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

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

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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, B10, B13 Compact heat pumps, split version for heating and cooling opera- tion For applicability, see the last page VITOCAL 222-S Please keep safe. 5782 201 GB...
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ Codes of practice of the 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 Repairing components that fulfil a safety function can compromise the safe operation of your sys- tem. Defective components must be replaced with genuine Viessmann spare parts. Auxiliary components, spare and wearing parts Please note Spare and wearing parts that have not been tested together with the system can compromise its function.
  • Page 4 Index Index Installation instructions Preparing for installation Intended use......................Requirements regarding on-site connections............Installation sequence Installing the external unit..................10 Installing the internal unit..................14 Connecting refrigerant lines................. 23 Connecting the secondary circuit................. 32 Connections on the DHW side................35 Connecting a cooling circuit if required..............
  • Page 5 Index Index (cont.) Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Ordering individual parts..................113 Overview of the assemblies................. 114 External unit casing....................115 Electrical equipment, external unit............... 117 Hydraulics, external unit..................119 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Ordering individual parts..................
  • Page 6 Preparing for installation Intended use The appliance is only intended to be Commercial or industrial usage for a pur- installed and operated in sealed unven- pose other than central heating/cooling ted heating systems that comply with or DHW heating shall be deemed inap- EN 12828, with due attention paid to the propriate.
  • Page 7 Preparing for installation Requirements regarding on-site connections Internal unit A Opening for LV leads < 42 V B DHW...
  • Page 8 Preparing for installation Requirements regarding 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 Preparing for installation Requirements regarding on-site connections (cont.) Cable lengths in the internal/external unit plus wall clearance Cables Internal unit External unit Power cables: ■ Heat pump control unit (230 V~) 2.0 m – ■ Compressor (230 V~/400 V~) – 1.5 m Other connecting cables: ■...
  • Page 10 Installation sequence Installing the external unit Please note Please note Avoid damaging the appliance If the compressor in the external during transport. unit is strongly tilted, lubricant will Never put weight on top of the enter the refrigerant circuit and appliance.
  • Page 11 Installation sequence Installing the external unit (cont.) Types of installation ■ Consider the heat emitted by the unit when planning your weatherproofing ■ Floorstanding installation with cable or an enclosure. entry above ground level ■ Ensure the condensate can drain ■...
  • Page 12 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 221.A04 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥...
  • Page 13 Installation sequence Installing the external unit (cont.) Floor mounting A Support for floorstanding installation (accessory)
  • Page 14 Installation sequence Installing the external unit (cont.) B Gravel bed as condensate soak- E Rubber mounts (supplied) away C Concrete foundations (see technical guide) D Drainage pipe DN 100 (only with entries below ground level) Note We recommend letting condensate drain away freely (without condensate pipe).
  • Page 15 Installation sequence Installing the internal unit (cont.) Total weight with filled DHW cylinder Minimum room volume (to EN 378): Type AWT-AC Weight in kg Type AWT-AC Minimum room 221.A04 volume in m 221.A07 221.A04 221.A10 221.A07 221.A13 221.A10 221.B10 221.A13 221.B13 221.B10 221.B13...
  • Page 16 Installation sequence Installing the internal unit (cont.) Removing the cylinder module...
  • Page 17 Installation sequence Installing the internal unit (cont.) 193B P501 P303 P302 P301...
  • Page 18 Installation sequence Installing the internal unit (cont.)
  • Page 19 Installation sequence Installing the internal unit (cont.)
  • Page 20 Installation sequence Installing the internal unit (cont.)
  • Page 21 Installation sequence Installing the internal unit (cont.) Note Do not damage sealing tape A when removing the cylinder module.
  • Page 22 Installation sequence Installing the internal unit (cont.) Assembly and sealing faces to bear in mind 2. Fit the cylinder module in reverse order to the cylinder module removal described on page 16. Please note Make tight hydraulic connec- tions between the heat pump module and cylinder module.
  • Page 23 Installation sequence Installing the internal unit (cont.) Connecting refrigerant lines ■ The external unit is pre-filled with refrigerant R 410A. ■ In the following cases, fit oil lift bends in the vertical pipe (see diagram below): – In heating mode, if the internal unit is installed higher than the external unit.
  • Page 24 Installation sequence Connecting refrigerant lines (cont.) Routing refrigerant lines Type AWT-AC 221.A04 221.A07 221.A10 221.A13 221.B10 221.B13 Refrigerant lines Min. line length Max. line length 20 m 30 m 30 m 30 m Max. height differential internal 10 m 15 m 15 m 15 m unit –...
  • Page 25 Installation sequence Connecting refrigerant lines (cont.) A Pipe bends as vibration compensa- D Electrical cables/leads, internal/ tors external unit B Pipe clips with EPDM lining C Cable entry, e.g. drainage pipe with thermal insulation Connection to the external unit 1. Type AWT-AC 221.A04 and A07: Remove the side cover;...
  • Page 26 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. Contamination (e.g. metal swarf) or moisture must not 4. Secure the pipes. enter the copper pipes. Therefore, hold the pipe open- ings downwards or tempora- rily plug them.
  • Page 27 Installation sequence Connecting refrigerant lines (cont.) Tighten nuts with the following torque: 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 28 Installation sequence Connecting refrigerant lines (cont.) C Liquid line D Hot gas line Please note Note Contamination (e.g. metal swarf) ■ The refrigerant lines of the internal unit or moisture must not enter the are filled with nitrogen; overpressure copper pipes. 2 bar (0.2 MPa).
  • Page 29 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 30 Installation sequence Connecting refrigerant lines (cont.) 5. Flare the pipe bends on their open end and secure connection piece (twin connector) 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 31 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 32 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 63–77 221.B10 Liquid line 7 10 mm ⅝...
  • Page 33 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 34 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 35 Installation sequence Connections on the DHW side For connecting the DHW side, observe DIN 1988 and DIN 4753 . P R H M O A DHW H Shut-off valve B DHW circulation pump K Flow regulating valve C Spring-loaded check valve L Pressure gauge connection D Heat pump connecting chamber M Non-return valve/pipe separator...
  • Page 36 Installation sequence Connections on the DHW side (cont.) Recommendation: Install the safety valve higher than the top edge of the cyl- inder. This protects the valve against contamination, scaling and high temper- atures. The DHW cylinder does not then need to be drained when working on the safety valve.
  • Page 37 Installation sequence Electrical connections (cont.) This ensures that, should there Please note be an error, for example when In terms of safety, the BUS cable detaching a wire, the wires can- for the internal/external unit not drift into the adjacent voltage (12 V or 43 V) does not count as area.
  • Page 38 Installation sequence Electrical connections (cont.) Internal unit: Routing electric cables to the wiring chamber 400/230 V > 42 V < 42 V...
  • Page 39 Installation sequence Electrical connections (cont.) A Power cables to switching module E Type AWT-AC 221.A04 and for instantaneous heating water 221.A07: heater 230 V~/400 V~ 43 V BUS cable: Routing in the B Connecting cables for 230 V~ func- 230 V~ voltage range (connection, tion components see page 51) C LV connecting leads (sensors, KM...
  • Page 40 Installation sequence Electrical connections (cont.) Internal unit: Overview of connections 12 V P202 P203 43 V F101...
  • Page 41 Installation sequence Electrical connections (cont.) A Expansion PCB on main PCB (con- F Switching module and power supply nect nothing on site) for instantaneous heating water B Main PCB (see page 41) heater (see page 56) F3 Fuse 6.3 A (slow) C Controller and sensor PCB (see page 46) D AVI PCB (see page 49)
  • Page 42 Installation sequence Electrical connections (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 to restrict the maximum temperature for underfloor heating systems (if installed) in series.
  • Page 43 Installation sequence Electrical connections (cont.) Connecting a temperature limiter as a maximum temperature limiter for under- floor heating Connecting a general temperature Connecting the temperature limiter, limiter B part no. 7151 728, 7151 729 B X2.N X2.N sÖ Heating circuit without mixer A1/ Connection Circulation pump C A to control...
  • Page 44 Installation sequence Electrical connections (cont.) Connecting the temperature limiter, part no. 7151 728, 7151 729 B to mixer extension kit sÖ sÖ A Connect plug sÖ to mixer extension B Temperature limiter C Heating circuit pump for heating cir- cuit with mixer Internal unit: Expansion PCB on main PCB (function compo- nents 230 V~) Make no on-site connections.
  • Page 45 Installation sequence Electrical connections (cont.) Terminals Function Explanation X3.1 Switched phase Via control unit ON/OFF switch. Note Observe the total load (1000 W) for all con- nected components. X3.3 Flow switch Requires zero volt N/O contact: X3.4 ■ Closed: Heat pump in operation ■...
  • Page 46 Installation sequence Electrical connections (cont.) Terminals Function Explanation X3.8 Frost stat and/or contact Requires zero volt N/C contact: X3.9 humidistat ■ Closed: Continuous safety chain ■ Open: Safety chain interrupted; heat Jumper pump shut down ■ Breaking capacity 230 V~, 0.15 A ■...
  • Page 47 Installation sequence Electrical connections (cont.) Plug Sensor Type KM BUS (wires interchangeable) Use the KM BUS distributor (accessories) if sev- eral devices are connected. KM BUS subscriber (examples): ■ Extension kit for one heating circuit with mixer M2/HC2 ■ Remote control for Vitotrol 200A or Vitotrol 300B (set the heating circuit assign- ment at the remote control) ■...
  • Page 48 Installation sequence Electrical connections (cont.) L1 N A Extension EA1 G Circulation pump for swimming pool B Power supply 1/N/PE 230 V/50 Hz heating (accessory) H Thermostat for swimming pool tem- C Junction box (on site) perature control (floating contact: D Fuses and contactor for circulation 230 V~, 0.1 A, accessories) pump for swimming pool heating...
  • Page 49 Installation sequence Electrical connections (cont.) Internal unit: AVI PCB Interface internal unit – external unit Plug Component F101 Fuse 1.0 A (slow L) P202 BUS connection (12 V to external unit for type AWT-AC 221.A10, A13, B10, B13) P203 BUS connection (43 V to external unit for type AWT-AC 221.A04, A07) Note ■...
  • Page 50 Installation sequence Electrical connections (cont.) 400 V~: Opening the external unit wir- ing chamber Type AWT-AC 221.B10 and B13 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 51 Installation sequence Electrical connections (cont.) Connecting internal and external unit 230 V~ 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 400 V~ A External unit wiring chamber (see Type AWT-AC 221.B10 and B13...
  • Page 52 Installation sequence Power supply Isolators for non-earthed conductors Danger ■ The mains isolator (if installed) must Incorrect core allocation can simultaneously isolate from the mains result in serious injury and dam- all non-earthed conductors with a min- age to the appliance. imum contact separation of 3 mm.
  • Page 53 Installation sequence Power supply (cont.) ■ In conjunction with on-site energy con- sumption (use of power generated by the PV system to meet own require- ments): Note During the power-OFF period, it is not possible to operate the compres- sor with power generated on site. ■...
  • Page 54 Installation sequence Power supply (cont.) External unit power supply (230 V~/400 V~) ■ Economy tariff and power-OFF can be Note used. Free terminals for internal use. ■ No parameters need to be set when using economy tariff with power-OFF. The compressor is shut down during the power-OFF period.
  • Page 55 Installation sequence Power supply (cont.) External unit power supply 400 V~ A External unit wiring chamber (see page 49) B Power supply 230 V/50 Hz Type AWT-AC 221.B10 and B13 C2 C1 ? N L3 L2L1 Type AWT-AC 221.B10 221.B13 Recommended power cable 5 x 2.5 mm 5 x 2.5 mm...
  • Page 56 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 ■ Fuse rating max. 16 A ■...
  • Page 57 Installation sequence Power supply (cont.) Power supply with power-OFF Power-OFF without on-site load disconnection The power-OFF signal is connected Note directly to the heat pump control unit. Observe the technical connection condi- The compressor is "forced" off when tions of the relevant power supply util- power-OFF is enabled.
  • Page 58 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 59 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 Power supply in conjunction with own energy consumption Without power-OFF E1E2 D /D L1 L1 L2 L2 L3 L3 A Heat pump C Electricity meter...
  • Page 60 Installation sequence Power supply (cont.) G Double-tariff meter (for special tariff K Meter with reverse block: for heat pump) For energy generated by PV sys- Not permissible in conjunction with L Isolator for the domestic power sup- PV systems for own energy con- sumption.

  • Page 61: Table Of Contents

    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..........63 • 2. Compiling reports............63 •...
  • Page 62 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • • 19. Starting the heat pump........... 76 • 20. Commissioning the system........... 76 • 21. Ticking the heat pump type on the type plate of the internal unit (as per external unit type plate) •...

  • Page 63: Opening The Heat Pump

    Commissioning, inspection, maintenance Further details regarding the individual steps Opening the heat pump Danger Please note Contact with 'live' components Wait at least 30 min between can lead to serious injury from installing and commissioning the electric current. appliance to prevent equipment ■...

  • Page 64: Evacuating The Refrigerant Lines And Internal Unit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Evacuating the refrigerant lines and internal unit Please note Please note Commissioning is weather- Before evacuating the refrigerant dependent. lines and the internal unit, check all connections for tightness with In the case of high relative humid- leak detection spray.
  • Page 65 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, the service valve is located at the C Liquid line connection of the liquid line.

  • Page 66: Filling The Refrigerant Lines And Internal Unit

    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 67 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note 2. Top up with the required amount of Topping up the system with refrigerant (see following table). refrigerant or evacuating the refrigerant can result in appliance Please note damage.

  • Page 68: Checking The Refrigerant Circuit For Tightness

    Observe VDI 2035 regarding the quality ■ Soften fill water with a hardness above and amount of heating water, incl. fill and 16.8 °dH (3.0 mol/m ), e.g. with the top-up water. small softening system for heating water (see the Viessmann Vitoset pricelist).
  • Page 69 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note protect electrical components To prevent appliance damage, mounted on the casing door from escaping liquids. 1. Open any non-return valves installed on site. 2. Check the pre-charge pressure of the expansion vessel.
  • Page 70 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 DHW heating air vent valve (see following chapter);...

  • Page 71: Checking Expansion Vessel And Heating Circuit Pressure

    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. Heat pump technical guide...

  • Page 72: Cleaning The Dhw Cylinder

    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 73 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 74: Replacing The Magnesium Anode

    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 75: Checking Thermal Insulation Of Flared Connections 17. Checking Electrical Connections Of The External Unit For Firm Seating

    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 76: 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 77 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning with the commissioning wizard The commissioning assistant automati- Switch on the ON/OFF switch on the cally guides you through all the menus heat pump control unit. where settings have to be made. For ■...
  • Page 78 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Language Date Date/time Time Start commissioning? Coding Parameter group Parameter level 1 select Sensor values Temperature sensors display Signal inputs Signal inputs display Actuator test Actuator test carry out Subscriber check Subscriber check carry out Function check...
  • Page 79 7. Set system scheme: "6" to each parameter. 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 221.B10 221.B13 "Output compressor stage...
  • Page 80 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Required parameters for components connected on site Detailed explanations regard- ing parameters Service instructions for Vitotronic 200 heat pump control unit System scheme Overview of all available system schemes Component System scheme Heating circuit A1/HC1...
  • Page 81 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 82 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pump/component Parameter Setting Vitocom 100, type GSM "System definition" Ó "1" "Vitocom 100 7017" External extension "System definition" Ó ■ "1" EA1 ■ "2" AM1 "External extension ■ "3"EA1 and AM1 7010"...
  • Page 83 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) External functions Parameter Setting External blocking of compres- "System definition" Ó "0" to "31" sor and pumps "Effect of external block- ing on pumps/compressor 701A" External blocking of the com- "System definition"...
  • Page 84 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Swimming pool water heating Parameters for swimming pool heating Setting "System definition" Ó "1" "External extension 7010" "System definition" Ó "1" "Swimming pool 7008" Ventilation Ventilation unit parameters Setting "Ventilation" Ó "1"...

  • Page 85: Checking The System Function

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Energy meter Electricity meter parameters Setting "Photovoltaics" Ó "1" "Enable own energy consumption PV 7E00" Extended menu: Enable the required functions/ "PV ctrl strategy" system components for own en- ergy consumption. "Photovoltaics"...

  • Page 86: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer should hand the operating instructions to the system user and instruct the user in operating the system. This includes all components installed as accessories, e.g.
  • Page 87 Troubleshooting Repairs Overview of electrical components See from page 40. Opening programming unit...
  • Page 88 Troubleshooting Repairs (cont.) Removing cover from programming unit, if necessary...
  • Page 89 Troubleshooting Repairs (cont.) Overview of internal components: Internal unit a:C]...
  • Page 90 Troubleshooting Repairs (cont.) Secondary circuit flow tempera- Internal unit service valve ture sensor (alternative posi- (Schrader valve; can be used in tions) place of the external unit service Cylinder temperature sensor valve for checking pressure and Return temperature sensor, evacuating the refrigerant cir- secondary circuit cuit;...
  • Page 91 Troubleshooting Repairs (cont.) DHW cylinder drain & fill valve positions A Closed C Open to drain or fill the cylinder B Open to drain the internal DHW line 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 92 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 93 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 94 Troubleshooting Repairs (cont.) External unit, type AWT-AC 221.A10, 221.A13, 221.B10, 221.B13 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 95 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 96 Troubleshooting Repairs (cont.) Temperature sensors in the internal unit (with ID label) Viessmann NTC 10 kΩ (blue ID label) Viessmann Pt500A (green ID label) Outside temperature sensor 140 180 Temperature in °C -20 -10 10 20 30 Temperature in °C...
  • Page 97 Troubleshooting Repairs (cont.) Temperature sensors in external unit (no marking) Type NTC 10 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C Type 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 40.
  • Page 98 Troubleshooting Repairs (cont.) Danger Removing the fuse does not switch the power circuit to zero volt. Contact with 'live' compo- nents can lead to serious injury from electric current. Before working on the equip- ment, always ensure that the power circuit is also at zero volt.
  • Page 99 Parts lists, internal unit 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 100 Parts lists, internal unit Overview of assemblies, internal unit A Type plate C Electrical equipment assembly, B Casing assembly, internal unit internal unit...
  • Page 101 Internal unit casing 0001 Front panel, top 0006 Top panel, back 0002 Front panel, bottom 0007 Viessmann logo 0003 Side panel, left 0008 Support, heat pump control unit 0004 Side panel, right 0009 Screws (set) 0005 Top panel, front...
  • Page 102 Parts lists, internal unit Internal unit casing (cont.) 0003 0006 0005 0001 0008 0007 0009 0010 0002 0004...
  • Page 103 Parts lists, internal unit Electrical equipment, internal unit 0001 Programming unit 0039 Service instructions 0002 Controller and sensor PCB with Vitotronic 200, type WO1C cover (CU401) 0040 Operating instructions 0005 Main PCB with cover (MB761) Vitotronic 200, type WO1C 0006 Expansion PCB with cover (SA135) Parts not shown 0007 Coding card...
  • Page 104 Parts lists, internal unit Electrical equipment, internal unit (cont.) 0018 0020 0033 0017 0019 0001 0032 0007 0006 0005 0010 0002 0009 0037 0011 0008 0030 0013 0023 0025 0024 0034 0035 0039 0040...
  • Page 105 Parts lists, internal unit Internal unit hydraulics 0001 Back panel, lower casing 0023 Air vent valve G ⅜ 0002 Bottom panel 0024 Clip for threaded pipe D 21-23, 0003 Angle profile, lower casing, left M8, EPDM insert 0004 Angle profile, lower casing, right 0025 Clip for threaded pipe D 26-28, 0005 Top panel, lower casing M8, EPDM insert...
  • Page 106 Parts lists, internal unit Internal unit hydraulics (cont.) 0037 0005 0038 0031 0032 0027 0043 0030 0023 0008 0030 0044 0031 0041 0034 0023 0032 0023 0043 0036 0037 0045 0038 0035 0036 0020 0042 0047 0031 0043 0035 0016 0028 0046 0035...
  • Page 107 Parts lists, internal unit Cylinder, internal unit 0001 DHW cylinder with internal indi- 0015 Flange gasket rect coil 170 litres 0016 Sleeve 0002 Back panel, casing top 0017 Sensor well 0003 Retaining bracket for connection 0018 Air vent valve G ⅜ hoses 0019 Spring clip ring 7 32 x 1.5 mm 0004 Retaining bracket, cylinder...
  • Page 108 Parts lists, internal unit Cylinder, internal unit (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 109 Parts lists for external unit 230 V~, type AWT-AC 221.A04 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...
  • Page 110 Parts lists for external unit 230 V~, type AWT-AC 221.A04 External unit (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...
  • Page 111 Parts lists for external unit 230 V~, type AWT-AC 221.A07 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...
  • Page 112 Parts lists for external unit 230 V~, type AWT-AC 221.A07 External unit (cont.) 0033 0032 0031 0036 0027 0036 0028 0030 0026 0035 0029 0004 0007 0034 0038 0003 0012 0020 0022 0021 0025 0043 0005 0006 0042 0024 0037 0023 0013 0014...
  • Page 113 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 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) ■...
  • Page 114 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Overview of the assemblies A Type plate B Casing assembly, external unit...
  • Page 115 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Overview of the assemblies (cont.) C Electrical equipment assembly, external unit D Hydraulic assembly, external unit External unit casing 0001 Top panel 0013 Transport handle, left 0002 Side panel, right 0014 Motor support 0003 Cover, power supply 0015 Air inlet ring...
  • Page 116 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 External unit casing (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 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Electrical equipment, external unit 0001 Main PCB 0020 Communication cable, drivers 0002 Driver PCB 0021 Communication cable, IDU 0003 Capacitor PCB 0022 Power cable, controller PCB, 0004 PCB, mains filter 0005 Coils 0023 Communication cable, starter 0006 Terminal...
  • Page 118 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Electrical equipment, external unit (cont.) 0002 0004 0003 0006 0005 0011 0009 0012 0010 0001 0013 0007 0008...
  • Page 119 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Hydraulics, external unit 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...
  • Page 120 Parts lists for external unit 230 V~, type AWT-AC 221.A10, A13 Hydraulics, external unit (cont.) 0002 0005 0008 0004 0010 0007 0006 0003 0009 0001 0011 0012...
  • Page 121 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 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) ■...
  • Page 122 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Overview of the assemblies A Type plate B Casing assembly, external unit...
  • Page 123 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Overview of the assemblies (cont.) C Electrical equipment assembly, external unit D Hydraulic assembly, external unit External unit casing 0001 Top panel 0012 Protective grille, left 0002 Side panel, right 0013 Transport handle, left 0003 Top cover 0014 Motor support...
  • Page 124 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 External unit casing (cont.) 0001 0012 0014 0017 0019 0009 0018 0013 0011 0010 0015 0005 0008 0007 0011 0002 0003 0020 0010 0015 0004 0007 0016 0006...
  • Page 125 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Electrical equipment, external unit 0001 Main PCB Parts not shown 0002 Driver PCB 0013 Cable harness, compressor 0003 Capacitor PCB 0014 Cable harness complete, com- 0004 PCB, mains filter pressor 0005 Coils 0015 Communication cable, drivers...
  • Page 126 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Electrical equipment, external unit (cont.) 0005 0002 0004 0003 0010 0001 0011 0017 0006 0008 0007 0009 0012...
  • Page 127 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Hydraulics, external unit 0001 Compressor 0007 Electronic expansion valve 0002 4-way diverter valve pipework, 0008 Compressor thermal insulation complete 0009 Temperature sensor NTC 50 kΩ 0003 Liquid separator (CTT) 0004 High pressure switch 0010 Shut-off valve, liquid line 0005 Shut-off valve, hot gas line...
  • Page 128 Parts lists for external unit 400 V~, type AWT-AC 221.B10, B13 Hydraulics, external unit (cont.) 0007 0004 0003 0002 0008 0006 0011 0010 0001 0009 0005 0008...
  • Page 129 Commissioning/service reports Hydraulic parameter report Setting and test values Set value Commis- sioning Testing the external heating circuit pumps Circulation pump type Circulation pump stage Overflow valve setting Commissioning, primary circuit Air intake temperature °C ("Diagnosis" Ó "System overview") Air discharge temperature °C ("Diagnosis"...
  • Page 130 Commissioning/service reports Control parameters report (cont.) System definition Parameter Code Delivered condi- Commis- tion sioning "System scheme" (see chapter "System 7000 scheme") "Temperature differential for calculat- 7003 40 (≙ 4 K) ing the heating limit" "Temperature differential for calculat- 7004 40 (≙...
  • Page 131 Commissioning/service reports Control parameters 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 6007 50 (≙...
  • Page 132 Commissioning/service reports Control parameters report (cont.) Internal hydraulics Parameter Code Delivered condi- Commis- tion sioning "Heat pump for drying a building" 7300 "Time program for screed drying" 7303 "Flow temperature for external de- 730C 500 (≙ 50 °C) mand" "Enable 3-way diverter valve heating/ 730D Do not adjust DHW"...
  • Page 133 Commissioning/service reports Control parameters report (cont.) Heating circuit 2 Parameter Code Delivered condi- Commis- tion sioning "Standard room temperature" 3000 200 (≙ 20 °C) "Reduced room temperature" 3001 160 (≙ 16 °C) "Remote control" 3003 "Heating curve level" 3006 0 (≙ 0 K) "Heating curve slope"...
  • Page 134 Commissioning/service reports Control parameters report (cont.) Ventilation Parameter Code Delivered condi- Commis- tion sioning "Vitovent enable" 7D00 "Enable preheater bank electric" 7D01 "Enable reheater bank hydraulic" 7D02 "Enable humidity sensor" 7D05 "Enable CO2 sensor" 7D06 "Extract air temperature with standard 7D08 200 (≙...
  • Page 135 Commissioning/service reports Control parameters report (cont.) Parameter Code Delivered condi- Commis- tion sioning "Enable own energy consumption for 7E13 heating" "Raise set DHW cylinder temperature 7E21 0 (≙ 0 K) PV" "Raise set heating water buffer cylin- 7E22 0 (≙ 0 K) der temp PV"...
  • Page 136 Specification Specification 230 V appliances Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Heating output data At 100 % according to EN 14511 (A2/W35 °C, spread 5 K) Rated heating out- 10.6 Compressor fre- quency Fan speed Power consump- 0.91 1.73 2.20 3.25 tion Coefficient of per-...
  • Page 137 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Cooling perform- ance data At 100 % according to EN 14511 (A35/W7 °C, spread 5 K) Rated cooling ca- pacity Compressor fre- quency Fan speed Power consump- 1.08 2.40 2.69 3.64 tion Energy efficiency 2.96...
  • Page 138 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Heating water at 10 K spread Capacity 16.7 16.7 17.7 17.7 Minimum flow rate 1200 1380 (always maintain) Max. external pres- mbar sure drop (RFH) at min. flow rate Max. flow tempera- °C ture External unit elec-...
  • Page 139 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Internal unit elec- trical values Heat pump con- trol unit/PCB ■ Rated voltage, 1/N/PE 230 V/50 Hz control unit/PCB ■ Fuse protection, 1 x B 16 A power supply ■ Internal fuse 6.3 A (slow)/250 V Instantaneous heating water...
  • Page 140 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Refrigerant cir- cuit Refrigerant R 410 A R 410 A R 410 A R 410 A Refrigerant charge kg 2.15 2.95 2.95 Top-up amount for line lengths >12 m to ≤ 30 m Compressor (her- Type Rotating...
  • Page 141 Specification Specification (cont.) Type AWT-AC 221.A04 221.A07 221.A10 221.A13 Total weight External unit Internal unit Permissible oper- ating pressure, secondary side Connections Heating water flow mm Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Heating water re- Cu 28 x 1 Cu 28 x 1...
  • Page 142 Specification Specification (cont.) 400 V appliances Type AWT-AC 221.B10 221.B13 Heating output data At 100 % according to EN 14511 (A2/W35 °C, spread 5 K) Rated heating output 7.57 9.06 Compressor frequency Fan speed Power consumption 2.99 2.45 Coefficient of performance ε (COP) in heat- 3.79 3.70 ing mode...
  • Page 143 Specification Specification (cont.) Type AWT-AC 221.B10 221.B13 Air intake temperature Cooling mode ■ Min. °C ■ Max. °C Heating mode ■ Min. °C –20 –20 ■ Max. °C Heating water at 10 K spread Capacity 17.7 17.7 Minimum flow rate (always maintain) 1200 1380 Max.
  • Page 144 Specification Specification (cont.) Type AWT-AC 221.B10 221.B13 Refrigerant circuit Refrigerant R 410 A R 410 A Refrigerant charge 2.95 2.95 Top-up amount for line lengths >12 m to ≤ 30 m Compressor (hermetically sealed) Type Double rotat- Double rotat- ing piston ing piston Permiss.
  • Page 145 Specification Specification (cont.) Type AWT-AC 221.B10 221.B13 Connections Heating water flow Cu 28 x 1 Cu 28 x 1 Heating water return Cu 28 x 1 Cu 28 x 1 Cold water ¾ ¾ ¾ ¾ DHW circulation Condensate pipe (external unit) 16 x 1 16 x 1 Liquid line...
  • Page 146 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...
  • Page 147 A The product characteristics determined as system values for the product Vitocal 222-S (see technical guide) can be utilised to assess the energy consumption of heating and ventilation systems to DIN V 4701-10 specified by the EnEV [Ger- many].
  • Page 148 Keyword index Keyword index Check valve........35 Adjustable feet........14 Chilled ceiling........36 Air discharge........12 Cleaning the cylinder......72 Air discharge grille removal....74 Closing the heat pump.......60 Air intake..........12 Coding level 1........77 Air short circuit........10 Cold water connection..8, 141, 145 Air vent valve, secondary circuit..90 Commissioning....63, 77, 146 Aligning the appliance......14 Commissioning order.......146...
  • Page 149 Keyword index Keyword index (cont.) Control parameters reports....129 Cooling..........42 Economy tariff......53, 54, 56 Cooling control........42 Economy tariff meter....57, 59 Cooling water flow......36 Electrical connection Copper seal ring.........31 ■ Circulation pumps.....41, 44 Corrosion damage.......73, 74 ■ External unit........49 Cover of external unit, fitting....60 ■...
  • Page 150 Keyword index Keyword index (cont.) External unit Flow temperature sensor, secondary cir- ■ Cable lengths........9 cuit.............95 ■ Checking electrical connections..75 Flow temperature sensor, system..95 ■ Cleaning.........74 Free running of the fan, check for..74 ■ Closing..........60 Freestanding siting......11 ■ Dimensions......140, 144 Frost stat connection......46 ■...
  • Page 151 Keyword index Keyword index (cont.) Hydraulic assembly Internal unit installation......14 ■ Internal unit........105 Isolators..........52 Hydraulic connecting chamber...35 Hydraulic connections......8 Hydraulic parameters.......129 KM BUS distributor......47 Impressed current anode....74 Leak detection spray......64 Inspection...........63 Lightning protection......11 Installation Line length ■ External unit........10 ■ For refrigerant lines....66, 67 ■...
  • Page 152 Keyword index Keyword index (cont.) ON/OFF switch........77 Pipe bends for vibration compensa- On-site connections......7 tion.............11 On-site energy consumption....53 Pipe ends, flaring.......26 Opening for 230 V cables....8 Pipe openings........26 Opening for LV leads......7 ■ For refrigerant lines......28 Opening programming unit....87 Pipe outlet..........22 Opening the heat pump.....63 Pipes, securing........26 Opening the internal unit....16...
  • Page 153 Keyword index Keyword index (cont.) Room volume........15 Quick-action air vent valve...34, 70 Rubber mounts........14 RCD..........52, 57 Safety assembly.........34 Recommended power cables....9 Safety assembly, installation....34 Reducer, connecting......31 Safety chain........46 Refrigerant......23, 66, 67 Safety connections......44 ■ Properties........68 Safety instructions for refrigerant..68 ■ Safety instructions......68 Safety valve.........34, 35 ■...
  • Page 154 Keyword index Keyword index (cont.) Standard tariff........53 Tilting angle........10 Starting the appliance......76 TNC system.........57, 59 Starting the heat pump.......76 Torque Start sequence, heat pump....76 ■ For refrigerant lines....27, 31 Start sequence of the heat pump..76 ■ Service valve union nut....67 Supplementary heating facility...11 Total weight........14 Supply..........52...
  • Page 156 7424692 7497344 7497345 7502079 7502080 7513685 7513686 7514941 7514942 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...

This manual is also suitable for:

Awt-ac 221.a04Awt-ac 221.a07Awt-ac 221.a10Awt-ac 221.a13Awt-ac 221.b10Awt-ac 221.b13

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