Viessmann Vitodens 222-F Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 222-F
Type FS2A
Compact gas condensing boiler
4.8 to 35 kW natural gas and LPG version
GC No 47-819-15 (19kW); 47-819-16 (26kW); 47-819-17 (35kW)
For applicability, see the last page
VITODENS 222-F
5692 816 GB 4/2009 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
5692 816 GB

3
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.)
5692 816 GB

4
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 code 1.................................................................................................. 62
General – Group 1................................................................................................ 63
Boiler – Group 2................................................................................................... 64
DHW – Group 3.................................................................................................... 67
Heating circuit 1/Heating circuit 2 – Group 5........................................................ 68
Code 2
Calling up coding level 2...................................................................................... 74
General – Group 1................................................................................................ 75
Boiler – Group 2................................................................................................... 77
DHW – Group 3.................................................................................................... 78
Heating circuit 1/Heating circuit 2 – Group 5........................................................ 80
Diagnosis and service scans
Diagnosis.............................................................................................................. 83
Checking outputs (relay test)................................................................................ 87
Troubleshooting
Fault display......................................................................................................... 90
Fault codes........................................................................................................... 91
Repairs................................................................................................................. 100
Function description
Constant temperature control unit........................................................................ 113
Weather-compensated control unit...................................................................... 114
Index
Index
5692 816 GB

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Internal extensions............................................................................................... 116
External extensions (accessories)........................................................................ 118
Control functions.................................................................................................. 120
Remote control DIP switches............................................................................... 126
Electronic combustion controller.......................................................................... 127
Designs
Internal connection diagram................................................................................. 129
External connection diagram................................................................................ 130
Parts lists............................................................................................................ 132
Commissioning/service reports........................................................................ 140
Specification....................................................................................................... 141
Certificates
Declaration of conformity...................................................................................... 142
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 142
Keyword index.................................................................................................... 143
Index
Index (cont.)
5692 816 GB

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Vitodens 222-F, FS2A
Set up for operation with natural gas H.
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.
Preparing the connections on site:
Connection set installation instructions
Preparing for installation
Product information
5692 816 GB

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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
236
50
595
50
600
55
220
330
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
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
Preparing for installation
Preparing for installation (cont.)
5692 816 GB
Installation

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Rated output range 4.8 to 19 kW 6.5 to 26 kW 8.8 to 35 kW
c (mm) 972 972 1172
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) 1477 1477 1677
p (mm) 1526 1526 1726
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. The DHW expansion vessel is
supplied as standard and will be fitted
inside the appliance.
Preparing for installation
Preparing for installation (cont.)
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9
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 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

10
Safety assembly to DIN 1988
ASafety assembly (accessory to con-
nection sets for unfinished walls)
BSafety valve
CVisible blow-off line outlet
DShut-off valve
EFlow regulating valve (installation
recommended)
FPressure gauge connection
GNon-return valve
HDrain
KCold water
LDrinking water filter
MPressure reducer
NNon-return valve/pipe separator
OCold water connection at connec-
tion set (accessory)
Note
Please read the additional mandatory
installation and maintenance instruc-
tions to comply with G3 Building regula-
tion and the requirements of the UK
Water Supply (Water Fittings) Regula-
tions/ Scottish Water Bylaws.
Preparing for installation
Preparing for installation (cont.)
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11
Assembling the boiler
8.
9.
5.
1.
3.
2.
2x 4.
6.
7.
Installation sequence
Installing the boiler
5692 816 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
Fitting the drain outlet and drain line
to the T&P valve
Separate installation instructions
Installation sequence
Installing the boiler (cont.)
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DHW circulation connection
DHW circulation connection with
DHW circulation pump connection
set (accessory)
Separate installation instructions
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 leak/tightness test.
Installation sequence
Installing the boiler (cont.)
5692 816 GB
Installation

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!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~
5
2
1
145
3217654
X3 40962035100
1
L
NLN L1N
2153
ARadio clock connection
BVitotrol 100 UTD (only for constant
temperature control units or third
party 230V programmers)
CVitotrol 100 UTA (only for constant
temperature control units)
or
Vitotrol 100 UTD-RF wireless
receiver (only for constant tempera-
ture control units or third party 230V
programmers)
Plug 230 V~
sA Cylinder primary pump E (fitted
and connected)
fÖ Power supply
■ Remove any existing individual
cores.
Installation sequence
Electrical connections (cont.)
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Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Take care not to inter-
change 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.
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 UTD
■ Vitotrol 100 UTD-RF
Low voltage plug X3
!Outside temperature sensor (only
for weather-compensated control)
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 200 or 300 remote con-
trol (only for weather-compensa-
ted control)
■ Vitocom 100
■ Extension kit for one heating cir-
cuit with mixer (only for weather-
compensated control)
■ External extension H1 or H2
■ Open Therm extension
Installation sequence
Electrical connections (cont.)
5692 816 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 cable
Installation sequence
Electrical connections (cont.)
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1.
4.
2.
5.
3. 2x
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.)
5692 816 GB