Viessmann Vitodens 222-F Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 222-F
Type FS2B, 4.8 to 35 kW
Gas condensing storage combi boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 222-F
5457 552 GB 3/2011 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............................................................................................... 10
Opening the control unit casing............................................................................ 13
Electrical connections........................................................................................... 14
Closing the control unit casing............................................................................. 20
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 22
Further details regarding the individual steps....................................................... 24
Code 1
Calling up coding level 1...................................................................................... 63
General/group "1"................................................................................................. 64
Boiler/group "2".................................................................................................... 66
DHW/group "3"..................................................................................................... 67
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 67
Code 2
Calling up coding level 2...................................................................................... 74
General/group "1"................................................................................................. 75
Boiler/group "2".................................................................................................... 82
DHW/group "3"..................................................................................................... 83
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 85
Diagnosis and service scans
Calling up the service level................................................................................... 95
Diagnosis.............................................................................................................. 96
Checking outputs (relay test)................................................................................ 101
Troubleshooting
Fault display......................................................................................................... 103
Fault codes........................................................................................................... 105
Repairs................................................................................................................. 119
Function description
Constant temperature control unit........................................................................ 132
Index
Index
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Weather-compensated control unit...................................................................... 133
Internal extensions............................................................................................... 136
External extensions (accessories)........................................................................ 138
Control functions.................................................................................................. 142
Allocating heating circuits to the remote control................................................... 150
Electronic combustion controller.......................................................................... 150
Designs
Internal connection diagram................................................................................. 152
External connection diagram................................................................................ 153
Parts lists............................................................................................................ 155
Commissioning/service reports........................................................................ 164
Specification....................................................................................................... 165
Certificates
Declaration of conformity...................................................................................... 166
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 167
Keyword index.................................................................................................... 168
Index
Index (cont.)
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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 30.
In principle, the Vitodens 222-F may 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
country in question.
Preparing for installation
Preparing for 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.)
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Installation

8
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
All height dimensions have a tolerance
of +15 mm due to the adjustable feet.
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.
M
L
>200
2. Prepare the connections on the DHW
side. Install the safety assembly
(accessory or on-site provision)
according to DIN 1988 in the cold
water line (see page 9).
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.
Preparing for installation
Preparing for installation (cont.)
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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 with a fall 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 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.
Safety assembly to DIN 1988
ASafety assembly to DIN 1988
(accessory to connection sets for
unfinished walls)
BSafety valve
CVisible discharge pipe outlet point
DShut-off valve
EFlow regulating valve (installation
recommended)
FPressure gauge connection
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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Installation

10
Assembling the boiler
2.
6.
7.
5.
1.
4.
2x
3.
Installation sequence
Installing the boiler
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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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Installation

12
Gas connection
Information on 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 contents (e.g. nitrites, sulphides)
can lead to material damage.
Remove residues of the leak detect-
ing agent after testing.
Installation sequence
Installing the boiler (cont.)
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13
!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 supply line.
For conversion to a different gas type
see page 30
Flue outlet
Connect the balanced flue. Flue gas system installation
instructions.
Opening the control unit casing
1.
3.
2. 2x
Installation sequence
Installing the boiler (cont.)
5457 552 GB
Installation

14
5.
4. 7x
Electrical connections
Information on accessory connection
For the connection, observe the separate installation instructions provided
with the accessory components.
!Please note
Electronic assemblies can be damaged by electrostatic discharge.
Before beginning work, touch earthed objects, such as heating or water pipes,
to discharge static loads.
Installation sequence
Opening the control unit casing (cont.)
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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 in the delivered con-
dition)
fÖ Power supply
Danger
Incorrectly executed electri-
cal installations can lead to
injury from electrical current
and result in equipment dam-
age.
Installation sequence
Electrical connections (cont.)
5457 552 GB
Installation

16
Make the power supply con-
nection and implement all
protective measures (e.g.
RCD circuit) in accordance
with the following regula-
tions:
■ IEC 60364-4-41
■ VDE regulations
■ Connection requirements
specified by your local
power supply utility
■ Remove any existing individual
cores.
Danger
Incorrect core allocation
can cause severe injury
and damage the appli-
ance.
Take care not to inter-
change wires 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 inte-
grated in the casing base (see
page 19).
■ Max. fuse rating 16 A.
Danger
Absence of component
earthing in the system can
result in serious injury due to
electric shock in the event of
an electrical fault.
Connect the appliance and
pipework to the equipotential
bonding of the building in
question.
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
If the boiler is installed in wet areas,
outside the wet area accessories
must not be connected to the power
supply at the control unit. The power
supply connection for accessories
can be made immediately at the
control unit, if the boiler is installed
outside wet areas. This connection
is switched directly with the ON/OFF
switch of the control unit.
If the total system current exceeds 6
A, connect one or more extensions
via a mains isolator directly to the
mains supply.
■ Vitotrol 100 UTA
■ Vitotrol 100 UTDB
■ Vitotrol 100 UTDB-RF
Installation sequence
Electrical connections (cont.)
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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.)
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Installation

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Connection of accessories
Power supply of all accessories via the boiler control unit
145 145 40 A 40 145 145 40 A 40
B C
145 40 96
A
145 145 40 A 40
D
E
Some accessories with direct power supply
145 145 40 A 40 145 145 40 A 40
B C
145 40 96
A
145 145 40 A 40
D
E
ABoiler control unit
BExtension kit for heating circuit with
mixer M2
CExtension kit for heating circuit with
mixer M3
DExtensions AM1 or EA1
EON/OFF switch
If the current flowing to the connected
working parts (e.g. circulation pumps) is
higher than the safety level of the acces-
sory, the output concerned should only
be used to control an on-site relay.
Accessories Internal fuse
protection
Extension kit for heat-
ing circuit with mixer
2 A
Extension AM1 4 A
Extension EA1 2 A
Installation sequence
Electrical connections (cont.)
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Routing the connecting cables
!Please note
Connecting cables will be damaged if they touch hot components.
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 cable
Installation sequence
Electrical connections (cont.)
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Installation

20
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
5457 552 GB