Viessmann VITOTRANS 222 Operating instructions

Service instructions
for contractors
VIESMANN
Vitotrans 222
Heat exchanger set for cylinder loading system
For applicability, see the last page
VITOTRANS 222
5549 892 GB 4/2014 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
!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 quali-
fied contractors.
■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
Observe the following when working on this system:
■National installation regulations
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■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 supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any 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 replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
5549 892 GB

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1. Product information Intended use .......................................................................................... 4
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 5
3. Display and troubleshoot-
ing
LED at the HE circulation pump ............................................................. 14
4. Parts lists Parts list ................................................................................................. 15
5. Commissioning/service
reports
.................................................................................................................. 17
6. Specification .................................................................................................................. 18
7. Certificates Declaration of conformity ....................................................................... 19
Index
Index
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The appliance is only intended to be installed and
operated in sealed unvented systems that comply with
EN 12828 / DIN 1988, or solar thermal systems that
comply with EN 12977, with due attention paid to the
associated installation, service and operating instruc-
tions. DHW cylinders are only designed to store and
heat water of potable water quality. Heating water buf-
fer cylinders are only designed to hold fill water of pot-
able water quality. Only operate solar collectors with
the heat transfer medium approved by the manufac-
turer.
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 heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and results in an exclusion of liability.
Incorrect usage also occurs if the components in the
system are modified from their intended use (e.g.
through direct DHW heating in the collector).
Adhere to statutory regulations, especially concerning
the hygiene of potable water.
Product information
Intended use
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Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the system on the heating water and DHW side.................................................. 6
••• 2. Checking connections....................................................................................................... 6
• • 3. System start-up.................................................................................................................. 6
••• 4. Setting the heating output................................................................................................. 6
• • 5. Setting the pumps.............................................................................................................. 8
••• 6. Setting the cylinder temperature...................................................................................... 11
• • 7. Shutting down the system................................................................................................. 12
• • 8. Checking the function of the safety valve
• • 9. Inspection and maintenance of the cylinder loading system........................................ 12
•10. Restarting the system
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Boiler service instructions and Vitocell 100-L
service instructions
Checking connections
1. Check the fittings on the heating water and DHW
side for leaks and retighten if required.
2. Check that all electrical connections have been
wired and have fuse protection.
System start-up
1. Set the pressure reducer (if installed) to the
required operating pressure.
Max. operating pressure: 10 bar (1 MPa)
2. Switch ON the power supply.
3. Monitor initial heat-up of the Vitotrans 222.
Note
For the adjustment of the DHW temperature, see
page 11.
Setting the heating output
The required heating output (see diagram below) is set
by adjusting the flow rates on the heating water and
DHW side.
The flow rate can be influenced via the speed of the
integral pumps (see from page 8) and, on the DHW
side, via the integral line regulating valve and shut-off
valve (Taco setter).
The flow rate can be checked at the line regulating
valve and shut-off valve.
Commissioning, inspection, maintenance
Filling the system on the heating water and DHW side
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A E
B C
10
A
B
C
D
15
20
28
30
40
D
Fig.1
1. Set sliding marker A on scale B to the flow rate
determined from the diagram below.
2. Push in bracket C.
3. Turn adjusting disc D anti-clockwise as far as it will
go to position "D".
4. Reduce the pump speed on the DHW side until the
bottom edge of indicator band E is at or above
sliding marker A.
5. Only if indicator band E is still above sliding
marker A: Turn adjusting disc D clockwise until
the bottom edge of indicator band E drops down to
the sliding marker.
6. Pull out bracket C. This keeps the window clean
for subsequent checking.
Commissioning, inspection, maintenance
Setting the heating output (cont.)
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Flow rate to be set on the DHW side (with temperature spread 10/60 °C) subject to heat exchanger output
40 60 80 100 120 140
0
10
20
30
40
50
60
70
80
Flow rate in l/min
HE output in kW
160 180 200 220 240
Fig.2
Setting the pumps
Vitotrans 222 (up to 80 kW and up to 120 kW) - circulation pump, DHW side
A B
AVariable differential pressure
BConstant speed I, II, III
1
4
7
80 kW setting
1
4
7
Min.
120 kW setting
Vitotrans 222 up to 80 kW and up to 120 kW
0.5 1.0 1.5 2.0 2.5 3.0
10
20
30
40
50
60
70
80
90
100
100
200
300
400
500
600
700
800
900
1000
0
mbar kPa
0
0
Flow rate in m³/h
Pressure drop/head
D
F
A
E
B
C
Fig.3
Commissioning, inspection, maintenance
Setting the heating output (cont.)
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AVitotrans 222 pressure drop
BResidual head
CMin. output
DMax. output
EDHW volume at 10/60 °C and max. transferable
heating output up to 80 kW = 1376 l/h,
Δp = 50 mbar (5 kPa)
FDHW volume at 10/60 °C and max. transferable
heating output up to 120 kW = 2064 l/h,
Δp = 150 mbar (15 kPa)
Note
The pump output can be variably restricted: From min.
output via I and II up to III (
≙
max. output).
Vitotrans 222 (up to 240 kW) - circulation pump, DHW side
2
5
8
1
4
8
AVariable differential pressure
BConstant differential pressure
2
5
8
1
4
8
240 kW setting
Vitotrans 222, up to 240 kW
E
A
D
3.0 6.0 9.0
10
20
30
40
50
60
70
80
90
100
100
200
300
400
500
600
700
800
900
1000
0
mbar kPa
00
Flow rate in m³/h
Pressure drop/head
1.0 2.0 4.0 5.0 7.0 8.0
B
C
Fig.4
AVitotrans 222 pressure drop
BResidual head
CMin. output
DMax. output
EDHW volume at 10/60 °C and max. transferable
heating output up to 240 kW = 4128 l/h,
Δp = 90 mbar (9 kPa)
Commissioning, inspection, maintenance
Setting the pumps (cont.)
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Vitotrans 222 (up to 80 kW and up to 120 kW) - circulation pump, heating water side
A B
AVariable differential pressure
BConstant speed I, II, III
1
3
6
80 kW setting
1
3
6
120 kW setting
Vitotrans 222 up to 80 kW and up to 120 kW
3.5
10
20
30
40
50
60
70
100
200
300
400
500
600
700
0
mbar kPa
00
Flow rate in m³/h
Pressure drop/head
3.02.52.01.51.00.5
E
C
DFG
B
A
Fig.5
APressure drop Vitotrans 222, up to 80 kW
BPressure drop Vitotrans 222, up to 120 kW
CResidual head
DMin. output
EMax. output
FHeating water volume at TF/TR = 75/35 °C and
max. transferable heating output up to
80 kW = 1720 l/h, Δp = 70 mbar (7 kPa)
GHeating water volume at TF/TR = 75/35 °C and
max. transferable heating output up to
120 kW = 2580 l/h, Δp = 130 mbar (13 kPa)
Note
The pump output can be variably restricted: From min.
output via I and II up to III (
≙
max. output).
Commissioning, inspection, maintenance
Setting the pumps (cont.)
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Vitotrans 222 (up to 240 kW) - circulation pump, heating water side
2
5
8
1
4
8
AVariable differential pressure
BConstant differential pressure
2
5
8
1
4
8
240 kW setting
Vitotrans 222, up to 240 kW
A
E
B
C
D
3.0 6.0 9.0
10
20
30
40
50
60
70
80
90
100
100
200
300
400
500
600
700
800
900
1000
0
mbar kPa
00
Flow rate in m³/h
Pressure drop/head
1.0 2.0 4.0 5.0 7.0 8.0
Fig.6
APressure drop Vitotrans 222, up to 240 kW
BResidual head
CMin. output
DMax. output
EHeating water volume at TF/TR 75/35 °C and max.
transferable heating output up to
240 kW = 5160 l/h, Δp = 250 mbar (25 kPa)
Setting the cylinder temperature
Vitotrans 222 for constant flow temperatures
The upper cylinder temperature controller starts cylin-
der heating, while the lower cylinder temperature con-
troller stops cylinder heating.
1. Limit the upper cylinder temperature controller to at
least 5 ºC below the actual heating temperature.
Example:
Heating temperature 60 ºC, maximum setting of the
upper cylinder temperature controller 55 ºC.
Commissioning, inspection, maintenance
Setting the pumps (cont.)
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2. Limit the lower cylinder temperature controller to at
least 5 ºC below the setting of the upper cylinder
temperature controller.
Example:
Heating temperature 60 ºC, upper cylinder tempera-
ture controller 55 ºC, maximum setting of the lower
cylinder temperature controller 50 ºC.
Note
Trouble-free operation of the cylinder loading system
cannot be guaranteed:
■If both cylinder temperature controllers are set to the
same temperature.
■If the differential between the heating temperature
and the selected start and stop temperature of the
cylinder temperature controller is too small.
Vitotrans 222 for modulating flow temperatures
The cylinder loading system can be controlled by the
following control units:
■Vitotronic 100
■Vitotronic 200
■Vitotronic 300
■Vitotronic 300-K
If these control units are not available or if there are
several cylinder loading systems, control can also be
achieved via the Vitotronic 200-H.
Vitotronic installation and service instructions
1. Set the system-specific code on the Vitotronic. For
this, carry out the following settings in code 2:
Group Code Function
"General" "4C:1" Primary pump, cylinder loading system
"General" "4E:2" Connection on plug gSA1
"DHW" "55:3" Cylinder temperature controller, cylinder loading system
In addition for the Vitotrans 222 with 240 kW:
"DHW" "6A:113" Set runtime 113 s.
2. Set the cylinder temperature (DHW temperature) on
the Vitotronic.
Vitotronic operating instructions
Shutting down the system
Switch OFF mains power and safeguard against unau-
thorised reconnection.
Checking the function of the safety valve
Inspection and maintenance of the cylinder loading system
DIN 1988 requires a visual inspection and (if neces-
sary) cleaning no later than two years after the cylinder
has been commissioned, and thereafter according to
requirements.
The Vitotrans 222 itself is maintenance-free.
Regularly maintain the following components of the
cylinder loading system (if installed):
■Loading cylinder
■Water treatment equipment in the cold water supply:
Sluices or injection systems in the cold water supply
should be refilled in good time and the equipment
should be maintained.
Commissioning, inspection, maintenance
Setting the cylinder temperature (cont.)
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■Dirt trap or filter in the cold water supply: Backwash
or replace and maintain regularly.
■Drinking water filter: Replace filter element on non-
backwashing filters every 6 months (visual inspection
every 2 months). On backwashing filters, backwash
every 2 months.
Service documents from the manufacturers
Restarting the system
Commissioning, inspection, maintenance
Inspection and maintenance of the cylinder… (cont.)
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LED Meaning Cause Action
Illuminates green Circulation pump in opera-
tion
— —
Flashes green in short in-
tervals
RKA version*1:
Pump runs for 10 min in
the venting function.
Then set the required out-
put.
— —
PWM version*2:
Pump on standby
— —
Fault indications
■Flashes red and green
alternately
Pump is ready for opera-
tion but does not run.
Note
The circulation pump
starts automatically after
the cause of the fault has
been removed.
■Undervoltage (< 160 V~)
■Overvoltage (> 253 V~)
Check power supply
(195 V~ < U < 253 V~)
Motor temperature too
high
Check ambient and heat
transfer medium tempera-
tures.
■Flashes red Circulation pump switched
off (blocked)
Circulation pump does not
start automatically.
Replace the circulation
pump.
■Is OFF —No power. Check connecting cable.
LED faulty Check whether the circula-
tion pump is running.
PCB faulty Replace the circulation
pump.
*1 Version with operating button for variable and constant differential pressure.
*2 Version with control via PWM signal.
Display and troubleshooting
LED at the HE circulation pump
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Pos. Component Serial no. (see type plate)
7537157 7537158 7537159
Part no. of individual part
0001 Flow temperature sensor NTC no. 2 l = 5800 7426463 7426463 7426463
0002 Plate heat exchanger WP4-40 7820385
0002 Plate heat exchanger WP4-60 7843370
0002 Plate heat exchanger WP7-M30 7820387
0003 Vitotrans 222 gasket set sizes 1 + 2 7840893 7840893
0003 Vitotrans 222 gasket set size 3 7840894
0004 Vitotrans 222 insulating parts sizes 1 + 2 7581794 7581794
0004 Vitotrans 222 insulating parts size 3 7581795
0005 Line regulating valve DN 25 7820393 7820393
0005 Line regulating valve DN 32 7820394
0006 Circulation pump Yonos PARA Z25/7.0 RKC MC180 6 7840886 7840886
0006 Circulation pump Stratos PARA Z30/1-8T3 DPC180 12 7840925
0007 Non-return valve 7325502 7325502
0007 Push-fit non-return valve DN 032 7820395
0008 Circulation pump Yonos PARA RS25/6 RKCMC180 6 7840885 7840885
0008 Circulation pump Stratos PARA 30/1-8 T3 DPC180 12 7840924
0009 Servomotor AMV 7836448 7836448 7836448
0010 Control valve DN 25 PN 16 VRG3 7835293 7835293
0010 Control valve DN 32 PN 16 VRG3 7835292
0011 Pump ball valve DN 25 7820399 7820399
0011 Pump ball valve DN 32 7820400
0012 Pump ball valve DHW DN 25 7840889 7840889
0012 Pump ball valve DHW DN 32 7840890
0013 Tee sizes 1 + 2 7835283 7835283
0013 Tee size 3 7835278
0014 Pipe section sizes 1 + 2 7835284 7835284
0014 Pipe section size 3 7835279
0015 Casing, non-return valve 7835285 7835285 7835280
0016 Union nut for fitting 7816012 7816012
0016 Union nut G 1½ d2 = 42.4 7835286
0017 Union nut G 1½ d2 = 42.4 7835286 7835286
0017 Union nut G 2 d2 = 53 +0.2 7835281
0018 Spacer pipe R 1 7811168 7811168
0018 Spacer pipe R 1¼ 7811169
0019 Connecting cable, plug 20, heating water 7840897 7840897 7840897
0020 Connecting cable, plug 21, DHW 7840895 7840895 7840895
0021 Vitotrans 222 type plate size 1 HE 5848103
0021 Vitotrans 222 type plate size 2 HE 5848904
0021 Vitotrans 222 type plate size 3 HE 5848905
0022 Vitotrans 222 installation instructions 5848105 5848105 5848105
0023 Vitotrans 222 service instructions 5848106 5848106 5848106
0024 Extension 7843096
Parts lists
Parts list
5549 892 GB

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0011
0013
0009
0011
0017
0010
0003
0018
0006
0003
0016
0005 0002
0024
0017
0017
0003
0003
0020 0019 0001 0022 0023 0021
0003
0008
0012
0012
0003
0017
0014
0004
0015
0007
Fig.7
Parts lists
Parts list (cont.)
5549 892 GB

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Commissioning Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Commissioning/service reports
Commissioning/service reports
5549 892 GB

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Serial no. 7537 157 7537 158 7537 159
Transferable heating output at
75 °C heating water flow temperature/
35 °C heating water return temperature and
10 °C cold water inlet temperature/
60 °C DHW outlet temperature
kW up to 80 up to 120 up to 240
Content
Heating water l 1.7 2.3 4.0
DHW l 1.7 2.3 4.0
Connections (DIN 2999)
Heating water flow and return R 1 1 1¼
Cold water, DHW R 1 1 1¼
Weight kg 25 27 60
Permiss. operating pressure
Heating water and DHW sides
bar
MPa
10
1
10
1
10
1
Power consumption per pump
On the primary/secondary side
■Min. W 3 3 8
■Max. W 45 45 130
Max. heating water temperature
With mixer assembly (for modulating operation) °C 110 110 110
Without mixer assembly (for constant operation) °C 75 75 75
Specification
Specification
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We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm as sole responsible body that the product
Vitotrans 222 complies with the following standards:
EN 60 335–1
EN 60 335-2-51
EN 61 000-6-3
EN 61 000-6-1
In accordance with the following Directives, this product is designated _:
2004/108/EC
2006/42/EC
2006/95/EC
Allendorf, 10 February 2014 Viessmann Werke GmbH & Co KG
Authorised signatory Manfred Sommer
Certificates
Declaration of conformity
5549 892 GB

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Applicability
Serial no. (see type plate):
7537157 7537158 7537159
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
5549 892 GB Subject to technical modifications.