Viessmann Vitocal 222-S Quick guide

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 mode
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
5700 562 GB 7/2015 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.
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
5700 562 GB

3
1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Preparing for installation Requirements regarding on-site connections ........................................ 7
■Recommended power cables ............................................................. 8
3. Installation sequence Installing the external unit ...................................................................... 10
■Installation information ........................................................................ 10
■Installation site .................................................................................... 11
■Minimum clearances ........................................................................... 11
■Transport and installation ................................................................... 12
■Floorstanding installation .................................................................... 13
■Wall mounting ..................................................................................... 13
Installing the internal unit ....................................................................... 13
■Transport ............................................................................................ 13
■Installation room requirements ........................................................... 14
■Minimum clearances ........................................................................... 15
■Removing the cylinder module ........................................................... 16
■Assembly and sealing faces to bear in mind ...................................... 20
Connecting refrigerant lines ................................................................... 22
■Routing refrigerant lines ..................................................................... 22
■Sound and vibration isolation when line entry is above ground level . 23
■Connection to the external unit ........................................................... 24
■Connection to the internal unit ............................................................ 25
Connecting the secondary circuit ........................................................... 28
Connecting the DHW side ..................................................................... 30
■Safety valve ........................................................................................ 30
Connecting a cooling circuit if required .................................................. 30
Electrical connection .............................................................................. 31
■Internal unit: Routing the cables to the wiring chamber ...................... 32
■Internal unit: Overview of connections ................................................ 33
■Internal unit: Main PCB (230 V~ components) ................................... 34
■Internal unit: Expansion PCB on main PCB (230 V~ components) .... 36
■Internal unit: Luster terminals (signal and safety connections) ........... 36
■Internal unit: Controller and sensor PCB (LV connections) ................ 37
■Internal unit: AVI PCB ......................................................................... 38
■External unit: Overview of connections .............................................. 39
■Connecting internal and external units ............................................... 40
Power supply ......................................................................................... 40
■Heat pump control unit power supply 230 V~ ..................................... 41
■External unit power supply 230 V~/400 V~ ........................................ 41
■Connecting instantaneous heating water heater power supply .......... 43
■Power supply with power-OFF: Without on-site load disconnect ....... 43
■Power supply with power-OFF: With on-site load disconnect ............ 44
■Mains power supply in conjunction with on-site power consumption . 46
■Smart Grid .......................................................................................... 46
Closing the heat pump ........................................................................... 47
■Fitting side cover for external unit ....................................................... 47
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 48
5. Maintenance Overview of electrical components ........................................................ 66
Opening programming unit .................................................................... 66
Overview of internal components: Internal unit ...................................... 68
DHW cylinder drain & fill valve positions ............................................... 69
Index
Index
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Overview of internal components: External unit .................................... 69
■External unit 4 kW, type AWT/AWT-AC 221.A04 ................................ 70
■External unit 5 to 7 kW, type AWT/AWT-AC 221.A05/A07 ................. 71
■External unit 10 to 16 kW, type AWT/AWT-AC 221.A10/A13,
221.B10 to B16 ................................................................................... 72
Draining secondary side heat pump ...................................................... 73
Checking the sensors ............................................................................ 73
■Internal unit: Viessmann NTC 10 kΩ (marked blue) ........................... 73
■Internal unit: Viessmann Pt500A (green ID label) ............................... 74
■External unit: NTC 10 kΩ (without ID) ................................................. 74
■External unit: NTC 50 kΩ (without ID) ................................................. 75
Checking fuses ...................................................................................... 75
6. Parts lists, internal unit Overview of assemblies, internal unit .................................................... 76
■Internal unit parts not shown .............................................................. 77
Internal unit casing ................................................................................. 78
Internal unit electrical equipment ........................................................... 80
Internal unit hydraulics ........................................................................... 82
Internal unit cylinder ............................................................................... 86
7. Parts list, external unit
230 V~, type AWT/AWT-AC
221.A04
Ordering parts ........................................................................................ 89
Parts, external unit 230 V~, type AWT/AWT-AC 221.A04 ..................... 90
8. Parts list, external unit
230 V~, type AWT/AWT-AC
221.A05/A07
Ordering parts ........................................................................................ 93
Parts, external unit 230 V~, type AWT/AWT-AC 221.A05/A07 .............. 94
9. Parts lists, external unit
230 V~, type AWT/AWT-AC
221.A10/A13
Overview of assemblies 230 V~, type AWT/AWT-AC 221.A10/A13 ...... 97
External unit casing 230 V~, type AWT/AWT-AC 221.A10/A13 ............ 98
External unit electrical equipment 230 V~, type AWT/AWT-AC
221.A10/A13 ..........................................................................................100
External unit hydraulics 230 V~, type AWT/AWT-AC 221.A10/A13 .......102
10. Parts lists, external unit
400 V~, type AWT/AWT-AC
221.B10/B13/B16
Overview of assemblies 400 V~, type AWT/AWT-AC
221.B10/B13/B16 ...................................................................................105
External unit casing 400 V~, type AWT/AWT-AC 221.B10/B13/B16 ..... 106
External unit electrical equipment 400 V~, type AWT/AWT-AC
221.B10/B13/B16 ...................................................................................108
External unit hydraulics 400 V~, type AWT/AWT-AC 221.B10/B13/B16 110
11. Commissioning/service
reports
Hydraulic parameter report .................................................................... 112
Control parameters report ......................................................................113
12. Specification ................................................................................................................ 119
13. Appendix Commissioning order .............................................................................127
Final decommissioning and disposal ..................................................... 127
14. Declaration of conformity ................................................................................................................128
15. Keyword index ................................................................................................................129
Index
Index (cont.)
5700 562 GB

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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 work sequences for commissioning, inspection
and maintenance are summarised in the chapter
"Commissioning, inspection and maintenance "and are
marked as follows:
Symbol Meaning
Work sequences required during commis-
sioning
Not required during commissioning
Work sequences required during inspec-
tion
Not required during inspection
Work sequences required during mainte-
nance
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
The range of functions can be extended with additional
components and accessories.
Information
Disposal of packaging
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Information

6
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
Design
Vitocal 222-S is a split air/water heat pump, comprising
1 internal unit with integral DHW cylinder and 1 exter-
nal 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 (if installed)
Cooling results either through a heating/cooling circuit
or via a separate cooling circuit. To do this, the refriger-
ant 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-AC
221.A
AWT-AC
221.B
Central heating X X
DHW heating X X
Central cooling X X
Integral instantaneous heat-
ing water heater
X X
Mains voltage at external unit 230 V~ 400 V~
Information
Intended use (cont.)
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Information

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Internal unit
1800
134
159
454
564
666
680
1803
1829
600
405
147
69
62 300
387
475
29
506
Fig. 1
AOpening for LV leads < 42 V
BDHW
CDHW circulation
DOpening for 230 V cables
ECold water
FLiquid line
GHot gas line
HHeating water flow
KHeating water return
Connection sizes for hydraulic connections
Pos. Sym-
bol
Meaning Connection to the internal unit
B–DHW Rp ¾
C–DHW circulation G 1
E–Cold water Rp ¾
Preparing for installation
Requirements regarding on-site connections
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Installation

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Pos. Sym-
bol
Meaning Connection to the internal unit
FLiquid line Type AWT/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
Internal 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 regarding on-site connections (cont.)
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Installation

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External 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
External 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 regarding on-site connections (cont.)
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Installation

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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 (such as
Sweden for example), 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 for vibration compensation:
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 external 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 113
Installation sequence
Installing the external unit
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Installation

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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.
■Never install closer than 3 m to pathways, down-
pipes or 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 external unit (cont.)
5700 562 GB
Installation

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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 installation
!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 external unit (cont.)
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Installation

13
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 internal unit
Transport
The cylinder module can be removed for easier han-
dling: See page 16.
Installation sequence
Installing the external unit (cont.)
5700 562 GB
Installation

14
!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 internal unit (cont.)
5700 562 GB
Installation

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Minimum clearances
Fig. 5
Note
When using the secondary circuit connection set
(accessories), maintain a wall clearance of
approx. 80 mm.
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 internal unit (cont.)
5700 562 GB
Installation

16
Removing the cylinder module
5.
4.
2x
2. 1.
3.
Fig. 6
Installation sequence
Installing the internal unit (cont.)
5700 562 GB
Installation

17
8.
6.
P301
P501
P303
P302
F6
X25
193B
7.
Fig. 7
10.
9.
11.
Fig. 8
Installation sequence
Installing the internal unit (cont.)
5700 562 GB
Installation

18
17.
14.
2x
12.
13.
18.
2x
16.
15.
X20
Fig. 9
Installation sequence
Installing the internal unit (cont.)
5700 562 GB
Installation

19
2x
4x
6x
4x
22.
21.
20.
19.
Fig. 10
Installation sequence
Installing the internal unit (cont.)
5700 562 GB
Installation

20
26.
2x
24.
25.
4x
23.
Fig. 11
Note
Do not damage sealing tape A when removing the
cylinder module.
Assembly and sealing faces to bear in mind
A
Fig. 12
ADiaphragm grommets
1. !Please note
Leaking hydraulic connections lead to appli-
ance damage.
Ensure the diaphragm grommets at the pipe
entries are seated correctly. Seal pipe entries
with sealing tape if necessary.
Installation sequence
Installing the internal unit (cont.)
5700 562 GB
Installation