Viessmann VITOCAL 242-G Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitocal 242-G
Type BWT 241.A06 to A10
Type BWT-M 241.A06 to A10
Compact heat pumps, 400 V~ and 230 V~
For applicability, see the last page
VITOCAL 242-G
5673 976 GB 1/2017 Please keep safe.

2
Please follow these safety instructions 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised contractors.
■Work on the refrigerant circuit may only be carried
out by authorised refrigeration engineers.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
Note
In addition to the control circuit there may be several
load circuits.
Danger
Contact with 'live' components can result in
severe injuries. Some components on PCBs
remain 'live' even after the power supply has
been switched off.
Wait at least 4 minutes before removing equip-
ment covers, to allow the voltage to dissipate.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Replace faulty components with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacement, use only spare parts supplied
or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5673 976 GB

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1. Information Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
2. Preparing for installation Requirements regarding on-site connections ........................................ 8
■Recommended power cables ............................................................. 9
Siting and transport requirements .......................................................... 9
■Transport ............................................................................................ 9
■Installation room requirements ........................................................... 10
■Minimum clearances ........................................................................... 10
3. Installation sequence Siting the heat pump .............................................................................. 11
■Removing the cylinder module ........................................................... 11
■Removing the heat pump module ....................................................... 16
■Assembly and sealing faces to note ................................................... 18
■Removing the transport brackets ........................................................ 19
Hydraulic connections ............................................................................ 19
■Connecting the primary/secondary circuits ......................................... 19
■Connecting the DHW side .................................................................. 21
■Connecting the solar circuit ................................................................ 21
■Connecting a heating/cooling circuit, if required ................................. 22
Electrical connections ............................................................................ 22
■Routing the cables to the wiring chamber .......................................... 22
■Overview of the heat pump control unit electrical connections ........... 23
■Main PCB (230 V~ components) ........................................................ 24
■Expansion PCB on main PCB (230 V~ components) ......................... 26
■Luster terminals (alarm and safety connections) ................................ 26
■Controller and sensor PCB (LV connections) ..................................... 27
Power supply ......................................................................................... 29
■Heat pump control unit power supply 230 V~ ..................................... 30
■Compressor power supply 400 V~ ..................................................... 30
■Compressor power supply 230 V~ ..................................................... 31
■Connecting 400 V~ instantaneous heating water heater power sup-
ply ....................................................................................................... 31
■Connecting 230 V~ instantaneous heating water heater power sup-
ply ....................................................................................................... 31
■Power supply with power-OFF: without on-site load disconnect ........ 31
■Power supply with power-OFF: with on-site load disconnect ............. 32
■Mains power supply in conjunction with on-site power consumption . 34
■Smart Grid .......................................................................................... 34
■Phase monitor (accessories) .............................................................. 35
Make connections at terminals X3.8/X3.9 ............................................. 37
Closing the heat pump ........................................................................... 37
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 38
5. Maintenance Overview of electrical components ........................................................ 52
Opening programming unit .................................................................... 54
Overview of internal components .......................................................... 55
DHW cylinder drain & fill valve positions ............................................... 56
Draining the heat pump on the secondary side ..................................... 56
Checking the sensors ............................................................................ 56
■Viessmann NTC 10 kΩ (blue marking) ............................................... 57
■Viessmann NTC 20 kΩ (orange marking) ........................................... 57
■Viessmann Pt500A (green marking) ................................................... 58
Checking the fuses ................................................................................ 58
Appliance is too noisy ............................................................................ 59
Index
Index
5673 976 GB

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6. Parts lists type BWT 241.A
(400 V~)
Overview of assemblies ......................................................................... 60
■Parts not shown .................................................................................. 61
Casing .................................................................................................... 62
Control unit and electrical equipment .................................................... 64
Heat pump module ................................................................................ 66
Hydraulics .............................................................................................. 68
Cylinder .................................................................................................. 70
7. Parts lists type
BWT-M 241.A (230 V~)
Overview of assemblies ......................................................................... 72
■Parts not shown .................................................................................. 73
Casing .................................................................................................... 74
Control unit and electrical equipment .................................................... 76
Heat pump module ................................................................................ 80
Hydraulics .............................................................................................. 82
Cylinder .................................................................................................. 84
Mounting set .......................................................................................... 86
8. Commissioning/service
reports
Hydraulic parameters report .................................................................. 88
Control parameter report ....................................................................... 88
9. Specification ................................................................................................................ 95
10. Appendix Heat pump commissioning request ....................................................... 100
11. Declaration of Conformity Declaration of conformity ....................................................................... 101
12. Keyword index ................................................................................................................102
Index
Index (cont.)
5673 976 GB

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Symbol Meaning
Reference to other document containing
further information
Additional information, not safety relevant
1.
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 Meaning
Work sequences required during commis-
sioning
Not required during commissioning
Work sequences required during inspec-
tion
Not required during inspection
Work sequences required during mainte-
nance
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.
Depending on the version, the appliance can only be
used for the following purposes:
■Central heating
■Central cooling
■DHW heating
The range of functions can be extended with additional
components and accessories.
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 central heating/cooling or DHW heating shall be
deemed inappropriate.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function.
Note
The appliance is intended exclusively for domestic or
semi-domestic use, i.e. even users who have not had
any instruction are able to operate the appliance
safely.
Information
Symbols
5673 976 GB
Information

7
Layout
The Vitocal 242-G is a brine/water heat pump with an
integral loading cylinder. Solar collectors can be con-
nected for solar DHW heating.
Subject to type, the compressor operates either with
230 V~ or 400 V~ mains voltage.
Hydraulics
The heat pump is equipped with a high efficiency circu-
lation pump (secondary pump) which transports the
heated heating water into the secondary circuit. The
integral 3-way diverter valve for "central heating/DHW
heating" changes over between central heating and
DHW heating.
Central heating
The heat pump is able to supply up to 2 heating cir-
cuits: 1 heating circuit without mixer and 1 heating cir-
cuit with mixer. The mixer extension kit (accessories) is
required to switch the mixer.
Central cooling
Central cooling utilising the natural cooling function
can be provided either by means of a heating/cooling
circuit or via a separate cooling circuit. This requires
accessories.
Heat pump control unit
The entire heating system including the solar circuit is
monitored and controlled by the integral heat pump
control unit Vitotronic 200, type WO1C.
Type overview
Vitocal 242-G, type BWT 241.A BWT-M 241.A
Central heating X X
Central cooling Accessories required Accessories required
DHW heating X X
Solar DHW heating X X
Integral instantaneous heating water heater X X
Mains voltage 400 V~ 230 V~
Information
Product information
5673 976 GB
Information

8
2047
2075
454
564
665
2075
600 680
500
218
147
69
29
300
387
134
159
62
D E GF
A
B
C
H
K
D E
F
G
AHK
29
/
61
111
80
< 42 V
230 V~
400 V~
Fig. 1
ADHW
BDHW circulation
CCold water
DPrimary circuit return (heat pump brine outlet)
EPrimary circuit flow (heat pump brine inlet)
FSecondary circuit flow (heating water)
GSecondary circuit return (heating water)
HSolar circuit flow
KSolar circuit return
Preparing for installation
Requirements regarding on-site connections
5673 976 GB
Installation

9
1. Prepare the connections on the heating water and
the DHW side.
Flush the heating system.
Connection of hydraulic pipes D to G:
■On-site connection:
Use straight pieces of pipe (standard delivery).
■With the connection set primary circuit/secondary
circuit (accessories):
Use pipe bends from the connection set.
2. Prepare the electrical connections.
Cable lengths:
■Required cable length inside the appliance plus dis-
tance to wall:
2.25 m
■Height of wall outlet:
2100 mm (see "Technical guides for heat pumps")
Recommended power cables
Type BWT/BWT-M 241.A06 241.A08 241.A10
Heat pump control unit 230 V~
Cable cross-section
■Without power-OFF 3 x 1.5 mm23 x 1.5 mm23 x 1.5 mm2
■With power-OFF 5 x 1.5 mm25 x 1.5 mm25 x 1.5 mm2
Compressor
Cable cross-section
■400 V~ 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
■230 V~ 3 x 4 mm23 x 4 mm23 x 4 mm2
Max. cable length 25 m 25 m 25 m
Instantaneous heating water heater 8.8 kW
Cable cross-section
■400 V~ 5 x 2.5 mm25 x 2.5 mm25 x 2.5 mm2
■230 V~ 7 x 2.5 mm27 x 2.5 mm27 x 2.5 mm2
Max. cable length 25 m 25 m 25 m
Siting and transport requirements
Transport
During handling, the cylinder module can be removed:
see page 11 onwards.
In addition, the heat pump module can be removed:
see page 16.
!Please note
Impacts, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never put weight on the top, front or side panels
of the appliance.
!Please note
Tilting the compressor at a steep angle inside
the heat pump can result in appliance damage.
Max. tilting angle: 45°
Preparing for installation
Requirements regarding on-site connections (cont.)
5673 976 GB
Installation

10
Installation room requirements
!Please note
Unfavourable ambient conditions can lead to
malfunction and appliance damage.
■The installation room must be dry and free
from the risk of frost.
■Ensure ambient temperatures between 0 and
35 °C.
Danger
Dust, gases and vapours can be damaging to
health and cause explosions.
Avoid dust, gases and vapours in the installation
room.
!Please note
Overloading the floor can result in damage to
the building structure.
Observe the permissible floor load. Take the
total weight of the appliance into account.
Total weight with full DHW cylinder
Type BWT/BWT-M Weight in kg
241.A06 480
241.A08 480
241.A10 486
To prevent the transmission of structure-borne noise,
never site the appliance above ceilings with wooden
joists, e.g. in the attic.
Minimum room volume (to DIN 378)
Type BWT/
BWT-M
Floor area in
m2
Minimum room vol-
ume in m3
241.A06 1.9 4.9
241.A08 1.9 4.9
241.A10 2.2 5.5
Minimum clearances
Fig. 2
Minimum room height h
Installation h in mm
■Without connection set for pre-instal-
lation/DHW (accessories)
2250
■With connection set for pre-installa-
tion/DHW (accessories)
2350
Observe engineering information.
Technical guides for heat pumps
Preparing for installation
Siting and transport requirements (cont.)
5673 976 GB
Installation

11
Removing the cylinder module
3.
1.
5.
4.
2.
2x
Fig. 3
Installation sequence
Siting the heat pump
5673 976 GB
Installation

12
6.
X3
sG
sH
lJ
aYH
7.
F23
F6
X25
a:C]
B
a:C]
A
a:C]
C
8.
Fig. 4
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

13
aCH
11.
SLP
N
9.
10.
Fig. 5
17.
14. 18.
X20
15.
13.
2x
16.
2x
12.
Fig. 6
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

14
4x
4x
6x
2x
22.
19.
21.
20.
Fig. 7
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

15
4x
23.
2x
26.
25.
24.
Fig. 8
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

16
Removing the heat pump module
6.
1.
4.
kK
1.
5.
2.
X3
sG
sH
lJ
aYH
3.
Fig. 9
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

17
8.
7.
9. 4x
sH
kK
aYH
X3
sG
lJ
?
aJ
10.
Fig. 10
2x
12.
11.
4x
Fig. 11
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

18
Assembly and sealing faces to note
A
Fig. 12
ADiaphragm grommets
1. Install the heat pump module in reverse order to
that described on page 16.
!Please note
Leaking hydraulic connections lead to appli-
ance damage.
Ensure the diaphragm grommets at the pipe
entries are seated correctly. Seal pipe
entries with sealing tape if necessary.
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
between the heat pump module and cylin-
der module.
■Ensure the diaphragm grommets at the
hose outlets are seated correctly.
Seal hose outlets with sealing tape if nec-
essary.
!Please note
Incorrectly closed casing doors can lead to
damage from condensation, vibrations and
excessive noise.
■Seal the casing door so it is soundproof
and diffusion-proof.
■The sealing tape on the side panels must
fit closely to the sealing faces of the cas-
ing: see Fig. 13.
Note
Because of the sound insulation mat, the casing
door stands out slightly when closed.
D
B
B
C
Fig. 13
BSealing faces
CDiaphragm grommets
DCasing door
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

19
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.
4.
1.
3.
2.
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)
!Please note
Leaking hydraulic connections lead to appliance
damage.
Ensure the diaphragm grommets at the pipe
entries are seated correctly. Seal pipe entries
with sealing tape if necessary.
Installation sequence
Siting the heat pump (cont.)
5673 976 GB
Installation

20
4x
4x
2.
1.
A
B
Fig. 15
AStraight pipe sections supplied
BPipe bends from primary circuit/secondary circuit
connection set (accessories): See separate instal-
lation instructions.
Connecting the primary circuit
!Please note
The heat transfer medium can cause corrosion
damage to on-site lines and components.
The components and lines used must be resist-
ant to the heat transfer medium. Never use zinc-
plated/galvanised pipes.
1. Equip the primary circuit with an expansion vessel
and safety valve (in accordance with DIN 4757).
Note
■The expansion vessel must be approved to
DIN 4807. The diaphragms of the expansion ves-
sel and safety valve must be suitable for the heat
transfer medium.
■The blow-down and drain pipes should terminate
in a container. This container must be able to
hold the maximum possible expansion volume of
the heat transfer medium.
2. Ensure adequate thermal and anti-vibration insula-
tion of all pipes routed through walls.
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.
Ensure the diaphragm grommets at the pipe
entries are seated correctly. Seal pipe
entries with sealing tape if necessary.
4. Insulate pipes inside the building to prevent heat
and vapour diffusion.
Connecting the secondary circuit
FE
D C
Fig. 16 Safety assembly supplied
CPressure gauge
DConnection G 1
EQuick-action air vent valve
FSafety valve
1. Equip the secondary circuit on site with an expan-
sion vessel and the safety assembly supplied (in
accordance with DIN 4757).
Fit the safety assembly to the on-site line in the
heating water return.
or
Fit the safety assembly to the primary circuit/
secondary circuit connection set (accessories).
Connection set installation instructions
Installation sequence
Hydraulic connections (cont.)
5673 976 GB
Installation