Viessmann Vitocal 222-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 222-S
Type AWT-AC 221.A04 to A13
Compact heat pumps, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 222-S
5600 950 GB 10/2011 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
designed for qualified contractors.
■ Work on the refrigerant circuit must
only be carried out by qualified and
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 requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of 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 and SWKI
Working on the system
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing the separate fuse or
by means of a main isolator
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can lead to severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Before removing covers from
appliances, wait at least 4
minutes for the power to dissi-
pate.
■ Safeguard the system against unau-
thorised reconnection
Safety instructions
Safety instructions
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3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
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.
Replace faulty components only
with original 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 orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5600 950 GB

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Installation instructions
Preparing for installation
Application............................................................................................................ 6
Requirements for on-site connections.................................................................. 7
Overview of possible system schemes................................................................ 9
Designations in the system examples.................................................................. 11
System example, ID: 4605418_1102_01............................................................. 11
Installation sequence
Installing the external unit..................................................................................... 18
Installing the internal unit...................................................................................... 23
Connecting refrigerant lines................................................................................. 32
Connecting the secondary circuit......................................................................... 41
Connecting a cooling circuit if required................................................................ 44
Connections on the DHW side............................................................................. 44
Electrical connection............................................................................................ 45
Power supply........................................................................................................ 59
Closing the heat pump......................................................................................... 65
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 66
Further details regarding the individual steps....................................................... 68
Troubleshooting
Repairs................................................................................................................. 89
Internal unit parts lists
Internal unit parts lists.......................................................................................... 100
Overview of internal unit assemblies.................................................................... 101
Internal unit parts not shown................................................................................ 102
Internal unit casing............................................................................................... 102
Internal unit electrical equipment.......................................................................... 104
Internal unit hydraulics......................................................................................... 106
Internal unit cylinder............................................................................................. 108
External unit parts lists
External unit parts lists......................................................................................... 110
External unit type AWT-AC 221.A04.................................................................... 110
External unit type AWT-AC 221.A07.................................................................... 112
Overview of external unit assemblies, type AWT-AC 221.A10, A13.................... 114
External unit casing, type AWT-AC 221.A10, A13............................................... 115
Index
Index
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External unit electrical equipment, type AWT-AC 221.A10, A13.......................... 117
External unit hydraulics, type AWT-AC 221.A10, A13......................................... 119
Commissioning/service reports
Hydraulic parameter report................................................................................... 121
Control parameter report...................................................................................... 121
Specification....................................................................................................... 126
Appendix
Heat pump commissioning order.......................................................................... 131
Certificates
Declaration of conformity...................................................................................... 132
Keyword index.................................................................................................... 133
Index
Index (cont.)
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The compact heat pumps Vitocal 222-S,
type AWT-AC 221.A04 to A13, can be
used for the following purposes:
■ Central heating and cooling via a heat-
ing system
■ DHW heating with a built-in DHW cyl-
inder
Any other or further use is considered
inappropriate.
Note
Vitocal 222-S is intended exclusively for
domestic use, i.e. even people who have
not had any instruction are able to oper-
ate the appliance safely.
Preparing for installation
Application
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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
AOpening for LV leads <42 V BDHW
Preparing for installation
Requirements for on-site connections
5600 950 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:
7 Connection pipe
(supplied pipe bends)
UNF
thread
■ Liquid line 10 mm 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 16 mm 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 return Cu 28 x 1 mm
KHeating water flow Cu 28 x 1 mm
1. Preparing connections on the heating
water and the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Note
The internal/external unit BUS con-
necting cable can be routed along the
refrigerant line and fixed to it.
Preparing for installation
Requirements for on-site connections (cont.)
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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~) – 1.5 m
Other connecting cables:
230 V~, e.g. for 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
Vitocal 222-S, type AWT-AC 221.A04 221.A07 221.A10 221.A13
External unit (compressor)
230 V~
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 16 m 20 m
or or
Cable cross-section – – 3 x 4.0 mm23 x 6.0 mm2
Max. cable length – – 26 m 30 m
Heat pump control unit (inter-
nal unit) 230 V~
Cable cross-section
■ Without power-OFF contact 3 x 1.5 mm23 x 1.5 mm23 x 1.5 mm23 x 1.5 mm2
■ With power-OFF contact 5 x 1.5 mm25 x 1.5 mm25 x 1.5 mm25 x 1.5 mm2
Instantaneous heating water
heater
Cable cross-section
■ 400 V~ 5 x 2.5 mm25 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 mm27 x 2.5 mm2
Max. cable length 25 m 25 m 25 m 25 m
Overview of possible system schemes
The following table provides an overview
of all possible system schemes.
Preparing for installation
Requirements for on-site connections (cont.)
5600 950 GB
Installation

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Components System scheme (parameter 7000)
0 1 2 3 4 5 6
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
Cooling (only possible via 1 heating/cooling circuit or via the separate cooling cir-
cuit)
A1/HC1 0 0 0 0
M2/HC2 0 0 0 0
Sep. cooling circuit SKK 0 0 0 0 0 0 0
X Components selected.
0Components can be added.
Preparing for installation
Overview of possible system schemes (cont.)
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--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: 4605418_1102_01
Setting system scheme 6
■ Internal unit of heat pump
type AWT-AC 221.A with instantane-
ous heating water heater
■ 1 radiator heating circuit without mixer
A1/HC1
■ 1 underfloor heating circuit with mixer
M2/HC2
■ DHW heating with heat pump
■ Heating water buffer cylinder
■ Cooling via heating circuit M2/HC2
(on-site) with active cooling function
Note
This scheme is a general example with-
out shut-off valves or safety equipment.
This does not replace the need for local
engineering.
Preparing for installation
Designations in the system examples
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Installation

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Hydraulic installation scheme
60
61
71
70
73
74
76
77
91
90
96
62
2
--2/F13--
--2/F4--
--2/212.2--
--212.3--
--212.2--
--F0--
--F13--
--F4--
--105/52--
--74/20--
-105/20--76-
--105/2--
-KM BUS-
--230V--
--2/211.5--
89
89
--2/211.5-----
--211.5--
-2/X3.8;3.9-
83
--52--
--2--
-KM BUS-
--20--
-230V-
105
8
--145-- --145--
--145--
--145--
-8/145- -8/145-
--
--X3.8;3.9--
A1 M2
1
29
3
--2/F0--
6
54
KW
WW
28
27
-2/212.3-
-2/X3.8;3.9-
18
37
30
12
13
--F6--
Note
In cooling mode, safeguard the minimum flow rate in the secondary circuit. Open
valves on the heating circuit distributor fully and permanently or install an overflow
valve.
Preparing for installation
System example, ID: 4605418_1102_01 (cont.)
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Pos. Designation
Heat source
1Internal unit, heat pump, Vitocal 222-S, type AWT-AC 221.A
2Heat pump control unit Vitotronic 200, type WO1B
3Outside temperature sensor ATS
4Instantaneous heating water heater with control module (integral)
53-way diverter valve "Heating/DHW heating" (integral)
6Secondary pump (integral)
qW Safety assembly
8KM BUS distributor (accessory)
qE Heating circuit expansion vessel
Primary circuit
wU Hot gas line
wI Liquid line
wO External unit of the heat pump Vitocal 222-S
DHW heating
eP DHW cylinder (integral)
eQ Cylinder temperature sensor STS (integral)
eU DHW circulation pump ZP (accessory)
zP Heating water buffer cylinder
zQ Buffer temperature sensor PTS
zW System flow temperature sensor VTS
Heating circuit with mixer M2/HC2 (KM BUS)
uP Underfloor heating circuit/cooling circuit
uQ Remote control Vitotrol 200A (accessory)
uE Flow temperature sensor
uR Temperature limiter to restrict the maximum temperature of underfloor
heating
■ as immersion thermostat
or
■ as contact thermostat
uZ Heating circuit pump
uU 3-way mixer, heating circuit
Mixer motor of the 3-way mixer
q-T Mixer extension kit
Active cooling function AC
qI Frost stat 230 V
iE Contact humidistat 230 V
iO 3-way diverter valve for "Heating/cooling"
Preparing for installation
System example, ID: 4605418_1102_01 (cont.)
5600 950 GB
Installation

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Pos. Designation
Heating circuit without mixer A1/HC1
oP Radiator heating circuit
oQ Remote control Vitotrol 200A (accessory)
oZ Heating circuit pump
Electrical installation scheme
For further information, an overview of
the electrical connections and more
details regarding the PCBs, see from
page 48 and service instructions for
the Vitotronic 200 heat pump control
unit.
For information regarding the power sup-
ply, see page 59.
Preparing for installation
System example, ID: 4605418_1102_01 (cont.)
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230 V/ 50 Hz
2
212.3
X2.N
X1.
212.2
X2.N
X1. HK A1 96
ZP 37
X2.N
X1.
1
2
145
8
145
145
145
145
40
145
52
21
2
N
L
UP M2
77
73
M
1~
74
76
M2
VTS M2
20
230 V/ 50 Hz
105
2
1
HK A1
HK M2
91
71
Low voltage
1 / N / PE
1
2H1
1
2H2
NTC
2
50W
100W
L
N
20
211.5
89
89
HK M2
X1.
X3.8
X3.9
8318
KM BUS distributor
UV
UV
211.2
X2.N
X1. UP 6
211.4
X2.N
X1. 5
UV
130W
130W
L3
N
L2
L1
137
4
3 / N / PE
400 V, 50 Hz
136
X2.N
211.3
224.4
M
1~
M
1~
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
1
3
2
M
1~
M
1~
M
1~
M
1~
Preparing for installation
System example, ID: 4605418_1102_01 (cont.)
5600 950 GB
Installation

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2
Low voltage
F4
PTS 61
PT500
F0
VTS 62
ATS
PT500
Ni500
3
F13
F6
STS 31
PT500
Power supplies, internal unit with
instantaneous heating water heater
4 for 400 V~ or 230 V~
2
1 / N / PE
230 V / 50 Hz
F1T6.3AH
L1
N
N1
1 / N / PE
230 V/ 50 Hz
N1
N1
L1
4
L1
L1
3 / N / PE
400 V/ 50 Hz
N
L2
4
L3
L1
X3.18
X1.1
X2.1
230 V
400 V
Instantaneous heating water heater power supply
Heat pump control unit power supply
External unit connections
C N L
29
4 kW
COM
43 V
> 42 V
2
L1
N
1 / N / PE
230 V/ 50 Hz
COM
29
7 kW
COM
43 V
> 42 V
2
L1
N1 / N / PE
230 V/ 50 Hz
Li No Lo
Ni
29
COM
12 V
2
L1
N1 / N / PE
230 V/ 50 Hz
NL
L
N
C1
C2
10 / 13 kW
< 42 V
Preparing for installation
System example, ID: 4605418_1102_01 (cont.)
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Required parameter settings
Parameter Setting
"System definition"
■"System scheme 7000" "6"
DHW heating:
"Time program DHW heating" Set time program (see oper-
ating instructions)
"Time program DHW circulation"
(if a DHW circulation pump is installed)
Set time program (see oper-
ating 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"
"Cooling"
■"Cooling function 7100" "3"
■"Cooling circuit 7101" "2"
Remote controls (if installed):
"Heating circuit 1"
■"Remote control 2003" "1"
"Heating circuit 2"
■"Remote control 3003" "1"
To call up "Coding level 1" for setting
the parameters, see the commissioning
wizard on page 81 and page 83.
Preparing for installation
System example, ID: 4605418_1102_01 (cont.)
5600 950 GB
Installation

18
!Please note
Avoid damaging the appliance
during transportation.
Never put weight on top of the
appliance.
!Please note
If the compressor in the external
unit is steeply angled, lubricant
will enter the refrigerant circuit
and damage the appliance.
Compliance is required with the
max. tilt angle according to the
following table.
Type AWT-AC Max. tilt angle
221.A04 45°
221.A07 45°
221.A10 30°
221.A13 30°
Installation requirements
Installation site
■ Select a site with good air circulation,
so that the cooled air can dissipate and
be replenished by warm air.
■ Avoid direct insolation.
■ When installing the unit where it is
exposed to wind, ensure that the wind
cannot influence the fan area. This
could result in an "air short circuit"
between the discharged and the
inrushing air. 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 lead
to 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 pressure faults.
Avoid "air short circuits".
Installation sequence
Installing the external unit
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■ 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 statutory regula-
tions on sound dissipation and reflec-
tions.
Technical guide "Heat pump
principles"
■ Never site in corners of rooms,
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 are below 10 °C.
■ The installation site should be easily
accessible, for example for mainte-
nance work (see "Minimum clearan-
ces").
Type of installation
■ Floorstanding installation with cable
entry above ground level
■ Floorstanding installation with cable
entry below ground level
■ Wall mounting
Technical guide
Installation information
■ Floor mounting:
Use supports (accessories) for floor
mounting.
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 account of the weight of the
external unit (see following table).
■ Wall mounting:
Use the wall mounting bracket set
(accessory).
■ Never install with the discharge side
facing the main wind direction.
■ Observe the wind loads when instal-
ling the unit on sites exposed to the
wind.
■ When mounting the unit on a wall, the
wall must offer sufficient load-bearing
capacity.
■ Design wall outlets and protective
pipes for the refrigerant lines and elec-
trical cables without moulded parts
and changes of direction.
■ Incorporate the external unit into the
lightning protection system.
■ Consider the heat emitted by the unit
when planning your weather proofing
measures or an enclosure.
■ Ensure the condensate can drain
freely, and create a permanent gravel
bed below the external unit as a soak-
away.
Installation sequence
Installing the external unit (cont.)
5600 950 GB
Installation

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■ In regions with prolonged cold sea-
sons (e.g. in Germany), provide an
electric supplementary heating facility
(accessory) for the condensate pan.
■ For insulation of structure-borne noise
and vibrations between the building
and the external unit, consider the fol-
lowing measures:
– When cable entry is above ground
level, fit pipe bends as anti-vibration
mounts in refrigerant lines (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.
– When mounting the unit on the floor,
use only the rubber mounts sup-
plied; for wall mounting use the anti-
vibration mounts supplied with the
wall mounting bracket set; never use
additional anti-vibration mounts,
springs, rubber buffers etc.
Weights of the external units
Type AWT-AC Weight in kg
221.A04 43
221.A07 66
221.A10 110
221.A13 110
Installation sequence
Installing the external unit (cont.)
5600 950 GB