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 operation For applicability, see the last page VITOCAL 200-S 2/2013 Please keep safe.
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained 2 Danger This symbol warns against the risk of injury.! Please note This symbol warns against the risk of material losses and environmental pollution. Note Details identified by the word "Note" contain additional information. Target group These instructions are exclusively intended 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 electrician. The system must be commissioned by the system installer or a qualified person 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 environmental 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 a ÖNORM, EN and ÖVE c SEV, SUVA, SVTI, SWKI and SVGW Working on the system Isolate the system from the power supply (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 reconnection.
Safety instructions Safety instructions (cont.)! Please note Electronic assemblies can be damaged by electrostatic discharge. 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 system. 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-authorised 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. 3
Index 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... 14 Connecting the refrigerant lines... 17 Connecting a secondary circuit... 23 Connecting a cooling circuit if required... 24 Electrical connections... 24 Power supply... 46 Closing the heat pump... 54 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance... 56 Further details regarding the individual steps... 58 Troubleshooting Repairs... 79 Parts lists, internal unit Parts lists, internal unit... 91 Overview of assemblies, internal unit... 92 Parts not shown, internal unit... 93 Casing, internal unit... 93 Electrical equipment, internal unit... 95 Hydraulics, internal unit, type AWB... 97 Hydraulics, internal unit, type AWB-AC... 99 Parts lists for external unit 230 V~, type AWB/AWB-AC 201.B04 Ordering individual parts... 101 External unit... 101 Parts lists for external unit 230 V~, type AWB/AWB-AC 201.B07 Ordering individual parts... 103 External unit... 103 Parts lists for external unit 230 V~, type AWB/AWB-AC 201.B10, B13 Ordering individual parts... 105 4 Index
Index Index (cont.) Overview of the assemblies... 106 External unit casing... 107 Electrical equipment, external unit... 109 Hydraulics, external unit... 111 Parts lists for external unit 400 V~, type AWB/AWB-AC 201.C10, C13 Ordering individual parts... 113 Overview of the assemblies... 114 External unit casing... 115 Electrical equipment, external unit... 117 Hydraulics, external unit... 119 Commissioning/service reports Hydraulic parameter report... 121 Control parameters report... 121 Specification... 129 Appendix Commissioning order... 137 Declaration of conformity... 138 Keyword index... 139 5
Preparing for installation Intended use The appliance is only intended to be installed and operated in sealed unvented heating systems that comply with EN 12828, with due attention paid to the associated installation, service and operating instructions. Depending on the version, the appliance can only be used for the following purposes: Central heating Central cooling DHW heating The range of functions can be extended with additional components and accessories. Intended use presupposes that a fixed installation in conjunction with permissible, system-specific components has been carried out. Commercial or industrial usage for a purpose other than central heating/cooling or DHW heating shall be deemed inappropriate. Any usage beyond this must be approved by the manufacturer for the individual case. Incorrect usage or operation of the appliance (e.g. the appliance being opened by the system user) is prohibited and results in an exclusion of liability. Incorrect usage also occurs if the components in the heating system are modified from their intended function. Note The appliance is intended exclusively for domestic use, i.e. even users who have not had any instruction are able to operate the appliance safely. 6
Requirements regarding on-site connections Preparing for installation Internal unit A B 450 360 360 58 50 40 905 150 AB / 960 75 147 219 294 369 + 1105 41 Installation 7
Preparing for installation Requirements regarding on-site connections (cont.) Symbol Meaning Connection Refrigerant lines from/to the external unit: Type AWB/ AWB-AC Pipe 7 UNF 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 16 mm 16 mm 16 mm 16 mm Liquid line 201.B04 6 mm ⅝ Reducer ⅝ x ⁷ ₁₆ DHW cylinder flow (heating water side) Heating water return and DHW cylinder return Heating water flow 201.B07 201.B10 201.B13 201.C10 201.C13 10 mm 10 mm 10 mm 10 mm 10 mm ⅞ ⅞ ⅞ ⅞ ⅞ ⅝ ⅝ ⅝ ⅝ ⅝ G 1¼ G 1¼ G 1¼ A Cable entry < 42 V B Cable entry 400 V~/230 V~, > 42 V 1. Prepare the connections on the heating water and the DHW side. Flush the heating system. 2. Prepare the electrical connections. 8
Requirements regarding on-site connections (cont.) Preparing for installation 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 mm 2 With power-off 5 x 1.5 mm 2 Instantaneous heating water heater Cable cross-section 400 V~ 5 x 2.5 mm 2 230 V~ 7 x 2.5 mm 2 Max. cable length 25 m Installation Type AWB, AWB-AC 201.B04 201.B07 201.B10 201.B13 External unit 230 V~ (compressor) Cable cross-section 3 x 2.5 mm 2 3 x 2.5 mm 2 3 x 2.5 mm 2 3 x 4.0 mm 2 Max. cable length 29 m 25 m 20 m 20 m or or Cable cross-section 3 x 4.0 mm 2 3 x 6.0 mm 2 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 mm 2 5 x 2.5 mm 2 Max. cable length 30 m 30 m 9
Installation sequence Installing the external unit! Please note Avoid damaging the appliance during transport. Never put weight on top of the appliance.! Please note If the compressor in the external unit is strongly tilted, lubricant will enter the refrigerant circuit and damage the appliance. Note the max. tilting angle of 45. Installation requirements Installation site Select a site with good air circulation, so that the cooled air can dissipate and be replaced by warm air. Avoid direct insolation. When siting the unit in a location exposed to wind, ensure that the wind does not affect the fan area. This could result in an "air short circuit" between the air being discharged and the air being drawn in. Strong wind can have a negative influence on the evaporator ventilation. Please note! An "air short circuit" during heating operation will result in the cooled discharged air reentering the unit. This can result in reduced heat pump efficiency and defrosting problems. Avoid "air short circuits". Please note! An "air short circuit" during cooling operation will result in the heated discharged air reentering the unit. This can lead to high pressure faults. Avoid "air short circuits". Take the lengths of the refrigerant lines into account (see "Connecting refrigerant lines"). Select the installation site so that the evaporator cannot be blocked by leaves, snow etc. Select the installation site with due consideration of the physical laws of sound dissipation and reflection. Technical guide "Heat pump principles" Never site in corners, recesses or between walls. Never install next to or below bedroom windows. Never install closer than 3 m to pathways, downpipes or sealed surfaces. The cooled air in the discharge area creates a risk of ice forming when outside temperatures fall below 10 C. The installation site should be easily accessible, for example for maintenance work (see "Minimum clearances"). 10
Installation sequence Installing the external unit (cont.) Types of installation Floorstanding installation with cable entry above ground level Floorstanding installation with cable entry below ground level Wall mounting Technical guide Installation information Floorstanding installation: Use supports (accessories) for floorstanding installation. Where such supports cannot be used, install the external unit freestanding on a solid base of at least 100 mm height (provide on site). In difficult climatic circumstances (temperatures below zero, snow, humidity) install the appliance on a plinth of approx. 300 mm height. Take account of the weight of the external unit (see following table). Wall mounting: Use the wall mounting bracket set (accessories). The wall must meet the structural requirements. Never install with the discharge side facing the main wind direction. Observe wind loads when installing the unit on sites exposed to wind. Provide wall ducts and protective pipes for the refrigerant lines and electrical cables without moulded parts and change of direction. Incorporate the external unit into the lightning protection system. Consider the heat emitted by the unit when planning your weatherproofing or an enclosure. Ensure the condensate can drain freely, and create a permanent gravel bed below the external unit as a soakaway. In regions with prolonged cold seasons (e.g. in Germany), provide an electric supplementary heating facility (accessories) for the condensate pan. For insulating against structure-borne noise and vibrations between the building and the external unit, consider the following measures: When cable entry is above ground level, fit pipe bends in the refrigerant lines for vibration compensation (see "Connecting 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/m 2 ), in other words not on lightweight walls, roof structures etc. When installing the unit on the floor, use only the rubber mounts supplied; for wall mounting use the antivibration mounts supplied with the wall mounting bracket set; never use additional anti-vibration mounts, springs, rubber buffers etc. Weight of external units Type Weight in kg AWB/AWB-AC 201.B04 43 201.B07 66 201.B10 110 201.B13 110 11 Installation
Installation sequence Installing the external unit (cont.) Type Weight in kg AWB/AWB-AC 201.C10 113 201.C13 113 Minimum clearances b A a c d B Example type AWB/AWB-AC 201.B04 A Air intake B Air discharge Type AWB/ AWB-AC 12 Dimensions in mm a b c d Cable entry above ground level below ground level 201.B04 100 100 400 300 1000 201.B07 100 100 400 300 1000 201.B10 100 200 400 300 1000 201.B13 100 200 400 300 1000 201.C10 100 200 400 300 1000 201.C13 100 200 400 300 1000
Installation sequence Installing the external unit (cont.) Floor mounting Installation 2. 4x E 1. 4x A B C D A Support for floorstanding installation (accessory) 13
Installation sequence Installing the external unit (cont.) B Gravel bed as condensate soakaway C Concrete foundations (see technical guide) D Drainage pipe DN 100 (only with entries below ground level) E Rubber mounts (supplied) Note We recommend letting condensate drain away freely (without condensate pipe). Wall mounting Installation must only be performed with the bracket set suitable for wall mounting (accessory). Separate installation instructions Installing the internal unit! Please note Avoid damaging the appliance during 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. Safeguard ambient temperatures between 0 and 35 C. Please note! Avoid the risk of explosion due to dust, gases and vapours in the installation room. Minimum room volume (to EN 378): Type AWB/AWB- AC Minimum room volume in m 3 201.B04 2.7 201.B07 4.8 201.B10 6.7 201.B13 6.7 201.C10 6.7 201.C13 6.7 14
Installation sequence Installing the internal unit (cont.) Minimum clearances A B 100 100 1000 A Cable entry <42 V B Cable entry 400 V~/230 V~, >42 V Installation 15
Installation sequence Installing the internal unit (cont.) Fitting the internal unit to the wall 5. 3. 1. 4. 2. 2x 16
Installation sequence Connecting the refrigerant lines The external unit is pre-filled with refrigerant R 410A. In the following cases, fit oil lift bends in the vertical pipe (see diagram below): In heating mode, if the internal unit is installed higher than the external unit. In cooling mode, if the internal unit is installed lower than the external unit. Routing refrigerant lines Type AWB/AWB-AC 201.B04 201.B07 201.B10 201.C10 201.B13 201.C13 Refrigerant lines Min. line length 3 m 3 m 3 m 3 m Max. line length 20 m 30 m 30 m 30 m Max. height differential, internal unit external unit 10 m 15 m 15 m 15 m Note No topping up is required for line lengths between 3 and 12 m. A C Liquid line D Hot gas line E Oil lift bends, Flow direction in heating mode, Flow direction in cooling mode Installation B C E 5000 D 5000 Example type AWB/AWB-AC 201.B07 A B Internal unit External unit 17
Installation sequence Connecting the refrigerant lines (cont.) Sound and vibration isolation when cable entry is above ground level Note Route connecting cables and refrigerant lines separately. A B C D A Pipe bends as vibration compensators B Pipe clips with EPDM lining C Cable entry, e.g. drainage pipe with thermal insulation D Electrical cables/leads, internal/ external unit 18
Installation sequence Connecting the refrigerant lines (cont.) Connection to the external unit 1. Type AWB/AWB-AC 201.B04 and 201.B07: Remove the side cover; see page 43. 2. D C 3. 2x Installation D C 4. Example type AWB/AWB-AC 201.B04 C Liquid line D Hot gas line 19
Installation sequence Connecting the refrigerant lines (cont.) 2.! Please note Contamination (e.g. metal swarf) or moisture must not enter the copper pipes. Therefore, hold the pipe openings down or plug them. 3. Flare the pipe ends. 4. Secure the pipes. Remove the nuts from connections C (liquid line) and D (hot gas line) of the refrigerant lines. Type AWB/AWB-AC 201.B04: Slide the nuts onto the refrigerant lines prepared on site. Type AWB/AWB-AC 201.B07 to B13, C10, C13: Replace nuts with the supplied union nuts (internal unit) (⅝ UNF for liquid line, ⅞ UNF for hot gas line). Tighten the nuts with the following torque: Type Line Connection to Torque in Nm AWB/ AWB-AC external unit 201.B04 Liquid line 7 6 mm ⁷ ₁₆ UNF 14 18 Hot gas line 7 12 mm ¾ UNF 50 62 201.B07 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.B10 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.B13 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.C10 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.C13 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 20
Installation sequence Connecting the refrigerant lines (cont.) Connection to the internal unit 2x 2. D C Installation 1. D C D C 3. C Liquid line Please note! Contamination (e.g. metal swarf) or moisture must not enter the copper pipes. Therefore, hold the pipe openings down or plug them. Note The refrigerant lines of the internal unit are filled with nitrogen; overpressure 1 to 2 bar (0.1 to 0.2 MPa). D Hot gas line 1. Remove the nuts from refrigerant connections C and D. Type AWB/AWB-AC 201.B04: Replace nuts with union nuts supplied (⁷ ₁₆ UNF for liquid line, ¾ UNF for hot gas line). Connect supplied reducer with copper sealing ring. Type AWB/AWB-AC 201.B07 to B13, C10, C13: Push the nuts onto the relevant refrigerant lines from the external unit. 21
Installation sequence Connecting the refrigerant lines (cont.) 2. Flare the pipe ends of the refrigerant lines. Note If solder fittings are used, solder the fittings using a shielding gas. 3. Fit refrigerant lines and insulate them to provide protection from heat and vapour diffusion. Tighten the nuts with the following torque: Type Line Connection to Torque in Nm AWB/ AWB-AC internal unit 201.B04 Liquid line 7 6 mm ⅝ UNF 33 42 with reducer ⅝ x ⁷ ₁₆ 14 18 Hot gas line 7 12 mm ⅞ UNF 63 77 with reducer ⅞ x ¾ 50 62 201.B07 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.B10 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.B13 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.C10 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 201.C13 Liquid line 7 10 mm ⅝ UNF 33 42 Hot gas line 7 16 mm ⅞ UNF 63 77 22
Installation sequence Connecting a secondary circuit + Installation Refrigerant lines from/to the external unit Symbol Meaning Connection DHW cylinder flow (heating water side) G 1¼ + Heating water return and DHW cylinder return Heating water flow G 1¼ G 1¼ 1. Equip the secondary circuit on site with an expansion vessel and safety assembly (in accordance with DIN 4757). Fit the safety assembly to the on-site line in the heating water return (see page 64). 2. Connect the secondary circuit lines to the heat pump. Please note! To prevent appliance damage, connect on-site secondary circuit lines to the heat pump so that they are free of load and torque stress. Make tight hydraulic connections on the secondary side. 3. Fill and vent secondary circuit. 23
Installation sequence Connecting a secondary circuit (cont.) 4. Thermally insulate pipes inside the building. 5. Connect the drain hose to the safety valve. Connect the drain hose to the public sewage system with a fall and a pipe vent. Note In underfloor heating circuits, install a temperature limiter to restrict the maximum temperature for underfloor heating systems (see page 31). Safeguard the minimum flow rate, e.g. with an overflow valve (see specification on page 129). Connecting a cooling circuit if required For area cooling systems (e.g. underfloor heating circuit, chilled ceiling), a contact humidistat (accessory) is required. Requirements for the 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 humidistats in series: Switching contacts as N/C contacts Electrical connections Danger Damaged cable insulation can cause injury and damage to the appliance. Route cables so that they cannot touch very hot, vibrating or sharpedged components. Danger Incorrectly routed wiring can lead to serious injury from electrical current and result in equipment damage. Route LV leads < 42 V and cables > 42 V/230 V~/400 V~ separately. Strip the insulation from the cables as close to the terminals as possible, and bundle tightly to the corresponding terminals. Secure cables with cable ties. 24
Installation sequence Electrical connections (cont.) This ensures that, should there be an error, for example when detaching a wire, the wires cannot drift into the adjacent voltage area. Note If two components are connected to the same terminal, press both cores together into a single wire ferrule. Note Make all connections on the control panel, (see page 28) with flexible cables to ensure that the control panel can be placed in the service position (see page 81).! Please note In terms of safety, the BUS cable for the internal/external unit (12 V or 43 V) does not count as a LV lead. The BUS cable must be routed together with the 230 V cables. Installation 25
Installation sequence Electrical connections (cont.) Internal unit: Routing electrical cables to the wiring chamber < 42V > 42V 400V 230V! B A 26
Installation sequence Electrical connections (cont.) A Type AWB/AWB-AC 201.B10, B13, C10, C13: 12 V BUS cable: Routing in the 230 V~ voltage range (connection, see page 45) B Type AWB/AWB-AC 201.B04 and 201.B07: 43 V BUS cable: Routing in the 230 V~ voltage range (connection, see page 45) Installation 27
Installation sequence Electrical connections (cont.) Internal unit: Overview of connections F101 A P202 12V COM P203 COM 43V B 3.8 3.3 X D 3.9 3.1 3.4 3.6 211.4 F1 3.7 211.2 L1? N C? X1 N 3 2 1 X2 X15 avg X24 F0 F6 F8 F27 F4 F11 F7 F13 F12 F16 F14 F21 F20 F26 F23 J4 X18 J3 sva F3 sxf sys sya sxs X25 F G X31 E 28
Installation sequence Electrical connections (cont.) A AVI PCB (see page 43) F101 MCB/fuse 1.0A (slow) B Switching module and power supply for instantaneous heating water heater (see from page 50) C Power supply 230 V~ (see page 46) F1 MCB/fuse 6.3 A (slow) D Luster terminals (see page 37) X1 Terminals for earth conductor of all associated system components X2 Terminals for neutral conductor of all associated system components E Controller and sensor PCB (see page 39) F Main PCB (see page 29) F3 MCB/fuse 6.3 A (slow) G Expansion PCB on main PCB (see page 33) Installation Internal unit: Main PCB (function components 230 V~) Information regarding the connection values The specified output is the recommended connected load. The total output of all components connected directly to the heat pump control unit must not exceed 1000 W (e.g. pumps, valves, message facilities, contactors). If the total output is < 1000 W, the individual rating of a component (e.g. pump, valve, message facility, contactor) can be greater than specified. However, the breaking capacity of the corresponding relay must not be exceeded. The specified current indicates the max. switching current of the switching contact (observe the total current of 5 A). Set the required parameters during commissioning; see from page 68. 29
Installation sequence Electrical connections (cont.) Plug sya Terminals Function Explanation 211.5 AC Type AWB-AC: Cooling control 3-way diverter valves for heating water buffer cylinder bypass in cooling mode Connection values Max. output: 10 W Voltage: 230 V~ Max. switching current: 4(2) A Connect the 3-way diverter valves for the bypass circuit in parallel. Plug sys Terminals Function Explanation 212.2 A1 Heating circuit pump for heating circuit without mixer (A1/HC1) This pump is connected in addition to the secondary pump if a heating water buffer cylinder is installed. Connect the temperature limiter to restrict the maximum temperature for underfloor heating systems (if installed) in series (see the following chapter) Connection values Output: 100 W Voltage: 230 V~ Max. switching current: 4(2) A 212.3 DHW circulation pump Connection values Output: 50 W Voltage: 230 V~ Max. switching current: 4(2) A 30
Installation sequence Electrical connections (cont.) Connecting a temperature limiter as a maximum temperature limiter for underfloor heating Connecting a general temperature limiter B Connecting the temperature limiter, part no. 7151 728, 7151 729 B X2.N X1.? A B X2.N X1.? A B sö Installation C M 1~ C M 1~ Heating circuit without mixer A1/ HC1 Connection Circulation pump C A to control unit 211.2 Secondary pump Without heating water buffer cylinder With heating water buffer cylinder 212.2 Heating circuit pump A1/ HC1 31
Installation sequence Electrical connections (cont.) Connecting the temperature limiter, part no. 7151 728, 7151 729 B to mixer extension kit A sö B sö C M 1~ A Connect plug sö to mixer extension kit B Temperature limiter C Heating circuit pump for heating circuit with mixer 32
Installation sequence Electrical connections (cont.) Internal unit: Expansion PCB on main PCB (function components 230 V~) Information regarding the connection values The specified output is the recommended connected load. The total output of all components connected directly to the heat pump control unit must not exceed 1000 W (e.g. pumps, valves, message facilities, contactors). If the total output is < 1000 W, the individual rating of a component (e.g. pump, valve, message facility, contactor) can be greater than specified. However, the breaking capacity of the corresponding relay must not be exceeded. The stated current indicates the max. switching current of the switching contact (observe the total current of 5 A). Safety LV is unsuitable for controlling external heat sources. Set the required parameters during commissioning; see from page 68. Installation Plug sxs Terminals Function Explanation 222.1 Mixer motor control for external heat source Signal mixer CLOSED Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 0.2(0.1) A 222.2 Mixer motor control for external heat source Signal mixer OPEN Connection values: Output: 10 W Voltage: 230 V~ Max. switching current: 0.2(0.1) A 33
Installation sequence Electrical connections (cont.) Plug sxs Terminals Function Explanation 222.3 222.4 Floating contact Control of external heat sources and 1 high limit safety cut-out each (on site, max. 70 C), to switch off or switch between the following components: Central heating: Secondary pump, heat pump External heat source DHW reheating: 3-way diverter valve for "Central heating/dhw heating" Note The switching contact is a zero volt N/O contact that is closed when a heat demand is issued. Never route low voltage via this contact; for that fit a relay on-site. 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: Central heating In series to the secondary pump (terminal 211.2 on the main PCB). In series for controlling external heat sources. DHW reheating In series to the 3-way diverter valve (terminal 211.4 on the main PCB). 34
Installation sequence Electrical connections (cont.) High limit safety cut-out for heat pump in conjunction with an external heat source 222.3 222.4 D A K1 X2.N X3.1 B C C Connection on the external heat source at terminals for external demand 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 Installation A Terminals on extension PCB B Move jumper from X3.1 to 222.3 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 Control of the immersion heater EHE (for connection, see the following diagram) 35
Installation sequence Electrical connections (cont.) Immersion heater (400 V~) L1 L2 L3 N? 224.7 B X2.N A A Immersion heater, power supply 3/N/PE 400 V/50 Hz B Terminals of the heat pump control unit Immersion heater (230 V~, on site) L1 L1 L1 N N N? 224.7 B X2.N A A Immersion heater, power supply 1/N/PE 230 V/50 Hz B Terminals of the heat pump control unit 36
Installation sequence Electrical connections (cont.) Internal unit: Luster terminals (signal and safety connections) Set the required parameters during commissioning; see from page 68. Terminals Function Explanation X3.1 Switched phase Via control unit ON/OFF switch. X3.3 X3.4 Flow switch Note Observe the total load (1000 W) for all connected components. Requires zero volt N/O contact: Closed: Heat pump in operation Open: Heat pump shut down Breaking capacity 230 V~, 0.15 A Installation X3.6 X3.7 G Power-OFF (jumper fitted at the factory) Remove jumper when connecting. Requires zero volt N/C contact: Closed: Heat pump in operation Open: Heat pump shut down Breaking capacity 230 V~, 0.15 A Remove jumper when connecting. 37
Installation sequence Electrical connections (cont.) Terminals Function Explanation Note No parameters need to be set. The compressor is "forced" off as soon as the contact opens. The supply voltage to the relevant function components 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 at power-off 790A"). The power supply for the heat pump control unit (3 x 1.5 mm 2 ) and the cable for the power-off signal can be combined in a 5-core cable. For further information regarding power-off, see chapter "Power supply". X3.8 X3.9 X40.L1 Type AWB-AC: Frost stat and/or contact humidistat, cooling or Jumper Type AWB: Jumper Heat pump control unit power supply: Phase L1 X40.? Earth conductor connection X40.N Neutral conductor connection Requires zero volt N/C contact: Closed: Safety chain has continuity Open: Safety chain interrupted; heat pump shut down Breaking capacity 230 V~, 0.15 A Connection: Connected in series, if both safety components are installed. Insert jumper if no safety components are installed. Power supply 230 V~, see from page 46. 38
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 211.4 r M 3-way diverter valve for "Central heating/dhw heating" In systems without a heating water buffer cylinder, no other heating circuit pump is required (see terminal 212.2). Connect the temperature limiter to restrict the maximum temperature for underfloor heating systems in series (see page 31). Secondary pump connected at the factory; the temperature limiter must be connected on site. Connection values Max. output: 130 W Voltage: 230 V~ Max. switching current: 4(2) A Installation In conjunction with the primary store system: Cylinder primary pump 3-way diverter valve connected at the factory; connect the cylinder primary pump on site in parallel. 2-way shut-off valve M Internal unit: Controller and sensor PCB (sensors) Set the required parameters during commissioning; see from page 68. Sensors Plug Sensor Type F0.1/F0.2 Outside temperature sensor NTC 10 kω F0.2/F0.3 Radio clock receiver DCF F4 Buffer temperature sensor NTC 10 kω F6 (X25.5/X25.6) Cylinder temperature sensor, top NTC 10 kω 39
Installation sequence Electrical connections (cont.) Plug Sensor Type F7 Cylinder temperature sensor, bottom NTC 10 kω (X25.7/X25.8) F11 Contact humidistat 24 V Note If a 230 V~ contact humidistat (connection to X3.8/X3.9) is used for cooling, insert a jumper, otherwise the heat pump will not start (message "Protectn device primry"). F13 F14 F16 F20 avg System flow temperature sensor (downstream of the heating water buffer cylinder and external heat source) Flow temperature sensor, cooling circuit (heating circuit without mixer A1/HC1 or separate cooling circuit SKK) Room temperature sensor for separate cooling circuit SKK (required) or for heating/cooling circuit without mixer A1/HC1 (recommended) Boiler water temperature sensor, external heat source KM BUS (wires interchangeable) Use the KM BUS distributor (accessories) if several devices are connected. NTC 10 kω NTC 10 kω NTC 10 kω NTC 10 kω KM BUS subscribers (examples): Extension kit for one heating circuit with mixer M2/HC2 Remote control for Vitotrol 200A or Vitotrol 300B (set the heating circuit assignment at the remote control) Extension EA1, extension AM1 Vitocom communication interface sva Modbus 2 (wires not interchangeable) Connection for 1-phase or 3-phase electricity meter J3 Jumper for terminator Modbus 2 Terminator enabled (delivered condition) Terminator disabled 40
Installation sequence Electrical connections (cont.) Plug Sensor Type J4 Jumper for setting master/slave Modbus 2 Heat pump control unit is slave Heat pump control unit is master (delivered condition) X18 Modbus 1 Connection for Vitovent 300-F X24 Connection for LON communication module (see LON communication module installation instructions) X31 Coding card slot Swimming pool heating Note Swimming pool heating is controlled via extension EA1 with KM BUS. Make connections to extension EA1 only according to the following diagram. A filter circuit pump cannot be controlled via the heat pump control unit. Installation 41
Installation sequence Electrical connections (cont.) L1 B N C D L1 N A 0-10V f-]a [{A DE [{S DE [{D DE [{{] 1 2 3 4 5 6 + - E H F G M 1~ 1 2 K A Extension EA1 B Power supply 1/N/PE 230 V/50 Hz C Junction box (on site) D Fuses and contactor for circulation pump for swimming pool heating (accessories) E Jumper F 3-way diverter valve for "Swimming pool" (zero volt: heating the heating water buffer cylinder) G Circulation pump for swimming pool heating (accessory) H Thermostat for swimming pool temperature control (floating contact: 230 V~, 0.1 A, accessories) K Connection on controller and sensor PCB 42
Installation sequence Electrical connections (cont.) Internal unit: AVI PCB Interface internal unit external unit Plug Component F101 Fuse 1.0 A (slow, L) P202 BUS connection (12 V) to the external unit (type AWB/AWB-AC 201.B10, B13, C10, C13) P203 BUS connection (43 V) to the external unit (type AWB/AWB-AC 201.B04, B07) Note Only one BUS connection should be connected. Do not interchange the BUS connection wires between the internal and external units. Route the BUS connecting cable in the 230 V~ voltage area. Installation External unit: Overview of connections 230 V~: Opening the external unit wiring chamber Type AWB/AWB-AC 201.B04 201.B07 201.B10 and B13 A A A 43
Installation sequence Electrical connections (cont.) 400 V~: Opening the external unit wiring chamber Type AWB/AWB-AC 201.C10 and C13 A A Wiring chamber: BUS connection to the internal unit Note Do not interchange the BUS connection wires between the internal and external units. Compressor power supply 44
Installation sequence Electrical connections (cont.) Connecting internal and external units 230 V~ Type AWB/AWB-AC 201.B04 201.B07 201.B10 and B13 C N L? COMNi? Li? N0 L0 C2 C1 N L?? N L A B C C A B A B C Installation 12V COM COM 43V 12V COM COM 43V 12V COM COM 43V 400 V~ Type AWB/AWB-AC 201.C10 and C13 C2 C1 N L?? N L3 L2L1 A B A External unit wiring chamber (see page 43) B BUS cable between the external and internal unit Recommended cable: 3 x 1.5 mm 2 The cores are not interchangeable. C AVI PCB in the internal unit (see page 29) Note Route BUS cable for internal/external unit in the 230 V~ voltage area. C 12V COM COM 43 V 45
Installation sequence Power supply Isolators for non-earthed conductors The mains isolator (if installed) must simultaneously isolate from the mains all non-earthed conductors with a minimum contact separation of 3 mm. We additionally recommend installing an AC/DC-sensitive RCD, type B, for DC (fault) currents that can occur with energy efficient equipment. RCDs of type A must not be used or installed upstream of the RCD type B. If no mains isolator is installed, all nonearthed conductors must be isolated from the mains by the upstream circuit breakers with a minimum contact separation of 3 mm. Danger Incorrectly executed electrical installations can result in injuries from electrical current and in appliance damage. Connect the power supply and implement all safety measures (e.g. RCD circuit) in accordance with the following regulations: IEC 60364-4-41 VDE regulations [IEE or local regulations] Technical connection requirements specified by the local power supply utility Danger The absence of component earthing can lead to serious injury from electric current if an electrical fault occurs. Connect the appliance and pipework to the equipotential bonding of the building in question. Danger Incorrect core allocation can result in serious injury and damage to the appliance. Never interchange cores "L" and "N". In negotiations with your power supply utility, different supply tariffs for the main power circuits may be offered. Observe the technical connection conditions of the power supply utility. If the compressor and/or instantaneous heating water heater are operated at an economy tariff (power-off), either provide an additional cable (e.g. 3 x 1.5 mm 2 ) for the power-off signal from the distribution board (meter box) to the heat pump control unit or combine the cable for the power-off signal and for the heat pump control unit power supply (3 x 1.5 mm 2 ) in a 5- core cable. The allocation of the power-off (for compressor and/or instantaneous heating water heater) is made via the type of connection and by setting parameters in the heat pump control unit. In Germany, the power supply can be cut off for up to 3 x 2 hours per day (24 h). The heat pump control unit/pcb must be supplied without power-off; tariffs that are subject to possible shutdown must not be used here. 46
Installation sequence Power supply (cont.) In conjunction with on-site energy consumption (use of power generated by the PV system to meet own requirements): Note During the power-off period, it is not possible to operate the compressor with power generated on site. Protect the power supply to the heat pump control unit with a fuse of 16 A (max.). For accessories and external components that are not connected to the heat pump control unit, connect the power supply with the same phase as the heat pump control unit, ideally 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. Installation Heat pump control unit power supply (230 V~) 1/N/PE 230 V/50 Hz A F1 T6,3 AH L1 L1?? N N X40 Note This supply must never be blocked. Max. fuse rating 16 A Standard tariff (no optional economy tariff with power-off) Recommended power cable: 3 x 1.5 mm 2 (5 x 1.5 mm 2 with power- OFF) 47
Installation sequence Power supply (cont.) External unit power supply (230 V~/400 V~) 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. Note Free terminals for internal use. External unit power supply 230 V~ Type AWB/AWB-AC 201.B04 201.B07 201.B10 and B13 C N L? COMNi? Li? N0 L0 C2 C1 N L?? N L A A A N L1? B? N L1 B? N L1 B A External unit wiring chamber (see page 43) B Power supply 230 V/50 Hz Type AWB/AWB-AC 201.B04 201.B07 201.B10 201.B13 Recommended power 3 x 2.5 mm 2 3 x 2.5 mm 2 3 x 2.5 mm 2 cable (max. 29 m) (max. 25 m) (max. 20 m) 48 or 3 x 4.0 mm 2 (max. 32 m) 3 x 4.0 mm 2 (max. 20 m) 3 x 6.0 mm 2 (max. 30 m) Fuse protection B20A B20A B20A B32A
Installation sequence Power supply (cont.) External unit power supply 400 V~ Type AWB/AWB-AC 201.C10 and C13 A External unit wiring chamber (see page 43) B Power supply 230 V/50 Hz C2 C1 N L?? N L3 L2L1 A? N L3 L2 L1 B Installation Type AWB/AWB-AC 201.C10 201.C13 Recommended power cable 5 x 2.5 mm 2 (max. 30 m) 5 x 2.5 mm 2 (max. 30 m) Fuse protection B20A B20A 49
Installation sequence Power supply (cont.) Connecting the power cable of the instantaneous heating water heater (only type AWB-AC) Internal unit L1 L1 L1 1/N/PE 230 V/50 Hz A Recommended power cable: 400 V~: 5 x 2.5 mm 2 230 V~: 7 x 2.5 mm 2 Fuse rating max. 16 A Economy tariff and power-off can be used N N N L3 L2 L1 B 3/N/PE 400 V/50 Hz A N N B A Internal unit wiring chamber (see chapter "Overview of connections":" Internal unit") B Jumpers 50
Installation sequence Power supply (cont.) 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. Parameter "Output for instant. heating water heater at power-off 790A" determines whether and at what stage an instantaneous heating water heater (if installed) remains operational during power-off. A X40 X3.7 X3.6 B Note Observe the technical connection conditions of the relevant power supply utility. C Installation D 3 5 (400 V~) 7 (230 V~) 3 3 kwh E 3/N 4 G F 3 kwh 3/N H 4 K 4 Diagram excluding fuses and RCD A Heat pump control unit (internal unit, luster terminals, see chapter "Overview of connections: Internal unit") B Instantaneous heating water heater (if installed) C Heat pump compressor (external unit) D Heat pump control unit power supply (see chapter "Heat pump control unit power supply (230 V~)") E Standard tariff meter F Backup fuse ripple control receiver G Ripple control receiver (contact open: power-off enabled), feed: TNC system 51
Installation sequence Power supply (cont.) H Economy tariff meter K Feed: TNC system Power-OFF with on-site load disconnection The power-off signal is connected to the on-site contactor of the economy tariff power supply and to the heat pump control unit. The compressor and instantaneous heating water heater (if installed) are "forced" off when power-off is enabled. Note Observe the technical connection conditions of the relevant power supply utility. A X40 D L 3 X3.7 X3.6 B C 5 (400 V~) 7 (230 V~) 3 3 3 kwh kwh 3/N E G 3/N H F 4 4 4 K Diagram excluding fuses and RCD A Heat pump control unit (internal unit, luster terminals, see chapter "Overview of connections: Internal unit") B Instantaneous heating water heater (if installed) C Heat pump compressor (external unit) D Heat pump control unit power supply (see chapter "Heat pump control unit power supply (230 V~)") 52 E Standard tariff meter F Backup fuse ripple control receiver G Ripple control receiver (contact open: power-off enabled) with backup fuse H Economy tariff meter K Feed: TNC system L Mains isolator
N E1E2 D /D L1 L1 L2 L2 L3 L3 Installation sequence Power supply (cont.) Power supply in conjunction with own energy consumption Without power-off B A A ~ = D F F C F E F Installation G H K kwh kwh kwh L L M M N N A Heat pump B Additional consumers in the household (powered by self-generated electricity) C Electricity meter D Inverter E Isolator for the PV system F Terminal G Double-tariff meter (for special tariff for heat pump) Not permissible in conjunction with PV systems for own energy consumption. 53
Installation sequence Power supply (cont.) H Bi-directional meter (for PV systems for own energy consumption): Energy taken from power supply utility and energy fed into power supply utility K Meter with reverse block: For energy generated by PV system L Isolator for the domestic power supply connection (distribution panel) M Distribution panel N Domestic distribution box Closing the heat pump! Please note Seal the appliance so it is soundproof and diffusion-proof. On pipe and hose outlets, ensure the thermal insulation is seated correctly. Danger The absence of component earthing can lead to serious injury from electric current if an electrical fault occurs. Attach earth conductor to front panel and side panel. 54
Installation sequence Closing the heat pump (cont.) Fitting the front panel of the internal unit 1. 3. 2. 2x Note Ensure that the locking screws are tightened before operating. Fitting the side cover of the external unit In reverse order to "Opening the external unit wiring chamber" (see page 43). Installation 55
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... 58 2. Compiling reports... 58 3. Purging the refrigerant lines and the internal unit with nitrogen (internal unit is filled with nitrogen; positive pressure 1 to 2 bar/0.1 to 0.2 MPa) 56 4. Check tightness and pressure with dry nitrogen with at least 20 bara/2.0 MPa (max. 43 bara/4.3 MPa) 5. Evacuating the refrigerant lines and internal unit... 59 6. Filling the refrigerant lines and internal unit... 61 7. Checking the refrigerant circuit for leaks... 63 8. Filling and venting on the secondary side... 63 9. Checking expansion vessel and heating circuit pressure... 66 10. Checking electrical connections of the internal unit for firm seating 11. Checking that condensate can drain away freely from the external unit condensate pan 12. Checking the free running of the fan in the external unit... 66 13. Cleaning the external unit heat exchanger (evaporator)... 66 14. Checking thermal insulation of flared connections 15. Checking electrical connections of the external unit for firm seating... 67 16. Closing the heat pump; resetting the circuit breaker/ main fuse 17. Starting the heat pump... 67 18. Commissioning the system... 68
Commissioning, inspection, maintenance Steps - commissioning, inspection and (cont.) Commissioning steps Inspection steps Maintenance steps Page 19. Ticking the heat pump type on the type plate of the internal unit (as per external unit type plate) 20. Checking the heat pump for unusual noises (e.g. operating noise of fan, compressor or pump); venting again if required 21. Checking the system function (e.g. actuators, temperatures, heat meter if applicable)... 78 22. Instructing the system user... 78 Service 57
Commissioning, inspection, maintenance Further details regarding the individual steps Opening the heat pump Danger Contact with 'live' components can lead to serious injury from electric current. Do not touch wiring chambers (heat pump control unit and power connections for internal and external units; see chapter "Overview of connections: Internal unit" and "Overview of connections: External unit"). Before working on the appliances (internal/external unit), isolate the system from the power supply (e.g. by removing a separate mains fuse or by means of a mains isolator) and safeguard against unauthorised reconnection.! Please note Wait at least 30 min between installing and commissioning the appliance to prevent equipment damage. Work on the refrigerant circuit may only be carried out by certified personnel (in accordance with EC Directives 842/2006 and 303/2008). 1. Remove front panel; see page 16. 2. When work is complete, close the heat pump; see page 54. For commissioning the appliance, see also the operating instructions. Danger The absence of component earthing can result in serious injury from electrical current and in component damage in the event of an electrical fault. All earth connectors must be reconnected. Compiling reports Enter the actual values recorded during the commissioning process described below into the reports from page 121 and into the operator's log (if available). 58
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Evacuating the refrigerant lines and internal unit! Please note Commissioning is weatherdependent. In the case of high relative humidity or outside temperatures below 0 C, please observe the following: Use nitrogen 5.0 for the pressure test. During evacuation, take suitable steps to keep the surface temperature of the refrigerant lines above 0 C.! Please note Before evacuating the refrigerant lines and the internal unit, check all connections for tightness with leak detection 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 pressure. Danger Direct contact with refrigerant can cause skin damage. Wear safety goggles and protective gloves when working on the refrigerant circuit. Service 59
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) A B C E D D F G H K L N O M Example type AWB/AWB-AC 201.B04 A Internal unit B External unit C Hot gas line D Fill valve E Service valve (Schrader valve) For AWB/AWB-AC, type 201.B07, the service valve is located at the liquid line connection. F Liquid line G Fill hose between pressure gauge set and external unit Please note! Do not subject vacuum gauge to positive pressure. 60 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 1. Close all valves at the pressure gauge set.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Make all connections, as shown above. Please note! Fill valve D must remain closed. Lastly, connect the end of the fill hose to service valve E. For all connections, counterhold with a second openended spanner. 3. Start the vacuum pump. At the pressure gauge set, open the valve to the vacuum pump and the valve to the hot gas connection. 5. On the pressure gauge set, close the valve to the vacuum pump. Stop the vacuum pump and wait approx. 5 min. If the indication on the vacuum gauge rises, there is a leak. Remove the leak and repeat the process. 6. Close all valves at the pressure gauge set. 7. Remove the vacuum pump and vacuum gauge. 4. After approx. 5 min, open the valve to the vacuum gauge. Leave the vacuum pump running until the indication on the vacuum gauge is almost at "0" (at least 30 min). Note The vacuum pump runtime will depend on the ambient conditions. Filling the refrigerant lines and internal unit Note The external unit is pre-filled with refrigerant R 410A. No topping up is required for line lengths from 3 to 12 m. For lengths of refrigerant lines, see page 17. Refrigerant R 410A may only be topped up in a liquid state. Danger Direct contact with refrigerant can cause skin damage. Wear safety goggles and protective gloves when working on the refrigerant circuit. Service 61