Viessmann Vitodens 222-F Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 222-F
Type FS2B
Compact gas condensing boiler
4.8 to 35 kW natural gas and LPG version
For applicability, see the last page
VITODENS 222-F
5457 552 GB 2/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Installation instructions
Preparing for installation
Product information.............................................................................................. 6
Preparing for installation....................................................................................... 6
Installation sequence
Installing the boiler............................................................................................... 11
Opening the control unit casing............................................................................ 14
Electrical connections........................................................................................... 15
Closing the control unit casing............................................................................. 19
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 21
Further details regarding the individual steps....................................................... 23
Code 1
Calling up coding level 1...................................................................................... 61
General/Group "1"................................................................................................ 62
Boiler/Group "2".................................................................................................... 64
DHW/Group "3".................................................................................................... 65
Heating circuit 1, heating circuit 2, heating circuit 3/Group "5"............................. 65
Code 2
Calling up coding level 2...................................................................................... 72
General/Group "1"................................................................................................ 73
Boiler/Group "2".................................................................................................... 81
DHW/Group "3".................................................................................................... 82
Heating circuit 1, heating circuit 2, heating circuit 3/Group "5"............................. 84
Diagnosis and service scans
Calling up the service menu................................................................................. 94
Diagnosis.............................................................................................................. 94
Checking outputs (relay test)................................................................................ 99
Troubleshooting
Fault display......................................................................................................... 102
Fault codes........................................................................................................... 104
Repairs................................................................................................................. 115
Function description
Constant temperature control unit........................................................................ 126
Index
Index
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Weather-compensated control unit...................................................................... 127
Internal extensions............................................................................................... 130
External extensions (accessories)........................................................................ 132
Control functions.................................................................................................. 136
Assigning the heating circuits to the remote control............................................. 144
Electronic combustion controller.......................................................................... 144
Designs
Internal connection diagram................................................................................. 146
External connection diagram................................................................................ 147
Parts lists............................................................................................................ 149
Commissioning/service reports........................................................................ 157
Specification....................................................................................................... 158
Certificates
Declaration of conformity...................................................................................... 159
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 160
Keyword index.................................................................................................... 161
Index
Index (cont.)
5457 552 GB

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Vitodens 222-F, FS2B
Set up for operation with natural gas E and LL.
For conversion to LPG P (without conversion kit), see page 29.
The Vitodens 222-F should generally only be delivered to those countries specified
on the type plate. For deliveries to alternative countries, an approved contractor, on
his own initiative, must arrange individual approval in accordance with the law of the
land.
Preparing for installation
Preparing the boiler installation
Use a connection set, available as an accessory, to make the connection on the gas
and water sides. The following overview shows sample connection sets for installa-
tion on finished walls to the top or side.
!Please note
To prevent equipment damage,
install all pipework free of load and torque stresses.
Preparing the connections on site:
Connection set installation instructions
Preparing for installation
Product information
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100
569
46
40
50
c
d
e
f
g
h
k
l
m
n
p
a b
140
50
320
361
398
410
80
q
50
595
50
600
55
220
330
G
C
A
B
F
D
E
AHeating flow R ¾
BDHW R ½
CGas connection R ¾
DCold water R ½
EHeating return R ¾
FDHW circulation R ½ (separate
accessory)
GCondensate drain to the back into
the wall
HSide condensate drain
KCable entry area
Rated output range 4.8 to 19 kW 6.5 to 26 kW 8.8 to 35 kW
a (mm) 745 745 945
b (mm) 750 750 950
c (mm) 972 972 1172
Preparing for installation
Preparing for installation (cont.)
5457 552 GB
Installation

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Rated output range 4.8 to 19 kW 6.5 to 26 kW 8.8 to 35 kW
d (mm) 1027 1027 1227
e (mm) 1082 1082 1302
f (mm) 1137 1137 1337
g (mm) 1191 1191 1391
h (mm) 1247 1247 1447
k (mm) 1302 1302 1562
l (mm) 1437 1437 1637
m (mm) 1466 1466 1666
n (mm) 1465 1465 1665
p (mm) 1526 1526 1726
q (mm) 201 224 224
Note
The adjustable feet give all height meas-
urements a tolerance of +15 mm.
1. Prepare the heating water connec-
tions.
Flush the heating system thor-
oughly.
Note
Should an additional diaphragm
expansion vessel be required on site,
connect that vessel into the heating
return.
Preparing for installation
Preparing for installation (cont.)
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9
M
L
2. Prepare the DHW connections.
Install the safety assembly (acces-
sory or on-site provision) in accord-
ance with DIN 1988 in the cold water
line (see page 10).
Recommendation:
Install the safety valve above the
DHW cylinder to protect it against
contamination, scaling and high tem-
peratures.
Connect the drain hose to conden-
sate collector L. Remove plug from
condensate collector.
3. Route condensate hose M to the
back (drain in wall G) or to the side
aperture H (see page 6).
Route condensate hose with a U-
bend and connect to on-site drain line
or siphon.
4. Prepare the gas connection accord-
ing to TRGI or TRF or all local regu-
lations.
5. Prepare the electrical connections.
■ Power supply cable: NYM-
J 3 x 1.5 mm2, fuse max. 16 A,
230 V/50 Hz.
■ Accessory cables: NYM with the
required number of conductors for
the external connections.
■Allow all cables in area "K" (see
page 7) to protrude 2000 mm from
the wall.
Preparing for installation
Preparing for installation (cont.)
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Installation

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Safety assembly to DIN 1988
ASafety assembly to DIN 1988
(accessory to connection sets for
unfinished walls)
BSafety valve
CVisible blow-off line outlet
DShut-off valve
EFlow regulating valve (installation
recommended)
FPressure gauge connector
GNon-return valve
HDrain
KCold water
LDrinking water filter
MPressure reducer to DIN 1988-2,
issue Dec. 1988
NNon-return valve/pipe separator
OCold water connection at connec-
tion set (accessory)
Preparing for installation
Preparing for installation (cont.)
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Assembling the boiler
2.
6.
7.
5.
1.
4.
2x
3.
Installation sequence
Installing the boiler
5457 552 GB
Installation

12
Connections on the heating water and the DHW side
Shown with connection sets for finished walls (accessories)
AHeating flow R ¾
BDHW R ½
CDHW circulation R ½ (separate
accessory)
DCold water R ½
EHeating return R ¾
DHW connection
The DHW expansion vessel, available
as an accessory, is installed in the cold
water supply inside the boiler.
Separate installation instructions
DHW circulation connection
DHW circulation connection with
DHW circulation pump connection
set (accessory)
Separate installation instructions
Installation sequence
Installing the boiler (cont.)
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Gas connection
Notes regarding operation with LPG.
We recommend the installation of an
external safety solenoid valve when
installing the boiler in rooms below
ground level.
1. Secure gas shut-off valve A at the
gas connection.
2. Carry out a tightness test.
Note
For the tightness test, use only suita-
ble and approved leak detecting
agents (EN 14291) and devices.
Leak detecting agents with unsuita-
ble constituents (e.g. nitrites, sul-
phides) can lead to material dam-
age.
Remove residues of the leak detect-
ing agent after testing.
Installation sequence
Installing the boiler (cont.)
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Installation

14
!Please note
Excessive test pressure may
damage the boiler and the gas
valve.
Max. test pressure 150 mbar.
Where higher pressure is
required for tightness tests,
separate the boiler and the
gas valves from the gas sup-
ply pipe (undo the fitting).
3. Vent the gas line.
For conversion to a different gas type
see page 29
Flue gas connection
Connect the balanced flue. Flue gas system installation
instructions.
Opening the control unit casing
1.
3.
2. 2x
Installation sequence
Installing the boiler (cont.)
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5.
4. 7x
Electrical connections
Information regarding the connection of accessories
For the connection, observe the separate installation instructions provided
with the accessory components.
!Please note
Electronic modules can be damaged by electrostatic discharges.
Before beginning work, touch earthed objects, such as heating or water pipes,
to discharge static loads.
Installation sequence
Opening the control unit casing (cont.)
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Installation

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L 1
L
M
1~
L N
230V~ 230V~
3217654
X3 40962035100
1
L
NLN L1N
2153
D
E
B
C
A
%
aVG !
?
ARadio clock receiver
BVitotrol 100 UTDB (only for constant
temperature control units)
CVitotrol 100 UTA (only for constant
temperature control units)
or
Vitotrol 100 UTDB-RF wireless
receiver (only for constant tempera-
ture control units)
Plug 230 V~
sA Cylinder primary pump E (fitted
and connected)
fÖ Power supply [terminals]
■ Remove any existing individual
cores.
Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Installation sequence
Electrical connections (cont.)
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Never interchange cores
"L1" and "N".
■ Install an isolator in the power
supply line that simultaneously
isolates all non-earthed conduc-
tors from the mains with at least
3 mm contact separation.
We additionally recommend
installing an AC/DC-sensitive
RCD (RCD class B ) for
DC (fault) currents that can occur
with energy-efficient equipment.
Remove the existing cable grom-
met when using larger cross-sec-
tions (up to 714 mm). Secure the
cable with cable grommet F (see
page 18) integrated into the cas-
ing base.
■ Max. fuse rating 16 A.
gD External safety solenoid valve
(LPG) D
Do not remove jumper between "1"
and "L" when making this connec-
tion.
lH Power supply of accessories
Where the boiler is installed in a wet
area, the connection of accessories
to the power supply must not be car-
ried out at the control unit. The
power supply connection for acces-
sories can be made immediately at
the control unit, if the boiler is instal-
led outside wet areas. This connec-
tion is controlled directly with the
system ON/OFF switch (max. 3 A)
■ Vitotrol 100 UTA
■ Vitotrol 100 UTDB
■ Vitotrol 100 UTDB-RF
Low voltage plug X3
!Outside temperature sensor (only
for weather-compensated control
units)
Installation:
■ North or north-western wall, 2 to
2.5 m above ground level; in multi-
storey buildings, in the upper half
of the second floor
■ Not above windows, doors or ven-
tilation outlets
■ Not immediately below balconies
or gutters
■ Never render over
■ Cable length max. 35 m with a
cross-section of 1.5 mm2
?Flow temperature sensor for low
loss header (accessories)
%Cylinder temperature sensor (fitted
and connected)
aVG KM BUS subscriber (accessory)
■ Vitotrol 200A or 300A remote
control (only for weather-com-
pensated control units)
■ Vitocom 100
■ Extension kit for one heating cir-
cuit with mixer (only for weather-
compensated control units)
■ Extension EA1 or AM1
Installation sequence
Electrical connections (cont.)
5457 552 GB
Installation

18
Routing the connecting cables
!Please note
Connecting cables will be damaged if they touch hot parts.
When routing and securing power cables on site, ensure that the maximum
permissible temperatures for these cables are not exceeded.
ALow voltage connections
B230 V connections
CInternal extension
DMain PCB
ECommunication module (accesso-
ries)
FCable grommet for power supply
cable
Installation sequence
Electrical connections (cont.)
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1.
4.
2.
5.
3. 2x
6.
Close control unit casing and insert pro-
gramming unit, packed separately.
Note
The programming unit can also be used
in a wall mounting base (accessory) near
the boiler.
Installation sequence
Closing the control unit casing
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Installation

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Wall mounting base installation
instructions
Installation sequence
Closing the control unit casing (cont.)
5457 552 GB