Viessmann Main Documentation Vitocal 100-AW Operating instructions

Installation, Service and
Operating Instructions
viesmann
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for use by heating contractor
Vitocal 100-AW AM2V
Models 020028, 0340043 and 051078
Outdoor Air to Water Heat Pump
Indoor Distribution and Control Unit
Heating Capacity: 20.5 to 58 MBH
6 to 17 kW
Cooling Capacity: 1.4 to 4.3 Ton
5 to 15 kW
VITOCAL 100-AW
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
6221389 - 02 03/2024
Please file in Service Binder
Safety
Vitocal 100-AW AM2V Installation, Service and Operating
About these Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important
1 product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.
1 WARNING
uWarnings draw your attention to the presence of
potential hazards or important product information.
Indicates an imminently hazardous situation
which, if not avoided, could result in death,
serious injury or substantial product/property
damage.
1 CAUTION
uCautions draw your attention to the presence of
potential hazards or important product information.
Indicates an imminently hazardous situation
which, if not avoided, may result in minor injury or
product/property damage.
IMPORTANT
u
uHelpful hints for installation, operation or
maintenance which pertain to the product.
uThis symbol indicates that additional, pertinent
Information is to be found.
6221389 - 02
uThis symbol indicates that This symbol indicates
that other instructions must be referenced.
2
Vitocal 100-AW AM2V Installation, Service and Operating
Safety
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to
comply with the instructions listed below and details printed in this manual can cause product/property
damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and
fulfilled (including detailed information found in manual subsections).
HHProduct documentation
Read all applicable documentation before
commencing installation. Store documentation
near heat pump in a readily accessible
location for reference in the future by service
personnel.
HHLicensed professional heating contractor
The installation, adjustment, service and
maintenance of this equipment must be
performed by a licensed professional heating
contractor.
u For a listing of applicable
literature, please see section entitled
“Important Regulatory and Safety
Requirements”.
HHWarranty
Information contained in this and
related product documentation must
be read and followed. Failure to do so
renders the warranty null and void.
6221389 - 02
HHAdvice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service annually before the
heating season begins.
u Please see section entitled “Important Regulatory and Installation
Requirements”.
3
Safety
Vitocal 100-AW AM2V Installation, Service and Operating
Safety, Installation and Warranty Requirements
Fiberglass wool and ceramic fiber materials
1 WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These
materials can also cause respiratory, skin and eye
irritation.
The state of California has listed the airborne fibers
of these materials as a possible cancer hazard
through inhalation. When handling these materials,
special care must be applied.
First aid measures
––If eye contact occurs, flush eyes with water to
remove dust. If symptoms persist, seek medical
attention.
––If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
Operating and Service Documentation
It is recommended that all product documentation
such as parts lists, operating and service
instructions be handed over to the system user
for storage. Documentation is to be stored near
the heat pump in a readily accessible location for
reference by service personnel.
6221389 - 02
Suppliers of ceramic fiber products recommend the
following first aid measures:
––Respiratory tract (nose and throat) irritation: If
respiratory tract irritation develops, move the person to
a dust free location.
––Eye irritation: If eyes become irritated, flush
Immediately with large amounts of lukewarm water for
at least 15 minutes. Eyelids should be held away from
the eyeball to ensure thorough rinsing. Do not rub eyes.
––Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin. Wash
area of contact thoroughly with soap and cold water
(as warm or hot water may worsen the irritation). Using
a skin cream or lotion after washing may be helpful.
––Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.
Suppliers of fiberglass wool products recommend
the following precautions be taken when handling
these materials:
––Avoid breathing fiberglass dust and contact with
skin and eyes.
––Use NIOSH approved dust/mist respirator.
––Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
––Wash work clothes separately from other
clothing. Rinse washer thoroughly.
––Operations such as sawing, blowing, tearout and spraying may generate airborne fiber
concentration requiring additional protection.
4
Vitocal 100-AW AM2V Installation, Service and Operating
Safety
Safety, Installation and Warranty Requirements
The outdoor unit contains flammable refrigerant
R32. If there is a leak, the escaping refrigerant may
form a flammable or explosive atmosphere in the
ambient air.
1 WARNING
Risk of explosion: Escaping refrigerant may form a
flammable or explosive atmosphere in the ambient
air.
Take the following measures to prevent fire and
explosion:
HHKeep ignition sources away, e.g. naked flames,
hot surfaces, electrical devices not free of ignition
sources, mobile devices with integrated batteries
(e.g. mobile phones, fitness watches, etc.).
HHPermissible tools: All tools for working must be
designed and explosion protected in accordance
with the applicable standards and regulations
for refrigerant in safety groups A2L and A3,
e.g. brushless machines (cordless screwdrivers),
extraction equipment, disposal containers,
installation aids, vacuum pumps, conductive hoses,
mechanical tools of non-sparking material, etc.
Note:
The tools must also be suitable for the pressure
ranges in use. Tools must be in good working order.
HHDo not use flammable materials, e.g. sprays or
other flammable gases.
HHDischarge static: Before beginning work, touch
earthed objects, such as heating or water pipes.
HHDo not remove, block or bridge safety equipment.
HHDo not make any changes: Do not modify
the outdoor unit, inlet/outlet lines, electrical
connections/cables or the surroundings. Do not
remove any components or seals.
Working on the system
HHSwitch off the power supply to the indoor unit
and outdoor unit, e.g. at a breaker. Check that
the system is no longer live.
Note:
In addition to the control circuit there may be
several power circuits.
6221389 - 02
1 WARNING
Contact with live components can result in severe
injuries. Some components on PCB’s remain live
even after the power supply has been switched off.
Prior to removing covers from the appliances, wait
at least 4 minutes until the voltage has completely
dropped out.
1 WARNING
HHSafeguard the system against reconnection.
HHWear suitable personal protective equipment
when carrying out any work.
1 WARNING
Hot surfaces and fluids can result in burns or
scalding. Cold surfaces may cause frostbite.
HHPrior to servicing or maintenance tasks, switch
off and allow the equipment to cool down or
warm up.
HHDo not touch hot or cold surfaces on the
appliance, fittings or pipework.
Note:
Electronic assemblies can be damaged by
electrostatic discharge. Before beginning work,
touch earthed objects, such as heating or water
pipes, to discharge any static. R32 refrigerant is
an air displacing, colorless, flammable gas which
forms explosive mixtures with air. Refrigerant
drained must be properly disposed of by authorised
contractors. Perform the following measures before
beginning work on the refrigerant circuit:
HHCheck the refrigerant circuit for leaks.
HHEnsure very good ventilation especially in the
floor area and sustain this for the duration of the
work.
HHSecure the area surrounding the work area.
HHInform the following persons of the type of work
to be carried out:
– All maintenance personnel
– All persons in the vicinity of the system.
HHInspect the area immediately around the heat
pump for flammable materials and ignition sources:
Remove all flammable, movable materials and any
ignition sources from the safety zone.
HHBefore, during and after the work, check the
surrounding area for escaping refrigerant using an
explosion-proof refrigerant detector suitable for
R32. This refrigerant detector must not generate
any sparks and must be suitably sealed.
HHA CO2 or powder extinguisher must be to hand in
the following cases:
– Refrigerant is being drained.
– Refrigerant is being topped up.
– Soldering or welding work is being carried out.
HHDisplay signs prohibiting smoking.
5
Safety
Vitocal 100-AW AM2V Installation, Service and Operating
Safety, Installation and Warranty Requirements
1 WARNING
Escaping refrigerant can lead to fire and explosions
that result in very serious injuries or death.
HHDo not drill or apply heat to a refrigerant circuit
filled with refrigerant.
HHDo not operate Schrader valves unless a fill valve
or extraction equipment is attached.
HHTake measures to prevent electrostatic charge.
HHNo smoking! Prevent naked flames and sparks.
Never switch lights or electrical appliances on or
off.
HHComponents that contain or contained refrigerant
must be labelled, and stored and transported
in well ventilated areas in accordance with the
applicable regulations and standards.
1 WARNING
Direct contact with liquid and gaseous refrigerant
can cause serious damage to health, e.g. frostbite
and/or burns. There is a risk of asphyxiation if it is
breathed in.
HHPrevent direct contact with liquid and gaseous
refrigerant.
HHWear personal protective equipment when
handling liquid and gaseous refrigerant.
HHNever breathe in refrigerant vapors.
1 WARNING
Refrigerant is under pressure:
Mechanical loading of lines and components
an cause leaks in the refrigerant circuit. Do not
apply loads to the lines and components, e.g. by
supporting or placing tools.
1 WARNING
Hot and cold metallic surfaces of the refrigerant
circuit may cause burns or frostbite if skin contact
is made. Wear personal protective equipment to
protect against burns or frostbite.
1 WARNING
Damage to the refrigerant circuit can cause
refrigerant to enter the hydronic system. After
completion of the work, vent the hydronic system
Damage to the refrigerant circuit can cause
refrigerant to enter the hydronic system. After
completion of the work, vent the hydronic system
correctly. When doing so, ensure the area is
sufficiently ventilated. Installation Frost protection.
Note:
Freezing can cause damage to the heat pump.
HHThermally insulate all the hydronic lines.
HHIn order to activate the frost protection function,
electrically connect the heat pump before filling
the secondary circuit. Switch on the power
supply. Switch on the ON/OFF switch on the
indoor unit.
1 WARNING
With short electrical cables, should there be
leakage in the refrigerant circuit, gaseous
refrigerant may reach the inside of the building.
Min. length of the electrical connecting cables
between the indoor and the outdoor unit: 3 m
Note:
Repairing components that fulfil a safety function
can compromise the safe operation of the system.
HHReplace faulty components only with genuine
Viessmann spare parts.
HHDo not undertake any repairs on the inverter.
Replace the inverter if there is a defect.
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 original spare
parts supplied or approved by Viessmann.
6221389 - 02
Note:
When refrigerant is being removed, hydronic
components may freeze. Drain heating water from
the heat pump beforehand.
6
Vitocal 100-AW AM2V Installation, Service and Operating
Safety
Safety, Installation and Warranty Requirements
1 WARNING
Escaping refrigerant can lead to fire and explosions
that result in very serious injuries or death.
HHEnsure very good ventilation especially in the
floor area of the outdoor unit.
HHNo smoking! Prevent naked flames and sparks.
Never switch lights or electrical appliances on or
off.
HHEvacuate any people from the danger zone.
HHFrom a safe position, switch off the electricity
supply for all system components.
HHRemove ignition sources
HHLet the system user know that no ignition source
may be brought into area for the duration of the
repair.
HHRepair work must be carried out by an authorised
contractor.
HHOnly recommission the system after it has been
repaired.
1 WARNING
Direct contact with liquid and gaseous refrigerant
can cause serious damage to health, e.g. frostbite
and/or burns. Prevent direct contact with liquid and
gaseous refrigerant.
1 WARNING
Breathing in refrigerant may cause suffocation.
Never breathe in refrigerant vapors.
1 WARNING
If water escapes from the appliance there is a risk
of electric shock. Switch off the heating system
at the external isolator (e.g. fuse box, domestic
distribution board).
1 WARNING
Note:
A build-up of ice in the condensate pan and in the
fan area of the outdoor unit can cause damage to
the equipment.
Please note the following:
HHDo not use mechanical items/aids for the removal
of ice.
HHBefore using electrical heating appliances, check
the refrigerant circuit for leaks with a suitable
measuring device.
HHThe heating appliance should not be a source of
ignition.
HHIf ice regularly builds up on the outdoor unit
(e.g. in areas where frost and heavy fog occur
frequently), install fan ring heating (accessories)
that is suitable for refrigerant R32 and/or an
electric ribbon heater in the condensate pan
(accessories or factory-fitted).
HHThe outdoor unit is charged at the factory with
refrigerant R32.
1 WARNING
Escaping refrigerant can lead to fire and explosions
that result in very serious injuries or death. There is
a risk of asphyxiation if it is breathed in.
Store the outdoor unit in the following conditions:
HHAn explosion prevention plan must be in place for
storage.
HHEnsure there is sufficient ventilation at the
storage location.
HHTemperature range for storage: -13°F to 158°F
(–25°C to 70°C)
HHOnly store the outdoor unit in its factory
protective packaging.
HHProtect the outdoor unit against damage.
HHThe maximum number of outdoor units that may
be stored in one place is determined by local
conditions.
6221389 - 02
If water escapes from the appliance, there is a risk
of scalding. Never touch hot heating water.
7
Table of Contents
Vitocal 100-AW AM2V Installation, Service and Operating
Index
Safety
About these Instructions.................................................................... 2
Safety, Installation and Warranty Requirements.................................... 3
Table of Contents
Index............................................................................................... 8
General Information
Important Regulatory and Installation Requirements............................... 10
Mechanical Room.............................................................................. 10
Applicability..................................................................................... 11
Product Information........................................................................... 12
Intended Use.................................................................................... 14
System Examples.............................................................................. 14
Fittings and Sealing Points................................................................. 14
Prior to Installation............................................................................ 14
Indoor Unit Installation
Dimensions...................................................................................... 15
Recommended Minimum Service Clearances......................................... 16
Mounting the Indoor Unit................................................................... 16
Accessing the Indoor Unit.................................................................. 17
Piping Connections............................................................................ 18
Domestic Hot Water.......................................................................... 19
Safety Valve.................................................................................... 20
Installation Fittings............................................................................ 21
Electrical Connections........................................................................ 22
Power Supply Indoor Unit................................................................... 23
Outdoor Unit Installation
Dimensions...................................................................................... 24
Recommended Minimum Service Clearances......................................... 26
Outdoor Unit Sound Pressure.............................................................. 28
Prior to Installation............................................................................ 29
Mounting on a Concrete Pad.............................................................. 30
Mounting using a Mounting Curb........................................................ 31
Mounting on Stand............................................................................ 32
Safety Valve.................................................................................... 33
Piping Connections............................................................................ 34
Accessing the Outdoor Unit................................................................ 35
Power Supply Outdoor Unit................................................................ 36
Communication................................................................................. 37
Installation Examples
Installation Examples......................................................................... 38
System Example 1............................................................................ 39
System Example 2............................................................................ 40
System Example 3............................................................................ 41
User Interface................................................................................... 42
Display Symbols and Indications......................................................... 43
Initial Start-up................................................................................... 44
Diagnostics Menu............................................................................. 44
Settings Menu.................................................................................. 44
Setting the Room Temperature........................................................... 45
Setting the DHW Temperature............................................................ 45
8
6221389 - 02
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Table of Contents
Index
Setting a Time Schedule.................................................................... 46
DHW Tank Hygiene Function.............................................................. 49
Setting Time and Date....................................................................... 50
Adjusting the Interface...................................................................... 50
Setting the Language......................................................................... 51
System Information........................................................................... 51
Time Schedule Override..................................................................... 52
Service/Configuration Menu................................................................ 53
Adjusting the Heating Curve............................................................... 58
Service
Troubleshooting................................................................................ 60
Fault Codes Indoor Unit..................................................................... 62
Fault Codes Outdoor Unit................................................................... 62
Preparing for Service......................................................................... 66
Check Sensors.................................................................................. 66
Checking Fuses................................................................................ 67
Maintenance..................................................................................... 68
Wiring
Indoor Unit Wiring Diagram................................................................ 72
Outdoor Unit Wiring Diagram.............................................................. 74
Parts
Parts List......................................................................................... 77
Technical Data
Indoor Unit Technical Data................................................................. 88
Outdoor Unit Technical Data............................................................... 89
Water Quality
6221389 - 02
Filling the System............................................................................. 90
9
General Information
Vitocal 100-AW AM2V Installation, Service and Operating
Important Regulatory and Installation Requirements
Codes
In Canada all electrical wiring is to be done in
accordance with the latest edition of CSA C22.1
Part 1 and/or local codes. In the U.S., use the
National Electrical Code ANSI/NFPA 70.
Instructing the system user
The installer of the system is responsible to ensure
the system operator/ultimate owner is made familiar
with the system functioning, its activation, and its
shut-down.
Initial start-up
Initial start-up must be performed by a qualified
heating contractor. Proper completion of the
Maintenance Record by the heating contractor is
also required.
Working on the equipment
The installation, adjustment, service, and
maintenance of this heat pump must be done by
a licensed professional heating contractor who
is qualified and experienced in the installation,
service, and maintenance of heat pumps. There are
no user serviceable parts on the heat pump.
Ensure main power supply to equipment, the
heating system, and all external controls has been
deactivated. Take precautions in all instances to
avoid accidental activation of power during service
work.
Technical literature
Leave all literature at the installation site and advise
the system operator/ultimate owner where the
literature can be found. Contact Viessmann for
additional copies.
This product comes with several safety instruction
labels attached. Do not remove! Contact Viessmann
immediately if replacement labels are required.
Literature for the Vitocal 100-AW AM2V Series:
––Technical Data Manual
––Installation, Service and Operating Instructions
––Instructions of other products utilized and
installed
––Installation codes mentioned in this manual and
as locally applicable
The completeness and functionality of field supplied
electrical controls and components must be
verified by the heating contractor. These include
flow switches (if used), staging controls, pumps,
motorized valves, air vents, thermostats, etc.
Leave all literature at the installation site and advise
the system operator/ultimate owner where the
literature can be found. Contact Viessmann for
additional copies. This product comes with several
safety instruction labels attached.
Do not remove!
Contact Viessmann immediately if replacement
labels are required.
Mechanical Room
During the early stages of designing a new
home, we recommend that proper consideration
be given to constructing a separate mechanical
room dedicated to the heat pump equipment and
domestic hot water storage tank(s).
The indoor unit must be located in a heated indoor
area, near a floor drain. Whenever possible, install
the unit near an outside wall so that it is easy to
connect the indoor unit to the outdoor unit. Locate
the indoor unit on a wall capable of supporting 100
lb. (45 kg) [the weight of the indoor unit].
6221389 - 02
The maximum room temperature of the mechanical room where the indoor unit is located must not
exceed 95°F (35°C).
10
General Information
Vitocal 100-AW AM2V Installation, Service and Operating
Applicability
1 CAUTION
The serial number must be provided when ordering
replacement parts. Some replacement parts are not
reverse compatible with previous versions of the
Vitocal 100-AW AM2V.
4
5
IMPORTANT
When ordering replacement parts, provide the
16-digit serial number which is found on either the
indoor unit rating plate or outdoor unit rating plate.
Indoor Unit:
Model No.
AM2V 020028
AM2V 034043
AM2V 051078
Serial No.
7228973jjjjjjjjj
7228974jjjjjjjjj
7228975jjjjjjjjj
Outdoor Unit:
Model No.
AM2V 020028
AM2V 034043
AM2V 051078
Serial No.
7986309jjjjjjjjj
7986310jjjjjjjjj
7986311jjjjjjjjj
1
2
3
Product may not be exactly as shown
1 Integrated resistive heating element
2 Integrated Space Heating/DHW Production
diverting valve
3 Integrated system pump
4 Integrated system expansion tank
5 Monochrome digit interface
Certifications
Indoor Unit
S
1
4
3
Outdoor Unit
2
Product may not be exactly as shown
6221389 - 02
1 Coil
2 Fan
3 Compressor
4 Brazed plate heat exchanger
11
General Information
Vitocal 100-AW AM2V Installation, Service and Operating
Product Information
The Vitocal 100-AW AM2V heat pump is designed for heating/cooling of a building and heating domestic
hot water. The unit consists of two modules:
Outdoor Unit
Indoor Unit
The working principle of the unit is to capture
heat from the environment and to transfer it to the
heating circuit in the building. The low-temperature
heat of the air is transferred through an evaporator
to the heat pump system filled with a refrigerant,
which turns into a gas as it evaporates. From the
evaporator, the gas is drawn in by the compressor,
which raises its temperature during its compression
and directs it to the condenser. In the condenser,
heat is transferred to the refrigerant, which fills the
central heating system, and the cooled liquid flows
through the expansion valve and returns to the
evaporator, after which the whole process starts
again. In the case of cooling, this cycle is reversed
and the heat is extracted from the building and
discharged outside.
The working principle of the unit is based on
the demand-dependent capacity control of the
heat pump compressor with an activation of the
electrical auxiliary heater via the controller of
the indoor module. The indoor module controller
regulates the heating output according to a preset heating curve. If the heat pump is not able to
cover the building’s heating demand on its own,
the controller automatically activates the electrical
auxiliary heater which, together with the heat pump
produces the desired heating medium temperature.
Outdoor temperature ranges for air-to-water heat pumps
All the components of the refrigeration circuit
are located in the outdoor module, including the
refrigeration circuit controller with an electronic
expansion valve. Depending on the operating
conditions, the compressor power is adjusted by
means of an inverter. When the space cooling
function is activated, the refrigeration circuit is
reversed.
Air-to-water heat pumps use the outdoor air as
the heat source. Operation is only efficient within
certain outdoor temperature ranges, e.g. between
-13°F and 113°F (-25°C and +43°C). If the
upper temperature limit is exceeded or the lower
temperature limit has been reached, heat pumps
switch off periodically. A corresponding notification
appears on the heat pump controller. To cover
the heat demand for space heating and tap water
heating beyond the temperature limits, the heat
pump controller automatically switches on the
available auxiliary heating equipment, e.g. electric
auxiliary heating, if necessary.
Plumbing system
Required equipment
The indoor and outdoor modules are connected to
each other via heating medium hydronic lines. A
high-efficiency circulation pump (secondary pump)
built into the indoor module supplies the heating
medium to the secondary circuit. A central 3-way
diverter valve: “space heating/DHW heating DHW”
is responsible for switching between space heating
and hot tap water heating.
A communication bus cable between the outdoor
module and the indoor module. Recommended:
LiYY 2 x 0.34mm2 max: 2 x 1.5mm2
Refrigeration circuit
Heat pump controller
HHSpace heating
The heat pump may heat up to 2 heating/cooling
circuits: 1 heating/cooling circuit without a mixer
and 1 heating/cooling circuit with a mixer.
HHSpace cooling
The heat pump may cool via up to 2 heating/
cooling circuits.
6221389 - 02
The entire heating system is monitored and
controlled by the heat pump controller. The heat
pump controller is integrated into the indoor
module. Communication between the indoor and
outdoor modules takes place via a communication
bus.
Installation with heating/cooling buffer storage tank
12
Vitocal 100-AW AM2V Installation, Service and Operating
General Information
Product Information
Wall mounted indoor unit in combination with air to
water outdoor unit heat pump, with the following
integrated components:
HHHeating or cooling operation
HHHydronics with 3-way diverter valve and variable
speed high efficiency circulation pump
HHWeather-compensated or constant temperature
control unit
HHDHW production
Heat pump model must be selected based on an
accurate heat loss calculation of the building.
Ensure heat pump model is compatible with
connected radiation.
A
The rating plate of the Vitocal 100 AW contains
extensive product information and is heat pumpspecific. Access code with the marking “i” for
direct access to product-specific information and
product registration on the internet. The access
code contains the credentials for the registration
and product information portal, as well as the
16-digit serial number.
6221389 - 02
A Rating plate for indoor unit registration
13
General Information
Vitocal 100-AW AM2V Installation, Service and Operating
Intended Use
The Vitocal 100 is only intended to be installed and
operated in sealed unvented heating systems with
due attention paid to the associated installation,
service and operating instructions. The heat pump
is only designed for:
HHSpace Heating
HHSpace Cooling
HHDHW Heating
Commercial or industrial use for a purpose other
than the heating of heating water shall be deemed
inappropriate.
Intended use presupposes that a permanent
installation in conjunction with permissible
components designed for this purpose has been
carried out. All other use is deemed inappropriate.
Any resulting losses are excluded from the
manufacturer’s liability. Any usage beyond
this must be approved by the manufacturer in
each individual case. Intended use also includes
adherence to maintenance and inspection intervals.
System Examples
System examples with hydronic and electrical
connection schemes and function descriptions are
available to help setting up the heating system,
refer to “Installation Examples” on page 38.
Fittings and Sealing Points
All connections must be fitted with new gaskets/
seals after opening or loosening.
1 WARNING
Risk of electric shock from escaping heating water
or DHW. When commissioning and after carrying
out maintenance work, check all water side
connections for leaks.
Prior to Installation
1 CAUTION
The indoor unit must be installed in such a way
that the system components are protected from
water (spraying, splashing, etc.) during operation
and service.
6221389 - 02
Before placing Vitocal 100 AW in its installation
location, ensure all necessary accessories are
installed.
14
Indoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Dimensions
A
B
C
D
E
F
F
G
H
I
J
5-b (138)
2 (48)
11-a (283)
7-b (190)
2-a (55)
Legend
A
B
C
D
E
F
G
c in. Electrical Knockouts (2 per side)
b in. Electrical Knockouts (8 per side)
Return to Heat Pump (1-a in. NPT)
Supply to Space Heating (1-a in. NPT)
DHW/Space Heating Return (1-a in. NPT)
Supply from Heat Pump (1-a in. NPT)
DHW Tank Heating Supply (1-a in. NPT)
6221389 - 02
Dimensions in. (mm)
A
16-a (416)
B
28-b (723)
C
12-c (323)
D
28-a (717)
E
11-a (285)
G
15
Indoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Recommended Minimum Service Clearances
Recommended minimum service clearances
For typical installation, it is recommended to install
the indoor unit with the clearances shown in the
illustration.
A - 12 in. (300 mm)
B - 20 in. (500 mm)
Front Clearance 39 in. (1000 mm)
These dimensions reflect the recommended service
clearance for the indoor unit only, ensure adequate
clearance is left for the installation of piping and
electrical connections.
Minimum Clearances to Combustibles
Top
Front
0
0 AL, CL
AL= Alcove
CL= Closet
Rear
0
Left
0
Right
0
Mounting the Indoor Unit
The indoor unit can be wall-mounted on a concrete wall.
Note: The enclosed screws and rawl plugs are
only suitable for concrete. For other construction
materials, use bolts and anchors that are suitable
for 100 lb. (46 kg) loads.
2.
3.
4.
1
(406 in.
6m
m)
1.
Installation of mounting bracket on brick/concrete wall:
1. Mark out the rawl plug holes.
2. Drill holes ne in. (n10 mm) and insert the rawl
plugs supplied.
3. Fit the wall mounting bracket with the screws
supplied.
4. Mount the indoor unit on the wall mounting
bracket. Ensure that both tabs have locked into
the indoor unit.
Note: Check the condition of the wall where the
indoor unit is to be installed. For the suitability
of the supplied rawl plugs for various building
materials, see the manufacturer’s instructions. For
other construction materials, use fixing materials
with sufficient load bearing capacity.
Whichever mounting method is used, ensure that
the bracket is tightly and securely fastened to wall.
Failure to secure indoor unit properly could cause
indoor unit to loosen, posing a severe safety hazard.
16
6221389 - 02
1 CAUTION
Vitocal 100-AW AM2V Installation, Service and Operating
Indoor Unit Installation
Accessing the Indoor Unit
Accessing the Indoor Unit for Installation
1. Remove the two door retaining screws.
2. Swing the door open to the right.
Note: If required the mid jacketing panel can be
removed to offer addition clearance for installation,
refer to “Preparing for Service” on page 66 for
instructions on removing the mid panel.
2.
6221389 - 02
1.
17
Indoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Piping Connections
2 imperfect threads
Use moderate amount of dope
Leave 2 threads bare
Proper piping practice
Support piping by proper suspension method.
Piping must not rest on or be supported by indoor
unit.
Connections on the heating water and DHW sides
If the connections have not been fitted previously,
make the connections on the heating water and
DHW sides.
Note: If no tank is connected, close off the DHW
tank supply connection with a cap.
Heating water connections
1. Thoroughly flush heating system (particularly
before connecting the heat pump to an existing
system).
2. Connect indoor unit to the heating system.
Note: Use an approved pipe sealant or Teflon
tape when connecting the installation fittings.
Maximum allowable working pressure (MAWP):
30 psig (2 bar)
1 WARNING
Exposing the Vitocal to pressures and temperatures
in excess of those listed will result in damages, and
will render warranty null and void.
Legend
A DHW tank heating return
B Heating system return
C Supply from the heat pump outdoor unit
D Return to the heat pump outdoor unit
E Heating system supply
F DHW tank heating supply
Note:
All fittings shown are field supplied
Note: Install temperature gauge (field supplied)
anywhere in the supply piping near the
indoor (not shown).
18
SUPPORT ALL PIPING USING HANGERS. DO NOT
support piping by the indoor unit or its components.
HHUse isolation valves to isolate system
components.
General
A distance of 2 in. (50 mm) from uninsulated hot
water pipes to combustible components must be
maintained.
If the pipes are provided with a suitable pipe
insulation of sufficient thickness and insulation, the
distance mentioned above is not necessary (see
also local regulations).
6221389 - 02
D E A B FC
HHUse a two-hand wrench method when tightening
fittings or piping onto the indoor unit connectors.
Use one wrench to prevent the indoor unit pipes
from twisting and the second wrench to tighten
the fitting or piping. Failure to support the indoor
unit connection could damage the heat pump and
its internal piping.
HHAll plumbing must meet or exceed all local state
and national plumbing codes.
Vitocal 100-AW AM2V Installation, Service and Operating
Indoor Unit Installation
Domestic Hot Water
The Vitocal-AW AM2V series can be used in
conjunction with the stand-alone DHW storage
tanks offered by Viessmann.
For the connection of a stand-alone DHW tank,
installation fittings (field supplied), and a DHW
temperature sensor (supplied with heat pump) is
required.
Size and select the DHW storage tank based on
the forecasted DHW consumption of the building in
question.
For further technical information on DHW storage
tanks, see the Vitocell Technical Data Manuals.
If no domestic hot water tank is being connected
to the indoor unit, the domestic hot water tank port
needs to be capped.
DHW storage tank information
The DHW sensor is required when using a standalone DHW storage tank with the heat pump. The
heat pump is supplied with a DHW sensor (all other
fittings are field supplied).
Making the DHW connections
1. With a Vitocell tanks, locate the DHW
temperature sensor well and install the DHW
temperature sensor using the installation
instructions provided with the DHW storage
tanks.
1 IMPORTANT
Follow the Installation Instructions supplied with
the Viessmann DHW storage tank when mounting
and securing DHW tank temperature sensor.
6221389 - 02
1 WARNING
If a DHW storage tank other than a Viessmann
Vitocell tank is used, the installer must verify
proper operation of the Viessmann DHW tank
temperature sensor with original manufacturer of
the tank. Viessmann strongly recommends the
installation of a temperature tempering valve in the
DHW supply line.
19
Indoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Safety Valve
Installing the pressure relief valve:
1. Use the supplied fittings to install the pressure
relief valve on the Supply from Outdoor Unit
Connection of the Indoor Unit refer to “Piping
Connections” on page 18.
Minimum connection diameters:
Pressure relief valve������������������������������������� c in.
Discharge pipe�������������������������������������������� c in.
Maximum operating pressure: 30 PSI (2 bar)
Minimum operating pressure: 8 PSI (0.5 bar)
F
E
D
A
C
B
Legend
A Supply from Outdoor Unit
B 1-a X 1 X 1 Inch Brass Reducing Tee
C 1 X 6 Inch Long Brass Nipple
D 1 X c Inch Brass Reducing Elbow
E c Inch Brass Close Nipple
F 30 PSI Pressure Relief Valve
Installing the discharge pipe:
1. Install discharge pipe on pressure relief valve in
such a way that...
- the end of the pipe is not threaded.
- the pressure relief discharge pipe extends to a
floor drain and ends approximately 6 in. (150
mm) above the drain.
Ensure that...
- there is no shutoff valve installed in the discharge pipe.
- discharge pipe diameter is not reduced.
- discharge is not piped to outdoors.
1 IMPORTANT
Install the (approved) factory supplied pressure
relief valve. Removal of air from the system must
occur via use of air vent(s) in the system supply.
To ensure the heat pump can be purged of all air,
ensure supply/return water lines do not contain
restrictive piping where air could be trapped.
1 WARNING
6221389 - 02
Do not install an isolation valve between heat
pump and pressure relief valve. The discharge pipe
for the pressure relief valve must be oriented to
prevent scalding of attendants. Pipe pressure relief
valve discharge pipe close to floor drain. Never
pipe discharge pipe to the outdoors.
20
Vitocal 100-AW AM2V Installation, Service and Operating
Indoor Unit Installation
Installation Fittings
Installation Fittings
The indoor unit is supplied with the installation
fittings described.
F
E
D
I
A
C
J
B
G
G
H
H
6221389 - 02
Legend
A Supply from Outdoor Unit
B 1-a X 1 X 1 Inch Brass Reducing Tee
C 1 X 6 Inch Long Brass Nipple
D 1 X c Inch Brass Reducing Elbow
E c Inch Brass Close Nipple
F 30 PSI Pressure Relief Valve
G 1 Inch Brass Close Nipple
H Drain/Fill/Isolate Ball Valve
I Return to Outdoor Unit
J 1-a X 1 Inch Brass Reducing Coupling
21
Indoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Electrical Connections
A
B
C
D
E
F
H
OUT
G
N
I
J
K
L
Legend:
Note:
-120VAC outputs rated current 2FLA
-Maximum output 5FLA shared between all
120V outputs.
22
6221389 - 02
A DHW Recirculation Pump (PHWC)
B Glycol Circuit Pump (PGC)
C Cooling/Heating Divertering Valve/Pump (VCH)
D Heating Circuit 1 Pump (PHC1)
E Heating Circuit 2 Pump (PHC2)
F Heating Circuit 2 Mixing Valve (VMCH2)
G MODBus Communication with ODU (EU)
H Heating Circuit 2 Temperature Sensor (THC2)
I Heating Circuit 1 Temperature Sensor (THC1)
J DHW Tank Temperature Sensor (TCYL)
K Room Temperature Sensor (TR)
L Outdoor Temperature Sensor (TO)
M Backup Heat Activation - Dry Contact (OUT)
Vitocal 100-AW AM2V Installation, Service and Operating
Indoor Unit Installation
Power Supply Indoor Unit
AM2V 020028/034043 Power Supply
G
L2
L1
N
A
230 VAC-1Ph-60Hz
AM2V 051078 Power Supply
230 VAC-1Ph-60Hz
1 WARNING
Incorrectly executed electrical installations can
lead to injuries from electrical current and result in
appliance damage.
1 WARNING
The control must be grounded.
Ensure that ‘L1’, ‘L2’, ‘N’ and ‘G’ are not
interchanged.
1 IMPORTANT
Legend
6221389 - 02
A 230V/1Ph/60Hz Power Supply Connection
Electrical installations must comply with the latest
edition of:
HHIn the U.S.A., the National Electrical Code (NEC),
ANSI/NFPA 70 and any other state, local codes
and/or regulations.
HHIn Canada, the Canadian Electrical Code (CEC),
CSA C22.1 Part 1 and any other province,
territory, local codes and/or regulations.
23
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Dimensions
AM2V 020028/034043 Outdoor Unit
A
B C
AM2V 034043
50-c (1285)
36-b (928)
18-d (460)
18-b (470)
20 (500)
38-e (975)
8-f (220)
14-d (360)
4-f (118)
Legend
A - Electrical Connections
B - Heat Pump Hydronic Supply (1 in. NPT Male)
C - Heat Pump Hydronic Return (1 in. NPT Male)
6221389 - 02
Dimensions in. (mm)
AM2V 020028
A
46 (1165)
B
31-a (795)
C
15-c (400)
D
17 (428)
E
17-c (450)
F
32-f (830)
G
9-d (232)
H
13 (330)
I
6-b (166)
24
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Dimensions
AM2V 051078 Outdoor Unit
J
A
B C
F
G
H
I
J
31-b (800)
6-d (155)
37-c (983)
8-b (215)
10 (252)
6221389 - 02
Dimensions in. (mm)
A
49-a (1250)
B
52-e (1329)
C
19-b (495)
D
20-a (515)
E
21-a (540)
Legend
A - Electrical Connections
B - Heat Pump Hydronic Supply (1 in. NPT Male)
C - Heat Pump Hydronic Return (1 in. NPT Male)
25
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Recommended Minimum Service Clearances
AM2V 020028/034043 Outdoor Unit
b
b
B
d
c
a
b
A
A
B
a
AM2V 020028/034043 Outdoor Unit
59 (1500)
20 (500)
39 (1000)
20 (500)
6221389 - 02
Legend
A - Air outlet
B - Air inlet
Dimensions in. (mm)
a
b
c
d
26
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Recommended Minimum Service Clearances
AM2V 051078 Outdoor Unit
b
b
B
a
d
c
b
A
B
A
a
AM2V 051078 Outdoor Unit
59 (1500)
20 (500)
39 (1000)
20 (500)
6221389 - 02
Legend
A - Air outlet
B - Air inlet
Dimensions in. (mm)
a
b
c
d
27
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Sound Pressure
Distance from the noise source ft (m)
Power level
acoustic Lw
[dB (A)]
Directivity
Factor
Q
3.3
(1)
AM2V
020028
60
2
52
46
42
40
38
36
34
32
30
28
4
55
49
45
43
41
39
37
35
33
32
8
58
52
48
46
44
42
40
38
36
35
AM2V
034043
63
2
55
49
45
43
41
39
37
35
33
31
4
58
52
48
46
44
42
40
38
36
35
8
61
55
51
49
47
45
43
41
39
38
2
56
50
46
44
42
40
38
36
34
32
4
59
53
49
47
45
43
41
39
37
36
8
62
56
52
50
48
46
44
42
40
39
Outdoor Unit
AM2V
051078
64
6.6
(2)
9.8
(3)
13.1 16.4 19.7 26.2 32.8 39.4 49.2
(4)
(5)
(6)
(8)
(10) (12) (15)
Sound pressure level [dB (A)]
Q = 2: freestanding heat pump on the outside of
the building.
Q = 4: heat pump on the building’s wall.
6221389 - 02
Q = 8: heat pump on the building’s wall situated in
the corner
28
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Installation
Prior to Installation
Mounting:
HHMount the outdoor module in a free-standing
position on a fixed supporting structure.
HHIn areas with snowfall, ensure the outdoor unit
has been installed using a snow stand or wall
mounting bracket that will elevate the outdoor
unit above the anticipated snow load.
HHThe weight of the outdoor unit must be taken
into account: see “Outdoor Unit Technical Data”
on page 89.
Setting:
HHDo not install the exhaust side upwind.
HHCarry out wall ducts and protective conduits for
plumbing and electrical connection lines without
using bent pipes and without changing the
direction of the lines.
Impact of weather conditions:
HHWhen installing in areas exposed to wind, pay
attention to wind loads. When the outdoor unit
is mounted on a flat roof, significant wind loads
may arise depending on the wind load zone and
the height of the building. Include the outdoor
unit in the lightning protection system.
HHWhen designing rain protection or canopy, pay
attention to the heat input (heating mode) and
heat output (cooling mode) of the unit.
Condensate:
HHEnsure free drainage of the condensate away
from the outdoor unit.
Damping of sound and vibration between the
building and the outdoor unit:
HHMake the hydronic connection to the outdoor unit
using flexible connections.
HHElectrical cables should be installed without
tension.
1 IMPORTANT
6221389 - 02
Strong impacts may lead to a damage to the
jacketing of the unit. Do not press against the
outdoor unit jacketing.
1 IMPORTANT
Tilting the outdoor module sharply may lead to the
oil from the compressor entering the refrigeration
circuit and to a consequent failure during the startup. Maximum tilt angle: 45° for approximately 4
min., otherwise 30°
Placement of the outdoor unit:
HHSelect a location with good air circulation so that
cooled air can flow out and warm air can flow in.
HHDo not install in corners, recesses or between
walls. This may lead to a recirculation of exhaust
air.
1 IMPORTANT
Restricting the free flow of air may lead to cooled
air (or heated in the cooling mode) being drawn
back in and lead to disruptions in the operation
of the unit, a loss of efficiency and a consequent
increase in electrical consumption.
HHIf set up in an area exposed to strong winds,
prevent the wind from affecting the fan area.
Strong winds may disrupt the air flow through the
evaporator.
HHSelect the installation location so that the
evaporator is not clogged by leaves, snow, etc.
HHConsider sound propagation and reflection when
selecting the mounting location.
Design guidelines
HHDo not mount the device under windows or next
to bedroom windows.
HHDo not install the device in basement sumps or
depressions in the ground.
HHMaintain a min. 10 ft. (3 m) distance from
basement sumps and windows.
HHMaintain a distance from terraces, gutters or
surfaces with a protective coating of min. 10
ft. (3 m). At outdoor temperatures below 50°F
(10°C), cooled air blown out causes a risk of
icing.
HHAvoid “short circulating” of air streams with
ventilation equipment. Maintain a min. 10 ft. (3
m) distance from the intake area of ventilation
units.
HHThe installation location must be easily
accessible, e.g. for service work
29
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Mounting on a Concrete Pad
A
A
A
A
Concrete Pad Mounting
1. A concrete pad cast in place or a single piece
pre-cast concrete or composite slab may be
used. Select the size of the pad based on the
dimensions provided
2. Center the outdoor unit on the pad
3. Place the rubber vibration isolators provided
under the mounting feet.
4. Anchor the unit to the concrete pad.
Legend
A - Outdoor Unit
B - Concrete anchor bolt
C - Rubber vibration isolator
D - Concrete pad
Note:
Ensure that the condensate drains freely.
B
Dimensions in. (mm)
A
B
2 (50)
4 (100)
A
B
C
6221389 - 02
D
30
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Installation
Mounting using a Mounting Curb
Curb Mounting
1. Slide two mounting bolts into each channel.
2. Align the mounting screws with the retaining
tabs on the outdoor unit, place the outdoor unit
over the bolts and secure in place.
Legend
A - Curb mounting bracket
B - Gravel bed to facilitate condensate absorption
C - Concrete foundation (if required)
2.
Note:
Ensure that the condensate drains freely.
A
1.
B
6221389 - 02
C
31
Outdoor Unit Installation
Vitocal 100-AW AM2V Installation, Service and Operating
Mounting on Stand
Stand Mounting
A
1. Assemble and secure stand (field supplied),
ensure that spacing aligns with mounting feet
of the outdoor unit.
2. Secure outdoor unit to the stand.
Legend
A - Outdoor Unit
B - Mounting Stand
B
Note:
Ensure that the condensate drains freely.
1 IMPORTANT
Ensure that the stand or wall mount bracket is
rated to support the weight of the outdoor unit.
Follow the manufactures instructions for assembly
and mounting requirements.
A
6221389 - 02
B
32
Vitocal 100-AW AM2V Installation, Service and Operating
Connections
Safety Valve
A
D
C
B
A
E
F
G
I
H
Legend
A Supply from Outdoor Unit
B 1 Inch Brass 90 Degree Elbow
C 1 X 8 Inch Long Brass Nipple
D Microbubble Air Separator
E 1 X 1 X c Inch Brass Reducing Tee
F c Inch Brass 90 Degree Street Elbow
G c Inch Brass Close Nipple
H 30 PSI Pressure Relief Valve
I Return to Outdoor Unit
Installing the pressure relief valve:
1 WARNING
Installing the discharge pipe:
1. Install discharge pipe on pressure relief valve in
such a way that...
- the end of the pipe is not threaded.
- the pressure relief discharge pipe approximately 6 in. (150 mm) above the ground.
Ensure that...
- there is no shutoff valve installed in the discharge pipe.
- discharge pipe diameter is not reduced.
Do not install an isolation valve between heat
pump and pressure relief valve. The discharge pipe
for the pressure relief valve must be oriented to
prevent scalding of attendants. Pipe pressure relief
valve discharge pipe close to floor drain. Never
pipe discharge pipe to the outdoors.
6221389 - 02
1 IMPORTANT
Install the (approved) factory supplied pressure
relief valve. Removal of air from the system must
occur via use of air vent(s) in the system supply.
To ensure the heat pump can be purged of all air,
ensure supply/return water lines do not contain
restrictive piping where air could be trapped.
1. Use the supplied fittings to install the pressure
relief valve on the Supply from Outdoor Unit.
Minimum connection diameters:
Pressure relief valve������������������������������������� c in.
Discharge pipe�������������������������������������������� c in.
Maximum operating pressure: 30 PSI (2 bar)
Minimum operating pressure: 8 PSI (0.5 bar)
33
Connections
Vitocal 100-AW AM2V Installation, Service and Operating
Piping Connections
Connection between Indoor and Outdoor Unit
6221389 - 02
This is a simplified schematic of the connection
points between the Indoor Unit and the Outdoor
Unit, and does not represent all the required
components.
34
Vitocal 100-AW AM2V Installation, Service and Operating
Connections
Accessing the Outdoor Unit
Accessing the Outdoor Unit
1. Remove the two access panel retaining screws
and set aside.
2. Slide the access panel down and pull out to
remove.
2.
1.
Connection Overview
A - Outdoor unit electrical connections board
B - Grommet for low voltage connections
C - 3/4 Inch knockout for power supply
A
6221389 - 02
B
C
35
Vitocal 100-AW AM2V Installation, Service and Operating
Power Supply Outdoor Unit
Power Supply
240 VAC-1Ph-60Hz
L1, L2, G
Power Supply Requirements
AM2V 020028
208/230V-1Ph-60Hz Maximum 25 Amp Breaker
AM2V 034043
208/230V-1Ph-60Hz Maximum 45 Amp Breaker
AM2V 051078
208/230V-1Ph-60Hz Maximum 70 Amp Breaker
1 WARNING
Incorrectly executed electrical installations can
lead to injuries from electrical current and result in
appliance damage.
1 WARNING
The control must be grounded.
Ensure that ‘L1’, ‘L2’, ‘N’ and ‘G’ are not
interchanged.
1 IMPORTANT
6221389 - 02
Electrical installations must comply with the latest
edition of:
HHIn the U.S.A., the National Electrical Code (NEC),
ANSI/NFPA 70 and any other state, local codes
and/or regulations.
HHIn Canada, the Canadian Electrical Code (CEC),
CSA C22.1 Part 1 and any other province,
territory, local codes and/or regulations.
36
Vitocal 100-AW AM2V Installation, Service and Operating
Communication
A
Communication
A - End of Line Resistor
The indoor unit communicates with the outdoor
unit through Modbus protocol. Using a two wire
twisted pair, shielded 22 AWG cable connect the
following terminals;
Indoor Unit terminal EU ‘A’ to Outdoor Unit DIN rail
terminal 1.
Indoor Unit terminal EU ‘B’ to Outdoor Unit DIN rail
terminal 2.
6221389 - 02
Install the supplied end of line resistor A across
terminals EU A and B with communnication wires
to the outdoor unit.
37
Installation Examples
Vitocal 100-AW AM2V Installation, Service and Operating
Installation Examples
Connection to the hydronic system
The Vitocal 100-AW AM2V series heat pump can
operate in a closed-loop hydronic system (the
minimum heating medium pressure is 8 PSI [0.5
bar]). The hydronic installation must be carried
out in compliance with the applicable standards.
The pipes connecting the heat pump to the indoor
unit must have an internal diameter to ensure an
adequate flow of the heating medium (see technical
data table).
Flexible piping must be used to connect the heat
pump to the hydronic system to prevent the
transmission of vibrations to the system. The
heating medium pipes and connections must be
thermally insulated. Do not switch off the unit
when the outdoor air temperature is below freezing.
This will protect the condenser of the outdoor unit
from damage. If there is a risk of power failure, the
heat pump heating circuit must be isolated from
the hydronic module by means of an additional
exchanger and the heat pump heating circuit must
be filled with an antifreeze. A prerequisite for the
warranty is an installation of a solids separator at
the unit inlet.
WARNING
1
If a DHW storage tank other than a Viessmann
Vitocell tank is used, the installer must verify
proper operation of the Viessmann DHW tank
temperature sensor with the original manufacturer
of the tank. Viessmann strongly recommends the
installation of a temperature tempering valve in the
DHW supply line.
1 IMPORTANT
The examples on the following pages depict
possible piping layouts of the Vitocal 100 AW
heat pump equipped with Viessmann System
Technology. For heat pump and tank combinations,
please install only feasible combinations listed
in the Viessmann Price List. Please note that
the following examples are simplified conceptual
drawings only! Piping and necessary componentry
must be field verified.
1 IMPORTANT
DHW supply and return piping between Vitocal
DHW connections and the Viessmann DHW tank
connections, shall be a minimum of 1b in. nominal
pipe diameter connection outlet sizes provided on
the Vitocal and the DHW tank). This will ensure
the residual head of the field supplied pump is fully
utilized to overcome the resistance of the DHW
heat exchanger coil and to provide sufficient water
flow to the Vitocal.
In non-Viessmann DHW tank applications, perform,
in addition to the above, accurate calculations for
DHW tank coil pressure drop versus Vitocal internal
pump residual head to ensure sufficient water flow
to the Vitocal heat exchanger. Failure to heed the
above instructions may inadequate DHW supply.
6221389 - 02
The hydronic installation must be made in such a
way that the indoor unit can be operated in the
heating circuit without the outdoor unit (according
to the following installation diagrams). This will
ensure the operation of the heating system in the
event of a failure of the outdoor unit.
Please note that in the following piping layout examples all pumps are field supplied.
38
Installation Examples
Vitocal 100-AW AM2V Installation, Service and Operating
System Example 1
Vitocal 100-AW AM2V with:
- One direct-connected heating circuit
- One heating circuit with a mixing valve
- Combination System Buffer/DHW Storage Tank
M
O
N
S
A
P
T
Q
U
C
L
R
J
I
B
H
K
F
D
6221389 - 02
E
Legend:
A Indoor Unit
B Outdoor Unit
C Outdoor Temperature Sensor
D System Feed
E Expansion Tank
F Wye Strainer
H DHW Temperature Sensor
I Combination System Buffer/DHW Storage Tank
J Temperature and Pressure Relief Valve
K Potable Water Inlet
L DHW Recirculation Pump
M DHW Outlet
N Room Temperature Sensor
O Low Temperature Heating Circuit
P Heating Circuit Temperature Sensor
Q Heating Circuit Pump
R Heating Circuit Mixing Valve
S High Temperature Heating Circuit
T Heating Circuit Temperature Sensor
U Heating Circuit Pump
1 IMPORTANT
System separation is required of underfloor heating
systems employing non-oxygen diffusion barrier
tubing. All components on the secondary side of
the heat exchanger must be made of corrosionresistant materials.
39
Installation Examples
Vitocal 100-AW AM2V Installation, Service and Operating
System Example 2
Vitocal 100-AW AM2V with:
- One direct-connected heating circuit
- One heating circuit with a mixing valve
- Vitocell System Buffer Tank
- Vitocell DHW Storage Tank
O
N
S
M
A
C
P
T
Q
U
R
L
J
I
B
F
V
H
K
D
E
Q Heating Circuit Pump
R Heating Circuit Mixing Valve
S High Temperature Heating Circuit
T Heating Circuit Temperature Sensor
U Heating Circuit Pump
V Vitocell MSCA 20USG (75L) Buffer Tank
1 IMPORTANT
System separation is required of underfloor heating
systems employing non-oxygen diffusion barrier
tubing. All components on the secondary side of
the heat exchanger must be made of corrosionresistant materials.
6221389 - 02
Legend:
A Indoor Unit
B Outdoor Unit
C Outdoor Temperature Sensor
D System Feed
E Expansion Tank
F Wye Strainer
H DHW Temperature Sensor
I DHW Storage Tank
J Temperature and Pressure Relief Valve
K Potable Water Inlet
L DHW Recirculation Pump
M DHW Outlet
N Room Temperature Sensor
O Low Temperature Heating Circuit
P Heating Circuit Temperature Sensor
40
Installation Examples
Vitocal 100-AW AM2V Installation, Service and Operating
System Example 3
Vitocal 100-AW AM2V with:
- One direct-connected heating circuit
- One heating circuit with a mixing valve
- One fan coil
- Vitocell System Buffer Tank
- Vitocell DHW Storage Tank
O
W
N
S
M
A
C
P
T
Q
U
R
L
J
I
B
F
V
H
K
D
E
Q Heating Circuit Pump
R Heating Circuit Mixing Valve
S High Temperature Heating Circuit
T Heating Circuit Temperature Sensor
U Heating Circuit Pump
V Vitocell MSCA 20USG (75L) Buffer Tank
W Fan Coil
1 IMPORTANT
System separation is required of underfloor heating
systems employing non-oxygen diffusion barrier
tubing. All components on the secondary side of
the heat exchanger must be made of corrosionresistant materials.
6221389 - 02
Legend:
A Indoor Unit
B Outdoor Unit
C Outdoor Temperature Sensor
D System Feed
E Expansion Tank
F Wye Strainer
H DHW Temperature Sensor
I DHW Storage Tank
J Temperature and Pressure Relief Valve
K Potable Water Inlet
L DHW Recirculation Pump
M DHW Outlet
N Room Temperature Sensor
O Low Temperature Heating Circuit
P Heating Circuit Temperature Sensor
41
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
User Interface
Use the mode selection dial C to set one of the
modes:
z +
Winter (Space heating + DHW)
A
9:37 Tu 04.02.2020
5,1°
24.2 °
Standby (Frost Protection Active)
55°
B
C
Legend
A - Display
B - Navigation Dial
C - Mode Selector Dial
+
Summer (Space Cooling + DHW)
9
Turning the navigation dial B (left or right), with
the winter or summer mode being active, switches
the function screens on the display A. To select
the desired menu item press on the navigation dial
B.
HHHome Screen: indicates the basic parameters of
the heat pump (see the table for details),
HHDiagnostics Menu: allows the input and output
signals of the heat pump to be viewed.
HHSettings Menu: allows the heat pump parameters
to be adjusted to the user’s preferences.
HHService Menu: allows for heating system
configuration to object’s conditions (available to
the installer and service contractors though an
access code) and preview of input and output
heat pump’s signals and current parameters.
HHTime Schedule Override: Allows the homeowner
to override the active heating/cooling function
without needing to adjust the time schedule
Pressing and holding the navigation dial when in
any menu will return you to the home screen.
6221389 - 02
The individual functions are accessed by selecting
the relevant menu screen and pressing the
navigation dial. If an error or warning in the system
occurs, the home screen will display either a Eerr or
1. By pressing on dial B, a list of detected errors
and warnings will be displayed.
42
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Display Symbols and Indications
E
G
Indication of the running program
m
Disinfection of the storage tank
9:37 Tu 04.02.2020
5,1°
C
A
24.2 °
B
D
According to a pre-set daily/weekly schedule
F
Legend
A - Signalling of heat take-up
B - Heating Program ‘ON’ Indication
C - Heater ‘ON’ Indication
D - Compressor Operation Indicator
E - Set Room Temperature
F - Actual Room Temperature
G - Outdoor Temperature
H - DHW Tank Temperature
55°
H
Defrost cycle running
PARTY - maintaining a comfortable temperature in the room and the cylinder
HOLIDAYS - maintaining an economic or
j frost-free temperature in the room and the
storage tank
Implementation of the frost protection
program
MANUAL - maintaining the desired
h
temperature in the room
Indication of realized Room Temperature
Signalling of heat take-up > central heating
Signalling of heat take-up > hot tap water
Cooling operation indication
Other Symbols
Eerr
Error indication
1
Warning indication
Indicates that the compressor is active.
Flashing symbol indicates bivalent mode.
Back-up Heating On
6221389 - 02
A
Electric heat element is active
43
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Initial Start-up
When first powering up the indoor unit, you will be
prompted to select the operating language, and the
model of connected outdoor unit.
Language
English
1. Scroll with the navigation dial to select the
desired language and press the dial to select.
2. Scroll with the navigation dial to select the
connected outdoor unit and press the dial to
accept
Espanol
Francais
Polski
Type
020028
034043
051078
Diagnostics Menu
This menu displays the current operating
conditions of the heat pump indoor and outdoor
units. Parameters displayed are based on the
configuration of the system
Settings Menu
9:37 Thu 22.04.2021
This menu provides access to the user adjustable
settings of the heat pump. These settings include
room temperature setpoint, DHW temperature
setpoint, time schedules, etc. Available menu items
may change depending on system configuration.
6221389 - 02
Settings
44
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
Setting the Room Temperature
There are four different programmable room
temperature setpoints for heating, these are used
when configuring the time schedule. The four
temperature setpoints are:
HHEconomy Temp.
HHCom. Minus Temp.
HHComfort Temp.
HHCom. Plus Temp.
The ‘Temporary Hold’ temperature setpoint uses
the selected comfort temperature setting for space
heating when the party mode is active.
DHW Recirc. Sched.
The ‘Holiday Override’ temperature setpoint uses the
selected economy or frost protection temperature
setting for space heating when the program is
active.
DHW Hygiene Settings
Cooling Sched.
The ‘Cooling’ temperature setpoint is for space
cooling (only available with panel cooling).
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the settings
menu.
Note: Frost protection ( ) in the standby and
summer modes, if the room temperature falls below
45°F (7°C), the central heating circuit will be
activated. A room temperature sensor is required to
activate the function.
Setting the DHW Temperature
There are two different programmable DHW
temperature setpoints for heating, these are used
when configuring the time schedule. The two
temperature setpoints are:
HHEconomy Temp.
HHComfort Temp.
DHW Recirc. Sched.
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the settings
menu.
DHW Hygiene Settings
6221389 - 02
Cooling Sched.
45
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Setting a Time Schedule
The control allows for a maximum of 8 space
heating time schedules, Sched. 1 through Sched. 8,
which and be applied to each day of the week.
Each of the 8 time schedules has five editable
time frames, which can have different temperature
setpoints.
For space heating, there are four selectable room
temperature setpoints ( , , , or ). The
default setting of the space heating schedule is the
economy temperature setpoint ( ).
For DHW, there are two selectable DHW
temperature setpoints ( , or ). The default
setting and times between temperature setpoints
of the DHW heating schedule is the economy
temperature setpoint ( ).
For DHW recirculation, only a start time and end
time for DHW recirculation are programmable.
For space cooling, only a start time and end time
for space cooling are programmable.
DHW Recirc. Sched.
The ‘Weekly Sched.’ setting option assigns one
of the eight daily time schedules to a selectable
day of the week, each day of the week can have a
different time schedule.
DHW Hygiene Settings
6221389 - 02
Cooling Sched.
46
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
Setting a Time Schedule
Space Heating Time Schedule
C
D
A
Heating Sched.
E
F
Sched. 1
1 6:00 - 9:15
B
2 15:20 - 22:15
Save
Koniecand End
Legend
A - active time frame (max 5)
B - no. of time frame according to schedule (max 5)
C - starting time of the selected temperature
D - finishing time of the selected temperature
E - temperature selection ( , , , , or )
F - command (active when editing):
HH
R accept
HH
T delete
HH
add
DHW Time Schedule
C
D
DHW Sched.
A
E
F
Sched. 1
1 6:00 - 9:15
B
2 15:20 - 22:15
Save
Koniecand End
Legend
A - active time frame (max 5)
B - no. of time frame according to schedule (max 5)
C - starting time of the selected temperature
D - finishing time of the selected temperature
E - temperature selection ( , or )
F - command (active when editing):
In daily schedule the heating circuits have a
defined starting time C and finishing time D
of maintaining selected temperature value E in
the room. Outside defined time frames economy
temperature will be maintained in the room
temperature. In buffer mode there is an automatic
adjustment of start time C and finish time D
which takes into consider the buffer tank charging
time.
In daily schedule the DHW heating has a defined
starting time C and finishing time D of
maintaining selected temperature value E in
the room. Outside defined time frames economy
temperature will be maintained in the reduced
temperature.
Adjusting the time schedule
1. Select chosen program number and press
navigation dial. The first parameter flashes
(start time).
2. Use the navigation dial to set the new time
frame value (hour and minutes separately) by
turning the dial, and confirm it by pressing the
dial.
3. Repeat the process for finishing time.
4. Use the navigation dial to set the new
temperature selection by turning the dial, and
confirm it by pressing the dial.
5. Use the navigation dial to select the command
column. To save changes select R command
and press the dial to finish editing. To delete
selected time frame select command T and
press the dial.
6. To add new time frame, select last defined time
frame and by pressing the dial go to command
position, select command
and press the dial
to add new time frame (edition of new time
frames described above).
The entire day program is saved in the controller’s
memory when you exit the day program by
pressing the “Save and end” command.
HH
R accept
HH
T delete
add
6221389 - 02
HH
47
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Setting a Time Schedule
In daily schedule the DHW Recirculation a defined
starting time B and finishing time C of operating
the DHW recirculation pump. Outside defined time
frames the DHW recirculation pump will not be
active.
DHW Recirculation Time Schedule
AB
C
DHW Recirc. Sched.
Sched. 1
2 18:30 - 23:00
In daily schedule the Space Cooling has a defined
starting time B and finishing time C of Space
Cooling. Outside defined time frames the Space
Cooling will not be active.
Koniec
Adjusting the time schedule
1 6:00 - 8:00
Legend
A - no. of time frame according to schedule (max 5)
B - start time of recirculation pump operation
C - finish time of recirculation pump operation
HH
R accept
HH
T delete
Space Cooling Time Schedule
AB
C
Cooling Sched.
1 6:00 - 8:00
Sched. 1
1. Select chosen program number and press
navigation dial. The first parameter flashes
(start time).
2. Use the navigation dial to set the new time
frame value (hour and minutes separately) by
turning the dial, and confirm it by pressing the
dial.
3. Repeat the process for finishing time.
4. Use the navigation dial to set the new
temperature selection by turning the dial, and
confirm it by pressing the dial.
5. Use the navigation dial to select the command
column. To save changes select R command
and press the dial to finish editing. To delete
selected time frame select command T and
press the dial.
The entire day program is saved in the controller’s
memory when you exit the day program by
pressing the “Save and end” command.
2 18:30 - 23:00
Koniec
Legend
A - active time frame (max. 5)
B - cooling function start time
C - cooling function completion time
6221389 - 02
HH
R accept
HH
T delete
48
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
DHW Tank Hygiene Function
DHW Hygiene function is only available in systems
with installed indirect DHW storage tanks.
You can heat the water in the DHW tank to above
140°F (60°C) once a week or for an hour every
day. This function is regularly carried out at the
specified time.
DHW Recirc. Sched.
The following parameters can be set for operation
of the tank cleansing function;
DHW Hygiene Settings
Run Sched.
DHW Recirculation
Cooling Sched.
HHDay of the week: the day of the week (Monday Sunday) hygiene function operates
HHStart time: Time of the selected day of the week
the hygiene function will run.
HHDuration: runtime of the hygiene function in
minutes
HHRun Sched.: Select ‘Yes’ to have the hygiene
function run automatically on the select time
and day of the week. Select ‘No’ for no hygiene
function.
HHDHW recirculation: DHW recirculation pump is
active during hygiene function
HHManual Operation: Manual start of hygiene
function, which will terminate when the working
time has expired.
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the settings
menu.
WARNING
1
High DHW temperatures can cause scalding, e.g. if
6221389 - 02
the DHW temperature is above 140°F (60°C). Mix
with cold water at the draw-off points.
49
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Setting Time and Date
The following parameters can be set for time and date;
DHW Recirc. Sched.
DHW Hygiene Settings
Cooling Sched.
HHDate
HHYear
HHMonth
HHDay
HHTime Format
HHHour
HHMinute
HHDaylight Savings: When set to ‘Yes’ Controller
automatically switches over for daylight
savings, when set to ‘No’ Controller does not
automatically switched over for daylight savings
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘Save and End’ to return to the
settings menu.
Adjusting the Interface
The following parameters can be set for the
interface;
DHW Recirc. Sched.
DHW Hygiene Settings
Cooling Sched.
HHBrightness Min: setting of the brightness of the
display in stand-by mode.
HHBrightness Max: setting of the brightness of the
display while interacting with the IDU.
HHSound: When set to ‘Yes’ rotating the dials will
generate a sound, when set to ‘No’ there is no
sound generated when rotating the dials.
HHDial Sensitivity: sets how fast or how slow the
cursor will scroll through menu items.
6221389 - 02
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the settings
menu.
50
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
Setting the Language
The following languages are available;
DHW Recirc. Sched.
DHW Hygiene Settings
Cooling Sched.
HHEnglish
HHFrench (Canadian)
HHSpanish
HHPolish
Scroll through the menu with the navigation dial
and press the navigation dial to select.
System Information
The following system information can be displayed;
DHW Recirc. Sched.
DHW Hygiene Settings
Cooling Sched.
HHS.W. Ver. HMI: shows the software version of
the IDU interface
HHS.W. Ver. PCB: shows the software version of
the control board
HHControl Reboot IDU: Restart of the IDU
HHFactory Settings: Restores the heatpump to
factory settings
6221389 - 02
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the settings
menu.
51
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Time Schedule Override
8:38 THU 14.04.2020
Time Schedule Override modes override the set
time schedule for a selectable amount of time.
Note: The symbol of the activated mode is
indicated on the home screen. Refer to “Display
Symbols and Indications” on page 43 for
description of symbols.
Time Schedule Overide
Time Schedule Override
Manual activation of extended operating conditions;
HHTemporary Hold: setting the duration of the mode
(from 1 to 24 hours or until cancelled).
HHHoliday Override: setting the duration of the
mode (from 1 to 60 days or until cancelled).
HHManual Temp. Hold: room temperature setting
implemented by the control system: until
cancelled.
Note: If any of the modes above is activated, it
is possible to deactivate it after entering “Time
Schedule Override”.
6221389 - 02
Scroll through the menu with the navigation dial
and press the navigation dial to select.
52
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
Service/Configuration Menu
Changes in the configuration menu are possible
after entering an access code. When prompted
for an access code, turn the navigation dial to the
required code and confirm the code by pressing
the dial. If you want to exit from the code request
screen, hold the navigation dial or wait until
automatic return to main function screen.
9:37 Thu 22.04.2021
Code: 987
Service
Control Strat.
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the Service
menu.
Heating:
Control Strat.:
HHHeating Curve Operation - Temperature in is
calculated on the basis of outside temperature
and room temperature based on schedule.
HHConstant Temperature - Supply temperature
MAN, set individual for Circuit 1 and Circuit 2.
Glycol Loop Heat Exchanger:
HHYes - there is an additional heat exchanger in the
system
HHNo - there is no additional heat exchanger in the
system.
Frost protection:
Room Temp. Offset
Air Vent Mode
6221389 - 02
Measuring Unit
HHYes - if the temperature in the building drops
below 45LF (7LC) in the stand-by mode and the
outside temperature is lower than 36LF (2LC),
heating will be turned on ,
HHNo - protection is disabled.
Electric Heater Delay:
53
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Service/Configuration Menu
This parameter defines the time after which the
heat pump activates the internal heater of the
indoor unit if the set values parameters. The
time is counted from the moment the setpoint
temperature is reached.
Warm Weather Shtdn:
In case of if the outside temperature is above
the bivalent point temperature, the back-up heat
source will not be turned on. In case of need for
an additional heat source, the condition for its
activation is the activation of the immersion heaters
Outside temp. offset: setting of selected temperature
above which circuit will be switched off.
TO Calibration: calibration of the displayed outside
temperature value.
Depending on the sign, the parameter is added to or
subtracted from the measured values.
Circuit 1 and Circuit 2:
Parameters in this menu allow the user to adjust
the operating conditions of the connected heating
circuits.
used and degree building insulation can be carried
out, among others, by to generate high operating
costs.
HHRecirculation:
Yes - activation of the Circuit 1,
No - turning off the circuit.
HHValve time (only available for Circuit 2):
time needed to switch the valve by 90
degrees. Adjustment range from 60 to 480
seconds, factory default 120 seconds. During
configuration, please check the set value with the
value of the valve drive used.
HHDynamics of regulation: the response speed of
the valve drive to achieve the corresponding
parameter in the Circuit 2.
Cooling:
HHOff: cooling function inactive, Fan coil, Radiant
Cooling. For radiant and slab cooling a third party
controller is required.
HHChilled water setpoint: temperature of the chilled
water
HHHeating curve no.: Selection of a heating curve
(see “Adjusting the Heating Curve” on page 58
to for instructions on adjusting the slope). Note:
The parameter is present when the control is set
according to heating curve (Adjust regulation type
to: Acc. curve).
HHCurve offset: Heating curve shift (see “Adjusting
the Heating Curve” on page 58 to for
instructions on adjusting the shift) Note The
parameter is present when the control is set
according to heating curve (Adjust regulation type
to: Acc. curve).
HHMIN supply temperature system: flow
temperature when operating with constants
parameters (manual setting of the heating
medium) [Configuration -> Heating -> Regulation
type: Fixed parameters],
HHTemp. MAX: maximum supply temperature of the
heating circuit.
ATTENTION: setting too high temperatures, not
suitable for building parameters, type of heating
54
DHW Tank:
6221389 - 02
Note: Heating circuit 1 is intended for heating
connection to a high temperature circuit;
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
Service/Configuration Menu
HHElectric Heater Delay: the parameter defines the
time after which the heat pump is supported it
will be an additional source of heat (immersion
heater) if it does not reach the set value water
temperature in the tank. Time is counted from the
moment of reaching temperature of bivalent point
HHRoom Temperature Sensor: room temperature
control.
HHIn case the outside temperature is above
temperature of the bivalent point, the additional
heat source will not remain included. If there is
a need for an additional heat, the condition for
its activation is the activation of the immersion
heaters.
No - room temperature control switched off. The
room temperature reading does not affect the
central heating operation.
HHFrost protection:
Yes - activation of the storage tank frost protection
in stand-by mode,
No - function inactive.
HHDHW Tank:
Yes - DHW tank circuit activation
No- DHW tank inactive.
The heat pump:
HHBivalent point: the limiting outdoor temperature
up to which the heat pump operates
autonomously. Below this point, an additional
heat source (heater) is activated
HHShut-down temperature: the limit outdoor
temperature at which the heat pump will shut
down. If heating is required for central heating
or hot tap water, the heater will be the only heat
source.
HHType: Model of the connected ODU.
Yes - heating will be switched off once the set
room temperature read by the room temperature
sensor has been reached
HHHysteresis: room temperature hysteresis when
Room Control is activated
HHRoom Temp. Offset: calibrates the value of the
indicated room temperature. The parameter is
added or subtracted from the value measured
depending on the sign.
DHW Recirculation:
Yes - DHW recirculation pump control system
enabled,
No - DHW circulation pump system turned off.
Pumps:
HHPumps exercise: brief pump operation to prevent
pump seizing
HHAir vent mode: During the venting procedure
(10 min) the heat pump in the hydraulic module
runs alternately at maximum and minimum speed
and the pumps the respective circuits are on.
Thanks to this, concentration occurs air bubbles,
which makes it easier to remove them from the
installation.
Off - system air purging turned off,
Circuit 1 - Heating circuit 1 purging enabled,
Circuit 2 - Heating circuit 2 purging enabled,
6221389 - 02
Communication:
- Device ID: device number on the communication
system.
Room temperature:
55
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Service/Configuration Menu
Heat Pump Module:
This menu provides access to view heat pump
operating conditions. When prompted for an access
code, turn the navigation dial to the required code
and confirm the code by pressing the dial. If you
want to exit from the code request screen, hold
the navigation dial or wait until automatic return to
main function screen.
Code: 65
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the Service
menu.
Parameters
Address Description
S12
Duration of defrost cycle
S13
Entering temperature of defrost water
S14
Defrost intervals
S90
Minimum compressor frequency
S91
Maximum compressor frequency
S94
Vitocal Model
Default Setting
10 minutes
13°C (55°F)
45 Minutes
30 Hz
90 Hz
Dependant on model
Settings Range
1-12 Minutes
0-30°C (32-86°F)
30-90 Minutes
Do Not Adjust
Do Not Adjust
Do Not Adjust
6221389 - 02
The default settings of addresses S12, S13, and
S14 ensure reliable and economical operation of
the heat pump, however in areas of heavy snow
fall addresses S12 and S13 can be increased and
S14 decreased when standard defrost settings are
determined to not be sufficient.
56
Vitocal 100-AW AM2V Installation, Service and Operating
Operating
Service/Configuration Menu
Service:
This menu accesses the actuator test function for
the IDU. When prompted for an access code, turn
the navigation dial to the required code and confirm
the code by pressing the dial. If you want to exit
from the code request screen, hold the navigation
dial or wait until automatic return to main function
screen.
Code: 45
6221389 - 02
Scroll through the menu with the navigation dial
and press the navigation dial to select. When
complete select ‘End’ to return to the Service
menu.
57
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Adjusting the Heating Curve
Setting the Heating Curve Slope
Adjusting the Slope
The purpose of the heat pump controller is to
maintain the temperature in the central heating
system depending on the outdoor temperature.
When the temperature outside the building is
low, the need for heat is greater, whereas if the
temperature outdoors is high, there is no need to
maintain a high temperature in the system. The
relationship between the outdoor temperature and
the temperature of the central heating system can
be represented in the form of a graph, the so-called
heating curve. The figure shows a family of heating
curves for a room temperature set point of 72°F
(22°C). Depending on the characteristics of the
building, the climate zone and the heating system
type, a suitable curve needs to be selected.
From the Circuit 1 and Circuit 2 configuration
menus:
1. Use the navigation dial to select the desired
heating circuit and press the dial to select.
2. Use the navigation dial to select ‘Use of
Immersion Heaters’ and press the dial to select
‘Yes’
Supply
Water
Temperature
F (C)
158 (70)
140 (60)
4
n=1 2
n=1
0
n=1
n=8
n=6
n=4
122 (50)
104 (40)
86 (30)
50
(10)
32
(0)
Outdoor Temperature F(C)
14
(-10)
-4
(-20)
6221389 - 02
68 (20)
68
(20)
58
Operating
Vitocal 100-AW AM2V Installation, Service and Operating
Adjusting the Heating Curve
Setting the Heating Curve Shift
Adjusting the Shift
If the curve needs to be shifted, change the [curve
shift] parameter. The figure shows as an example
curve no. 8 with a shift of -14°F and 50°F (-10°C
and 10°C).
From the Circuit 1 and Circuit 2 configuration
menus:
1. Use the navigation dial to select the desired
heating circuit and press the dial to select.
2. Use the navigation dial to select ‘Use of
Immersion Heaters’ and press the dial to select
‘Yes’
Supply
Water
Temperature
F (C)
158 (70)
140 (60)
122 (50)
104 (40)
86 (30)
68 (20)
68
(20)
=10
p
n=8,
=0
p
n=8,
-10
p=
n=8,
50
(10)
32
(0)
Outdoor Temperature F(C)
14
(-10)
-4
(-20)
6221389 - 02
Tips on setting the heating curve
Course of heating
During cold seasons, it is too cold indoors.
During cold seasons, the rooms are too warm.
During transitional and cold seasons, it is too cold
indoors.
During transitional and cold seasons, the rooms are
too warm.
It is too cool indoors in transitional seasons, yet it is
warm enough in cold seasons.
It is too warm indoors in transitional seasons, yet
warm enough in cold seasons.
Actions concerning the “heating curve”
Set the ‘slope’ to the next higher value.
Set the ‘slope’ to the next lower value.
Set the ‘level’ to a higher value.
Set the ‘level’ to a lower value.
Set the ‘slope’ to the next lower value and the
‘level’ to a higher value.
Set the ‘slope’ to the next higher value and the
‘level’ to a lower value.
59
Service
Vitocal 100-AW AM2V Installation, Service and Operating
Troubleshooting
Rooms are too cold
Cause
Corrective Action
The heat pump is switched HHSwitch on the power switch
off.
HHSwitch on the main switch (if installed, outside the mechanical room).
HHSwitch on the fuse in the electrical switchboard (the house fuse).
The settings on the heat
HHSpace heating/cooling must be activated. Check and correct the following
pump controller have been
settings if necessary:
altered or are incorrect.
HHWork programme
HHHeating curve
HHRoom temperature
HHTime
HHTime program for space heating/cooling
HHRun additional electric heating for space heating, if necessary
Heating of water in the
HHWait until the water in the hot tap water exchanger has warmed up.
hot tap water exchanger in HHIf necessary, reduce the hot water intake or, temporarily, the normal hot
progress
water temperature.
The display shows
HHRead out the type of notification. Confirm the notification.
“Warning” or “Fault”.
HHIf necessary, contact an Authorised Service Centre
Rooms are too hot
Cause
The settings on the heat
pump controller have been
altered or are incorrect.
The display shows
“Warning” or “Fault”.
Corrective Action
Space heating/cooling must be activated. Check and correct the following
settings if necessary:
HHWork programme
HHRoom temperature
HHHeating curve/cooling temperature
HHTime
HHTime program for space heating/cooling
HHActivate the “active cooling mode” if necessary
HHRead out the type of notification. Confirm the notification.
HHIf necessary, contact an Authorised Service Centre
Cause
Corrective Action
The heat pump is switched HHSwitch on the power.
off.
HHSwitch on the main switch (if installed, outside the mechanical room).
HHSwitch on the fuse in the electrical switchboard (the house fuse).
The settings on the heat
DHW heating must be started. Check and correct the following settings if
pump controller have been necessary:
altered or are incorrect.
HHSpace heating or cooling time program
HHDHW Temperature setpoint.
HHDHW Time Program
HHTime setting
HHRun additional electric heating, if necessary, to heat DHW
The display shows
HHRead out the type of notification.
“Warning” or “Fault”.
HHIf necessary, contact an contact heating contractor.
60
6221389 - 02
No Domestic Hot Water
Vitocal 100-AW AM2V Installation, Service and Operating
Service
Troubleshooting
Domestic Hot Water is too hot
Cause
The settings on the heat
pump controller have been
altered or are incorrect.
Warning
Corrective Action
Check and, if necessary, correct the DHW setpoint temperature.
Cause
Corrective Action
Warning concerning
If necessary, contact heating contractor.
special occurrence,
operating condition of heat
pump, heating system
Fault
Corrective Action
If necessary, contact heating contractor.
6221389 - 02
Cause
Fault in heat pump or in
heating system
61
Service
Vitocal 100-AW AM2V Installation, Service and Operating
Fault Codes Indoor Unit
Fault Code
Temp. HC2
Cooling temp.
DHW Tank Temp.
Room Temp.
Outlet Temp.
Inlet Temp.
Press. Sensor
Temp. HC1
Cause
Circuit 2 temperature sensor error
Cold buffer temperature sensor error
DHW tank temperature sensor error
Room temperature sensor error
Flow temperature sensor error
Return temperature sensor error
Pressure sensor error IDU
Circuit 1 temperature sensor error
Outside Temp.
Low Battery
PIU Pump
Heat Pump Module
Low Pressure
Communication
Thermal Cut-off
HP Inlet Temp.
HP Outlet Temp.
Curves Config. Error
Circuit Config. Error
HP Low Pressure
Outside temperature sensor error
Battery to be replaced
Circulation pump error in indoor unit
Heat pump error - outdoor unit
Low pressure of the heating medium
Communication error IDU - ODU
Thermal switch triggered
Inlet temperature sensor error - ODU
Outlet temperature sensor error - ODU
Heating curves configuration error
Error in the configuration of the heating circuits
PC low refrigerant pressure
Fault Code
E10
E11
E12
E13
E14
E15
E16
E17
E18
E19
E110
E111
E112
E113
E114
E115
E20
E21
62
Cause
Reserved
Reserved
Heating return temp sensor failure
Heating outlet water temp sensor failure
High pressure protection
Reserved
Low pressure protection
Reserved
Water flow protection
Electric heating overload protection
Winter first class anti-freeze protection
Winter second class anti-freeze protection
Anti-freeze protection
Reserved
Room temp failure
Reserved
Exhaust temperature overprotection
Reserved
6221389 - 02
Fault Codes Outdoor Unit
Vitocal 100-AW AM2V Installation, Service and Operating
Service
6221389 - 02
Fault Codes Outdoor Unit
Fault Code
E22
E23
E24
E25
E26
E27
E28
E29
E210
E211
E212
E213
E214
E215
E30
E31
E32
E33
E34
E35
E36
E37
E38
E39
E310
E311
E312
E313
E314
E315
E40
E41
E42
E43
E44
E45
E46
E47
E48
E49
E410
E411
Cause
Reserved
Fan 1 overload speed limit
Fan 2 overload speed limit
The temp difference of inlet water and outlet water over large protection
Outlet water over heat
Mixing outlet water temp sensor failure
Hot water return temp sensor failure
Hot water outlet water temp sensor failure
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
High pressure protection 3 times
Reserved
Low pressure protection 3 times
Reserved
Water flow protection 3 times
Electric heating protection 3 times
Reserved
Reserved
Anti-freeze protection 3 times
Reserved
Reserved
Reserved
Discharge over heat protection 3 times
Reserved
The temp difference of inlet water and outlet water temp over large 3 times
The outlet water temp too lower 3 times
Outlet water over temperature protection 3 times
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
63
Service
Vitocal 100-AW AM2V Installation, Service and Operating
Fault Code
E412
E413
E414
E415
E50
E51
E52
E53
E54
E55
E56
E57
E58
E59
E510
E511
E512
E513
E514
E515
E60
E61
E62
E63
E64
E65
E66
E67
E68
E69
E610
E611
E612
E613
E614
E615
E70
E71
E72
E73
E74
E75
E76
64
Cause
Reserved
Reserved
Reserved
Reserved
Inlet water temp failure
Outlet water temp failure
Coil temp failure
Ambient temp failure
Suction temp failure
Anti- freeze temp failure
The coil outlet water temp sensor failure
Reserved
Reserved
EVI inlet temp failure
EVI outlet temp failure
Discharge temp failure
Reserved
System 1 pressure sensor failure
Low ambient temp failure
Outlet temp too low protection
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Hot water temp failure
Reserved
Reserved
Fan 1 failure
Fan 2 failure
Communication failure(main board with fan motor module board)
Reserved
Communication failure(main board with fan motor 2 module board)
IPM overheat
Compressor start failure
Compressor over currents
Input voltage phase loss
IPM current sampling fault
Overheat protection of drive board devices
Pre-charge failure
6221389 - 02
Fault Codes Outdoor Unit
Vitocal 100-AW AM2V Installation, Service and Operating
Service
Fault Codes Outdoor Unit
Cause
DC bus bar over voltage
DC bus under voltage
AC input voltage under voltage
AC input over current shutdown
Input voltage sampling fault
DSP and PFC communication failure
Drive plate temperature fault
DSP and communication board communication failure
Mainboard communication failure
IPM overheat stop
Reserved
Reserved
15VDC undervoltage
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Voltage electromechanical current down frequency alarm
Compressor weak magnetic protection alarm
Power unit overheating alarm
Reserved
AC input current down alarm
EEPROM failure warning
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
6221389 - 02
Fault Code
E77
E78
E79
E710
E711
E712
E713
E714
E715
E80
E81
E82
E83
E84
E85
E86
E87
E88
E89
E810
E811
E812
E813
E814
E815
E90
E91
E92
E93
E94
E95
E96
E97
E98
E99
E910
E911
E912
65
Service
Vitocal 100-AW AM2V Installation, Service and Operating
Preparing for Service
Preparing for Service
The mid panel of the jacketing can be remove
to provide additional access of the internal
components for service and maintenance. To
remove the mid panel;
2.
1.
2.
3.
4.
Remove the two door retaining screws.
Swing the door open to the right.
Remove the four mid panel retaining screws
Slide the mid panel forward to remove
4.
1.
When service has been completed reassemble in
reverse order.
3.
Check Sensors
Sensors
Resistance in k ohms
All sensor connection are made to indoor unit, all
sensors are NTC 10 kΩ. The temperature sensors
are connected to a low-voltage printed circuit
board.
HHDHW Tank Temperature sensor
HHSystem supply water temperature sensor
HHRoom temperature sensors
Temperature
Temperature
66
6221389 - 02
Resistance in k ohms
HHOutdoor temperature sensor
Vitocal 100-AW AM2V Installation, Service and Operating
Service
Checking Fuses
F3
Fuse F3 of the indoor unit is located on the main
board of the indoor unit.
Fuse type:
- T 5.0 A H, 250 V~
1. Switch off the power supply
2. Check the fuse, replace if necessary.
1 IMPORTANT
Incorrect or improperly installed fuses may lead to
an increased risk of fire.
1 IMPORTANT
6221389 - 02
Removing the fuses does not result in the load
circuit being disconnected from voltage. Contact
with any live parts may lead to electrocution. When
working on the unit, it is essential that the load
circuit is also disconnected.
67
Service
Vitocal 100-AW AM2V Installation, Service and Operating
Maintenance
Cleaning
Note:
Commercially available cleaners and special
cleaners for heat exchangers (evaporators) may
cause damage to the heat pump.
HHClean the surfaces of the unit with a damp cloth
only.
HHIf necessary, clean the shutters of the heat
exchanger (evaporator) with a long bristle brush.
Operating module of the heat pump controller
The surface of the operating module can be cleaned
with the microfibre cloth.
Technical inspection and maintenance of the
heating system. Regular maintenance ensures
trouble-free, energy-efficient and environmentallyfriendly operation in the heating/cooling mode.
For this purpose, it is best to contract a specialist
company for inspection and maintenance.
Damaged connection wires
If the connection wires of the unit or of outdoor
accessories are damaged, they must be replaced
with specific connection cables. Only use the
cables recommended by the manufacturer for
replacement. Notify a specialist company for this
purpose.
Refrigerant
The unit contains fluorinated greenhouse gases
(a refrigerant) listed in the Kyoto Protocol. The
refrigerant type which the device operates with is
indicated on the rating plate.
The Global Warming Potential (GWP) of the
refrigerant is given as a multiple of the GWP of
carbon dioxide (CO2). The GWP of carbon dioxide
CO2 is 1.
Refrigerant
R32
Global Warming Potential GWP
675*1/677*2
According to the Fourth Assessment Report adopted by the Intergovernmental Panel on Climate Change
(IPCC)
*2
According to the Fifth Assessment Report adopted by the Intergovernmental Panel on Climate Change
(IPCC)
6221389 - 02
*1
68
Vitocal 100-AW AM2V Installation, Service and Operating
Service
Maintenance
6221389 - 02
For systems with flammable refrigerants
HHAnyone working on a refrigeration system is
required to submit a proof of qualification issued
by an accredited body authorised to issue
industry certifications. The proof of qualification
is a certificate of competence in the safe
handling of refrigerants as prescribed in industry
standards.
HHMaintenance work must always be carried
out in accordance with the manufacturer’s
requirements. If assistance by other persons is
required during maintenance and repair work,
then a person trained in the safe handling of
flammable refrigerants is required to supervise the
work being carried out at all times.
HHIn order to minimise the risk of fire, it is necessary
to carry out safety checks before working on
equipment where flammable refrigerants are used.
Before working on a refrigeration circuit, the
following measures must be taken:
General: place of work
HHInform the persons listed below of the work to be carried out:
- All maintenance staff
- All persons who are in the vicinity of the installation.
HHClose off the area near the heat pump.
HHCheck the surroundings of the heat pump for combustible materials and sources of ignition.
Remove all combustible materials and sources of ignition.
Monitoring the presence of refrigerant
HHTo identify flammable atmosphere in good time: Before, during and after the work, check the
surroundings for refrigerant leaks using an ignition-protected refrigerant detector designed
for R32. The refrigerant detector must not cause any sparks and must be properly sealed.
Fire extinguisher
A CO2 or powder extinguisher must be available in the cases described below:
HHFilling the system with refrigerant.
HHPerforming welding or soldering work.
Sources of ignition
HHDuring any work carried out on a refrigeration circuit that contains or contained a refrigerant,
ignition sources that could ignite the refrigerant must not be used. Any possible sources
of ignition, including cigarettes, must be removed from the area where installation, repair,
dismantling or disposal work is to be carried out that involves a hazard of the refrigerant
leak.
HHBefore starting work, check that there are no combustible materials or sources of ignition
around the heat pump. Remove all combustible materials and sources of ignition.
HHPlace no-smoking signs
Work area ventilation
HHCarry out repairs in the open air or ventilate the work area well before working on the
cooling system or carrying out welding or soldering work.
HHVentilation must be in operation at all times. The purpose of the ventilation is to dilute the
refrigerant in the event of a leak and to discharge it outdoors if possible.
69
Service
Vitocal 100-AW AM2V Installation, Service and Operating
Inspection of the refrigeration installation
HHReplaced electrical components must be suitable for the application and comply with the
specifications provided by the manufacturer. Replace any defective components with original
spare parts only.
HHReplace components according to the recommendations issued by the company of
Viessmann. Contact Viessmann technical service if necessary.
HHCheck the surroundings of the heat pump for combustible materials and sources of ignition.
Remove all combustible materials and sources of ignition.
Carry out the following checks
HHCheck the operation of the ventilation. Ventilation openings must not be blocked or
obstructed.
HHIf a system with hydronic decoupling is used, check the secondary circuit for the refrigerant.
HHInscriptions and symbols must be clearly visible and legible. Replace any illegible inscriptions
or symbols.
HHRefrigerant lines or components must be fitted in such a way that they do not come into
contact with corrosive substances.
Exception: refrigerant lines are made of a corrosion-resistant material or are reliably protected
against corrosion.
Inspection of electric components
HHWhen carrying out maintenance and repair work on eclectic parts, safety checks must be
carried out: see below.
HHIf a safety-critical fault occurs, do not connect the installation until the fault has been
rectified. If it is not possible to rectify the fault immediately, a suitable interim solution for
the operation of the installation must be found if possible. Notify the user of the installation
Carry out the following safety checks:
HHDischarging of capacitors: ensure that no sparks are generated during the discharge process.
HHWhen filling or draining the refrigerant, as well as when flushing the refrigeration circuit, do
not place any electrical parts or live wires near the device.
HHCheck the earthing connection.
Repairs to sealed casings
HHDuring work on sealed components, the device must be powered off before the sealed cover
is removed.
HHTo warn of a potentially hazardous situation, a permanently operating refrigerant detector
should be placed at critical locations.
HHParticular care must be taken when working on electrical parts so as not to modify the
casing in a way that weakens its protective effect. This applies to a damage to cables, the
creation of too many connectors on one connection terminal, the creation of connectors that
do not meet the manufacturer’s requirements, damage to seals and incorrect installation of
cable restraints.
HHEnsure that the unit is installed correctly.
HHCheck that the seals are properly installed. Thereby, check that the seals reliably protect the
device against the penetration of a flammable atmosphere. Replace any damaged hoses. !
Attention Silicone as a sealing agent may affect the performance of a leak detection devices.
Do not use silicone as a sealing agent.
HHSpare parts must comply with the manufacturer’s guidelines.
HHWork on components that are suitable for flammable atmospheres: these components do not
need to be powered off.
70
6221389 - 02
Maintenance
Vitocal 100-AW AM2V Installation, Service and Operating
Service
Maintenance
6221389 - 02
Repairs to parts that operate in a combustible atmosphere
HHUnless it can be established that the permissible voltage and current values will not be
exceeded, no capacitive or inductive loads must be connected to the device.
HHOnly those components that meet the requirements for operation in a flammable atmosphere
may be connected to voltage in a flammable atmosphere.
HHUse only original spare parts or parts approved by the Viessmann. In the event of a leak, all
other parts may ignite the refrigerant.
Wiring
HHCheck that the wiring is not exposed to wear, corrosion, stretching, vibration or any adverse
environmental conditions and that it is not located near sharp edges.
HHWhen inspecting, also consider the effects of ageing and the effects of continuous vibration
on the compressors and fans.
Refrigerant detectors
HHUnder no circumstances use ignition sources to detect the refrigerant and refrigerant leaks.
HHNo flame detectors may be used to detect leaks.
Leak detection
The methods described below are suitable for detecting leaks in systems filled with a flammable refrigerant: Leak detection with electronic refrigerant detectors:
HHElectronic leak detectors may not be adequately sensitive or need to be calibrated for a
specific detection range. Calibrate the detector in a refrigerant-free environment.
HHThe refrigerant detector must be suitable for detecting R32.
HHThe refrigerant detector must contain no potential ignition sources.
HHCalibrate the refrigerant detector for the refrigerant used. Set the trip threshold < 3 g/a,
which is suitable for R32. Leak detection using leak detection fluids, Leak detection fluids
are suitable for most of refrigerants.
Note:
Chlorine-containing leak detection fluids may react with the refrigerant.
As a result, rust may form.
Do not use any leak detection fluids that contain chlorine.
Procedure when leaks are found in the refrigeration circuit:
HHImmediately extinguish any fire in the vicinity of the heat pump.
HHDo not solder leaks on the refrigeration circuit.
Refrigerant suction and evacuation
Perform the steps described in the “Refrigerant suction” section.
Perform the steps described in the “Vacuum generation in refrigerant lines and indoor unit”
section.
Refrigerant filling
Follow the steps described in the “Filling the refrigerant lines and indoor unit” section.
Marking (inscriptions on the heat pump)
A plate with the date and signature and the following information must be placed in a clearly visible position on the heat pump which has been decommissioned:
HHFlammable refrigerant
HHInstallation is not working.
HHRefrigerant has been removed.
71
Wiring
Vitocal 100-AW AM2V Installation, Service and Operating
Indoor Unit Wiring Diagram
AM2V 020028/034043 Indoor Unit
F2
T5A
>
Legend
E1 - Heating Box
A1 - Main Board
CP - Control Panel
F1 - Fixed High Limit
F2 - Automatic Reset High Limit
CB1 - Circuit Breaker
72
K1 - Contactor
M1 - Internal Diverting Valve
M2 - Internal Circulation Pump
Tin - Return Tempurature Sensor
Tout - Flow Sensor
P - Pressure Sensor
6221389 - 02
MCU
Vitocal 100-AW AM2V Installation, Service and Operating
Wiring
Indoor Unit Wiring Diagram
AM2V 051078 Outdoor Unit
F2
T5A
>
6221389 - 02
MCU
Legend
E1 - Heating Box
A1 - Main Board
CP - Control Panel
F1 - Fixed High Limit
F2 - Automatic Reset High Limit
CB1 - Circuit Breaker
K1 - Contactor
M1 - Internal Diverting Valve
M2 - Internal Circulation Pump
Tin - Return Tempurature Sensor
Tout - Flow Sensor
P - Pressure Sensor
73
Wiring
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Wiring Diagram
AM2V 020028 Outdoor Unit
74
Description
Anti-freeze Temperature
Ambient Temperature
Compressor
Coil Temperature
Crankcase Heater
EVI Inlet Gas Temperature
EVI Outlet Gas Temperature
Electronic Expansion Valve
Electronic Expansion Valve for EVI
Exhaust Temperature
Fan Motor
Flow Switch
High Pressure Protection
Inlet Water Temperature
Relay of Circulation Pump
Relay of Hot Water Pump
Relay of 3-Way Valve
Relay of Pan Heater
Designation
LP
LPS
OT
OHP
PH
RT
SUT
SPS
4V
TT
Description
Low Pressure Protection
Low Pressure Sensor
Outlet Water Temperature
Overheat Protection
Pan Heater
Room Temperature
Suction Temperature
Switching Power Supply
4-Way Valve
Tank Temperature
6221389 - 02
Designation
AFT
AT
COMP
CT
CH
EIT
EOT
EEV
EVIV
ET
FM
FS
HP
IT
K4
K5
K9
K11
Wiring
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Wiring Diagram
6221389 - 02
AM2V 034043 Outdoor Unit
Designation
AFT
AT
COMP
CT
CH
EIT
EOT
EEV
EVIV
ET
FM
FS
HP
IT
K4
K5
K9
K11
Description
Anti-freeze Temperature
Ambient Temperature
Compressor
Coil Temperature
Crankcase Heater
EVI Inlet Gas Temperature
EVI Outlet Gas Temperature
Electronic Expansion Valve
Electronic Expansion Valve for EVI
Exhaust Temperature
Fan Motor
Flow Switch
High Pressure Protection
Inlet Water Temperature
Relay of Circulation Pump
Relay of Hot Water Pump
Relay of 3-Way Valve
Relay of Pan Heater
Designation
LP
LPS
OT
OHP
PH
RT
SUT
SPS
4V
TT
Description
Low Pressure Protection
Low Pressure Sensor
Outlet Water Temperature
Overheat Protection
Pan Heater
Room Temperature
Suction Temperature
Switching Power Supply
4-Way Valve
Tank Temperature
75
Wiring
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Wiring Diagram
AM2V 051078 Outdoor Unit
76
Description
Anti-freeze Temperature
Ambient Temperature
Compressor
Coil Temperature
Crankcase Heater
EVI Inlet Gas Temperature
EVI Outlet Gas Temperature
Electronic Expansion Valve
Electronic Expansion Valve for EVI
Exhaust Temperature
Fan Motor
Flow Switch
High Pressure Protection
Inlet Water Temperature
Relay of Circulation Pump
Relay of Hot Water Pump
Relay of 3-Way Valve
Relay of Pan Heater
Designation
LP
LPS
OT
OHP
PH
RT
SUT
SPS
4V
TT
Description
Low Pressure Protection
Low Pressure Sensor
Outlet Water Temperature
Overheat Protection
Pan Heater
Room Temperature
Suction Temperature
Switching Power Supply
4-Way Valve
Tank Temperature
6221389 - 02
Designation
AFT
AT
COMP
CT
CH
EIT
EOT
EEV
EVIV
ET
FM
FS
HP
IT
K4
K5
K9
K11
Vitocal 100-AW AM2V Installation, Service and Operating
Parts
Parts List
Indoor Unit Model No. Serial No.
AM2V 020028
7228973999999999
AM2V 034043
7228974999999999
AM2V 051078
7228975999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating
plate when ordering replacement parts.
Order replacement components from your
Viessmann distributor.
0001 - Wall Mounting Bracket
0002 - Electrical Knockout Panel
0003 - Indoor Unit User Interface
0004 - Mid-panel
0005 - Door
0001
0002
0003
0004
6221389 - 02
0005
77
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Indoor Unit Model No. Serial No.
AM2V 020028
7228973999999999
AM2V 034043
7228974999999999
AM2V 051078
7228975999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating
plate when ordering replacement parts.
Order replacement components from your
Viessmann distributor.
0001 - DIN Rail
0002 - Fixed High Limit
0003 - Contactor
0004 - Control Board
0005 - Temperature Sensor
0001
0002
0003
0004
Other Items not Illustrated
0005
6221389 - 02
0006 - Immersion Temperature Sensor (System)
0007 - Strap-on Temperature Sensor System
0008 - Room Temperature Sensor
0009 - Outdoor Temperature Sensor
0010 - Fuse 5A 250VAC Time Delay
78
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Indoor Unit Model No. Serial No.
AM2V 020028
7228973999999999
AM2V 034043
7228974999999999
AM2V 051078
7228975999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating
plate when ordering replacement parts.
Order replacement components from your
Viessmann distributor.
0002
0015
0010
0003
0013
0012
0004
0014
0009
0006
0011
0005
0008
0007
6221389 - 02
0001 - Expansion vessel
0002 - Automatic Air Vent
0003 - Electric Heating Element
0004 - Gasket
0005 - DHW Heating Supply Pipe
0006 - Diverting Valve Body
0007 - System Supply Pipe
0008 - Diverting Valve Actuator
0009 - System Return Pipe
0010 - Pressure Sensor
0011 - Outdoor Unit Return Pipe
0012 - Manual Bleeder Screw
0013 - Circulation Pump
0014 - Outdoor Unit Supply Pipe
0015 - Auto Reset Temperature Limit
0001
79
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Outdoor Unit Model No.
Serial No.
AM2V 0200287986309999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate when ordering replacement parts.
Order replacement components from your Viessmann distributor.
0011
0012
0013
0010
0014
0008
0009
0015
0016
0018
0017
0005
0020
0022
0023
0024
0021
0035
0037
0036
0041
0038
0040
0039
0042
0043
0019
0034
0025
0026
0027
0028
0033
0029
0030
0031
0032
6221389 - 02
0001 Fan Grill
0002 Front Panel
0003 Wind Deflector
0006
0004 Fan Blade
0007
0005 Fan Motor
0006 Left Panel
0007 Corner Panel
0004
0008 Air to Refrigerant Coil
0003
0009 Fan Motor Bracket
0002
0010 Electrical Box
0011 Top Panel
0001
0012 Top Rail
0013 Electrical Box Cover
0014 Rear Grill Panel
0015 Interior Separation Panel
0016 System Water Supply Pipe
0017 Refrigerant to System Water Plate Heat Exchanger
0018 System Water Return Pipe
0019 Reversing Valve
0020 System Water Flow Switch
0021 Electrical Grommet
0022 Rear Connection Panel
0023 Side Access Panel
0024 Support Bracket
0025 Low Pressure Switch
0026 High Pressure Switch
0027 Isolation Fill Valve
0028 One Way Safety Valve
0029 Electronic Expansion Valve
0030 Filter
0031 Electronic Expansion Valve
0032 Schrader Valve
0033 EVI Plate Heat Exchanger
0034 EVI Plate Heat Exchanger Bracket
0035 Refrigerant to System Water Plate Heat Exchanger Bracket
0036 Base Plate
0037 Compressor
0038 Transformer
0039 Compressor Cover 1
0040 Compressor Cover 2
0041 Transformer Housing
0042 Compressor Cover 3
0043 Compressor Cover 4
80
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Outdoor Unit Model No.
Serial No.
AM2V 0200287986309999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate when ordering replacement parts.
Order replacement components from your Viessmann distributor.
0001 Fuse
0002 2 Pole Terminal
0003 Driver Board
0004 Switching Power Supply
0005 PC4003-G Board
0006 Electrical Enclosure
0007 Relay
0008 BHB21 Board
0009 DIN Rail 2 Pole
0010 Power Supply Terminal
0010
0008
0009
0007
0006
0005
0004
0003
0002
6221389 - 02
0001
81
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Outdoor Unit Model No.
Serial No.
AM2V 0340437986310999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate when ordering replacement parts.
Order replacement components from your Viessmann distributor.
0011
0012
0013
0010
0014
0008
0009
0015
0016
0017
0020
0019
0005
0021
0038
0037
0041
0023
0024
0025
0022
0042
0040
0018
0039
0036
0043 0035
0026
0027
0028
0029
0030
0031
0032
0033
0034
6221389 - 02
0001 Fan Grill
0002 Front Panel
0003 Wind Deflector
0004 Fan Blade
0006
0005 Fan Motor
0007
0006 Left Panel
0007 Corner Panel
0008 Air to Refrigerant Coil
0009 Fan Motor Bracket
0004
0010 Electrical Box
0003
0011 Top Panel
0002
0012 Top Rail
0013 Electrical Box Cover
0001
0014 Rear Grill Panel
0015 Interior Separation Panel
0016 System Water Supply Pipe
0017 System Water Return Pipe
0018 Reversing Valve
0019 Refrigerant to System Water Plate Heat Exchanger Bracket
0020 Refrigerant to System Water Plate Heat Exchanger
0021 System Water Flow Switch
0022 Electrical Grommet
0023 Side Access Panel
0024 Rear Connections Panel
0025 Support Bracket
0026 Low Pressure Switch
0027 High Pressure Switch
0028 Schrader Valve 1
0029 Isolation Fill Valve
0030 One Way Safety Valve
0031 Electronic Expansion Valve
0032 Filter
0033 Electronic Expansion Valve 2
0034 Schrader Valve 2
0035 EVI Plate Heat Exchanger
0036 Fluid Reservoir
0037 Base Plate
0038 Compressor
0039 Compressor Cover 1
0040 Compressor Cover 2
0041 Transformer
0042 Compressor Cover 3
0043 Compressor Cover 4
82
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Outdoor Unit Model No.
Serial No.
AM2V 0340437986310999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate when ordering replacement parts.
Order replacement components from your Viessmann distributor.
0001 Switching Power Supply
0002 Fan Speed Control Module
0003 Driver Board
0004 2 Pole Terminal
0005 PC4003-G Board
0006 Relay
0007 Fuse
0008 8 Pole Terminal
0009 BHB21 Board
0010 EMC Filter
0011 DIN Rail 2 Pole
0012 Power Supply Terminal
0011
0009
0008
0012
0010
0007
0006
0005
0004
0003
0002
6221389 - 02
0001
83
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Outdoor Unit Model No.
AM2V 051078 Serial No.
7986311999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate when ordering replacement parts.
Order replacement components from your Viessmann distributor.
Large
0011
0012
0013
0010
0014
0006
0007
0008
0009
0016
0003
0017
0018
0004
0019
0021
0015
0022
0002
0005
0001
0044
0041
0020
0040
0046
0042
0037
0047
0048
84
0024
0025
0026
0023
0038
0039
0045
0028
0027
0029
0030
0043
0036
0031
0032
0033
0034
0035
6221389 - 02
0001 Fan Grill
0002 Front Panel
0003 Wind Deflector
0004 Fan Blade
0005 Fan Motor
0006 Left Panel
0007 Corner Panel
0008 Air to Refrigerant Coil
0009 Fan Motor Bracket
0010 Electrical Box
0011 Top Panel
0012 Top Rail
0013 Electrical Box Cover
0014 Rear Grill Panel
0015 Interior Separation Panel
0016 Refrigerant to System Water Plate Heat Exchanger
0017 System Water Supply Pipe
0018 System Water Return Pipe
0019 Refrigerant to System Water Plate Heat Exchanger Bracket
0020 Reversing Valve
0021 Transformer
0022 Schrader Valve 1
0023 Electrical Grommet
0024 Side Access Panel
0025 Rear Connections Panel
0026 Support Bracket
0027 Isolation Fill Valve
0028 High Pressure Switch
0029 Low Pressure Switch
0030 One Way Safety Valve
0031 Electronic Expansion Valve
0032 Filter
0033 Electronic Expansion Valve
0034 Schrader Valve 2
0035 Schrader Valve 3
0036 EVI Plate Heat Exchanger
0037 EVI Plate Heat Exchanger Bracket
0038 Bracket
0039 Compressor
0040 Compressor Cover 1
0041 Base Plate
0042 Compressor Cover 2
0043 Compressor Cover 3
0044 Compressor Cover 4
0045 Transformer
0046 Transformer Cover
0047 Transformer Base
0048 Mounting Bracket
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Outdoor Unit Model No.
Serial No.
AM2V 0510787986311999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate when ordering replacement parts.
Order replacement components from your Viessmann distributor.
0001 PC4003-G Board
0002 Switching Power Supply
0003 Fan Speed Control Module
0004 8 Pole Terminal
0005 Fuse
0006 Driver Board
0007 2 Pole Terminal
0008 Temperature Sensor
0009 Electrical Enclosure
0010 BHB21 Board
0011 EMC Filter
0012 Relay
0013 Power Supply Terminal
0014 DIN Rail 2 Pole
0014
0013
0012
0011
0010
0008
0009
0007
0006
0004
0005
0002
0003
6221389 - 02
0001
85
Parts
Vitocal 100-AW AM2V Installation, Service and Operating
Parts List
Indoor Unit Model No. Serial No.
AM2V 020028
7228973999999999
AM2V 034043
7228974999999999
AM2V 051078
7228975999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating
plate when ordering replacement parts.
Order replacement components from your
Viessmann distributor.
0001 - Reducer 1-a to 1 in. Brass
0002 - 1 in. Close Nipple Brass
0003 - Isolation Valve
0004 - 1-a X 1 X 1 in. Reducing Tee Brass
0005 - Pressure Relief Valve 30 PSI
0006 - c in. Close Nipple Brass
0007 - 1 in. X 6 in. Long Nipple Brass
0008 - 1 to c in. Reducing Elbow Brass
0005
0001
0004
0002
0002
0006
0007
0008
0003
6221389 - 02
0003
86
Vitocal 100-AW AM2V Installation, Service and Operating
Parts
Parts List
Outdoor Unit Model No.
Serial No.
AM2V 0200287986309999999999
AM2V 0340437986310999999999
AM2V 0510787986311999999999
Ordering Replacement Parts:
Please provide Model and Serial Number from rating
plate when ordering replacement parts.
Order replacement components from your
Viessmann distributor.
0001 - Pressure Relief Valve 30 PSI
0002 - c in. Close Nipple Brass
0003 - c in. Street Elbow Brass
0004 - 1 X 1 X c in. Reducing Tee Brass
0005 - Microbubble Air Separator
0006 - 1 in. Elbow Brass
0007 - 1 in. X 8 in. Long Nipple Brass
0006
0001
0002
0005
0007
0006
0003
6221389 - 02
0004
87
Technical Data
Vitocal 100-AW AM2V Installation, Service and Operating
Indoor Unit Technical Data
Indoor Unit
Electrical Data
Power Supply
Electric Heater Output
Heating Elements
Hydronic Data
Hydronic connection
Voltage
Phase
Hertz
Amperage
(FLA)
Maximum Fuse
(Amps)
kW (BTU)
AM2V 020028 AM2V 034043 AM2V 051078
230 VAC
1
60
31
230 VAC
1
60
31
230 VAC
1
60
43
40
40
50
6 (20500)
2
6 (20500)
2
9 (30700)
3
PSI (bar)
PSI (bar)
LF (LC)
LF (LC)
LF (LC)
1a NPT (Male
Threads)
8 (0.5)
30 (2)
140 (60)
167 (75)
165 (74)
1a NPT (Male
Threads)
8 (0.5)
30 (2)
140 (60)
167 (75)
165 (74)
1a NPT (Male
Threads)
8 (0.5)
30 (2)
140 (60)
167 (75)
165 (74)
LF (LC)
USG (l)
PSI (bar)
186 (86)
3.2 (12)
14 (1)
186 (86)
3.2 (12)
14 (1)
186 (86)
3.2 (12)
14 (1)
GPM (m3/h)
GPM (m3/h)
ft. of hd (kPa)
MBH
2.6 (0.6)
4.4 (1.0)
0.6 (2)
510
3.1 (0.7)
7.5 (1.7)
1.6 (5)
510
3.7 (0.85)
12.8 (2.9)
5.0 (15)
510
in. (mm)
in. (mm)
in. (mm)
lbs (kg)
28-b (723)
16-a (416)
12-c (323)
64 (29)
28-b (723)
16-a (416)
12-c (323)
64 (29)
28-b (723)
16-a (416)
12-c (323)
64 (29)
6221389 - 02
Min. Operating Pressure
Max. Operating Pressure
Max. System Temperature
Max. DHW Temperature
Max. Operating
Temperature
Fixed High Limit
Expansion vessel volume
Expansion vessel
precharge
Minimum flow
Maximum flow
Pressure drop
Minimum Relief Valve Capacity
Dimensional Data
Dimensions
Height
Width
Depth
Weight
Model
88
Technical Data
Vitocal 100-AW AM2V Installation, Service and Operating
Outdoor Unit Technical Data
Outdoor Unit
Heating/Cooling Data
Heating Capacity
Cooling Capacity Range
Model
Low
High
Energy Efficiency Ratio (EER)
COP
Electrical Data
Power Supply
Total Electrical Load
Compressor Load Rating
Fan Motor Load Rating
Minimum Circuit Ampacity
Maximum Fuse
Refrigerant
Refrigerant
Factory Charge
Max. Allowable Pressure Heating
Max. Allowable Pressure Cooling
Max. Operating Pressure Low Side
Max. Operating Pressure High Side
Hydronic Data
Hydronic connection
Water Flow Rate
Pressure drop
Maximum temperature of
heating medium
Air and Noise
Maximum DC power of fan
Maximum air flow
Minimum/maximum air
temperature
Maximum sound pressure
level at 3.3 ft. (1m) distance
Maximum sound power level
Dimensional Data
Dimensions (HXWXD)
20.5 (6.0)
1.4 (5.0)
1.5 (5.2)
16.81
4.927
34.0 (10.0)
2.8 (9.8)
3.0 (10.5)
16.75
4.909
58.0 (17.0)
4.2 (14.7)
4.3 (15.1)
14.46
4.238
Voltage
Phase
Hertz
Amps
Amps
Amps
Amps
Amps
208/230 VAC
1
60
13.0
12.2
0.8
17
25
208/230 VAC
1
60
21.8
21.0
0.8
28
45
208/230 VAC
1
60
35.1
33.5
2 X 0.8
44
70
lbs (kg)
PSIG (MPa)
R32
2.43 (1.1)
725 (5.0)
R32
3.97 (1.8)
740 (5.1)
R32
4.41 (2.0)
972 (6.7)
PSIG (MPa)
624 (4.3)
609 (4.2)
624 (4.3)
PSIG (MPa)
305 (2.1)
305 (2.1)
305 (2.1)
PSIG (MPa)
638 (4.4)
638 (4.4)
638 (4.4)
GPM
(m3/h)
ft. of hd (kPa)
LF(LC)
1 NPT (Male
Threads)
3.7-8.8
(0.85-2.0)
3.3 (10)
149 (65)
1 NPT (Male
Threads)
6.2-15.0
(1.4-3.4)
6.7 (20)
149 (65)
1 NPT (Male
Threads)
11.4-25.5
(2.6-5.8)
15.0 (45)
149 (65)
W
CFM (m3/h)
85
1765 (3000)
170
2650 (4500)
dB(A)
-13/109
(-25/43)
52
-13/109
(-25/43)
55
2X75
2X1470
(2X2500)
-13/109
(-25/43)
56
dB(A)
60
63
64
in. (mm)
in. (mm)
in. (mm)
lbs (kg)
31-a (795)
46 (1165)
15-c (400)
198 (90)
36-b (928)
50-c (1285)
18-d (460)
291 (132)
52-e (1329)
49-a (1250)
19-b (495)
353 (160)
6221389 - 02
Weight
MBH (kW)
Tons (kW)
Tons (kW)
LF(LC)
Height
Width
Depth
AM2V 020028 AM2V 034043 AM2V 051078
89
Water Quality
Vitocal 100-AW AM2V Installation, Service and Operating
Filling the System
Water quality
Treatment for Vitocal 100 AW feed water should
be considered in areas of known problems, such as
where a high mineral content and hardness exist.
In areas where freezing might occur, an antifreeze
may be added to the system water to protect the
system. Please adhere to the specifications given
by the antifreeze manufacturer.
Do not use automotive silicate based antifreeze.
Please observe that an antifreeze/water mixture
may require a backflow preventer within the
automatic water feed and influence components
such as diaphragm expansion tanks, radiation, etc.
Maximum antifreeze content is 50% for the Vitocal
100 AW.
Do not use sulphur-containing Vitocal feed water.
Check pH-level after some operating time. It should
be in the range from 8.2 to 9.5. If it is not, please
take appropriate measures. Total permissible
hardness of the fill and top-up water - 70 ppm.
6221389 - 02
Do not use antifreeze other than specifically made
for hot water heating systems. System also may
contain components which might be negatively
affected by antifreeze. Check total system
frequently when filled with antifreeze. Advise
system operator/ultimate owner that system is
filled with a glycol mix. The heating contractor
must provide a SDS (Safety Data Sheet) for the
antifreeze used to the system operator/ultimate
owner.
90
6221389 - 02
Vitocal 100-AW AM2V Installation, Service and Operating
91
Printed on environmentally friendly
F(recycled and recyclable) paper.
Technical information subject to change without notice.
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario · N2V 2G5 · Canada
TechInfo Line 1-888-484-8643
1-800-387-7373 · Fax (519) 885-0887
www.viessmann.ca · [email protected]
6221389 - 02
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island · 02886 · USA
TechInfo Line 1-888-484-8643
1-800-288-0667 · Fax (401) 732-0590
www.viessmann-us.com · [email protected]
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