Viessmann Vitocal 222-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 222-S
Type AWT-AC 221.A04 to A13, B10, B13
Compact heat pumps, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 222-S
5782 201 GB 2/2013 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
5782 201 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.)
5782 201 GB

4
Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Requirements regarding on-site connections....................................................... 7
Installation sequence
Installing the external unit..................................................................................... 10
Installing the internal unit...................................................................................... 14
Connecting refrigerant lines................................................................................. 23
Connecting the secondary circuit......................................................................... 32
Connections on the DHW side............................................................................. 35
Connecting a cooling circuit if required................................................................ 36
Electrical connections........................................................................................... 36
Power supply........................................................................................................ 52
Closing the heat pump......................................................................................... 60
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 61
Further details regarding the individual steps....................................................... 63
Troubleshooting
Repairs................................................................................................................. 87
Parts lists, internal unit
Ordering individual parts...................................................................................... 99
Overview of assemblies, internal unit................................................................... 100
Parts not shown, internal unit............................................................................... 101
Internal unit casing............................................................................................... 101
Electrical equipment, internal unit........................................................................ 103
Internal unit hydraulics......................................................................................... 105
Cylinder, internal unit............................................................................................ 107
Parts lists for external unit 230 V~, type AWT-AC 221.A04
Ordering individual parts...................................................................................... 109
External unit......................................................................................................... 109
Parts lists for external unit 230 V~, type AWT-AC 221.A07
Ordering individual parts...................................................................................... 111
External unit......................................................................................................... 111
Index
Index
5782 201 GB

5
Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13
Ordering individual parts...................................................................................... 113
Overview of the assemblies................................................................................. 114
External unit casing.............................................................................................. 115
Electrical equipment, external unit....................................................................... 117
Hydraulics, external unit....................................................................................... 119
Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13
Ordering individual parts...................................................................................... 121
Overview of the assemblies................................................................................. 122
External unit casing.............................................................................................. 123
Electrical equipment, external unit....................................................................... 125
Hydraulics, external unit....................................................................................... 127
Commissioning/service reports
Hydraulic parameter report................................................................................... 129
Control parameters report.................................................................................... 129
Specification....................................................................................................... 136
Appendix
Commissioning order........................................................................................... 146
Declaration of conformity.................................................................................. 147
Keyword index.................................................................................................... 148
Index
Index (cont.)
5782 201 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
Internal unit
1800
134
159
454
564
666
680
1803
1829
600
405
147
69
62 300
387
475
29
506
AOpening for LV leads < 42 V BDHW
Preparing for installation
Requirements regarding on-site connections
5782 201 GB
Installation

8
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 Connections to the internal unit
B– DHW Rp ¾
C– DHW circulation G 1
E– Cold water Rp ¾
FRefrigerant lines from/to
the external unit:
■ Liquid line 7 connection pipe:
(supplied pipe bends)
10 mm
UNF thread: ⅝
For type AWT-AC 221.A04, a reduction
from 10 to 6 mm is necessary down-
stream of the pipe bend (reducer ⅝ to ⁷⁄₁₆
supplied).
G■ Hot gas line 7 connection pipe:
(supplied pipe bends)
16 mm
UNF thread: ⅞
For type AWT-AC 221.A04, a reduction
from 16 to 10 mm is necessary down-
stream of the pipe bend (reducer ⅞ to
¾ supplied).
HHeating water flow Cu 28 x 1 mm
KHeating water return Cu 28 x 1 mm
1. Prepare the connections on the heat-
ing water and the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Preparing for installation
Requirements regarding on-site connections (cont.)
5782 201 GB

9
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 –
Internal/external unit connecting cable:
■ 12 V BUS 2.5 m 1.5 m
■ 43 V BUS 2.5 m 1.5 m
Recommended power cables
Type AWT-AC 221.A04 to A13, B10, B13
Heat pump control unit (internal 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
Type AWT-AC 221.A04 221.A07 221.A10 221.A13
External unit 230 V~ (compres-
sor)
Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 4.0 mm2
Max. cable length 29 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
Type AWT-AC 221.B10 221.B13
External unit 400 V~ (compressor)
Cable cross-section 5 x 2.5 mm25 x 2.5 mm2
Max. cable length 30 m 30 m
Preparing for installation
Requirements regarding on-site connections (cont.)
5782 201 GB
Installation

10
!Please note
Avoid damaging the appliance
during transport.
Never put weight on top 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.
Note the max. tilting angle of
45°.
Installation requirements
Installation site
■ Select a site with good air circulation,
so that the cooled air can dissipate and
be replaced by warm air.
■ Avoid direct insolation.
■ When siting the unit in a location
exposed to wind, ensure that the wind
does not affect the fan area. This could
result in an "air short circuit" between
the air being discharged and the air
being drawn in. Strong wind can have
a negative influence on the evaporator
ventilation.
!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 prob-
lems.
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 pressure faults.
Avoid "air short circuits".
■ Take the lengths of the refrigerant
lines into account (see "Connecting
refrigerant lines").
■ Select the installation site so that the
evaporator cannot be blocked by
leaves, snow etc.
■ Select the installation site with due
consideration of the physical laws of
sound dissipation and reflection.
Technical guide "Heat pump
principles"
■ Never site in corners, recesses or
between walls.
■ Never install next to or below bedroom
windows.
■ Never install closer than 3 m to path-
ways, downpipes or sealed surfaces.
The cooled air in the discharge area
creates a risk of ice forming when out-
side temperatures fall below 10 °C.
■ The installation site should be easily
accessible, for example for mainte-
nance work (see "Minimum clearan-
ces").
Installation sequence
Installing the external unit
5782 201 GB