Viessmann VITOCAL 222-G Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 222-G
Type BWT 221.A06 to A10
Type BWT-M 221.A06 to A10
Compact heat pump, 400 V~ and 230 V~
For applicability, see the last page
VITOCAL 222-G
5601 574 GB 4/2011 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 contractors.
■ Work on the refrigerant circuit must
only be carried out by qualified and
authorised refrigeration engineers
■ 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:
■ National installation requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can lead to severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Before removing covers from
appliances, wait at least 4
minutes for the power to dissi-
pate.
■ Safeguard the system against unau-
thorised reconnection
Safety instructions
Safety instructions
5601 574 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5601 574 GB

4
Installation instructions
Preparing for installation
Use....................................................................................................................... 6
Requirements concerning on-site connections.................................................... 7
Overview of possible system schemes................................................................ 9
Markings in the system examples........................................................................ 10
System example, ID: 4605445_1104_01............................................................. 11
Installation sequence
Siting the heat pump............................................................................................ 16
Hydraulic connections.......................................................................................... 29
Electrical connections........................................................................................... 32
Connecting power cables..................................................................................... 42
Connecting to terminals X3.8/X3.9....................................................................... 49
Closing the heat pump......................................................................................... 50
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 51
Further details regarding the individual steps....................................................... 52
Troubleshooting
Repairs................................................................................................................. 67
Parts lists type BWT (400 V~)
Parts lists type BWT (400 V~).............................................................................. 78
Overview of the assemblies................................................................................. 79
Parts not shown.................................................................................................... 80
Casing.................................................................................................................. 80
Electrical equipment............................................................................................. 82
Heat pump module............................................................................................... 86
Hydraulics............................................................................................................. 88
Cylinder................................................................................................................ 90
Parts lists type BWT-M (230 V~)
Parts lists type BWT-M (230 V~).......................................................................... 92
Overview of the assemblies................................................................................. 93
Parts not shown.................................................................................................... 94
Casing.................................................................................................................. 94
Electrical equipment............................................................................................. 96
Heat pump module............................................................................................... 98
Hydraulics............................................................................................................. 100
Index
Index
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5
Cylinder................................................................................................................ 102
Fitting set.............................................................................................................. 104
Commissioning/service reports
Hydraulic parameters report................................................................................. 106
Control parameters report.................................................................................... 106
Specification....................................................................................................... 111
Declaration of Conformity
Declaration of conformity...................................................................................... 116
Keyword index.................................................................................................... 117
Index
Index (cont.)
5601 574 GB

6
The compact heat pumps Vitocal 222-G,
type BWT 221.A06 to A10,
BWT-M 221.A06 to A10, are intended for
the following purposes:
■ Central heating and cooling via a heat-
ing system.
■ DHW heating with the integral DHW
cylinder.
Any other use is considered inappropri-
ate.
Note
The Vitocal 222-G is exclusively inten-
ded for domestic use, i.e. even individu-
als that have not been instructed in its
use may safely operate this appliance.
Preparing for installation
Use
5601 574 GB

7
454
564
665
680
1804
1829
600
218
147
69
134
159
62
300
387
500
1800
D E
F
G
A
DE GF
A
B
C
29
/
80
< 42 V
230 V~
400 V~
ADHW
BDHW circulation
CCold water
DPrimary circuit return (heat pump
brine outlet)
Preparing for installation
Requirements concerning on-site connections
5601 574 GB
Installation

8
EPrimary circuit flow (heat pump
brine inlet)
FSecondary circuit flow (heating
water)
GSecondary circuit return (heating
water)
1. Prepare the connections on the heat-
ing water and the DHW side.
Flush the heating system.
Connection of hydraulic pipes D
to G:
■ On-site connection:
Use straight pieces of pipe (stand-
ard delivery).
■ With the connection set primary cir-
cuit/secondary circuit (accesso-
ries):
Use pipe bends from the connec-
tion set.
2. Prepare the electrical connections.
Pipe lengths:
■ Required pipe length inside the appli-
ance plus wall clearance
2.0 m
■ Height, wall outlet:
1850 mm (see "Technical guides for
heat pumps")
Recommended power cables:
Type BWT/BWT-M 221.A06 221.A08 221.A10
Heat pump control unit 230 V~
Cable cross-section
■ Without power-OFF 3 x 1.5 mm23 x 1.5 mm23 x 1.5 mm2
■ With power-OFF 5 x 1.5 mm25 x 1.5 mm25 x 1.5 mm2
Compressor
Cable cross-section
■ 400 V~ 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
■ 230 V~ 3 x 4 mm23 x 4 mm23 x 4 mm2
Max. cable length 25 m 25 m 25 m
Instantaneous heating water
heater 8.8 kW
Cable cross-section
■ 400 V~ 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
■ 230 V~ 7 x 2.5 mm27 x 2.5 mm27 x 2.5 mm2
Max. cable length 25 m 25 m 25 m
Preparing for installation
Requirements concerning on-site connections (cont.)
5601 574 GB

9
The following table provides an overview
of all possible system schemes.
Components System scheme
0 2 4 6 11
Heating circuit
A1 (HC1) — X — X —
M2 (HC2) — — X X —
DHW cylinder
X X X X —
Heating water buffer cylinder
— 0X X —
Cooling
A1 (HC1) — 0—0—
M2 (HC2) — — 0 0 —
Sep. cooling circuit (SKK) 0 0 0 0 —
X Components selected.
0Components can be added.
Preparing for installation
Overview of possible system schemes
5601 574 GB
Installation

10
--A/137--
--2/212.3--
--230V-- -KM BUS-
KW
WW
--2/F6--
--2/F14--
--2/211.2--
--2/F0--
-2/211.4-
--94/20--
--
--2/F8--
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
-2/145-
A1
--2/X3.8;3.9--
2
1
qE
qW
6
4
3
7
5
eU
eQ
eP
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
2
[H
F
[YF
F
Preparing for installation
Markings in the system examples
5601 574 GB

11
Setting system scheme 6
■ Vitocal 222-G with integral DHW cyl-
inder and Vitotronic 200, type WO1B
■ Heating circuit distributor with one
heating circuit without mixer and one
heating circuit with mixer
■ Heating water buffer cylinder
Note
This scheme is a basic example without
shut-off valves or safety equipment. This
does not replace the need for local engi-
neering.
Hydraulic installation scheme
P1
21
20
22
27
KW
WW
--2/X3.8;3.9--
37
--2/212.3--
4
1
12
13
3
2
P1
--X3.8;3.9--
--212.3--
--230V--
--F0--
--F13--
-KM BUS-
--2/F0--
61
62
96
90
91 71
70
73
74
76
77
60
--2/F4--
--2/F13--
--2/212.2--
75
--20--
--52--
--230V--
--2--
-KM BUS-
--75/2--
--75/20--
--75/20--
--75/52--
--F4--
--212.2--
8
--145-- --145--
-8/145- -8/145-
--145--
A1 M2
Preparing for installation
System example, ID: 4605445_1104_01
5601 574 GB
Installation

12
Equipment required
Pos. Description
Heat source
1
2
Compact heat pump:
■ Integral heat pump control unit
■ Primary pump
■ Secondary pump
■ 3-way diverter valve for "Heating/DHW"
■ DHW cylinder
■ Cylinder temperature sensor
3Outside temperature sensor ATS
4Instantaneous heating water heater
8KM BUS distributor
qW Safety assembly
qE Heating circuit expansion vessel
Primary circuit
wP Brine accessory pack
wQ Pressure switch, primary circuit
wW Brine distributor for geothermal probes/geothermal collectors
wU Geothermal probe/geothermal collector
DHW heating
eU Connection set with DHW circulation pump ZP
Heating water buffer cylinder
zP Heating water buffer cylinder
zQ Buffer temperature sensor PTS
zW Flow temperature sensor, system VTS
■ As immersion sensor
or
■ As contact sensor
Preparing for installation
System example, ID: 4605445_1104_01 (cont.)
5601 574 GB

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Pos. Description
Heating circuit with mixer M2
uP Underfloor heating circuit M2 with mixer controlled by the heat pump control
unit
uQ Vitotrol 200A remote control
uE Flow temperature sensor VTS
uR Temperature limiter to restrict the maximum temperature of underfloor
heating systems
■ Version with immersion sensor
or
■ Version with contact sensor
uT Mixer extension kit
uZ Heating circuit pump
uU Mixer motor for 3-way mixer
Heating circuit without mixer A1
oP Radiator heating circuit
oQ Vitotrol 200A remote control
oZ Heating circuit pump
Electrical installation scheme
For an overview of the electrical connec-
tions and more information on the PCBs,
see from page 34 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
For information regarding the power sup-
ply, see page 42.
230 V/ 50 Hz
2
212.2
X2.N
X1. UP A1
212.3
X2.N
X1. ZP 37
X1.1
X2.1
X3.18
230 V / 50 Hz
N
L1
X3.8
X1. 230 V; 0.5 A 21
X3.9
<16A
100 W
50 W
96
M
1~
M
1~
Preparing for installation
System example, ID: 4605445_1104_01 (cont.)
5601 574 GB
Installation

14
2
Low voltage
F4
VTS 62
PTS
PT500
PT500
61
F13
1
2
145 145
8
145
145
HK M2 71
1
2H2
HK A1 91
1
2H1
145
F0
ATS
Ni500
3
40
145
52
21
2
N
L
UP M2
77
73
M
1~
74
76
M2
VTS M2
20
230 V/ 50 Hz
1
2
1 / N / PE
NTC
20
100 W
75
2
L
N
HK M2
KM BUS distributor
1
3
2
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
R
L1
N
1 / N / PE
230 V, 50 Hz
L1
N
PE
RMains terminals for compressor
230 V~
V
L3
3 / PE
400 V, 50 Hz L3
N
L1 L1
L2
L2
PE
VMains terminals for compressor
400 V~
Preparing for installation
System example, ID: 4605445_1104_01 (cont.)
5601 574 GB

15
N
1 / N / PE
230 V/ 50 Hz
N
N
L1
L1
L1
N1
N1
N1
L1
L1
L1
PE
PE
Instantaneous heating water heater
power supply 230 V~
3 / N / PE
400 V/ 50 Hz
N
L2
L3
L1
N2
L2
L3
L1
N3
N1
PE
PE
Instantaneous heating water heater
power supply 400 V~
Required parameter settings
To call up "Coding level 1" for setting
the parameters, see the commissioning
assistant on page 59 and page 62.
Parameter Setting
"System definition"
■"System scheme 7000" "6"
DHW heating:
"Time program DHW heating" Set time program (see oper-
ating instructions)
"Time program DHW circulation"
(if a DHW circulation pump is installed)
Set time program (see oper-
ating instructions)
"DHW"
■"Enable booster heaters for DHW heating 6014" "1"
■"Enable electric heaters for DHW heating 6015" "1"
Instantaneous heating water heater:
"Electr booster heater"
■"Enable instantaneous heating water heater
7900"
"1"
■"Enable instant. heating water heater for central
heating 7902"
"0"
"Heating water buffer cylinder"
■"Enable buffer cylinder / low loss header 7200" "1"
Remote controls (if installed):
"Heating circuit 1"
■"Remote control 2003" "1"
"Heating circuit 2"
■"Remote control 3003" "1"
Preparing for installation
System example, ID: 4605445_1104_01 (cont.)
5601 574 GB
Installation

16
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Ambient temperatures of 0 to
35 ºC must be ensured.
!Please note
Avoid risk of explosion due to
dust, gases and vapours
in the installation room.
!Please note
Observe the permissible floor
load.
■ Align the appliance horizon-
tally.
If the adjustable feet are used
to compensate for an uneven
floor (max. 10 mm), the pres-
sure load on the feet must be
distributed evenly.
■ The total weight must be con-
sidered (see table).
Total weight with full DHW cylinder
Type BWT/BWT-
M
Weight in kg
221.A06 420
221.A08 420
221.A10 426
Minimum room volume (to DIN EN 378):
Type BWT/BWT-M Minimum room volume
in m3
Floor area in m2
221.A06 4.7 1.9
221.A08 4.1 1.7
221.A10 4.1 1.7
Installation sequence
Siting the heat pump
5601 574 GB

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Minimum clearances Minimum room height h
Installation h in mm
■Without connection set for
pre-installation/DHW
(accessory)
2000
■With connection set for
pre-installation/DHW
(accessory)
2100
Observe design information.
Vitocal technical guide
Handling
During handling, the cylinder module can
be removed (see from page 18). In
addition, the heat pump module can be
removed (see page 24).
!Please note
Prevent damage to the appliance
during handling.
Never put weight on the top, front
or side panels of the appliance.
!Please note
If the compressor is at a steep
angle in the heat pump, lubricant
will enter the refrigerant circuit
and damage the appliance.
Max. tilting angle 45°.
Installation sequence
Siting the heat pump (cont.)
5601 574 GB
Installation

18
Removing the cylinder module
3.
1.
5.
4.
2x
2.
Installation sequence
Siting the heat pump (cont.)
5601 574 GB

19
6.
8.
F6
X3
sG
sH
lJ
aYH
7.
Installation sequence
Siting the heat pump (cont.)
5601 574 GB
Installation

20
aCH
10.
9.
Installation sequence
Siting the heat pump (cont.)
5601 574 GB