Viessmann VITOCAL 222-S Installation And Service Instructions Manual
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Viessmann VITOCAL 222-S Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
for contractors
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
Please keep safe.
5600 950 GB
10/2011

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Summary of Contents for Viessmann VITOCAL 222-S

  • Page 1 VIESMANN Installation and service instructions for contractors 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 Please keep safe. 5600 950 GB 10/2011...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ The Code of Practice of relevant trade associations Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, VDE and risk of injury.
  • Page 3 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...

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Application......................Requirements for on-site connections..............Overview of possible system schemes..............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.................

  • Page 5: Table Of Contents

    Index Index (cont.) 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....................

  • Page 6: Application

    Preparing for installation Application The compact heat pumps Vitocal 222-S, Note type AWT-AC 221.A04 to A13, can be Vitocal 222-S is intended exclusively for used for the following purposes: domestic use, i.e. even people who have ■ Central heating and cooling via a heat-...

  • Page 7: Requirements For On-Site Connections

    Preparing for installation Requirements for on-site connections Internal unit A Opening for LV leads <42 V B DHW...
  • Page 8 Preparing for installation Requirements for on-site connections (cont.) C DHW circulation G Hot gas line D Opening for 230 V cables H Heating water flow E Cold water K Heating water return F Liquid line Connection sizes for hydraulic connections Sym- Meaning Connections to the internal unit...

  • Page 9: Overview Of Possible System Schemes

    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 mm 3 x 2.5 mm...
  • Page 10 Preparing for installation Overview of possible system schemes (cont.) Components System scheme (parameter 7000) Heating circuit A1/HC1 – – – M2/HC2 – – – DHW cylinder – – – Heating water buffer cylinder – Cooling (only possible via 1 heating/cooling circuit or via the separate cooling cir- cuit) A1/HC1 M2/HC2...

  • Page 11: Designations In The System Examples

    Preparing for installation Designations in the system examples -2/145- --2/F14-- --2/F14-- --2/X3.8;3.9-- --2/211.2-- System example, ID: 4605418_1102_01 Setting system scheme 6 ■ Heating water buffer cylinder ■ Internal unit of heat pump ■ Cooling via heating circuit M2/HC2 type AWT-AC 221.A with instantane- (on-site) with active cooling function ous heating water heater ■...
  • Page 12 Preparing for installation System example, ID: 4605418_1102_01 (cont.) Hydraulic installation scheme -8/145- -8/145- -2/X3.8;3.9- --105/2-- -105/20--76- --2/212.2-- --74/20-- --105/52-- --2/F13-- -2/X3.8;3.9- -2/212.3- 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.
  • Page 13 (cont.) Pos. Designation Heat source Internal unit, heat pump, Vitocal 222-S, type AWT-AC 221.A Heat pump control unit Vitotronic 200, type WO1B Outside temperature sensor ATS Instantaneous heating water heater with control module (integral) 3-way diverter valve "Heating/DHW heating" (integral)
  • Page 14 Preparing for installation System example, ID: 4605418_1102_01 (cont.) Pos. Designation Heating circuit without mixer A1/HC1 Radiator heating circuit Remote control Vitotrol 200A (accessory) Heating circuit pump Electrical installation scheme For further information, an overview of For information regarding the power sup- the electrical connections and more ply, see page 59.
  • Page 15 Preparing for installation System example, ID: 4605418_1102_01 (cont.) X3.8 X3.9 212.3 X2.N 100W 212.2 HK A1 X2.N 211.5 X2.N 130W 211.2 X2.N 130W 211.4 X2.N 211.3 400 V, 50 Hz 3 / N / PE 224.4 X2.N KM BUS distributor HK A1 HK M2 HK M2...

  • Page 16: Instantaneous Heating Water Heater

    Preparing for installation System example, ID: 4605418_1102_01 (cont.) PT500 PT500 PT500 Ni500 Power supplies, internal unit with External unit connections instantaneous heating water heater 4 for 400 V~ or 230 V~ 4 kW Heat pump control unit power supply X1.1 1 / N / PE 230 V/ 50 Hz 1 / N / PE...
  • Page 17 Preparing for installation System example, ID: 4605418_1102_01 (cont.) 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" Set time program (see oper- (if a DHW circulation pump is installed) ating instructions) "DHW"...

  • Page 18: Installing The External Unit

    Installation sequence Installing the external unit Please note Type AWT-AC Max. tilt angle Avoid damaging the appliance 221.A04 45° during transportation. 221.A07 45° Never put weight on top of the 221.A10 30° appliance. 221.A13 30° Please note If the compressor in the external unit is steeply angled, lubricant will enter the refrigerant circuit and damage the appliance.
  • Page 19 Installation sequence Installing the external unit (cont.) ■ Take the lengths of the refrigerant Installation information lines into account (see "Connecting refrigerant lines"). ■ Floor mounting: ■ Select the installation site so that the Use supports (accessories) for floor evaporator cannot be blocked by mounting.
  • Page 20 Installation sequence Installing the external unit (cont.) ■ In regions with prolonged cold sea- Weights of the external units sons (e.g. in Germany), provide an Type AWT-AC Weight in kg electric supplementary heating facility 221.A04 (accessory) for the condensate pan. 221.A07 ■...
  • Page 21 Installation sequence Installing the external unit (cont.) Minimum clearances Example: type AWT-AC 221.A04 A Air intake B Air discharge Type AWT-AC Dimensions in mm Cable entry above below ground ground level level ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥...
  • Page 22 Installation sequence Installing the external unit (cont.) Floor mounting A Support for floor mounting (acces- sory)

  • Page 23: Installing The Internal Unit

    Installation sequence Installing the external unit (cont.) B Gravel bed as condensate soak- D Drainage pipe DN 100 (only with away entry points below ground level) C Concrete foundations (see technical guide) E Rubber mounts (supplied) Note We recommend letting condensate drain away freely (without condensate drain pipe).
  • Page 24 Installation sequence Installing the internal unit (cont.) Total weight with filled DHW cylinder Minimum room volume (to Type AWT-AC Weight in kg DIN EN 378): 221.A04 Type AWT-AC Minimum room 221.A07 volume in m 221.A10 221.A04 221.A13 221.A07 221.A10 221.A13 Minimum clearances Minimum room height h Installation...
  • Page 25 Installation sequence Installing the internal unit (cont.) Removing the cylinder module...
  • Page 26 Installation sequence Installing the internal unit (cont.) P501 P303 P302 P301...
  • Page 27 Installation sequence Installing the internal unit (cont.)
  • Page 28 Installation sequence Installing the internal unit (cont.)
  • Page 29 Installation sequence Installing the internal unit (cont.)
  • Page 30 Installation sequence Installing the internal unit (cont.) Note Do not damage sealing tape A when removing the cylinder module.
  • Page 31 Installation sequence Installing the internal unit (cont.) Assembly and sealing faces to note 2. Fit the cylinder module in reverse order to that described on page 25. Please note Make tight hydraulic connec- tions between the heat pump module and cylinder module. With pipe outlets, ensure lock- ing tabs C are seated cor- rectly (see following illustra-...

  • Page 32: Connecting Refrigerant Lines

    Installation sequence Installing the internal unit (cont.) Connecting refrigerant lines ■ The external unit is pre-filled with refrigerant R410A. ■ Install oil lift bends (see illustration) into the vertical lines in the following cases: – In heating mode, if the internal unit is installed higher than the external unit.
  • Page 33 Installation sequence Connecting refrigerant lines (cont.) Routing refrigerant lines Vitocal 222-S, type AWT-AC 221.A04 221.A07 221.A10 221.A13 Refrigerant lines Min. line length Max. line length 20 m 30 m 30 m 30 m Max. height differential internal 10 m 15 m...
  • Page 34 Installation sequence Connecting refrigerant lines (cont.) Insulation against noise and vibrations with entry points above ground level Note Route connecting cables and refrigerant lines separately. A Pipe bends as vibration compensa- D Electrical cables/leads, internal/ tors external unit B Clips with EPDM lining C Cable entry, e.g.
  • Page 35 Installation sequence Connecting refrigerant lines (cont.) Example: type AWT-AC 221.A04 C Liquid line D Hot gas line Please note 3. Flare the pipe ends. No contamination (e.g. metal swarf) or moisture should 4. Secure the pipes. enter the copper pipes. Therefore, hold the pipe open- ings downwards or tempora- rily plug them.
  • Page 36 Installation sequence Connecting refrigerant lines (cont.) Tighten nuts with the following torques: Type AWT-AC Line Connection Torque in Nm to external unit ⁷⁄₁₆ UNF 221.A04 Liquid line 7 6 mm 14–18 Hot gas line 7 12 mm ¾ UNF 50–62 221.A07 Liquid line 7 10 mm ⅝...
  • Page 37 Installation sequence Connecting refrigerant lines (cont.) C Liquid line D Hot gas line Please note Note No contamination (e.g. metal ■ The internal unit refrigerant lines are swarf) or moisture should enter filled with nitrogen, overpressure the copper pipes. 2 bar. Therefore, hold the pipe open- ■...
  • Page 38 Installation sequence Connecting refrigerant lines (cont.) 1. Remove nuts from refrigerant con- nections C and D and slide onto the supplied pipe bends. 2. Flare the pipe ends of the supplied pipe bends on the short side. Note Flare the pipe end of the hot gas line by approx.
  • Page 39 Installation sequence Connecting refrigerant lines (cont.) 5. Flare the pipe bends on their open end and secure connection piece (twin nipple) with union nuts. Note ■ Flare the pipe end of the hot gas line by approx. 0.5 mm. ■ Connection pieces must not be positioned diagonally.
  • Page 40 Installation sequence Connecting refrigerant lines (cont.) 6. Type AWT-AC 221.A04: ■ Slide the supplied union nuts (⁷⁄₁₆ UNF for liquid line, ¾ UNF for hot gas line) over the refrigerant lines from the external unit. ■ Flare the refrigerant lines from the external unit.

  • Page 41: Connecting The Secondary Circuit

    Installation sequence Connecting refrigerant lines (cont.) Type AWT-AC Line Connection Torque in Nm to internal unit 221.A13 Liquid line 7 10 mm ⅝ UNF 33–42 Hot gas line 7 16 mm ⅞ UNF 63–77 Connecting the secondary circuit Opening the door...
  • Page 42 Installation sequence Connecting the secondary circuit (cont.) A Straight pipe sections supplied B Pipe bends from secondary circuit connection set (accessories, see separate installation instructions) Symbol Meaning Connection Heating water return Cu 28 x 1 mm Heating water flow Cu 28 x 1 mm...
  • Page 43 Installation sequence Connecting the secondary circuit (cont.) 2. Install the supplied safety assembly: Either to the on-site line in the heating water return to the secondary circuit connection set (accessory) Connection set installation instructions 3. Fill and vent the secondary circuit. 4.

  • Page 44: Connecting A Cooling Circuit If Required

    Installation sequence Connecting a cooling circuit if required For area cooling systems (e.g. under- Requirements for the contact humidistat: floor heating circuit, chilled ceiling), a ■ Electrical connection: 230 V~, 0.5 A contact humidistat (accessory) is ■ Installation inside the room to be required.

  • Page 45: Electrical Connection

    Installation sequence Connections on the DHW side (cont.) Information on drinking water filter According to DIN 1988-2, a drinking water filter should be installed in systems with metal pipework. We also recom- mend the installation of a drinking water filter when using plastic pipes, according to DIN 1988, to prevent contaminants entering the DHW system.
  • Page 46 Installation sequence Electrical connection (cont.) Please note The BUS cable must be routed From a safety viewpoint, the BUS together with the 230 V cables. cable for the internal/external unit (12 V or 43 V) does not count as an LV lead.
  • Page 47 Installation sequence Electrical connection (cont.) 400/230 V > 42 V < 42 V A Control module power cable for B Connecting cables for 230 V~ func- instantaneous heating water heater tion components 230 V~/400 V~...
  • Page 48 Installation sequence Electrical connection (cont.) C Low voltage connecting cables E Type AWT-AC 221.A04 and A07: (sensors, KM BUS) <42 V 43 V BUS cable: Routing in the D Type AWT-AC 221.A10 and A13: 230 V~ voltage area (for connection, 12 V BUS cable: Routing in the see page 58) 230 V~ voltage area (for connection,...
  • Page 49 Installation sequence Electrical connection (cont.) 12 V P202 P203 43 V F101...
  • Page 50 Installation sequence Electrical connection (cont.) A Expansion PCB on main PCB (con- E Luster terminals (see page 53) nect nothing on site) F1 Fuse 6.3 A (slow) B Main PCB (see page 50) F Control module and power supply F3 Fuse 6.3 A (slow) for instantaneous heating water C Controller and sensor PCB (see heater...
  • Page 51 Installation sequence Electrical connection (cont.) Plug sYA Terminals Function Explanation 211.2 Secondary pump ■ In systems without a heating water buffer cylinder, no other heating circuit pump is required (see terminal 212.2). ■ Connect the temperature limiter in ser- ies as maximum temperature limiter for underfloor heating circuit (if instal- led).
  • Page 52 Installation sequence Electrical connection (cont.) Plug sYS Terminals Function Explanation 212.2 Heating circuit pump for ■ This pump is connected in addition to heating circuit without mixer the secondary pump if a heating water A1/HC1 buffer cylinder is installed. ■ Connect temperature limiter as a max- imum temperature limiter for under- floor heating circuit (if installed) in ser- ies (see following chapter)
  • Page 53 Installation sequence Electrical connection (cont.) Heating circuit without mixer A1/ Connection Circulation pump C A to control unit ■ Without heating water buffer cylin- 211.2 Secondary pump ■ With heating water buffer cylinder 212.2 Heating circuit pump A1/ Connecting the temperature limiter, part no.
  • Page 54 Installation sequence Electrical connection (cont.) Terminals Function Explanation Heat pump control unit 6.3 A (slow) fuse X3.1 Phase switched Via control unit ON/OFF switch. Note Observe the total load (1000 W) of all con- nected components. X3.6 Power-OFF (factory-fitted Floating contact required: X3.7 jumper) ■...
  • Page 55 Installation sequence Electrical connection (cont.) Terminals Function Explanation X3.8 Frost stat and/or contact Floating contact required: X3.9 humidistat ■ Closed: Continuous safety chain ■ Open: Safety chain interrupted; heat Jumper pump shut down ■ Breaking capacity 230 V~, 0.15 A Connect on site: ■...
  • Page 56 Installation sequence Electrical connection (cont.) Plugs Sensor Type KM BUS Connection of components on site (cores interchangea- ble). If several of the following devices are to be connec- ted, use a KM BUS distributor (accessory). ■ Extension kit mixer for heating circuit M2 ■...
  • Page 57 Installation sequence Electrical connection (cont.) Overview of connections: External unit Vitocal 222-S, type AWT-AC 221.A04 221.A07 221.A10 and A13 A Wiring chamber: ■ BUS connection to the internal unit Note Do not interchange the BUS con- nection wires between the internal and external units.
  • Page 58 Installation sequence Electrical connection (cont.) Connecting internal and external unit Vitocal 222-S, type AWT-AC 221.A04 221.A07 221.A10 and A13 C N L ? C2 C1 ? N L 12V COM COM 43V 12V COM COM 43V 12V COM COM 43V...

  • Page 59: Power Supply

    Installation sequence Power supply Isolators for non-earthed conductors Danger ■ The mains isolator (if installed) must An absence of component earth- simultaneously isolate all non-earthed ing in the system can lead to seri- conductors from the power supply with ous injury from electrical current a minimum contact separation of 3 mm if an electrical fault occurs.
  • Page 60 Installation sequence Power supply (cont.) ■ The heat pump control unit/PCB must be supplied without power-OFF; tariffs that are subject to possible shut- down must not be used here ■ Protect the power supply to the heat pump control unit with max. 16 A ■...
  • Page 61 Installation sequence Power supply (cont.) External unit power supply (230 V~) Vitocal 222-S, type AWT-AC 221.A04 221.A07 221.A10 and A13 C N L ? C2 C1 ? N L ? N L1 ? N L1 A External unit wiring chamber (see...
  • Page 62 Installation sequence Power supply (cont.) Connecting instantaneous heating water heater power cable Internal unit ■ Recommended power cable: 400 V~: 5 x 2.5 mm 1/N/PE 230 V~: 7 x 2.5 mm 230 V/50 Hz ■ Max. fuse protection 16 A ■...
  • Page 63 Installation sequence Power supply (cont.) Note Observe the technical connection condi- tions of the relevant power supply util- ity. X3.7 X3.6 X3.18/X2.1/X1.1 (400 V~) 7 (230 V~) ≈ Diagram excluding fuses and RCD. A Heat pump control unit (internal unit, E High tariff meter luster terminals, see chapter "Over- F Backup fuse ripple control receiver...
  • Page 64 Installation sequence Power supply (cont.) Power-OFF with on-site load disconnection The power-OFF signal is connected to Note the on-site contactor of the economy tar- Observe the technical connection condi- iff power supply and in the heat pump tions of the relevant power supply util- control unit.

  • Page 65: Closing The Heat Pump

    Installation sequence Power supply (cont.) G Ripple control receiver (contact H Economy tariff meter open: power-OFF enabled) with K Feed: TNC system backup fuse L Mains isolator Closing the heat pump Please note 1. Close casing door, in reverse order to Seal the appliance so it is sound- page 41.

  • Page 66: Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Opening the heat pump..........68 • 2. Writing reports..............68 •...
  • Page 67 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • 20. Commissioning the system........... 81 • 21. Ticking the heat pump type on the type plate of the internal unit (as per external unit type plate) •...

  • Page 68: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Opening the heat pump Danger Please note Touching 'live' components can Wait at least 30 min between the result in severe injury due to elec- installation and commissioning of tric shock. the appliance to prevent equip- ■...
  • Page 69 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Evacuating refrigerant lines and internal unit Please note Please note Commissioning is weather- Before evacuating the refrigerant dependent. lines and the internal unit, check In the event of high relative all connections for tightness with humidity (e.g.
  • Page 70 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Example: type AWT-AC 221.A07 A Internal unit E Service valve (Schrader valve) B External unit For type AWT-AC, type 221.A07, C Liquid line the service valve is located at the connection of the liquid line.
  • Page 71 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) G Fill hose between pressure gauge L Vacuum pump set and external unit M Connection hose between pressure H Pressure gauge set gauge set and vacuum gauge K Connection hose between pressure N Valve for vacuum gauge gauge set and vacuum pump O Vacuum gauge...
  • Page 72 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling refrigerant lines and internal unit Note 3. Unscrew the caps on the external unit ■ The external unit is pre-filled with fill valves, open both fill valves and refrigerant R410A. refit the caps.
  • Page 73 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Unscrew the caps on the external unit Refrigerant filling capacity per metre fill valves, open both fill valves and line length (for line lengths from 12 to refit the caps. 30 m) Type AWT-AC R410A in g/m...
  • Page 74 ■ Soften fill water with a hardness above 16.8 °dH (3.0 mol/m ), e.g. with the small softening system for heating water (see the Viessmann Vitoset pricelist). 1. Open any non-return valves installed on site. 2. Check the pre-charge pressure of the expansion vessel.
  • Page 75 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Fill (flush) and vent the secondary cir- cuit: ■ Slightly open the quick-action air vent valve (see safety assembly, chapter "Connecting the secon- dary circuit"); it remains open. ■ Open the DHW heating air vent valve (see following chapter);...
  • Page 76 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Opening the air vent valve for DHW heating Checking expansion vessel and heating circuit pressure Observe engineering informa- tion. Vitocal technical guide...
  • Page 77 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the DHW cylinder Danger Please note Uncontrolled escape of DHW or Pointed or sharp cleaning heat transfer medium can cause objects scalding and building damage. may damage the DHW cylinder. Only open DHW and heating water connections with a depres- Please note...
  • Page 78 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note A short circuit between the mag- nesium anode and internal indi- rect coil increases the protective effect of the magnesium anode and leads to corrosion damage on the DHW cylinder. Before inserting the electrical cables, measure the resistance between terminals A and B.
  • Page 79 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Replacing the magnesium anode Note Please note If the magnesium anode needs to be A short circuit between the mag- replaced, a maintenance-free impressed nesium anode and internal indi- current anode (accessory) can be used. rect coil increases the protective effect of the magnesium anode For removal of the magnesium anode,...
  • Page 80 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note 3. Check the aluminium fins of the heat Excessive air pressure from exchanger for deformation and the front and sides can result scratches; if necessary, repair with a in the deformation of the alu- suitable tool (e.g.

  • Page 81: Starting The Heat Pump

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Starting the heat pump Please note 2. Wait 2 min. Operation of the heat pump with insufficient refrigerant results in 3. Switch ON internal unit voltage. damage to the appliance. ■...
  • Page 82 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning with the commissioning wizard The commissioning wizard guides you Switch on the ON/OFF switch on the automatically through all the menus heat pump control unit. where settings have to be made. For ■...
  • Page 83 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Language Date Date / Time Time Start commissioning? Coding Parameter group Parameter select level 1 Sensor values Temperature sensors display Signal inputs Signal inputs display Actuator test Actuator test carry out Function check Function Function...
  • Page 84 2. Select "Coding level 1" Required heat pump parameters "Output compressor stage 5030" During commissioning, the heating out- put of the heat pump must be selected subject to type. Vitocal 222-S, type AWT-AC 221.A04 221.A07 221.A10 221.A13 "Output compressor stage...
  • Page 85 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pumps and other components Pump/component Parameter Setting Heating circuit pump "System definition" Ó ■ With heating circuit A1/ HC1 (for heating circuit "System scheme 7000" without mixer) ■ With heating circuit M2/ HC2 (for heating circuit with mixer) DHW circulation pump...
  • Page 86 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) External functions External functions Parameter Setting External demand "Internal hydraulics", if Set flow temperature applicable Ó for external demand "Flow temperature for external demand 730C" External starting of the com- "System definition"...
  • Page 87 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cooling function Parameters for cooling function Setting "Cooling" Ó "3" "Cooling 7100" "Cooling" Ó ■ "1" (heating circuit A1/HC1) "Cooling circuit 7101" ■ "2" (heating circuit M2/HC2) ■ "4" (separate cooling circuit SKK) Instantaneous heating water heater Parameters for...
  • Page 88 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct him/her in the operation of the system.

  • Page 89: Repairs

    Troubleshooting Repairs Opening programming unit...
  • Page 90 Troubleshooting Repairs (cont.) Removing cover from programming unit, if necessary...
  • Page 91 Troubleshooting Repairs (cont.) Overview of internal components: Internal unit...
  • Page 92 Troubleshooting Repairs (cont.) A Cylinder air vent valve for internal K Secondary circuit drain & fill valve coil L Internal unit service valve (Schrader B Cylinder temperature sensor valve; can be used in place of the C Cylinder drain & fill valve (see fol- external unit service valve for check- lowing chapter) ing pressure and evacuating the...
  • Page 93 Troubleshooting Repairs (cont.) C Cylinder drain & fill valve open to drain or fill the cylinder Overview of internal components: External unit Danger Contact with 'live' components can result in severe injuries. Capacitors remain 'live' after the power supply has been switched OFF.
  • Page 94 Troubleshooting Repairs (cont.) External unit, type AWT-AC 221.A04 A Fan F Electronic expansion valve (EEV) B Heat exchanger (evaporator) G Compressor head temperature sen- C Evaporator air intake temperature sor (CTT) sensor (OAT) H Liquid separator D Evaporator temperature sensor K Evaporator refrigerant inlet temper- (OMT) ature sensor (OCT)
  • Page 95 Troubleshooting Repairs (cont.) External unit, type AWT-AC 221.A07 A Fan F Electronic expansion valve (EEV) B Heat exchanger (evaporator) G Compressor head temperature sen- C Evaporator air intake temperature sor (CTT) H Liquid separator sensor (OAT) D Evaporator temperature sensor K Evaporator refrigerant inlet temper- (OMT) ature sensor (OCT)
  • Page 96 Troubleshooting Repairs (cont.) External unit, type AWT-AC 221.A10 and A13 A Fan G Compressor head temperature sen- B Heat exchanger (evaporator) sor (CTT) C Evaporator air intake temperature H Liquid separator sensor (OAT) K Evaporator refrigerant inlet temper- D Evaporator temperature sensor ature sensor (OCT) (OMT) L Compressor...
  • Page 97 Troubleshooting Repairs (cont.) Draining secondary side heat pump 1. Close the on-site boiler drain & fill 2. Drain the heat pump at the secondary valve. circuit fill & drain valve (see chapter "Overview of internal components: Internal unit"). Checking the sensors Sensor Captur- Installed loca-...
  • Page 98 Troubleshooting Repairs (cont.) Temperature sensors type Ni 500 Temperature sensors type Pt 500 140 180 Temperature in °C -40 -20 Temperature in °C Temperature sensors NTC 10 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C...
  • Page 99 Troubleshooting Repairs (cont.) Temperature sensors NTC 50 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C Checking fuses For fuse locations, see from page 48: ■ Fuse F1 is located on the mains ter- minal of the heat pump control unit.

  • Page 100: Internal Unit Parts Lists Internal Unit Parts Lists

    Internal unit parts lists Internal unit parts lists Ordering individual parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local dealer. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list)

  • Page 101: Overview Of Internal Unit Assemblies

    Internal unit parts lists Overview of internal unit assemblies A Type plate C Electrical equipment assembly B Casing assembly...

  • Page 102: Internal Unit Parts Not Shown

    Internal unit parts not shown 0005 Spray paint, Vitowhite 0007 Operating instructions 0006 Touch-up paint stick, Vitowhite Vitotronic 200, type WO1B 0006 Vitocal 222-S installation and 0008 Service instructions service instructions Vitotronic 200, type WO1B Internal unit casing 0001 Front panel, top...
  • Page 103 Internal unit parts lists Internal unit casing (cont.) 0003 0006 0005 0001 0008 0007 0009 0010 0002 0004...

  • Page 104: Internal Unit Electrical Equipment

    Internal unit parts lists Internal unit electrical equipment 0001 Programming unit 0035 Outside temperature sensor 0002 Controller and sensor PCB with 0037 Separator cover (CU401) 0005 Main PCB with cover (MB761) Parts not shown 0006 Expansion PCB with cover 0003 PCB with connection adaptor (SA135) (SA136-A10) 0007 Coding card...
  • Page 105 Internal unit parts lists Internal unit electrical equipment (cont.) 0018 0020 0033 0017 0019 0001 0032 0007 0006 0005 0010 0002 0009 0037 0011 0008 0030 0013 0023 0025 0024 0034 0035...

  • Page 106: Internal Unit Hydraulics

    Internal unit parts lists Internal unit hydraulics 0001 Back panel, casing bottom 0025 Air vent valve G ⅜ 0002 Bottom panel 0026 Clip for threaded pipe D 21-23, 0003 Angle profile, casing bottom, left M8, EPDM insert 0004 Angle profile, casing bottom, right 0027 Clip for threaded pipe D 26-28, 0005 Top panel, casing bottom M8, EPDM insert...
  • Page 107 Internal unit parts lists Internal unit hydraulics (cont.) 0039 0047 0029 0005 0040 0043 0046 0033 0032 0025 0048 0045 0034 0049 0037 0022 0009 0025 0033 0045 0021 0036 0044 0018 0045 0030 0037 0034 0037 0031 0037 0038 0019 0037 0044...

  • Page 108: Internal Unit Cylinder

    Internal unit parts lists Internal unit cylinder 0001 DHW cylinder with internal indi- 0015 Flange gasket rect coil, 170 litres 0016 Sleeve 0002 Back panel, casing top 0017 Sensor mount 0003 Retaining panel for connection 0018 Air vent valve G ⅜ hoses 0019 Spring clip ring 7 32 x 1.5 mm 0004 Retaining bracket, cylinder...
  • Page 109 Internal unit parts lists Internal unit cylinder (cont.) 0007 0027 0019 0029 0012 0029 0008 0019 0016 0029 0029 0029 0013 0004 0028 0014 0015 0001 0015 0002 0014 0018 0026 0017 0029 0010 0016 0029 0025 0026 0026 0029 0020 0011 0009...

  • Page 110: External Unit Parts Lists External Unit Parts Lists

    External unit parts lists External unit parts lists Ordering individual parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local dealer. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) External unit type AWT-AC 221.A04...
  • Page 111 External unit parts lists External unit type AWT-AC 221.A04 (cont.) 0024 0022 0026 0010 0021 0020 0031 0028 0023 0027 0009 0014 0006 0005 0004 0030 0025 0002 0008 0019 0015 0017 0016 0001 0003 0032 0018 0013 0029 0007 0011 0012...

  • Page 112: External Unit Type Awt-Ac 221.A07

    External unit parts lists External unit type AWT-AC 221.A07 0001 Air discharge grille 0025 Coil EEV 0002 Side panel, left 0026 Heat exchanger (evaporator) 0003 M8 nut 0027 Protective grille 0004 Axial fan 0028 Retainer, temperature sensor 0005 4-way diverter valve, complete 0029 Transformer 0006 4-way diverter valve 0030 Partition...
  • Page 113 External unit parts lists External unit type AWT-AC 221.A07 (cont.) 0033 0032 0031 0027 0036 0036 0028 0030 0026 0035 0029 0034 0004 0007 0006 0038 0003 0012 0022 0020 0021 0025 0005 0013 0024 0037 0023 0014 0011 0017 0015 0016 0001...

  • Page 114: Overview Of External Unit Assemblies, Type Awt-Ac 221.A10, A13

    External unit parts lists Overview of external unit assemblies, type AWT-AC 221.A10, A13 A Type plate C Electrical equipment assembly B Casing assembly D Hydraulic assembly...

  • Page 115: External Unit Casing, Type Awt-Ac 221.A10, A13

    External unit parts lists External unit casing, type AWT-AC 221.A10, A13 0001 Top panel 0013 Transport handle, left 0002 Side panel, right 0014 Motor support 0003 Cover, power supply 0015 Air inlet ring 0004 Front panel, left 0016 Transport handle, right 0005 Front panel, right 0017 ODU control unit 0006 Air discharge grille...
  • Page 116 External unit parts lists External unit casing, type AWT-AC 221.A10, A13 (cont.) 0012 0001 0019 0018 0013 0014 0009 0021 0010 0015 0011 0004 0008 0006 0020 0021 0010 0003 0015 0017 0016 0006 0007 0002 0016 0005...

  • Page 117: External Unit Electrical Equipment, Type Awt-Ac 221.A10, A13

    External unit parts lists External unit electrical equipment, type AWT-AC 221.A10, A13 0001 Main PCB 0016 Wiring harness, compressor 0002 Driver PCB 0017 Wiring harness complete, com- 0003 Capacitor PCB pressor 0004 PCB, mains filter 0018 Temperature sensor NTC 10 kΩ 0005 Coils (OCT) 0006 Terminal...
  • Page 118 External unit parts lists External unit electrical equipment, type AWT-AC… (cont.) 0002 0004 0003 0006 0005 0011 0009 0012 0010 0001 0013 0007 0008...

  • Page 119: External Unit Hydraulics, Type Awt-Ac 221.A10, A13

    External unit parts lists External unit hydraulics, type AWT-AC 221.A10, A13 0001 Compressor 0009 Compressor thermal insulation 0002 EEV pipework, complete 0010 Temperature sensor NTC 50 kΩ 0003 4-way diverter valve pipework, (CTT) complete 0011 Shut-off valve, liquid line 0004 Liquid separator 0012 Compressor power supply cover 0005 High pressure switch 0006 Shut-off valve, hot gas line...
  • Page 120 External unit parts lists External unit hydraulics, type AWT-AC 221.A10,… (cont.) 0002 0005 0008 0004 0010 0007 0006 0003 0009 0001 0011 0012...

  • Page 121: Hydraulic Parameter Report

    Commissioning/service reports Hydraulic parameter report Setting and test values Set value Commission- Testing the external heating circuit pumps Circulation pump type Circulation pump stage Overflow valve setting Primary circuit commissioning Air inlet temperature °C Air discharge temperature °C Temperature differential ΔT: Secondary circuit flow temperature = 35 °C 4 to 8 at air inlet temperature ≤...
  • Page 122 Commissioning/service reports Control parameter report (cont.) Parameter Code Delivered condi- Commis- tion sioning System definition System scheme 7000 Language 7001 German Temperature differential for calculating 7003 40 (≙ 4 K) the heating limit Temperature differential for calculating 7004 40 (≙ 4 K) the cooling limit External extension 7010...
  • Page 123 Commissioning/service reports Control parameter report (cont.) Parameter Code Delivered condi- Commis- tion sioning Set DHW temperature 6000 500 (≙ 50 °C) Min. DHW temperature 6005 100 (≙ 10 °C) Max. DHW temperature 6006 600 (≙ 60 °C) Hysteresis DHW temperature heat pump 6007 70 (≙...
  • Page 124 Commissioning/service reports Control parameter report (cont.) Parameter Code Delivered condi- Commis- tion sioning Heating water buffer cylinder Enable buffer cylinder/low loss header 7200 Temp. in operating status fixed value for 7202 500 (≙ 50 °C) buffer cyl Hysteresis temperature heating buffer 7203 50 (≙...
  • Page 125 Commissioning/service reports Control parameter report (cont.) Parameter Code Delivered condi- Commis- tion sioning Cooling curve slope 7111 12 (≙1.2) Time Automatic changeover summertime - 7C00 wintertime Start summertime - month 7C01 Start summertime - week 7C02 Start summertime - day 7C03 Start wintertime - month 7C04...

  • Page 126: Specification

    Specification Specification Vitocal 222-S Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Heating output data at 100 % to EN 14511 (A2/W35 °C, spread 5 K) Rated heating output 10.6 Compressor frequency Fan speed Power consumption 0.91 1.73 2.20 3.25 Coefficient of perform- 3.27...
  • Page 127 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Air intake temperature Cooling mode ■ Min. °C ■ Max. °C Heating mode ■ Min. °C –15 –15 –15 –15 ■ Max. °C Heating water at 10 K spread Capacity 16.7 16.7 17.7 17.7...
  • Page 128 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Electrical values Internal unit Heat pump control unit/PCB ■ Rated voltage, con- 1/N/PE 230 V/50 Hz trol unit/PCB ■ Fuse protection, 1xB16A power supply ■ Internal fuse/MCB 6.3A (slow)/250 V Instantaneous heat- ing water heater ■...
  • Page 129 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Integral cylinder Capacity Continuous output when heating DHW from 10 to 60 °C Performance factor N to DIN 4708 Max. draw-off rate at l/min 14.3 14.8 15.9 16.5 the stated performance factor N and DHW heating from 10 to...
  • Page 130 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Connections Heating water flow Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Heating water return Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cold water...

  • Page 131: Heat Pump Commissioning Order

    Installation completed in full up to refrigerant circuit All windows and external doors sealed Components for cooling mode fully installed (optional) Preferred appointment: Date Time Date Time All work ordered from Viessmann will be charged to me/us in accordance with the current Viessmann pricelist. Place/date Signature...

  • Page 132: Declaration Of Conformity

    Declaration of conformity We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole respon- sible body that the product Vitocal 222-S, type AWT-AC, including heat pump control unit Vitotronic 200, type WO1B, complies with the following standards: DIN 8901 EN 61 000-3-11;...

  • Page 133: Keyword Index

    Keyword index Keyword index Checking free running of fan....79 Activating cooling.......51 Checking solder joints......73 Adjustable feet........23 Checking swaged connections..73 Air discharge........21 Checking system pressure....75 Air discharge grille removal....79 Checking the sensors......97 Air intake..........21 Checking threaded fittings....73 Air short circuit........18 Check valve........44 Air vent valve, secondary circuit..92 Chilled ceiling........44 Aligning the appliance......23...
  • Page 134 Keyword index Keyword index (cont.) Connection Cylinder ■ Cooling circuit.........44 ■ Drain & fill valve......92 ■ DHW..........44 ■ Specification.........129 ■ Electric components.......45 Cylinder, cleaning......77 ■ Secondary circuit......43 Cylinder assembly Connection conditions ■ Internal unit........108 ■ Power supply utility......63 Cylinder drain & fill valve....92 Connections......7, 8, 130 Cylinder module, fitting......31 ■...
  • Page 135 Keyword index Keyword index (cont.) Electrical connection External changeover in operating status ■ Circulation pumps.....50, 53 ■ Parameter settings......86 ■ External unit........57 External demand ■ Internal unit........48 ■ Parameter settings......86 ■ Temperature sensors.....55 External extension H1......56 Electrical connections ■ Parameter settings......85 ■...
  • Page 136 Keyword index Keyword index (cont.) Fill valve Heating output data......126 ■ External unit......70, 72, 73 Heating output subject to type...84 Fill water..........74 Heating water buffer cylinder.....13 Fitting cylinder module.......31 Heating water flow...8, 41, 42, 130 Floor load...........23 Heating water return..8, 41, 42, 130 Floor mounting Heat pump, closing......65 ■...
  • Page 137 Keyword index Keyword index (cont.) Instantaneous heating water Liquid gas temperature sensor heater 13, 63, 64, 92 ■ Curve..........97 ■ Enable..........87 Liquid line..8, 13, 33, 35, 37, 70, 130 ■ High limit safety cut-out reset..87 ■ Torque........36, 40 ■ Parameter settings......87 Liquid separator.....94, 95, 96 ■...
  • Page 138 Keyword index Keyword index (cont.) Operator's log........73 Pipe ends, flaring.......35 Output compressor stage....84 Pipe openings Outside temperature sensor..13, 55 ■ For refrigerant lines....35, 37 ■ Curve..........97 Pipe outlet..........31 Overflow valve........43 Pipes, securing........35 Overview Pipe separator........44 ■ Internal components....91, 93 Power cable........9, 60 ■...
  • Page 139 Keyword index Keyword index (cont.) Protective gloves....69, 72, 73 Report Pumps........85, 91, 93 ■ Control parameters.......121 Reports..........121 Required parameter settings Quick-action air vent valve...43, 75 ■ For system scheme......17 Reset button ■ For instantaneous heating water Radiator heating circuit......14 heater..........87 RCD...........63 Return temperature sensor, secondary Recommended power cables....9...
  • Page 140 Keyword index Keyword index (cont.) Service menu ■ Calling up........84 Temperature limiter......13, 52 ■ Disabling.........84 Temperature sensor ■ Enabling..........83 ■ Compressor head (CTT)..94, 95, 96 Service valve ■ Evaporator (OMT)....94, 95, 96 ■ External unit......69, 70, 72 ■ Evaporator air intake (OAT)94, 95, 96 ■...
  • Page 141 Keyword index Keyword index (cont.) Vitocom Water quality........74 ■ Parameter settings......85 Weather proofing.......19 Vitocom 100........56 Weight..........20 ■ External unit........129 ■ Internal unit........129 Wall mounting Wind direction........19 ■ Bracket set........23 Wind loads.........19 ■ External unit........23 Working on the refrigerant circuit..73 Wall mounting bracket set....19 Writing reports........68 Warranty..........82...
  • Page 144 Serial No.: 7424689 7424690 7424691 7424692 7452479 7452480 7497344 7497345 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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