Viessmann VITOCAL 222-G User manual

Connection and wiring diagram
for contractors
VIESMANN
Vitocal 222-G
Type BWT-M 221.B06 to B10
Heat pump compact appliance with integral DHW cylinder, 230 V~
VITOCAL 222-G
6170481 GB 1/2021 Please keep safe.

2
Please follow these safety instruc-
tions closely to prevent accidents
and material 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for authorised contractors.
■Work on the refrigerant circuit may only
be carried out by authorised refrigera-
tion 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 to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions
Safety instructions
6170481

3
Safety instructions for working on the system
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 PCBs remain live
even after the power supply has
been switched off.
Prior to removing covers from the
appliances, wait at least 4 minutes
until the voltage has completely
dropped out.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
appliance, fittings or pipework.
Danger
Risk of fire: Electrostatic discharge
can cause sparks which may be
ignited by escaping, flammable
refrigerant (R32).
Before beginning work, touch
earthed objects, such as heating or
water pipes, to discharge any static.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Work on the refrigerant circuit
Refrigerants are air displacing, colour-
less, odourless gases.
■R32 forms flammable mixtures with air.
■R410A is not flammable.
Danger
Direct contact with liquid and gas-
eous refrigerant can cause serious
damage to health.
■Avoid direct contact with liquid and
gaseous refrigerant.
■Wear personal protective equip-
ment when handling liquid and
gaseous refrigerant.
Danger
Unregulated escape of refrigerant in
enclosed spaces can lead to
breathing difficulties and suffoca-
tion.
■Never breathe in refrigerant
vapours.
■Ensure adequate ventilation in
enclosed spaces.
Perform the following measures before
beginning work on the refrigerant circuit:
■Check the refrigerant circuit for leaks.
■Ensure very good ventilation especially
in the floor area and sustain this for the
duration of the work.
Safety instructions
Safety instructions (cont.)
6170481

4
■Inform all persons in the vicinity of the
system about the type of work to be
carried out.
■Secure the area surrounding the work
area.
Further measures before starting work
on the refrigerant circuit with flammable
refrigerants (R32):
■Remove all flammable materials and
ignition sources from the immediate
vicinity of the heat pump.
■Before, during and after the work,
check the surrounding area for escap-
ing refrigerant using a suitable refriger-
ant detector.
This refrigerant detector must not gen-
erate any sparks and must be suitably
sealed.
■A CO2 or powder extinguisher must be
to hand in the following cases:
–Refrigerant is being topped up.
–Soldering or welding work is being
carried out.
■Display signs prohibiting smoking.
Danger
Damage to the refrigerant circuit
can cause refrigerant to enter the
hydraulic system. This can cause
serious damage to health.
After completion of the work, pro-
fessionally vent the hydraulic sys-
tem on the primary and secondary
sides.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
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 func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions for operating the system
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Safety instructions
Safety instructions (cont.)
6170481

5
1. Notes Notes ..................................................................................................... 6
Electrical equipment .............................................................................. 6
2. Connection and wiring dia-
gram
Sheet 1a: Compressor 230 V~ .............................................................. 7
Sheet 2a: Heat pump control unit power supply 230 V~ ....................... 8
Sheet 3: EEV PCB (refrigerant circuit controller [4-7]) ........................... 9
Sheet 4: Main PCB ................................................................................ 10
Sheet 5: Expansion PCB ....................................................................... 11
Sheet 6: Controller and sensor PCB ...................................................... 12
Sheet 7b: Instantaneous heating water heater ...................................... 13
Overview of internal components .......................................................... 14
Index
Index
6170481

6
■Observe the information on electrical connections in
the installation and service instructions.
■In the case of a power supply with power-OFF
facility, the power to the control circuit (heat pump
control unit) must be supplied without interruption by
the power supply utility.
■Identification of electrical equipment (in accordance
with IEC 81346-2):
Example: /7.5
/ = cross-reference
7. = sheet number
5 = current path
Electrical equipment
B Pressure switch, temperature switch, thermal relay
E Instantaneous heating water heater
F Fuse, thermal relay
J Plug-in connector
K Contactors, relays
M Motor, circulation pump, motorised valve, compressor
N Controller
Q Mains isolator, power contactor, output relay
R Start-up resistor
S Control switch
X Terminals, plugs
Y 3-way diverter valve
Notes
Notes
6170481
Service

7
B
A
2a.6
4.5
2a.2
2a.5
C
D
E
F
G
H
K
L
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann Compressor 230 V
Sheet 1a
M 3~
~
-X41 L1 N PE
L1 N PE
1
-PE1
C R S PE
-M1
1 2
3 4
5 6
1 2
3 4
5 6
A1
A2
Q1
95 96
F4
x1 x2
-C1
R RC L N Uc S
13
14
-K1
1 2
-F6
1
X11 2 3 7
-N
-PE
1/N/PE
230 V/50 Hz
Fig. 1
ACompressor power supply
BMains terminals, compressor
CCompressor contactor
DThermal relay, compressor
EFuse, control circuit of full wave soft starter
FRelay, control circuit of full wave soft starter
GFull wave soft starter
HRun capacitor
KMale jack, compressor
LCompressor motor
Connection and wiring diagram
Sheet 1a: Compressor 230 V~
6170481
Service

8
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann Heat pump control unit power supply
Sheet 2a
1
-X42 2 3
1 2
-F2
6.3 A
L N PE
13 14
-S5
23 24
-X2 12 3 4 5 6 7 8 9 10 11 12
-X1 1 2 3 4 5 6 7 8 9 1011 12
11 12
X3 1 1 3 8 9 6 7 12 13 2 14
A1 A2
-K1
5
X11 61
X10 2 3 4
L
BN GY
BK BU
4.5
E
4.4 4.4 4.4
F G H
4.5K
4.5
1a.5
1a.5
N
13
P
3.0
3.1
3.2
3.2
3.2
CE
B
A
O
M
N
4.2
4.2
1a.5
L
14/1.a.6
4.5
4
D
Fig. 2
AMains terminals, heat pump control unit
BHeat pump control unit fuse 6.3 A (slow)
CHeat pump control unit ON/OFF switch
DPrimary circuit flow switch
EPrimary circuit pressure switch and/or frost stat
FPower-OFF
GExternal demand
HExternal blocking
KJumper
LRelay, control circuit of full wave soft starter
MPlug, safety chain
NSafety high pressure switch
OMale jack, compressor
Connection and wiring diagram
Sheet 2a: Heat pump control unit power supply 230 V~
6170481
Service

9
24 V 4-20 mA
N
-X50
PE
-X51
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann EEV PCB (refrigerant circuit controller [4-7])
Sheet 3
1 2 3 5 46 3 2 1
2 31
-M4
4
1 2 1 2
-J5
1 2 3
2 31 4
1 2 3 4
1 2 3 4 5 6
2 3 4 1
+ -
-T4
+ -
-T5
+ -
-T6
+ -
-T7
x1 x2
-P1
Ux1 x2
-P2
U
5 6
7 8
4321
+ -
-T2
+ -
-T1
+ -
-T3
1 2
1 2
PE
-M5
9
1 2
PE
-M6 910
1
1
11
12
PE
-Y1
11
1
97
N
PE
GND1 6.3/ -B-/6.3
-A+/6.3
24 V DC
-PE
-J14 -J17
-J15 -J19 -J7 -J27 -J26
-J10
-J13
-J21
-J20
M 1~
M 1~
M 1~
10
GND
PWM out
+8.2 V
GND
PWM in
PWM out
+8.2 V
A
B
C
D E
V
U
T
F
G
H
K
L
M
N
O
P
R
L
-J9
2 1
S
X W24 V
4-20 mA
/2a.5
/2.5
/2a.6
/2.6
M
Fig. 3
ANever connect anything here.
BModbus: Connecting cable to the controller and
sensor PCB, terminal X18
CElectronic expansion valve
DPWM signal, primary pump
EPWM signal, secondary pump
FLow pressure sensor
GHigh pressure sensor
HSuction gas temperature sensor (NTC 10 kΩ)
KPrimary circuit flow temperature sensor
(NTC 10 kΩ)
LHot gas temperature sensor (NTC 10 kΩ)
MLiquid gas temperature sensor (NTC 10 kΩ)
NSecondary circuit flow temperature sensor
(NTC 10 kΩ)
OSecondary circuit flow temperature sensor down-
stream of instantaneous heating water heater
(NTC 10 kΩ)
PSecondary circuit flow temperature sensor
(NTC 10 kΩ)
RInternal power supply (factory connection)
SSafety high pressure switch
T3-way diverter valve "central heating/DHW heat-
ing"
Connection and wiring diagram
Sheet 3: EEV PCB (refrigerant circuit controller [4-7])
6170481
Service

10
UPrimary pump
VSecondary pump
WCompressor relay (230 V~)
xEnable compressor switching
Sheet 4: Main PCB
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann Main PCB
Sheet 4
1
-216
2 3 4 1
-215
2 3 4 5 6 7 1
-214
2345
-210
12
N
-40
PE
L
1
-213
1
-212
2 3 4 2
1
-211
2 3 4 5
-136
1 2
A1 A2
-K1
A1 A2
-K2
N
-L
/5.7
-L1´
5.6
-N -PE
-N
2.3 2a.3
A
2.4 2a.4
2.3 2a.3
2.3 2a.3
2.7 2a.3 2.5
2a.5 1.5
1a.5
B
C
F
E
D
K
H
F3 2.0 A (slow)
X1
X2
ML
14
13 /7.1
1413 /7.a.5
1413 /7.b.2
2423 /7.1
2423 /7.a.5
2423 /7.b.3
3433 /7.a.5
14
13 /7.1
1413 /7.a.3 1413 /7.b.2
2423 /7.a.3
3433 /7.a.4
2.2 2a.2
G
Fig. 4
AExternal demand
BExternal blocking
CPower-OFF
DPhase monitor (if installed) or jumper
EPrimary circuit pressure switch and/or frost stat
FSafety high pressure switch
GPrimary circuit flow switch
HThermal relay
KRibbon cable to the controller and sensor PCB
Connection and wiring diagram
Sheet 3: EEV PCB (refrigerant circuit… (cont.)
6170481
Service

11
LOutput relay for instantaneous heating water
heater, stage 2
MOutput relay for instantaneous heating water
heater, stage 1
Sheet 5: Expansion PCB
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann Expansion PCB
Sheet 5
2 1 1 2 3 4 1 2 1 12 3 4 5 6 7 23
-L1´
4.5
4.2
-225
-224-223
-222
-220
X1
A
B
Fig. 5
ARibbon cable to the controller and sensor PCB
BOutput relay for instantaneous heating water
heater, stage 2
Connection and wiring diagram
Sheet 4: Main PCB (cont.)
6170481
Service

12
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann Controller and sensor PCB
Sheet 6
A
X3 X20 X31
B C
F
E D
3 2
4
-X5
5 6 4
-X25
3+-
-F3
PT500A
+-
-F6
GND1
/3.4 A+
/3.4
B-
/3.4
-N1
NTC 10 kΩ
Fig. 6
ARibbon cable to the main PCB and expansion PCB
BRibbon cable to the programming unit
CCoding card
DPrimary circuit return temperature sensor (heat
pump brine outlet)
ETop cylinder temperature sensor
FModbus: Connecting cable to EEV PCB
Connection and wiring diagram
Sheet 6: Controller and sensor PCB
6170481
Service

13
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
viesmann Instantaneous heating water heater
Sheet 7b
1 2 3 N PE 1 2 3 4 7
1
-PE2
13 14
-K1
/4.0
13 14 -K2
/4.0
23 24
x1 x2 x1 x2 x1 x2
3200 W
-E1
-PE:1
31 32
-S2
N N 5 6
-N
-PE
-N -N
F
A
B
CDE
1/N/PE
230 V/50 Hz
2600 W
3000 W
21 22 11 12
21 22
1
X12
2
3 4
7 5 6
Fig. 7
AInstantaneous heating water heater power supply
BMains terminals, instantaneous heating water
heater
COutput relay for instantaneous heating water
heater, stage 1
DOutput relay for instantaneous heating water
heater, stage 2
EHigh limit safety cut-out for instantaneous heating
water heater
FInstantaneous heating water heater
Connection and wiring diagram
Sheet 7b: Instantaneous heating water heater
6170481
Service

14
A
F6
B
C
D
F3
Y
X
W
T5
T4
V
U
S
R
P
O
E
F
T1
T6
G
T2
H
T3
T7
M
N
K
L
L
M
N
K
S
R
T
O
Fig. 8
AAir vent valve, secondary circuit
BDrain & fill valve, DHW cylinder
CAir vent valve, secondary circuit
DAir vent valves, primary circuit
EAir vent valve, condenser on secondary side
FCondenser
G3-way diverter valve "central heating/DHW heat-
ing"
HInstantaneous heating water heater
KCompressor
LSecondary pump
MDrain & fill valve, secondary circuit
Connection and wiring diagram
Overview of internal components
6170481
Service

15
NHigh limit safety cut-out for instantaneous heating
water heater
ODrain & fill valve, primary circuit
PElectronic expansion valve
RPrimary pump
SLow pressure Schrader valve
THigh pressure Schrader valve
ULow pressure sensor
VFilter
WSafety high pressure switch
XHigh pressure sensor
YEvaporator
F3 Primary circuit flow temperature sensor (Viess-
mann Pt500A)
F6 Cylinder temperature sensor (Viessmann
NTC 10 kΩ)
T1 Secondary circuit flow temperature sensor
(NTC 10 kΩ)
T2 Secondary circuit flow temperature sensor down-
stream of instantaneous heating water heater
(NTC 10 kΩ)
T3 Secondary circuit flow temperature sensor
(NTC 10 kΩ)
T4 Suction gas temperature sensor (NTC 10 kΩ)
T5 Primary circuit flow temperature sensor
(NTC 10 kΩ)
T6 Hot gas temperature sensor (NTC 10 kΩ)
T7 Liquid gas temperature sensor (NTC 10 kΩ)
Note on the temperature sensors
F.. Temperature sensor is connected to controller and
sensor PCB.
D.. Temperature sensor is connected to EEV PCB.
"Vitotronic 200" service instructions
Connection and wiring diagram
Overview of internal components (cont.)
6170481
Service

16
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH & Co. KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
6170481 Subject to technical modifications.