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
5772 567 GB 5/2013 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 inten-
ded for qualified contractors.
■ Work on the refrigerant circuit may
only be carried out by 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 regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the 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, SWKI and
SVGW
Working on the system
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can result in severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Prior to removing equipment
covers, wait at least 4 min. to
allow the voltage to dissipate.
■ Safeguard the system against recon-
nection.
Safety instructions
Safety instructions
5772 567 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
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.
Defective components must be
replaced with genuine
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 spare
parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5772 567 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Requirements regarding on-site connections....................................................... 7
Overview of possible system schemes................................................................ 9
Designations in the system examples.................................................................. 10
System example, ID: 4605445_1201_02............................................................. 10
Installation sequence
Siting the heat pump............................................................................................ 16
Hydraulic connections.......................................................................................... 29
Electrical connections........................................................................................... 32
Connecting power cables..................................................................................... 44
Connecting to terminals X3.8/X3.9....................................................................... 53
Closing the heat pump......................................................................................... 54
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 55
Further details regarding the individual steps....................................................... 56
Troubleshooting
Maintenance......................................................................................................... 73
Parts lists type BWT (400 V~)
Parts lists type BWT (400 V~).............................................................................. 85
Overview of the assemblies................................................................................. 86
Parts not shown.................................................................................................... 87
Casing.................................................................................................................. 87
Electrical equipment............................................................................................. 89
Heat pump module............................................................................................... 93
Hydraulics............................................................................................................. 95
Cylinder................................................................................................................ 97
Parts lists type BWT-M (230 V~)
Parts lists type BWT-M (230 V~).......................................................................... 99
Overview of the assemblies................................................................................. 100
Parts not shown.................................................................................................... 101
Casing.................................................................................................................. 101
Electrical equipment............................................................................................. 103
Heat pump module............................................................................................... 105
Hydraulics............................................................................................................. 107
Index
Index
5772 567 GB

5
Cylinder................................................................................................................ 109
Fitting set.............................................................................................................. 111
Commissioning/service reports
Hydraulic parameter report................................................................................... 113
Control parameters report.................................................................................... 113
Specification....................................................................................................... 120
Appendix
Commissioning order........................................................................................... 125
Declaration of conformity.................................................................................. 126
Keyword index.................................................................................................... 127
Index
Index (cont.)
5772 567 GB

6
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions.
Depending on the version, the appliance
can only be used for the following pur-
poses:
■ Central heating
■ Central cooling
■ DHW heating
The range of functions can be extended
with additional components and acces-
sories.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than central heating/cooling
or DHW heating shall be deemed inap-
propriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function.
Note
The appliance is intended exclusively for
domestic use, i.e. even users who have
not had any instruction are able to oper-
ate the appliance safely.
Preparing for installation
Intended use
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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 regarding on-site connections
5772 567 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.
Cable lengths:
■ Required cable 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 regarding on-site connections (cont.)
5772 567 GB

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The following table provides an overview
of all possible system schemes.
System schemes
Component System scheme
0 1 2 3 4 5 6 11
Heating circuit
A1/HC1 — X X — — X X —
M2/HC2 — — — X X X X —
DHW cylinder
X — X — X — X —
Heating water buffer cylinder
— 0 0 X X X X —
Instantaneous heating water heater
X X X X X X X —
Swimming pool
— 0 0 0 0 0 0 —
Cooling
A1/HC1 — 0 0 — — 0 0 —
M2/HC2 — — — 0 0 0 0 —
SKK 0 0 0 0 0 0 0 —
Ice store and solar absorber
0 0 0 0 0 0 0 0
Electricity meter 1-phase/3-phase
0 0 0 0 0 0 0 0
Vitovent
0 0 0 0 0 0 0 0
X Component selected.
0Component may be added.
Preparing for installation
Overview of possible system schemes
5772 567 GB
Installation

10
--230V-- -KM BUS-
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
2
2
[H
F
[YF
F
--2/F14--
--2/211.2--
-2/145-
A1
--2/X3.8;3.9--
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
System example, ID: 4605445_1201_02
Note
This scheme is a general example with-
out shut-off valves or safety equipment.
This does not replace the need for on-
site engineering.
Preparing for installation
Designations in the system examples
5772 567 GB

11
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--
--230 V--
--F0--
--F13--
-KM BUS-
--2/F0--
61
96
90
91 71
70
73
74
76
77
60
--2/F4--
--2/212.2--
75
--20--
--52--
--230 V--
--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_1201_02 (cont.)
5772 567 GB
Installation

12
Equipment required
Pos. Description
Heat source
1
2
Vitocal 222-G compact heat pump:
■ Integral control unit Vitotronic 200, type WO1C
■ Primary pump
■ Secondary pump
■ 3-way diverter valve for "Heating/DHW heating"
■ 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
Heating circuit with mixer M2
uP Underfloor heating circuit M2 with mixer controlled by the heat pump control
unit
uQ Vitotrol 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 3-way mixer, heating circuit M2
Mixer motor for 3-way mixer
Preparing for installation
System example, ID: 4605445_1201_02 (cont.)
5772 567 GB

13
Pos. Description
Heating circuit without mixer A1
oP Radiator heating circuit
oQ Vitotrol 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 35 and the separate
service instructions, Vitotronic 200 heat
pump control unit.
For information regarding the power sup-
ply, see page 44.
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_1201_02 (cont.)
5772 567 GB
Installation

14
2
Low voltage
F4
PTS
NTC 10 kΩ
61
1
2
145 145
8
145
145
HC M2 71
1
2
HC A1 91
1
2
145
F0
ATS
NTC 10 kΩ
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 10 kΩ
20
100 W
75
2
L
N
HC 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~
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~
Preparing for installation
System example, ID: 4605445_1201_02 (cont.)
5772 567 GB

15
Required parameter settings
To call up "Coding level 1" for setting
the parameters, see the commissioning
assistant on page 63 and page 66.
Parameter Setting
"System definition"
■"System scheme 7000" "6"
DHW heating:
"Time program DHW heating" Set time program (see
operating instructions)
"Time program DHW circulation"
(if a DHW circulation pump is installed)
Set time program (see
operating 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"
■"Time prog elec heater" Set time program (see
operating instructions)
"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_1201_02 (cont.)
5772 567 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 filled DHW cylinder
Type BWT/BWT-
M
Weight in kg
221.A06 420
221.A08 420
221.A10 426
Minimum room volume (to 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
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Minimum clearances Minimum room height h
Installation h in mm
■Without connection set for
pre-installation/DHW (ac-
cessories)
2000
■With connection set for
pre-installation/DHW (ac-
cessories)
2100
Observe engineering informa-
tion.
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.)
5772 567 GB
Installation

18
Removing the cylinder module
3.
1.
5.
4.
2x
2.
Installation sequence
Siting the heat pump (cont.)
5772 567 GB

19
6.
X3
sG
sH
lJ
aYH
7.
X25
8.
F6
Installation sequence
Siting the heat pump (cont.)
5772 567 GB
Installation

20
aCH
10.
9.
Installation sequence
Siting the heat pump (cont.)
5772 567 GB