Air/water heat pumps with indoor and outdoor units, monoblock version, 2.4 to 14.7 kw (152 pages)
Summary of Contents for Viessmann Vitocal 222-G
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VIESMANN Installation and service instructions for contractors Vitocal 222-G Type BWT 221.A06 to A10 Type BWT-M 221.A06 to A10 Compact heat pumps, 400 V~ and 230 V~ For applicability, see the last page VITOCAL 222-G Please keep safe. 5674 003 GB...
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■ Safeguard the system against reconnection. 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.
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Spare and wearing parts that have not been tes- ted together with the system can compromise its function. Installing non-authorised components and making non-approved modifications or con- versions can compromise safety and may inva- lidate our warranty. For replacement, use only spare parts supplied or approved by Viessmann.
■ Viessmann NTC 20 k (orange marking) ........... 56 Ω ■ Viessmann Pt500A (green marking) ........... 57 ■ Checking the fuses ................57 Appliance is too noisy ................58 6. Parts lists type BWT 221.A Overview of assemblies ................. 60 (400 V~) Parts not shown ..................
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Index Index (cont.) Casing ....................62 Control unit and electrical equipment ............ 64 Heat pump module ................66 Hydraulics ....................68 Cylinder ....................70 7. Parts lists type Overview of assemblies ................. 72 BWT-M 221.A (230 V~) Parts not shown .................. 73 ■...
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Information Symbols Symbol Meaning Reference to other document containing further information Additional information, not safety relevant Step in a diagram: The numbering corresponds to the se- quence of work. The work sequences for commissioning, inspection and maintenance are summarised in the chapter "Commissioning, inspection and maintenance "and are marked as follows: Symbol...
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Information Product information Layout Central cooling The Vitocal 222-G is a brine/water heat pump with an Central cooling utilising the natural cooling function integral DHW cylinder. can be provided either by means of a heating/cooling Subject to type, the compressor operates either with circuit or via a separate cooling circuit.
Preparing for installation Requirements regarding on-site connections (cont.) Recommended power cables Type BWT/BWT-M 221.A06 221.A08 221.A10 Heat pump control unit 230 V~ Cable cross-section Without power-OFF 3 x 1.5 mm 3 x 1.5 mm 3 x 1.5 mm ■ With power-OFF 5 x 1.5 mm 5 x 1.5 mm 5 x 1.5 mm...
Preparing for installation Siting and transport requirements (cont.) Minimum room volume (to EN 378): Type BWT/ Floor area in Minimum room vol- BWT-M ume in m 221.A06 221.A08 221.A10 Minimum clearances Fig. 2 Minimum room height h Installation h in mm Without connection set for pre-instal- 2000 ■...
Installation sequence Siting the heat pump (cont.) Assembly and sealing faces to note 2. Mount the cylinder module in reverse order to that described on page 11. Please note Leaking hydraulic connections lead to appli- ance damage. Make watertight hydraulic connections ■...
Installation sequence Siting the heat pump (cont.) Removing the transport brackets Please note Operating the appliance without first removing the transport brackets may cause vibrations and excessive noise. Remove the transport brackets. Fig. 14 Hydraulic connections For arrangement of hydraulic connections: see page 8. Connecting the primary/secondary circuits Connecting the pipe sections or pipe bends sup- plied with the connection set (accessories)
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Installation sequence Hydraulic connections (cont.) 3. Connect primary pipes to heat pump. Please note Mechanically loaded hydraulic connections lead to leaks, vibration and appliance dam- age. Connect on-site lines so that they are free of load and torque stress. Please note Leaking hydraulic connections lead to appli- ance damage.
Installation sequence Hydraulic connections (cont.) 2. Connect secondary lines to the heat pump. Note ■ With underfloor heating circuits, install a temperature Please note limiter to restrict the maximum temperature of under- Mechanically loaded hydraulic connections floor heating systems: See chapter "Connecting a lead to leaks, vibration and appliance dam- temperature limiter to restrict the maximum tempera- age.
Installation sequence Hydraulic connections (cont.) Installation instructions for contact humidistat (24 V – ■ Install in the coolant flow of the room to be cooled. If necessary remove parts of the thermal installation in order to provide direct contact with the pipe. ■...
Installation sequence Electrical connections (cont.) Overview of the heat pump control unit electrical connections a:C] a:C] 400 V / 50 Hz 230 V / 400 V / 50 Hz 50 Hz 230 V / 50 Hz Fig. 19 Expansion PCB on main PCB: connect nothing on site.
Installation sequence Electrical connections (cont.) Main PCB (230 V~ components) Information regarding the connection values Set the required parameters during commissioning: The specified output is the recommended connected see page 42 onwards. ■ load. ■ The total output of all components connected directly to the heat pump control unit (e.g.
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Installation sequence Electrical connections (cont.) Plug Terminals Function Explanation 212.3 DHW circulation pump Connection values Output: 50 W ■ Voltage: 230 V~ ■ Max. switching current: 4(2) A ■ 212.4 3-way diverter valve for heating water Connection values buffer cylinder bypass or heat pump Output: 130 W ■...
Installation sequence Electrical connections (cont.) Expansion PCB on main PCB (230 V~ components) Do not make any on-site connections. Luster terminals (alarm and safety connections) Set the required parameters during commissioning: see page 42 onwards. Terminals Function Explanation X3.1 Switched phase Via control unit ON/OFF switch Note Observe the total load 1000 W of all connected compo-...
Installation sequence Electrical connections (cont.) Terminals Function Explanation X3.8 Pressure switch, primary circuit Requires floating N/C contact: X3.9 and/or Closed: Continuous safety chain ■ Open: Safety chain interrupted; heat pump shut down ■ Breaking capacity 230 V~, 0.15 A ■ Connection: Connected in series if both safety components are in- ■...
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— Connection for Viessmann appliances, e.g. Vitovent 300-F Note If further Viessmann appliances are to be connected to Modbus 1, plug in the Modbus distributor (accessories) (see "Modbus distributor" installation in- structions). Connection for LON communication module (see "LON communication mod- —...
Installation sequence Power supply Isolators for non-earthed conductors The assignment of the power-OFF (for compressor ■ ■ Install an isolator in the power cable to provide and/or instantaneous heating water heater) is made omnipolar separation from the mains for all active via the type of connection and by setting parameters conductors, corresponding to overvoltage category in the heat pump control unit.
Installation sequence Power supply (cont.) Heat pump control unit power supply 230 V~ Note This supply must never be blocked. ■ Max. fuse rating 16 A ■ Standard tariff (no economy tariff with power-OFF possible) ■ Recommended power cable: 3 x 1.5 mm (5 x 1.5 mm with power-OFF) F1 T6,3AH...
Installation sequence Power supply (cont.) Connecting 230 V~ instantaneous heating water heater power supply 230V / 50 Hz Max. fuse rating 16 A: See "Specification". ■ 1/N/PE Economy tariff and power-OFF can be applied ■ ■ Recommended power cable: 7 x 2.5 mm Max.
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Installation sequence Power supply (cont.) X3.7 X3.6 X3.18/X2.1/X1.1 5 (400 V~) (230 V~) ≈ Fig. 30 Diagram excluding fuses and RCDs Heat pump control unit Instantaneous heating water heater Compressor Heat pump control unit power supply Premium tariff meter Ripple control receiver backup fuse Ripple control receiver (contact open: power-OFF enabled) with backup fuse Economy tariff meter...
Installation sequence Power supply (cont.) Mains power supply in conjunction with on-site power consumption Without power-OFF E1E2 D /D L1 L1 L2 L2 L3 L3 Fig. 31 Heat pump Bi-directional meter (for PV systems to consume Additional consumers (of power generated on site) power on site): Energy taken from power supply utility and energy in the household...
Installation sequence Power supply (cont.) [{{] 0-10V Fig. 32 EA1 extension Floating N/O contact 2: The agreement of the Connection to controller and sensor PCB power supply utility may be required Floating N/O contact 1: The agreement of the Power supply 1/N/PE 230 V/50 Hz power supply utility may be required Note ■...
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Installation sequence Power supply (cont.) Version 1 Version 2 N 11 21 <>U <>U L1 L2 L3 12 14 22 24 Fig. 34 LEDs explained in Fig. 34 Fig. 33 Voltage "U": ■ Illuminates green if voltage is applied. Over/undervoltage in % Relay "R": Phase asymmetry in % ■...
Installation sequence Power supply (cont.) Version 3 LEDs explained in Fig. 35 Voltage "Un": ■ Illuminates green if voltage is applied. Relay "R": ■ Illuminates yellow if the phase sequence is cor- rect. L1, L2, L3 Does not illuminate if the phase sequence is ■...
Commissioning, inspection, maintenance Opening the heat pump Danger Please note Contact with 'live' components can lead to seri- Commissioning immediately after installation ous injury from electric current. can lead to appliance damage. ■ Never touch the wiring chambers (for heat Wait at least 30 min between installing and pump control unit and power supply connec- commissioning the appliance.
Temperature differential between primary circuit flow and return: 3 K to 5 K 1. Check the pre-charge pressure of the expansion vessel. 2. Charge the primary circuit with Viessmann heat transfer medium and vent. Note Ensure frost protection down to 19 °C.
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Commissioning, inspection, maintenance Filling and venting the secondary side (cont.) Fig. 36 5. Open any non-return valves installed on site. 6. Check the pre-charge pressure of the expansion vessel: see page 41. 7. Fill (flush) and vent secondary circuit: Open air vent valve of the secondary circuit. ■...
Commissioning, inspection, maintenance Checking the expansion vessel and heating circuit pressure Observe engineering information. Technical guides for heat pumps Cleaning the DHW cylinder Danger Please note Uncontrolled escape of DHW or heat transfer A short circuit between the magnesium anode medium can cause scalding and building dam- and the internal indirect coil negates the protec- age.
Commissioning, inspection, maintenance Checking the anode protective current with an anode tester 1. Remove cover and pull earth cable 2. Connect the tester (measuring range up to 5 mA) from tab See Fig. in chapter "Cleaning the DHW cylinder". in series across tab and earth cable Anode pro- Magnesium anode...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Commissioning with the commissioning assistant The commissioning assistant automatically guides you Switch ON the ON/OFF switch on the control unit. through all the menus where settings have to be made. The prompt "Start commissioning?" appears auto- ■...
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Commissioning, inspection, maintenance Commissioning the system (cont.) language date/time time date Start commissioning? Coding Select level 1 parameter group parameter Temperature Display sensors sensor values Signal inputs Display signal inputs Actuator test Carry out actuator test Subscriber check (LON) Carry out subscriber check Start Functional...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Required parameters for components connected on site Parameters may need to be set subject to the type of Detailed explanations of parameters appliance, the selected system scheme and the acces- "Vitotronic 200" service instructions sories used.
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Commissioning, inspection, maintenance Commissioning the system (cont.) Parameters for pumps and other components Parameter Setting Heating circuit pump "System definition" Ó "System scheme 7000" With heating circuit A1/HC1 for heat- ■ ing circuit without mixer With heating circuit M2/HC2 for ■...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Parameters for external functions Parameter Setting External demand If applicable "Internal hydraulics" Ó "Flow temperature for external demand 730C" Set flow temperature for external de- mand External starting of the compressor; mixer in control mode or OPEN "System definition"...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Parameters for swimming pool water heating Parameter Setting "System definition" Ó "External extension 7010" "1" or "3" "Swimming pool 7008" "1" Parameters for ventilation Parameter Setting "Ventilation" Ó "Vitovent enable 7D00" "1" Other enabling settings, if applicable: "Ventilation"...
Commissioning, inspection, maintenance Commissioning the system (cont.) Parameters for Smart Grid Parameter Setting "Smart Grid" Ó "Enable Smart Grid 7E80" "1" "Smart Grid Enable elec heat 7E82" "1" Stage 1 "2" Stage 2 "3" Stage 3 Specify the temperature differential to the selected set value for the chosen function. "Smart Grid"...
Commissioning, inspection, maintenance Checking the system function (cont.) Fig. 41 Reset button Instructing the system user The system installer should hand the operating instruc- tions to the system user and instruct the user in oper- ating the system. This includes all components installed as accessories, e.g.
Maintenance Overview of electrical components Type BWT 221.A (400 V~) Reset button of the high limit safety cut-out of the instantaneous heating water heater Compressor contactor Cable channel 3 rows of luster terminals Controller and sensor PCB Programming unit Main PCB Expansion PCB on the main PCB Compressor power supply Switching module with power supply for instanta-...
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Maintenance Overview of electrical components (cont.) Type BWT-M 221.A (230 V~) Reset button of the high limit safety cut-out of the instantaneous heating water heater Compressor contactor Cable channel 3 rows of luster terminals Controller and sensor PCB Programming unit Main PCB Expansion PCB on the main PCB Compressor power supply...
Maintenance DHW cylinder drain & fill valve positions Fig. 47 Closed Open to drain the internal DHW line Open to drain or fill the cylinder Draining the heat pump on the secondary side 1. Close the on-site boiler drain & fill valve. 2.
Maintenance Checking the sensors (cont.) Viessmann NTC 10 k (blue marking) Ω Outside temperature sensor Other sensors Temperature in °C Temperature in °C Fig. 48 Fig. 49 Viessmann NTC 20 k (orange marking) Ω Temperature in °C Fig. 50...
Maintenance Checking the sensors (cont.) Viessmann Pt500A (green marking) Temperature in °C Fig. 51 Checking the fuses For fuse locations, see page 23 onwards. Fuse F1 is located on the mains terminal of the heat Fuses F1 and F3: ■...
Maintenance Appliance is too noisy Possible causes: ■ Transport bracket not removed: see page 19. ■ Casing door not closed: see page 18. ■ The secondary circuit return line touches the primary circuit return line, other lines or the compressor. Fig.
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Maintenance Appliance is too noisy (cont.)
Parts lists type BWT 221.A (400 V~) Overview of assemblies The following details are required when ordering parts: ■ Serial no. (see type plate ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) Fig.
The following details are required when ordering parts: ■ Serial no. (see type plate in Fig. 53) ■ Position number of the part (from this parts list) Pos. Part 0006 Touch-up spray paint, white 0007 Touch-up paint stick, white 0008 Vitocal 222-G installation and service instructions...
Parts lists type BWT 221.A (400 V~) Casing 0003 0006 0005 0001 0008 0004 0007 0009 0002 0010 Fig. 54...
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Front panel, top, with logo 0002 Front panel, bottom 0003 Side panel, left 0004 Side panel, right 0005 Top panel, front 0006 Top panel, back 0007 Support, heat pump control unit 0008 Viessmann logo and Vitocal logo 0009 Screws (set) 0010 Fixing parts (set)
Parts lists type BWT 221.A (400 V~) Control unit and electrical equipment 0014 0016 0015 0010 0001 0012 0014 0015 0017 0011 0016 0040 0017 0007 0006 0038 0039 0013 0004 0005 0041 0002 0003 0042 0032 0035 0036 0019 0018 0022 0029...
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Parts lists type BWT 221.A (400 V~) Control unit and electrical equipment (cont.) Pos. Part 0001 Programming unit 0002 Controller and sensor PCB with cover (CU401) 0003 Base support, controller and sensor PCB 0004 Main PCB with cover (MB761) 0005 Base support, main PCB 0006 Expansion PCB with cover (SA135)
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Parts lists type BWT 221.A (400 V~) Hydraulics (cont.) Pos. Part 0001 Back panel, lower casing 0002 Base plate 0003 Anti-vibration mount 0004 Top panel, lower casing 0005 Strut, lower casing, left 0006 Strut, lower casing, right 0007 Retaining rail 0008 Insulation, base plate 0009...
Parts lists type BWT-M 221.A (230 V~) Overview of assemblies The following details are required when ordering parts: ■ Serial no. (see type plate ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) Fig.
The following details are required when ordering parts: ■ Serial no. (see type plate in Fig. 59) ■ Position number of the part (from this parts list) Pos. Part 0006 Touch-up spray paint, white 0007 Touch-up paint stick, white 0008 Vitocal 222-G installation and service instructions...
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Front panel, bottom 0003 Side panel, left 0004 Side panel, right 0005 Top panel, front 0006 Top panel, back 0007 Support, heat pump control unit 0008 Viessmann logo and Vitocal logo 0009 Screws (set) 0010 Fixing parts (set) 0011 Top panel, front...
Parts lists type BWT-M 221.A (230 V~) Control unit and electrical equipment 0014 0016 0015 0012 0001 0014 0010 0040 0015 0016 0017 0006 0017 0007 0039 0011 0038 0013 0004 0005 0002 0003 0041 0019 0042 0032 0029 0035 0018 0036 0027...
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Parts lists type BWT-M 221.A (230 V~) Control unit and electrical equipment (cont.) Pos. Part 0001 Programming unit 0002 Controller and sensor PCB with cover (CU401) 0003 Base support, controller and sensor PCB 0004 Main PCB with cover (MB761) 0005 Base support, main PCB 0006 Expansion PCB with cover (SA135)
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Parts lists type BWT-M 221.A (230 V~) Hydraulics (cont.) Pos. Part 0001 Back panel, lower casing 0002 Base plate 0003 Anti-vibration mount 0004 Top panel, lower casing 0005 Strut, lower casing, left 0006 Strut, lower casing, right 0007 Retaining rail 0008 Insulation, base plate 0009...
Parts lists type BWT-M 221.A (230 V~) Mounting set 0004 0005 0006 0001 0002 0003 0003 0002 Fig. 65...
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Parts lists type BWT-M 221.A (230 V~) Mounting set (cont.) Pos. Part 0001 Flange for magnesium anode 0002 Magnesium anode 0003 Flange gasket 0004 Safety valve 0005 Extension R x 30 mm ½ 0006 Flange insulation...
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Commissioning/service reports Control parameter report (cont.) Internal hydraulics Parameter Code Delivered condition Commission- Maintenance/ service "Heat pump for drying a building" 7300 "Time program for screed drying" 7303 ≙ "Set flow temperature for external de- 730C 500 ( 50 °C) mand"...
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Commissioning/service reports Control parameter report (cont.) Cooling Parameter Code Delivered condition Commission- Maintenance/ Service "Cooling function" 7100 "Cooling circuit" 7101 ≙ "Set room temperature separate cooling 7102 200 ( 20 °C) circuit" ≙ "Min. flow temperature cooling" 7103 100 ( 10 °C) "Influence room temperature hook-up 7104...
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Commissioning/service reports Control parameter report (cont.) Photovoltaics Parameter Code Delivered condition Commission- Maintenance/ service "Enable own energy consumption PV" 7E00 ≙ "Prop. of external current" 7E02 10 ( 10 %) ≙ "Threshold for electrical power" 7E04 0 W) "Enable own energy consumptn for set 7E10 DHW temperature 2"...
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Commissioning/service reports Control parameter report (cont.) Communication Parameter Code Delivered condition Commission- Maintenance/ service "Enable LON communication module" 7710 "LON subscriber number" 7777 "LON fault manager" 7779 "LON system number" 7798 "Interval for data transfer via LON" 779C 20 min "Source outside temperature"...
Specification Specification 400 V appliances Type BWT 221.A06 221.A08 221.A10 Output data to EN 14511 (B0/W35, 5 K spread) Rated heating output 10.0 Cooling capacity Power consumption 1.40 1.87 2.35 Coefficient of performance (COP) ε Output data with reference to EN 255 (B0/W35, 10 K spread) Rated heating output 10.4...
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Specification Specification (cont.) Type BWT 221.A06 221.A08 221.A10 Power consumption Primary pump (high efficiency circulation pump) W 4 to 72 ■ Secondary pump (high efficiency circulation 6 to 87 ■ pump) Max. power consumption, control unit 1000 1000 1000 Rated output, control unit/PCB Refrigerant circuit Refrigerant R410A...
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Specification Specification (cont.) 230 V appliances Type BWT-M 221.A06 221.A08 221.A10 Output data to EN 14511 (B0/W35, 5 K spread) Rated heating output 10.1 Cooling capacity Power consumption 1.50 1.86 2.36 Coefficient of performance (COP) ε Output data with reference to EN 255 (B0/W35, 10 K spread) Rated heating output 10.4...
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Specification Specification (cont.) Type BWT-M 221.A06 221.A08 221.A10 Refrigerant circuit Refrigerant R410A R410A R410A Refrigerant charge 2.05 Compressor Type Hermetically sealed scroll compressor Oil in compressor Type Emkarate RL32 3MAF Permiss. operating pressure High pressure side ■ Low pressure side ■...
Components for ventilation fully installed (optional) Components for PV system fully installed (optional) Preferred appointment: Date Time Date Time The work that is requested to be carried out by Viessmann will be billed in accordance with the latest Viessmann pricelist. Place / Date Signature...
Vitocal 222-G, type BWT/BWT-M 221.A including heat pump control unit Vitotronic 200, type WO1C We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, declare as sole responsible body that the named product complies with the provisions of the following directives and regulations:...
Keyword index Keyword index Connection values Air vent valve – Circulation pumps........... 26 – Primary circuit............54 – Components............26 – Secondary circuit.............54 Contact humidistat..........22, 27 Ambient temperatures..........9 Controller and sensor PCB...... 51, 52, 65, 77 Anode protective current..........42 Control parameters............
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Keyword index Keyword index (cont.) Expansion vessel............39 Instantaneous heating water – Checking..............41 heater........... 31, 32, 47, 54, 93, 95 Extended menu............44 – Power supply.............30, 31 Extension kit, mixer..........27, 46 – Resetting high limit safety cut-out......49 External extension............46 Instantaneous heating water heater switching mod- External functions............47...
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Keyword index Keyword index (cont.) Overview Power supply............29, 34 – Electrical connections..........51 – Compressor..........30, 51, 52 – Internal components..........54 – Heating water heat pump control unit..... 27 – Pumps..............54 – Heat pump control unit........ 30, 31, 32 – Sensors..............54 –...
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Keyword index Keyword index (cont.) Secondary circuit Temperature sensor – Connecting.............. 20 – Curve, type NTC 10 k ........... 56 Ω – Draining..............55 – Curve, type NTC 20 k ........... 56 Ω – Filling and venting........... 39 – Curve, type Pt500A..........57 Secondary pump..........
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