Viessmann Vitovalor PT2 Operating instructions

Installation and service instructions
for contractors
VIESMANN
Vitovalor PT2
Type F11T, F19T, F25T, F32T, 0.9 to 30.8 kW
Fuel cell based micro CHP unit with integral gas condensing boiler and adjacent
cylinder module
Natural gas version
VITOVALOR PT2
5853335 GB 10/2019 Please keep safe.

2
Please follow these safety instruc-
tions closely to prevent accidents
and material losses.
Safety instructions explained
Danger
This symbol warns against the risk
of injury.
!Please note
This symbol warns against the risk
of material losses and environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on gas installations may only be
carried out by a registered gas fitter.
■Work on electrical equipment may only
be carried out by a qualified electrician.
■The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, e.g. by removing the separate fuse
or by means of a mains isolator, and
check that it is no longer live.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
5853335

3
Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
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 func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5853335

4
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not smoke. Prevent naked
flames and sparks. Never switch
lights or electrical appliances on
or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the
danger zone.
■Notify your gas or electricity sup-
ply utility from outside the building.
■Have the power supply to the
building shut off from a safe place
(outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening
poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be
harmful to health.
Never let condensate touch your
skin or eyes and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion air can cause life threatening
poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good
working order. Vents for supplying
combustion air must be non-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
5853335

5
Danger
The simultaneous operation of the
boiler and appliances that exhausts
air to the outside can result in life
threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5853335

6
1. Information Disposal of packaging ............................................................................ 9
Symbols ................................................................................................. 9
Intended use .......................................................................................... 9
Product information ................................................................................ 10
■Vitovalor PT2 ...................................................................................... 10
■Note on positioning ............................................................................. 10
System examples .................................................................................. 10
Spare parts lists ..................................................................................... 10
2. Preparing for installation Handling ................................................................................................. 11
Siting ...................................................................................................... 11
■Dimensions of siting options ............................................................... 11
Preparing for installation ........................................................................ 14
Notes on connecting to the mains supply .............................................. 17
■Vitovalor PT2 in mains parallel mode ................................................. 17
■Metering generated power .................................................................. 17
■Property boundaries and transfer point without power storage sys-
tem ...................................................................................................... 19
■Property boundaries and transfer point with power storage system ... 20
■Connection for excess export without power storage system ............ 21
■Connection for excess export with power storage system ................. 23
■Fuse protection ................................................................................... 24
3. Installation sequence Installing and aligning the Vitovalor PT2 ................................................ 26
■Fitting the connection lines on the gas condensing and fuel cell
module ................................................................................................ 26
■Routing drain lines .............................................................................. 27
■Aligning the gas condensing and fuel cell module at the installation
site ...................................................................................................... 28
■Fitting the surface mounting connection set (accessories) on left/
right of the cylinder module ................................................................ 29
■Further installation on the cylinder module ......................................... 34
■Aligning the cylinder module at the installation site ............................ 34
■Detaching the front panels of the gas condensing and fuel cell mod-
ules ..................................................................................................... 36
■Removing the cylinder module front panel ......................................... 37
■Removing the module connection lines .............................................. 38
Heating water and DHW connections .................................................... 39
■Safety assembly to DIN 1988 and EN 806 at the cold water connec-
tion ...................................................................................................... 40
Balanced flue terminal ........................................................................... 40
■Connecting the downstream balanced flue pipe ................................. 40
Condensate connection ......................................................................... 41
Gas connection ...................................................................................... 41
Opening heat management unit (HMU) on gas condensing and fuel
cell module ............................................................................................. 42
Electrical connections ............................................................................ 42
■Connecting the circulation pump to P1 ............................................... 43
■Connecting power supply aBH and PlusBus jF to the cylinder mod-
ule ....................................................................................................... 44
■Connecting outlet temperature sensor $ of the cylinder module ...... 44
■Outside temperature sensor ! .......................................................... 45
■Floating switching contact connection ................................................ 45
■Connections on the M2IO electronics module of the cylinder module 46
■Power supply for accessories (230 V ~) ............................................. 47
■Power supply to the system ................................................................ 48
■Routing connecting cables/leads ........................................................ 48
■Checking the CAN bus terminator switch setting ............................... 48
Closing the wiring chamber ................................................................... 49
Index
Index
5853335

7
Fitting the front panels of the gas condensing and fuel cell module ...... 50
■Fitting the programming unit ............................................................... 50
Fitting the cylinder module front panel ................................................... 51
Splitting the gas condensing and fuel cell modules ............................... 52
■Reassemble the gas condensing and fuel cell module in reverse
order. .................................................................................................. 54
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 55
5. System configuration
(parameters)
Calling up parameters ............................................................................ 90
General .................................................................................................. 90
Boiler ...................................................................................................... 92
DHW ...................................................................................................... 94
Heating circuit 1, Heating circuit 2, Heating circuit 3, Heating circuit 4 .. 96
Fuel cell ................................................................................................. 102
Subscriber numbers of the connected extensions .................................104
6. Diagnosis and service
checks
Gas condensing module ........................................................................ 106
■Service menu ......................................................................................106
■Changing the service password ......................................................... 106
■Resetting all passwords to delivered condition ...................................107
■Diagnosis ............................................................................................ 107
■Calling up messages (message history) .............................................107
■Checking outputs (actuator and sensor test) ...................................... 108
Fuel cell module .....................................................................................110
■Checking power generated ................................................................. 110
■Checking the gas consumption to reclaim fuel tax ............................. 110
■Checking operating condition ............................................................. 110
■Checking grid monitoring parameters ................................................. 111
■Removing the SD card ....................................................................... 111
■Inserting the SD card and saving the fuel cell module data ............... 112
7. Troubleshooting Fault display and other messages on the programming unit ................. 113
Fault messages on the gas condensing module/fuel cell module pro-
gramming unit ........................................................................................ 115
Service messages ................................................................................. 135
Warnings ................................................................................................136
Repairs .................................................................................................. 136
■Moving the programming unit to the service position ......................... 136
■Draining the system on the heating water and DHW sides ................ 137
■Checking the temperature sensors .....................................................140
■Information on replacing the HMU heat management unit and BCU
burner control unit ...............................................................................142
■Checking the cylinder loading plate heat exchanger .......................... 142
■Checking the system separation plate heat exchanger ...................... 142
■Removing the flow sensor .................................................................. 143
■Removing the hydraulic unit ............................................................... 144
■Replacing the power cable ................................................................. 144
■Checking the fuse ............................................................................... 145
■Mixer extension kit .............................................................................. 145
8. Function description Control unit ............................................................................................ 147
■Heating mode ..................................................................................... 147
■Heating the loading cylinder ............................................................... 147
■Operating the fuel cell module ............................................................ 147
Connection, heating circuit pump for heating circuit without mixer ........147
External extensions (accessories) ......................................................... 148
■EM-EA1 extension .............................................................................. 148
Control functions ....................................................................................148
■Venting program ................................................................................. 148
Index
Index
5853335

8
■Filling program .................................................................................... 149
■Heating curve ..................................................................................... 149
■Screed drying ..................................................................................... 151
■Raising the reduced room temperature .............................................. 152
Electronic combustion controller of gas condensing module .................154
Electrical output of the fuel cell .............................................................. 154
9. Connection and wiring dia-
gram
Overview connection diagrams ..............................................................155
Mains distributor box ..............................................................................156
Connection scheme heat management unit, gas condensing module .. 157
Burner control unit connection scheme ................................................. 159
Electronics module M2IO connection scheme (cylinder module) .......... 160
10. Commissioning/service
reports
................................................................................................................162
11. Specification ................................................................................................................163
12. Disposal Final decommissioning and disposal ..................................................... 164
13. Certificates Declaration of conformity ....................................................................... 165
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 165
14. Keyword index ................................................................................................................166
Index
Index (cont.)
5853335

9
Please dispose of packaging waste in line with statu-
tory regulations.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for the heating of water that is
of potable water quality and for power generation.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Information
Disposal of packaging
5853335
Information

10
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and results in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Product information
Vitovalor PT2
Preset for operation with natural gas E, adjustable to
natural gas LL
The Vitovalor PT2 may in principle be supplied only to
the countries indicated on the type plate. For deliveries
to other countries, approved contractors must arrange
individual approval on their own initiative and in
accordance with the law of the country in question.
Note on positioning
If the Vitovalor PT2 is installed in close proximity to the
coast, the appliance should be positioned so that the
flue gas and ventilation air apertures do not come into
direct contact with saline air, in order to prevent dam-
age due to corrosion.
Do not install or operate the Vitovalor PT2 in unheated
rooms. Minimum temperature inside the installation
room +3 °C
Vitovalor PT2 in systems with photovoltaic and
solar thermal equipment
It is not possible to operate the Vitovalor PT2 in con-
junction with a solar thermal system. This would
reduce the runtimes of the Vitovalor PT2 and economi-
cally efficient operation would no longer be guaran-
teed.
If combining with a photovoltaic system, ensure that
the electricity meter is arranged correctly. An incor-
rectly arranged electricity meter would distort the stat-
istical data of the energy manager. This would reduce
the runtimes of the Vitovalor PT2 and economically
efficient operation would no longer be guaranteed.
System examples
System examples with hydraulic and electrical connec-
tion diagrams and function descriptions are available
to help setting up the heating system.
Detailed information on system examples can be found
at: www.viessmann-schemes.com
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Intended use (cont.)
5853335
Information

11
Gas condensing and fuel cell module:
■If possible, leave the modules in their packaging dur-
ing handling.
■When transporting, keep upright at all times on the
pallet or its base.
■If possible, remove from pallet only at final location.
■Never subject the module to strong vibrations or
shaking.
■Always store standing up.
■May be tilted briefly, up to a maximum of 90°, during
handling. See following diagram.
!Please note
To prevent damage to the appliance, when
transporting up or down
stairs, always keep the underside of the appli-
ance lower than the top.
A
Fig. 1
AAppliance top
!Please note
Prevent damage to the appliance during han-
dling.
Never set the appliance down on its front or
sides, or apply any load to these surfaces.
If space constraints make it necessary, the gas
condensing and fuel cell module can be split for
handling.
See page 52 for an illustration of the necessary
measures.
Siting
Dimensions of siting options
Install the Vitovalor so that one side of the cylinder
module is accessible for the water side connections on
the connection set.
No clearance is required behind the appliance.
Make sure there is sufficient space for the condensate
drain pipe opposite the cylinder module adjacent to the
gas condensing and fuel cell module.
Note
All height dimensions have a tolerance of +15 mm on
account of the adjustable feet.
Preparing for installation
Handling
5853335
Installation

12
Siting options for room heights > 2030 mm
Cylinder module to the left of the gas condensing and fuel cell module
1800
185
475
1205
595
1240
1310
1829
1979 3°
1979 3°
A
Fig. 2
AWiring area
Note
Height of balanced flue terminal including balanced
flue pipe 1000 mm in length
Preparing for installation
Siting (cont.)
5853335
Installation

13
Cylinder module to the right of the gas condensing and fuel cell module
1979
1800
125
185
595
1240
1310
1829
1979
3°
3°
1205
A
Fig. 3
AWiring area
Note
Height of balanced flue terminal including balanced
flue pipe 1000 mm in length
Preparing for installation
Siting (cont.)
5853335
Installation

14
Siting option for room heights ≥ 2000 mm ≤2030 mm
A special inspection tee (part no. ZK04464) is required
for this siting option. The cylinder module can only be
installed to the right of the gas condensing and fuel cell
module.
125
185
595
1205
1240
1310
1829
A
3°
1800
1920
Fig. 4
AWiring area
Preparing for installation
Use a connection set – available as an accessory – to
make the connections on the water side.
Fitting accessories
Before final siting, attach all of the accessories that are
to be mounted from the back of the boiler (e.g. connec-
tion set).
!Please note
Avoid damaging the appliance.
Connect all pipework free of load and torque
stress.
Preparing connections on site:
Connection set installation instructions
Preparing for installation
Siting (cont.)
5853335
Installation

15
1800
1826
1800
22 1205
190
595
A
300
B
C
352
Fig. 5
ACondensate drain
Observe the necessary fall.
BClearance for connections on the water side
CClearance for condensate drain pipe connection
Note
All height dimensions have a tolerance of +15 mm on
account of the adjustable feet.
Preparing for installation
Preparing for installation (cont.)
5853335
Installation

16
Connections on the water side with connection set (standard delivery)
1676
1621
1511
1456
1566
A
B
C
D
E
E
D
C
B
A
F
1882
G
F
62
110
Fig. 6
AHeating return R ¾
BCold water R ½
CDHW circulation R ½ (accessory)
DDHW R ½
EHeating flow R ¾
FManometer and drain valve
GGas shut-off valve
Depending on the layout of the modules: Connections
towards the free side on the cylinder module to the
right or left.
Note
All height dimensions have a tolerance of +15 mm on
account of the adjustable feet.
1. Prepare the connections on the heating water side.
Thoroughly flush the heating system.
Note
Fit the on-site expansion vessel (if required) to the
heating return.
2. Prepare the connections on the DHW side. Install
the safety assembly (accessories or on-site provi-
sion) in the cold water line to DIN 1988 and
EN 806 (see page 40).
Recommendation:
Install the safety valve above the DHW cylinder.
This protects the valve against contamination, scal-
ing and high temperatures.
3. Prepare gas connection to TRGI [or local regula-
tions].
Preparing for installation
Preparing for installation (cont.)
5853335
Installation

17
4. Prepare electrical connections: See following chap-
ter.
The appliance is delivered fitted with a power cable
(approx. 2 m long).
!Please note
Switching off by means of an emergency
stop switch for the heating system can dam-
age the appliance.
Remove any emergency stop switches from
the existing heating system.
Accessory cables: Flexible cables with required
number of cores for external connections
Notes on connecting to the mains supply
Vitovalor PT2 in mains parallel mode
During operation of the Vitovalor PT2, any generated
power is fed into the building distribution system and/or
exported to the grid. This operating mode is described
as mains parallel mode. For this, the Vitovalor PT2 is
mechanically coupled to the grid.
Separate guidelines and regulations apply to this mode
of operation which must be taken into account when
making the electrical connection to the mains:
■TAR medium voltage VDE-AR-N-4110
■Current technical connection conditions for connec-
tions to the LV grid. These connection conditions
must be obtained from the relevant power supply util-
ity.
■The applicable DIN VDE guidelines, specifically
DIN VDE 0100, Part 701, DIN VDE 0100-551,
DIN VDE 0126-1-1 and DIN VDE AR-N 4105
■Connect the power supply (230 V/50 Hz) via a per-
manent connection.
■Regulations on safety at work and those of appropri-
ate trade associations
■LV connection ordinances as well as supplementary
conditions of the relevant grid operator
■Any applicable statutory or local regulations
Notify the local grid operator before commissioning the
Vitovalor PT2. We recommend you contact the local
grid operator prior to installation and clarify any techni-
cal points as well as the acceptance procedure. Hand
the relevant application forms as per VDE AR-N 4105
[or local regulations] to the relevant grid operator.
Application forms [for German grid operators] are
available at www.viessmann.de.
Note
Different documentation may be required by grid oper-
ators in other regions.
Metering generated power
A net AC meter (Z2) is integrated into the
Vitovalor PT2. This meter captures total electrical
power generated, minus that consumed by the
Vitovalor PT2 itself. This meter is MID-calibrated and is
licensed for statements to DIN VDE AR-N 4105 and
the German CHP Act (KWKG).
The calibration of the integral meter is valid for 8 years.
After expiry of this time, the meter must be recalibrated
or be replaced by a qualified contractor. The power
supply utility must also be notified of any new meter.
Replace any existing main electricity meter installed in
the LV distribution board (meter cupboard) with a bal-
ancing bidirectional meter if excess power is exported
to the grid [check local regulations]. The change of
meter with all necessary formalities must be under-
taken by an authorised electrician in agreement with
the grid operator.
Preparing for installation
Preparing for installation (cont.)
5853335
Installation

18
Arrangement of excess export system when con-
nected into a sub-distribution board
RCDRCD
M400V / 230V~ N
L
K
HkWh
Z2
1~
BC
F
G
E
~
PO
kWh
Z1
kWh
A
D
S1
Fig. 7
AVitovalor PT2
BFuel cell module ON/OFF switch
CGas condensing module ON/OFF switch
DControl unit, gas condensing module
EInternal circulation pump
FInternal consumers
GGS protection
HSub-distribution board
KOn-site consumers
LMeter cupboard
MProperty boundary
NLow voltage grid
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell stack
S1 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter
Z2 Export meter (standard delivery on Vitovalor PT2)
Arrangement of excess export when connected
into a main LV distribution board
RCDRCD
kWh
Z1
L
AC 400V / 230V~ M
K
HkWh
Z2
1~
F
G
E
kWh
S1
~
ON
BC
A
D
Fig. 8
AVitovalor PT2
BFuel cell module ON/OFF switch
CGas condensing module ON/OFF switch
DControl unit, gas condensing module
EInternal circulation pump
FInternal consumers
GGS protection
HMeter cupboard
KOn-site consumers
LProperty boundary
MLow voltage grid
NInverter (DC/AC converter) SEMAX = 0.75 kVA
OFuel cell stack
S1 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter
Z2 Export meter (standard delivery on Vitovalor PT2)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5853335
Installation

19
Property boundaries and transfer point without power storage system
B
C
D
E
F
G
K
L
Z2
1~
A
N
O
H
1~/N/PE
M
400V / 230V~
~
P
kWh
Z1
kWh
S1
kWh
Fig. 9 Source: VDE AR-N 4105
ALow voltage grid
BMain power supply
CDomestic distribution box
DProperty boundary
EGrid operator
FCustomer
GPower distribution
HOn-site consumers
KShort circuit protection
LOverload protection, RCD
MVitovalor PT2
NGS protection
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell
S1 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter (observe meter cir-
cuit)
Z2 Export meter (standard delivery on Vitovalor PT2)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5853335
Installation

20
Property boundaries and transfer point with power storage system
B
C
D
E
F
G
K
L
Z2
1~
A
N
O
H
1~/N/PE
M
400V / 230V~
~
P
kWh
Z1
kWh
S2
kWh
kWh
S1
~
U
V
Fig. 10 Source: VDE AR-N 4105
ALow voltage grid
BMain power supply
CDomestic distribution box
DProperty boundary
EGrid operator
FCustomer
GPower distribution
HOn-site consumers
KShort circuit protection
LOverload protection, RCD
MVitovalor PT2
NGS protection
OInverter (DC/AC converter) SEMAX = 0.75 kVA
PFuel cell
UPower storage system inverter
VPower storage unit
S1 Bidirectional power storage management meter
(power storage system standard delivery)
S2 Bidirectional energy management meter (not rele-
vant for billing by the grid operator)
Z1 Balancing bidirectional meter (observe meter cir-
cuit)
Z2 Export meter (standard delivery on Vitovalor PT2)
Preparing for installation
Notes on connecting to the mains supply (cont.)
5853335
Installation