Viessmann Vitocal 222-S Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitocal 222-S
Type AWT 221.A04 to A13, 221.B10 to B16
Compact heat pumps, split version for heating operation
Type AWT-AC 221.A04 to A13, 221.B10 to B16
Compact heat pumps, split version for heating and cooling operation
For applicability, see the last page
VITOCAL 222-S
5776 028 GB 1/2017 Please keep safe.

2
Please follow these safety instructions 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised 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 electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
Working on the system
■Isolate the system from the power supply (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
load 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.
Wait at least 4 minutes before removing equip-
ment covers, to allow the voltage to dissipate.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Replace faulty components with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5776 028 GB

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Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacement, use only spare parts supplied
or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5776 028 GB

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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
2. Preparing for installation Requirements for on-site connections ................................................... 8
■Recommended power cables ............................................................. 9
3. Installation sequence Installing the outdoor unit ....................................................................... 11
■Installation information ........................................................................ 11
■Installation site .................................................................................... 12
■Minimum clearances ........................................................................... 12
■Transport and siting ............................................................................ 13
■Floorstanding installation .................................................................... 14
■Wall mounting ..................................................................................... 14
Installing the indoor unit ......................................................................... 14
■Transport ............................................................................................ 14
■Installation room requirements ........................................................... 15
■Minimum clearances ........................................................................... 16
■Removing the cylinder module ........................................................... 17
■Assembly and sealing faces to note ................................................... 21
Connecting the refrigerant lines ............................................................. 23
■Routing the refrigerant lines ............................................................... 23
■Sound and vibration isolation when line entry is above ground level . 24
■Connection to outdoor unit ................................................................. 25
■Connection to indoor unit .................................................................... 26
Connecting the secondary circuit ........................................................... 29
Connecting the DHW side ..................................................................... 31
■Safety valve ........................................................................................ 31
Type AWT-AC only: connecting the cooling circuit ................................ 31
Electrical connection .............................................................................. 32
■Indoor unit: routing cables to the wiring chamber ............................... 33
■Indoor unit: overview of connections .................................................. 34
■Indoor unit: main PCB (230 V~ components) ..................................... 35
■Indoor unit: expansion PCB on main PCB (230 V~ components) ...... 37
■Indoor unit: luster terminals (signal and safety connections) .............. 37
■Indoor unit: controller and sensor PCB (LV connections) ................... 38
■Indoor unit: AVI PCB ........................................................................... 39
■Outdoor unit: overview of connections ............................................... 40
■Connecting indoor and outdoor units .................................................. 41
Power supply ......................................................................................... 41
■Heat pump control unit power supply 230 V~ ..................................... 42
■Outdoor unit power supply 230 V~/400 V~ ......................................... 42
■Connecting instantaneous heating water heater power supply .......... 44
■Power supply with power-OFF: without on-site load disconnect ........ 44
■Power supply with power-OFF: with on-site load disconnect ............. 45
■Mains power supply in conjunction with on-site power consumption . 47
■Smart Grid .......................................................................................... 47
Closing the heat pump ........................................................................... 48
■Fitting the side cover for the outdoor unit ........................................... 48
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 49
5. Maintenance Overview of electrical components ........................................................ 67
Opening programming unit .................................................................... 67
Overview of internal components: indoor unit ........................................ 69
DHW cylinder drain & fill valve positions ............................................... 70
Overview of internal components: outdoor unit ..................................... 70
■Outdoor unit 4 kW, type AWT/AWT-AC 221.A04 ................................ 71
Index
Index
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■Outdoor unit 5 to 7 kW, type AWT/AWT-AC 221.A05/A07 ................. 72
■Outdoor unit 10 to 16 kW, type AWT/AWT-AC 221.A10/A13,
221.B10 to B16 ................................................................................... 73
Draining secondary side heat pump ...................................................... 73
Checking the sensors ............................................................................ 74
■Indoor unit: Viessmann NTC 10 kΩ (marked blue) ............................. 74
■Indoor unit: Viessmann Pt500A (green ID label) ................................ 75
■Outdoor unit: NTC 10 kΩ (without ID) ................................................. 75
■Outdoor unit: NTC 50 kΩ (without ID) ................................................. 76
Checking the fuses ................................................................................ 76
6. Indoor unit parts lists Overview of assemblies, indoor unit ...................................................... 78
■Indoor unit parts not shown ................................................................ 79
Indoor unit casing .................................................................................. 80
Indoor unit electrical equipment ............................................................. 82
Indoor unit hydraulics ............................................................................. 84
Indoor unit cylinder ................................................................................ 88
7. Outdoor unit parts list
230 V~, type AWT/
AWT-AC 221.A04
Ordering parts ........................................................................................ 91
Outdoor unit parts 230 V~, type AWT/AWT-AC 221.A04 ...................... 92
8. Outdoor unit parts list
230 V~, type AWT/
AWT-AC 221.A05/A07
Ordering parts ........................................................................................ 95
Outdoor unit parts 230 V~, type AWT/AWT-AC 221.A05/A07 ............... 96
9. Outdoor unit parts lists
230 V~, type AWT/
AWT-AC 221.A10/A13
Overview of assemblies 230 V~, type AWT/AWT-AC 221.A10/A13 ...... 99
Outdoor unit casing 230 V~, type AWT/AWT-AC 221.A10/A13 .............100
Outdoor unit electrical equipment 230 V~, type AWT/
AWT-AC 221.A10/A13 ........................................................................... 102
Outdoor unit hydraulics 230 V~, type AWT/AWT-AC 221.A10/A13 ....... 104
10. Outdoor unit parts lists
400 V~, type AWT/
AWT-AC221.B10/B13/B16
Overview of assemblies 400 V~, type AWT/AWT-AC
221.B10/B13/B16 ...................................................................................107
Outdoor unit casing 400 V~, type AWT/AWT-AC 221.B10/B13/B16 ..... 108
Outdoor unit electrical equipment 400 V~, type AWT/AWT-AC
221.B10/B13/B16 ...................................................................................110
Outdoor unit hydraulics 400 V~, type AWT/AWT-AC 221.B10/B13/B16 112
11. Commissioning/service
reports
Hydraulic parameter report .................................................................... 114
Control parameter report ....................................................................... 115
12. Specification ................................................................................................................121
13. Appendix Commissioning order .............................................................................129
Final decommissioning and disposal ..................................................... 129
14. Declaration of Conformity Declaration of conformity ....................................................................... 130
15. Keyword index ................................................................................................................131
Index
Index (cont.)
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions.
Depending on the version, the appliance can only be
used for the following purposes:
■Central heating
■Central cooling
■DHW heating
Information
Disposal of packaging
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Information

7
The range of functions can be extended with additional
components and accessories.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than central heating/cooling or DHW heating shall be
deemed inappropriate.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic or
semi-domestic use, i.e. even users who have not had
any instruction are able to operate the appliance
safely.
Product information
Layout
Vitocal 222-S is a split air/water heat pump, comprising
1 indoor unit with integral DHW cylinder and 1 outdoor
unit.
Refrigerant circuit
All components of the refrigerant circuit including the
refrigerant circuit controller with an electronic expan-
sion valve are located in the external unit, except for
the condenser. Subject to operating conditions, com-
pressor output is matched via inverter control.
The internal and external units are connected to each
other hydraulically via the refrigerant lines.
Hydraulics
The internal unit is equipped with a high efficiency [HE]
circulation pump (secondary pump) which transports
the heated heating water into the secondary circuit.
The integral 3-way diverter valve for "Heating/DHW"
changes over between central heating and DHW heat-
ing.
Central heating
The heat pump can supply up to 2 heating circuits: 1
heating circuit without mixer and 1 heating circuit with
mixer. The mixer extension kit (accessories) is
required to switch the mixer.
Central cooling
The Vitocal 222-S, type AWT-AC can be used for cen-
tral cooling.
Central cooling results either through a heating/cooling
circuit or via a separate cooling circuit. For this, the
refrigerant circuit is reversed and heat is extracted
from the cooling circuit.
Heat pump control unit
The entire heating system is monitored and controlled
by the integral heat pump control unit Vitotronic 200,
type WO1C.
Type overview
Vitocal 222-S, type AWT AWT-AC
221.A 221.B 221.A 221.B
Central heating X X X X
DHW heating X X X X
Central cooling — — X X
Integral instantane-
ous heating water
heater
X X X X
Outdoor unit power
supply
230 V~ 400 V~ 230 V~ 400 V~
Information
Intended use (cont.)
5776 028 GB
Information

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Indoor unit
1800
134
159
454
564
666
680
1803
1829
600
405
147
69
62 300
387
475
29
506
Fig. 1
Pos. Sym-
bol
Meaning Connection to the internal unit
A–Cable entry < 42 V —
B–DHW Rp ¾
C–DHW circulation G 1
D–Cable entry 400 V~/230 V~,
> 42 V
—
E–Cold water Rp ¾
Preparing for installation
Requirements for on-site connections
5776 028 GB
Installation

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Pos. Sym-
bol
Meaning Connection to the internal unit
FLiquid line Type AWT-AC Pipe 7UNF thread
221.A04 6 mm ⅝
(Reducer
⅝ x ⁷⁄₁₆ supplied)
221.A05 to A13 10 mm ⅝
221.B10 to B16 10 mm ⅝
GHot gas line 221.A04 12 mm ⅞
(Reducer
⅞ x ¾ supplied)
221.A05 to A13 16 mm ⅞
221.B10 to B16 16 mm ⅞
HHeating water flow Cu 28 x 1 mm
KHeating water return Cu 28 x 1 mm
1. Prepare the connections on the heating water and
the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Cable lengths in the internal/external unit plus wall clearance
Cables Internal unit External unit
Power cables
■Heat pump control unit 230 V~ 2.0 m —
■Compressor 230 V~/400 V~ —1.5 m
Other connecting cables
■230 V~, e.g. for circulation pumps 2.0 m —
■< 42 V, e.g. for sensors 2.0 m —
BUS cable for internal/external unit
■12 V 2.5 m 1.5 m
■43 V 2.5 m 1.5 m
Recommended power cables
Indoor unit
Type AWT/AWT-AC 221.A04 to A13, 221.B10 to B16
Heat pump control unit 230 V~
Cable cross-section
■Without power-OFF 3 x 1.5 mm2
■With power-OFF 5 x 1.5 mm2
Instantaneous heating water heater
Cable cross-section
■400 V~ 5 x 2.5 mm2
■230 V~ 7 x 2.5 mm2
Max. cable length 25 m
Preparing for installation
Requirements for on-site connections (cont.)
5776 028 GB
Installation

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Outdoor unit 230 V~
Type AWT/AWT-AC 221.A04 221.A05 221.A07 221.A10 221.A13
Compressor
Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 4.0 mm2
Max. cable length 29 m 25 m 25 m 20 m 20 m
or or
Cable cross-section — — — 3 x 4.0 mm23 x 6.0 mm2
Max. cable length — — — 32 m 30 m
Outdoor unit 400 V~
Type AWT/AWT-AC 221.B10 221.B13 221.B16
Compressor
Cable cross-section 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
Max. cable length 30 m 30 m 30 m
Preparing for installation
Requirements for on-site connections (cont.)
5776 028 GB
Installation

11
Installation information
Types of installation:
■Floorstanding installation with line entry above
ground level
■Floorstanding installation with line entry below
ground level
■Wall mounting
Technical guide
Floorstanding installation:
■Use supports for floorstanding installation (accesso-
ries).
■Where such supports cannot be used, install the
external unit freestanding on a solid base of
at least 100 mm height.
■In difficult climatic circumstances (temperatures
below zero, snow, humidity) install the appliance on
a plinth of approx. 300 mm height.
■Take into account the weight of the external unit: See
the following table.
Wall mounting:
■Use the wall mounting bracket set (accessories).
■The wall must meet the structural requirements.
Positioning:
■Never install with the discharge side facing the main
wind direction.
■Provide wall ducts and protective pipes for the refrig-
erant lines and electrical cables without moulded
parts and change of direction.
Weather influences:
■Observe wind loads when installing the unit on sites
exposed to the wind.
■Incorporate the external unit into the lightning protec-
tion system.
■Consider the heat emitted by the unit when planning
your weatherproofing or an enclosure.
Condensate:
■Ensure the condensate can drain freely, and create a
permanent gravel bed below the external unit as a
soakaway.
■In regions with prolonged cold seasons (e.g. Swe-
den), provide an electric ribbon heater (accessory)
for the condensate pan.
Insulation against structure-borne noise and vibra-
tions between building and external unit:
■When line entry is above ground level, fit pipe bends
in the refrigerant lines to isolate vibrations: See
"Connecting refrigerant lines".
■Route electrical cables/leads between the internal
and external units free of stress.
■Installation only on walls with high weight per area (>
250 kg/m2), in other words not on lightweight walls,
roof structures etc.
■For floorstanding installation, only use the rubber
mounts supplied.
■For wall mounting, only use the anti-vibration mounts
from the bracket set.
■Never use additional anti-vibration mounts, springs,
rubber mounts, etc.
Weight of outdoor units
Type AWT/AWT-AC Weight in kg
221.A04 43
221.A05 66
221.A07 66
221.A10 113
221.A13 113
221.B10 113
221.B13 113
221.B16 121
Installation sequence
Installing the outdoor unit
5776 028 GB
Installation

12
Installation site
■Select a site with good air circulation, so that the
cooled air can dissipate and be replaced by warm
air.
■Never install in interior corners, in recesses or
between walls. This could result in an "air short cir-
cuit" between the air being discharged and the air
being drawn in.
!Please note
An "air short circuit" during heating operation
will result in the cooled discharged air re-
entering the unit. This can result in reduced
heat pump efficiency and defrosting problems.
Avoid "air short circuits".
!Please note
An "air short circuit" during cooling operation
will result in the heated discharged air re-
entering the unit. This can lead to high pres-
sure faults.
Avoid "air short circuits".
■When siting the unit where it is exposed to wind,
ensure that the wind cannot influence the fan area.
Strong wind can have a negative influence on the
evaporator ventilation.
■Take into account the lengths of the refrigerant lines:
See "Connecting refrigerant lines".
■Select the installation site so that the evaporator can-
not be blocked by leaves, snow etc.
■Select the installation site giving due consideration to
the physical laws concerning the propagation and
reflection of sound.
Technical guide "Heat pump principles"
■Never install next to or below bedroom windows.
■Maintain a min. 3 m distance from footpaths, drain
pipes and sealed surfaces. The cooled air in the dis-
charge area creates a risk of ice forming when out-
side temperatures are below 10 °C.
■The installation site must be easily accessible,
for example for maintenance work: See "Minimum
clearances".
Minimum clearances
A
B
b
d
ac
Fig. 2 Example type AWT/AWT-AC 221.A04
AAir intake
BAir discharge
Installation sequence
Installing the outdoor unit (cont.)
5776 028 GB
Installation

13
Type AWT/AWT-AC Dimensions in mm
a b c d
Line entry
Above ground
level
Below ground
level
221.A04 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
221.A05 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
221.A07 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
221.A10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
221.A13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
221.B10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
221.B13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
221.B16 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
Transport and siting
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never apply loads/weight to the top, front or
side panels of the appliance.
!Please note
If the compressor in the external unit is strongly
tilted, lubricant will enter the refrigerant circuit
and damage the appliance.
Max. tilting angle: 45°
Installation sequence
Installing the outdoor unit (cont.)
5776 028 GB
Installation

14
Floorstanding installation
4x
4x
E
A
C
D
2.
1.
B
Fig. 3
4x
4x
B
C
D
E
A
2.
1.
Fig. 4
ASupport for floorstanding installation (accessories)
BGravel bed as condensate soakaway
CConcrete foundations (see technical guide)
DKG conduit DN 100 (only with entries below
ground level)
ERubber mounts (supplied)
Note
We recommend letting condensate drain away freely
(without condensate pipe).
Wall mounting
Installation must only be performed with the bracket
set suitable for wall mounting (accessory).
Separate installation instructions
Installing the indoor unit
Transport
During handling, the cylinder module can be removed:
see page 17.
Installation sequence
Installing the outdoor unit (cont.)
5776 028 GB
Installation

15
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never apply loads/weight to the top, front or
side panels of the appliance.
Installation room requirements
!Please note
Unfavourable ambient conditions can lead to
malfunction and appliance damage.
■The installation room must be dry and free
from the risk of frost.
■Ensure ambient temperatures between 0 and
35 °C.
Danger
Dust, gases and vapours can be damaging to
health and cause explosions.
Avoid dust, gases and vapours in the installation
room.
!Please note
Overloading the floor can result in damage to
the building structure.
Observe the permissible floor load. Take the
total weight of the appliance into account.
Total weight with filled DHW cylinder
Type AWT/AWT-AC Weight in kg
221.A04 364
221.A05 364
221.A07 364
221.A10 367
221.A13 367
221.B10 367
221.B13 367
221.B16 367
Minimum room volume (to EN 378):
Type AWT/AWT-AC Minimum room volume in m3
221.A04 2.7
221.A05 4.9
221.A07 4.9
221.A10 6.1
221.A13 6.1
221.B10 6.1
221.B13 6.1
221.B16 6.1
Installation sequence
Installing the indoor unit (cont.)
5776 028 GB
Installation

16
Minimum clearances
a a
80
1000
Fig. 5
a■To the left or right of the appliance:
≥ 600 on the side where the refrigerant lines are to
be connected
■≥ 20 on the opposite side
Minimum room height h
Installation h in mm
■Without connection set for pre-instal-
lation/DHW (accessories)
2000
■With connection set for pre-installa-
tion/DHW (accessories)
2100
Observe engineering information.
Technical guides for heat pumps
Installation sequence
Installing the indoor unit (cont.)
5776 028 GB
Installation

17
Removing the cylinder module
5.
4.
2x
2. 1.
3.
Fig. 6
Installation sequence
Installing the indoor unit (cont.)
5776 028 GB
Installation

18
8.
6.
P301
P501
P303
P302
F6
X25
193B
7.
Fig. 7
10.
9.
11.
Fig. 8
Installation sequence
Installing the indoor unit (cont.)
5776 028 GB
Installation

19
17.
14.
2x
12.
13.
18.
2x
16.
15.
X20
Fig. 9
Installation sequence
Installing the indoor unit (cont.)
5776 028 GB
Installation

20
2x
4x
6x
4x
22.
21.
20.
19.
Fig. 10
Installation sequence
Installing the indoor unit (cont.)
5776 028 GB
Installation