parts not shown internal unit 5601 429 GB Servi...

Page 98: ...98 0008 0001 0008 0011 0006 0007 0003 0004 0010 0009 0005 0012 0002 Parts lists internal unit Casing internal unit cont 5601 429 GB ...

Page 99: ...panel programming unit 0035 Retaining spring 0036 Outside temperature sensor Parts not shown 0003 PCB with connection adaptor SA136 A10 0004 PCB with connection adaptor ON OFF switch SA137 A10 0012 Connecting cable instantaneous heating water heater 0014 Connecting cable secondary pump 0015 Cable harness 230 V power supply 0016 Connecting cable 3 way diverter valve 0017 Cable harness X5 low voltag...

Page 100: ...ics internal unit 0001 Hot gas line 0002 Liquid line 0003 Connecting cable condenser instantaneous heating water heater 0004 Connecting cable condenser circulation pump 0005 DHW cylinder flow 0006 Intermediate piece with plug in connector DN 28 Parts lists internal unit Electrical equipment internal unit cont 5601 429 GB ...

Page 101: ...ection line expansion ves sel 0022 Clip 7 8 0023 Clip 7 10 0024 Clip 7 18 0025 Air vent valve G 0026 Pressure gauge 0027 Expansion vessel 0028 Instantaneous heating water heater 9 kW 0029 Schrader valve 0030 Hose ferrule G 7 19 0031 Safety valve 3 bar 7 19 9 x G 0032 Temperature sensor Pt 500 0033 Union nut G with sealing cap 0034 Spring clip 7 28 0035 Circulation pump VIRS 15 7 3 0036 Distributor...

Page 102: ...3 0029 0013 0019 0001 0011 0029 0041 0023 0022 0036 0022 0032 0040 0011 0033 0040 0029 0037 0034 0034 0006 0034 0007 0034 0010 0039 0032 0026 0028 0003 0025 0042 0017 0014 0043 0021 0043 0027 0043 0015 0043 0039 0004 0043 0043 0020 0016 Parts lists internal unit Hydraulics internal unit cont 5601 429 GB ...

Page 103: ...nnection plate 0015 Valve cover 0016 4 way diverter valve complete 0017 4 way diverter valve 0018 Coil EEV 0019 Side panel right 0020 Protective grille 0021 Heat exchanger evaporator 0022 Connecting plate 0023 Heat exchanger mounting plate 0024 Top panel 0025 M5 nut 0026 Transport handle 0027 Side panel left 0028 Terminal strip 4 pole 0029 Electronic expansion valve 0030 Temperature sensor NTC 10 ...

Page 104: ...08 0025 0005 0004 0019 0015 0006 0023 0027 0009 0014 0028 0026 0024 0021 0010 0022 0016 0002 0001 0003 0017 0032 0013 0018 0029 0007 0011 0012 Parts lists external unit External unit type AWB AWB AC 201 A04 cont 5601 429 GB ...

Page 105: ...dryer 0021 Cover power supply 0022 PCB mains filter 0023 Connection plate 0024 Electronic expansion valve 0025 Coil EEV 0026 Heat exchanger evaporator 0027 Protective grille 0028 Retainer temperature sensor 0029 Transformer 0030 Partition 0031 ODU control unit 0032 Motor support 0033 Top panel 0034 Transport handle 0035 Cover 0036 Temperature sensor NTC 10 kΩ OAT OMT 0037 Temperature sensor NTC 10...

Page 106: ...0032 0028 0033 0035 0034 0004 0007 0021 0022 0023 0012 0038 0020 0013 0019 0018 0010 0009 0002 0001 0008 0003 0037 0011 0006 0005 0025 0024 0014 0015 0017 0016 Parts lists external unit External unit type AWB AWB AC 201 A07 cont 5601 429 GB ...

Page 107: ... B C D A Type plate B Casing assembly C Electrical equipment assembly D Hydraulic assembly Parts lists external unit Overview of the assemblies external unit type AWB AWB AC 201 A10 A13 5601 429 GB Service ...

Page 108: ...hanger evaporator top 0010 Axial fan 0011 DC motor 0012 Protective grille left 0013 Transport handle left 0014 Motor support 0015 Air inlet ring 0016 Transport handle right 0017 ODU control unit 0018 Temperature sensor NTC 10 kΩ OAT 0019 Temperature sensor NTC 10 kΩ OMT 0020 Temperature sensor NTC 10 kΩ OCT 0021 M8 nut Parts lists external unit Casing external unit type AWB AWB AC 201 A10 A13 5601...

Page 109: ...0014 0001 0018 0011 0009 0008 0006 0006 0004 0016 0005 0007 0015 0017 0021 0010 0015 0021 0010 0002 0016 0003 0020 0019 Parts lists external unit Casing external unit type AWB AWB AC 201 A10 cont 5601 429 GB Service ...

Page 110: ...ature sensor 0016 Wiring harness compressor 0017 Wiring harness complete com pressor 0018 Temperature sensor NTC 10 kΩ OCT 0019 Temperature sensor NTC 50 kΩ CTT 0020 Communication cable drivers 0021 Communication cable IDU 0022 Power cable controller PCB ODU 0023 Communication cable starter controller 0024 Power cable driver filter 0025 Power cable line filter 0026 Power cable controller input 002...

Page 111: ...111 0013 0010 0009 0008 0007 0001 0012 0006 0011 0005 0003 0002 0004 Parts lists external unit Electrical equipment external unit type cont 5601 429 GB Service ...

Page 112: ...alve 0007 Oil separator 0008 Electronic expansion valve 0009 Compressor thermal insulation 0010 Temperature sensor NTC 50 kΩ CTT 0011 Shut off valve liquid line 0012 Compressor power supply cover Parts not shown 0013 Connection set for condensate line if installed Parts lists external unit Hydraulics external unit type AWB AWB AC 201 A10 A13 5601 429 GB ...

Page 113: ...113 0012 0009 0001 0011 0008 0002 0004 0010 0006 0007 0005 0003 Parts lists external unit Hydraulics external unit type AWB AWB AC cont 5601 429 GB Service ...

Page 114: ...ary circuit flow temperature 35 C at air intake temperature 15 C K 2 to 4 Testing the mixer heat pump and cylinder heating Tested under the following conditions Room temperature C Outside air temperature C Temperature Cylinder temp top con stant Yes 1 K Secondary circuit flow temperature C Rising From To Temperature differential ΔT Flow temp secondary Return temp sec 6 to 8 K Control parameters re...

Page 115: ...demand on heat pump heating circuits 7014 4 Effect of ext blocking on heat pump heat ing circuits 7015 4 Vitocom 100 7017 0 Effect of external blocking on pumps compressor 701A 0 Common flow temperature sensor sys tem 701B 1 Compressor Enable compressor 5000 1 Output compressor stage 1 5030 Rated heating out put according to type plate External heat source Enable external heat source 7B00 0 Priori...

Page 116: ...th combi cylin der 6016 0 Start attempts for DHW after high pres sure shutdown 6017 1 Operating mode cylinder primary pump 6020 Never adjust Electric heater Enable instantaneous heating water heater 7900 0 Enable instant heating water heater for central heating 7902 1 Max output instantaneous heating water heater 7907 3 Output for instant heating water heater at power OFF 790A 0 Dual mode temp ins...

Page 117: ...emperature hook up 200B 3 Max flow temperature heating circuit 200E 400 40 C Room temperature in party mode 2022 200 20 C Heating circuit 2 Standard room temperature 3000 200 20 C Reduced room temperature 3001 200 20 C Remote control 3003 0 Heating curve level 3006 0 0 K Heating curve slope 3007 6 0 6 Influence room temperature hook up 300A 10 Room temperature hook up 300B 3 Max flow temperature h...

Page 118: ...er summertime wintertime 7C00 1 Start summertime month 7C01 3 Start summertime week 7C02 5 Start summertime day 7C03 7 Start wintertime month 7C04 10 Start wintertime week 7C05 5 Start wintertime day 7C06 7 Control Lock out controls 8800 0 Commissioning service reports Control parameters report cont 5601 429 GB ...

Page 119: ... Power consumption kW 0 97 1 88 2 36 3 40 Coefficient of perform ance ε COP in heat ing mode 4 64 4 26 4 62 4 29 Cooling capacity data at 100 to EN 14511 A35 W7 C spread 5 K Rated cooling capacity kW 3 2 6 2 7 4 9 1 Compressor frequency Hz 60 65 55 70 Fan speed rpm 870 650 650 650 Power consumption kW 1 08 2 40 2 69 3 64 Energy efficiency ratio EER in cooling mode 2 96 2 60 2 75 2 50 Output contro...

Page 120: ...l h 600 820 1200 1380 Max external pressure drop RFH at min flow rate mbar 590 540 440 380 Max flow temperature C 55 55 55 55 Electrical values External unit Rated voltage com pressor 1 N PE 230 V 50 Hz Max rated current compressor A 5 9 10 15 Starting current compressor A 10 5 15 10 10 Starting current compressor with stalled armature A 20 25 25 32 Starting current heating of the DC condensers A ...

Page 121: ... voltage 1 N PE 230 V 50 Hz 3 N PE 400 V 50 Hz Heating output kW 9 9 9 9 Fuse protection power supply 3xB16A 3xB16A 3xB16A 3xB16A Electrical power con sumption Fan max W 65 70 130 130 External unit max W 3 0 3 6 5 8 5 8 Secondary pump at stage 3 2 1 W 132 92 62 132 92 62 132 92 62 132 92 62 Control unit PCB external unit max W 150 150 150 150 Control unit PCB internal unit max W 5 5 5 5 Max output...

Page 122: ...43 4 3 43 4 3 43 4 3 Low pressure side bar MPa 43 4 3 43 4 3 43 4 3 43 4 3 Dimensions External unit Total length mm 869 1040 900 900 Total width mm 290 340 340 340 Total height mm 610 865 1255 1255 Internal unit Total length mm 450 450 450 450 Total width mm 360 360 360 360 Total height mm 850 850 850 850 Total weight External unit kg 43 66 110 110 Internal unit type AWB kg 48 48 53 53 Internal un...

Page 123: ...e Pipe 7 mm 6 x 1 6 x 1 6 x 1 6 x 1 Internal unit UNF External unit UNF Hot gas line Pipe 7 mm 12 x 1 16 x 1 16 x 1 16 x 1 Internal unit UNF External unit UNF Max line length liquid line hot gas line m 20 30 30 30 Weighted total sound power level test with reference to DIN EN 12102 DIN EN ISO 9614 2 Weighted total sound power level at A7 C 3 K W35 C 5 K at rated heating output dB A 60 62 62 63 Spe...

Page 124: ...System example 2 Sketch for alternative hydraulic scheme Heating circuits fully installed and filled Electrical installation completed Hydraulic lines fully thermally insulated Installation completed in full up to refrigerant circuit All windows and external doors sealed Components for cooling mode fully installed optional Preferred appointment 1 Date Time 2 Date Time All work ordered from Viessma...

Page 125: ...EN 60 335 2 40 2010 03 DIN EN 349 DIN EN 60 335 1 with A14 2010 11 EN 378 DIN EN 61 000 3 2 2010 02 BGR 500 Chapter 2 35 DIN EN 61 000 3 3 2009 06 In accordance with the following Directives this product is designated with _ 2004 108 EC 2006 42 EC 97 23 EC 2006 95 EC Details according to the Pressure Equipment Directive 97 23 EC Category I Mod ule A1 The product characteristics determined as syste...

Page 126: ...rant circuit 69 Checking solder joints 69 Checking swaged connections 69 Checking the electrical connections of the external unit 74 Checking the fan 73 Checking the free running of the fan 73 Checking the pressure 72 Checking the sensors 92 Checking the system pressure 72 Checking threaded fittings 69 Chilled ceiling 36 Circulation pump for DHW reheating 78 Cleaning the heat exchanger 73 Closing ...

Page 127: ...ameter settings 81 Electric heater 41 Electronic expansion valve 89 90 91 Enable Electric booster heater 81 Instantaneous heating water heater 81 Enable electric booster heater 81 Evacuating a refrigerant circuit 65 Evacuating refrigerant lines 65 Evacuation refrigerant circuit 65 Evaporator 89 90 91 Expansion vessel 70 72 Extended menu 77 Extension kit mixer 78 Extension PCB 44 External blocking ...

Page 128: ...3 Heating water return heating water flow 35 Heat pump control unit Power cable 9 Heat pump start sequence 74 Height differential of internal unit exter nal unit 31 High pressure fault 25 Hot gas line 123 External unit 33 Internal unit 34 Hydraulic installation scheme 12 18 Hydraulic parameters 114 I Ice formation 26 Immersion heater 47 Inspection 64 Installation External unit 25 Internal unit 28 ...

Page 129: ...tions 48 Minimum clearances External unit 26 Internal unit 29 Minimum room volume 28 Mixer extension kit 43 N NTC curve Temperature sensors 93 94 O Oil lift bends 31 ON OFF switch 75 On site connections 7 On site load disconnection 57 59 Opening the heat pump 64 Opening the programming unit 83 Operating components 41 44 Operator s log 69 Output compressor stage 77 Output data heating 119 Outside t...

Page 130: ...ernal unit 27 Power cable 9 External unit 56 Heat pump control unit 55 Instantaneous heating water heater57 Power OFF 9 56 57 Power OFF signal 57 59 Power supply Compressor 52 External unit 56 General information 54 Instantaneous heating water heater57 Power supply utility 57 Recommended power cables 9 Preparing connections 8 Pressure gauge set 66 Primary store system 50 Protective gloves 65 68 69...

Page 131: ...pump 74 Switching contacts Contact humidistat 36 Switching on appliance 74 System schemes 12 18 System schemes overview 9 T Temperature limiter 42 Temperature sensor 92 Air intake evaporator OAT 89 90 91 Compressor head CTT 89 90 91 Evaporator OMT 89 90 91 NTC curve 93 94 Refrigerant inlet evaporator OCT 89 90 91 Temperature sensor air intake evapo rator 92 Temperature sensor compressor head 92 Te...

Page 132: ...al No 7424689 7424690 7424691 7424692 7454115 7454116 7454117 7454118 Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5601 429 GB Subject to technical modifications Printed on environmentally friendly chlori...

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