Viessmann Vitocal 242-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 242-S
Type AWT-AC 241.A04 to A13, B10, B13
Compact heat pumps, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 242-S
5546 699 GB 7/2014 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ National installation regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the relevant trade
associations.
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and
SVGW
Working on the system
■ 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'.
Note
In addition to the control circuit, there
may be several power circuits.
Danger
Contact with 'live' components
can result in severe injuries.
Some components on the
PCBs will remain 'live' even
after the power supply has
been switched off.
Prior to removing equipment
covers, wait at least 4 min. to
allow the voltage to dissipate.
■ Safeguard the system against recon-
nection.
Safety instructions
Safety instructions
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!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Before beginning 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 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. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only spare
parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Installation instructions
Preparing for installation
Intended use......................................................................................................... 6
Requirements regarding on-site connections....................................................... 7
Installation sequence
Installing the external unit..................................................................................... 10
Installing the internal unit...................................................................................... 15
Connecting refrigerant lines................................................................................. 24
Connecting the secondary circuit......................................................................... 34
Connecting the DHW side.................................................................................... 37
Connecting the solar circuit.................................................................................. 38
Connecting a cooling circuit if required................................................................ 38
Electrical connection............................................................................................ 38
Power supply........................................................................................................ 54
Closing the heat pump......................................................................................... 62
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 63
Further details regarding the individual steps....................................................... 65
Troubleshooting
Repairs................................................................................................................. 88
Parts lists, internal unit
Ordering parts...................................................................................................... 101
Overview of assemblies, internal unit................................................................... 102
Parts not shown, internal unit............................................................................... 103
Casing, internal unit.............................................................................................. 103
Electrical equipment, internal unit........................................................................ 105
Hydraulics, internal unit........................................................................................ 108
Cylinder, internal unit............................................................................................ 111
Parts lists, external unit 230 V~, type AWT-AC 241.A04
Ordering parts...................................................................................................... 113
External unit 230 V~............................................................................................. 113
Parts lists, external unit 230 V~, type AWT-AC 241.A07
Ordering parts...................................................................................................... 116
External unit 230 V~............................................................................................. 116
Index
Index
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Parts lists, external unit 230 V~, type AWT-AC 241.A10, A13
Ordering parts...................................................................................................... 119
Overview of assemblies 230 V~........................................................................... 120
Casing, external unit 230 V~................................................................................ 121
Electrical equipment, external unit 230 V~........................................................... 123
Hydraulics, external unit 230 V~.......................................................................... 125
Parts lists, external unit 400 V~, type AWT-AC 241.B10, B13
Ordering parts...................................................................................................... 127
Overview of assemblies 400 V~........................................................................... 128
Casing, external unit 400 V~................................................................................ 129
Electrical equipment, external unit 400 V~........................................................... 131
Hydraulics, external unit 400 V~.......................................................................... 133
Commissioning/service reports
Hydraulic parameter report................................................................................... 135
Control parameters report.................................................................................... 135
Specification....................................................................................................... 145
Appendix
Heat pump commissioning order.......................................................................... 154
Declaration of conformity.................................................................................. 155
Keyword index.................................................................................................... 156
Index
Index (cont.)
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions.
Depending on the version, the appliance
can only be used for the following pur-
poses:
■ Central heating
■ Central cooling
■ DHW heating
The range of functions can be extended
with additional components and acces-
sories.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than central heating/cooling
or DHW heating shall be deemed inap-
propriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function.
Note
The appliance is intended exclusively for
domestic use, i.e. even users who have
not had any instruction are able to oper-
ate the appliance safely.
Preparing for installation
Intended use
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Internal unit
405
147
69
134
159
62 300
387
475
29 2051
2075
2047
600 680
61
111
454
564
666
506
AOpening for LV leads < 42 V BDHW
Preparing for installation
Requirements regarding on-site connections
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Installation

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CDHW circulation
DOpening for 230 V cables
ECold water
FLiquid line
GHot gas line
HHeating water flow
KHeating water return
LSolar circuit return
MSolar circuit flow
Connection sizes for hydraulic connections
Pos. Sym-
bol
Meaning Connection
B– DHW Rp ¾
C– DHW circulation G 1
E– Cold water Rp ¾
FRefrigerant lines from/to
the external unit:
■ Liquid line 7 connection pipe:
(supplied pipe bends)
10 mm
UNF thread: ⅝
For type AWT-AC 241.A04, a reduction
from 10 to 6 mm is necessary down-
stream of the pipe bend (reducer ⅝ to ⁷⁄₁₆
supplied).
G■ Hot gas line 7 connection pipe:
(supplied pipe bends)
16 mm
UNF thread: ⅞
For type AWT-AC 241.A04, a reduction
from 16 to 12 mm is required down-
stream of the pipe bend (reducer ⅞ to
¾ supplied).
HHeating water flow Cu 28 x 1 mm
KHeating water return Cu 28 x 1 mm
L– Solar circuit return DN 20 pipe sleeve for multi connect sys-
tem
M– Solar circuit flow
1. Prepare the connections on the heat-
ing water and the DHW side.
Flush the heating system.
2. Prepare the electrical connections.
Preparing for installation
Requirements regarding on-site connections (cont.)
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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:
■ 230 V~, e.g. for circulation pumps 2.0 m –
■ < 42 V, e.g. for sensors 2.0 m –
Internal/external unit connecting cable:
■ 12 V BUS 2.5 m 1.5 m
■ 43 V BUS 2.5 m 1.5 m
Recommended power cables
Type AWT-AC 241.A04 to A13, B10, B13
Heat pump control unit (internal unit) 230 V~
Cable cross-section
■ Without power-OFF 3 x 1.5 mm2
■ With power-OFF 5 x 1.5 mm2
Instantaneous heating water heater
Cable cross-section
■ 400 V~ 5 x 2.5 mm2
■ 230 V~ 7 x 2.5 mm2
Max. cable length 25 m
Type AWT-AC 241.A04 241.A07 241.A10 241.A13
External unit 230 V~ (compres-
sor)
Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 4.0 mm2
Max. cable length 29 m 25 m 20 m 20 m
or or
Cable cross-section – – 3 x 4.0 mm23 x 6.0 mm2
Max. cable length – – 32 m 30 m
Type AWT-AC 241.B10 241.B13
External unit 400 V~ (compressor)
Cable cross-section 5 x 2.5 mm25 x 2.5 mm2
Max. cable length 30 m 30 m
Preparing for installation
Requirements regarding on-site connections (cont.)
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Installation

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Installation information
Types of installation:
■ Floorstanding installation with line
entry above ground level
■ Floorstanding installation with line
entry below ground level
■ Wall mounting
Technical guide
Floorstanding installation:
■ Use supports for floorstanding instal-
lation (accessories).
■ Where such supports cannot be used,
install the external unit freestanding on
a solid base of at least 100 mm height.
■ In difficult climatic circumstances
(temperatures below zero, snow,
humidity) install the appliance on a
plinth of approx. 300 mm height.
■ Take into account the weight of the
external unit: See the following table.
Wall mounting:
■ Use the wall mounting bracket set
(accessories).
■ The wall must meet the structural
requirements.
Positioning:
■ Never install with the discharge side
facing the main wind direction.
■ Provide wall ducts and protective
pipes for the refrigerant lines and elec-
trical cables without moulded parts
and change of direction.
Weather influences:
■ Observe wind loads when installing
the unit on sites exposed to the wind.
■ Incorporate the external unit into the
lightning protection system.
■ Consider the heat emitted by the unit
when planning your weatherproofing
or an enclosure.
Condensate:
■ Ensure the condensate can drain
freely, and create a permanent gravel
bed below the external unit as a soak-
away.
■ In regions with prolonged cold sea-
sons (such as Sweden for example),
provide an electric ribbon heater
(accessory) for the condensate pan.
Insulation against structure-borne
noise and vibrations between build-
ing and external unit:
■ When line entry is above ground level,
fit pipe bends in the refrigerant lines for
vibration compensation: See "Con-
necting refrigerant lines".
■ Route electrical cables/leads between
the internal and external units free of
stress.
■ Installation only on walls with high
weight per area (> 250 kg/m2), in other
words not on lightweight walls, roof
structures etc.
■ For floorstanding installation, only use
the rubber mounts supplied.
■ For wall mounting, only use the anti-
vibration mounts from the bracket set.
■ Never use additional anti-vibration
mounts, springs, rubber mounts, etc.
Installation sequence
Installing the external unit
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Weight of external units
Type AWT-AC Weight in kg
241.A04 43
241.A07 66
241.A10 113
241.A13 113
241.B10 113
241.B13 113
Installation site
■ Select a site with good air circulation,
so that the cooled air can dissipate and
be replaced by warm air.
■ Avoid direct insolation.
■ When siting the unit where it is
exposed to wind, ensure that the wind
cannot influence the fan area. Strong
wind can have a negative influence on
the evaporator ventilation.
■ Take into account the lengths of the
refrigerant lines: See "Connecting
refrigerant lines".
■ Select the installation site so that the
evaporator cannot be blocked by
leaves, snow etc.
■ Select the installation site giving due
consideration to the physical laws con-
cerning the propagation and reflection
of sound.
Technical guide "Heat pump
principles"
■ Never install in interior corners, in
recesses or between walls. This could
result in an "air short circuit" between
the air being discharged and the air
being drawn in.
!Please note
An "air short circuit" during
heating operation will result in
the cooled discharged air re-
entering the unit. This can
result in reduced heat pump
efficiency and defrosting prob-
lems.
Avoid "air short circuits".
!Please note
An "air short circuit" during
cooling operation will result in
the heated discharged air re-
entering the unit. This can lead
to high pressure faults.
Avoid "air short circuits".
■ Never install next to or below bedroom
windows.
Installation sequence
Installing the external unit (cont.)
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Installation

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■ Never install closer than 3 m to path-
ways, downpipes or sealed surfaces.
The cooled air in the discharge area
creates a risk of ice forming when out-
side temperatures are below 10 °C.
■ The installation site must be easily
accessible, for example for mainte-
nance work: See "Minimum clearan-
ces".
Minimum clearances
A
B
b
d
ac
Example: type AWT-AC 241.A04
AAir intake BAir discharge
Type AWT-AC Dimensions in mm
a b c d
Cable entry
above
ground
level
below
ground
level
241.A04 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
241.A07 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥ 1000
241.A10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
241.A13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
Installation sequence
Installing the external unit (cont.)
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Type AWT-AC Dimensions in mm
a b c d
Cable entry
above
ground
level
below
ground
level
241.B10 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
241.B13 ≥ 100 ≥ 200 ≥ 400 ≥ 300 ≥ 1000
Handling and siting
!Please note
Avoid damaging the appliance
during transport.
Never put weight on top of the
appliance.
!Please note
If the compressor in the external
unit is strongly tilted, lubricant will
enter the refrigerant circuit and
damage the appliance.
Note the max. tilting angle of
45°.
Installation sequence
Installing the external unit (cont.)
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Installation

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Floor mounting
2.
1.
4x
4x
A
B
C
E
D
ASupport for floorstanding installation
(accessories)
Installation sequence
Installing the external unit (cont.)
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BGravel bed as condensate soak-
away
CConcrete foundations (see technical
guide)
DDrainage pipe DN 100 (only with
entries below ground level)
ERubber mounts (supplied)
Note
We recommend letting condensate drain
away freely (without condensate pipe).
Wall mounting
Installation must only be performed with
the bracket set suitable for wall mounting
(accessory).
Separate installation instructions
Installing the internal unit
!Please note
Avoid damaging the appliance
during transportation.
Never put weight on top of the
appliance.
Installation room requirements
!Please note
The installation room must be dry
and free from the risk of frost.
Ensure ambient temperatures
between 0 and 35 °C.
!Please note
Avoid risks of explosion due to
dust, gases and vapours.
Avoid dust, gases and vapours in
the installation room.
!Please note
Observe the permissible floor
load.
■ Align the appliance horizon-
tally.
If the adjustable feet are used
to compensate for an uneven
floor (max. 10 mm), the pres-
sure load on the feet must be
distributed evenly.
■ The total weight must be con-
sidered (see table).
Installation sequence
Installing the external unit (cont.)
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Installation

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Total weight with filled DHW cylinder
Type AWT-AC Weight in kg
241.A04 424
241.A07 424
241.A10 427
241.A13 427
241.B10 427
241.B13 427
Minimum room volume (to EN 378)
Type AWT-AC Minimum room
volume in m3
241.A04 2.7
241.A07 4.9
241.A10 6.1
241.A13 6.1
241.B10 6.1
241.B13 6.1
Minimum clearances
Note
When using the secondary circuit con-
nection set (accessory), maintain a wall
clearance of approx. 80 mm.
Minimum room height h
Installation h in mm
■Without connection set for
pre-installation/DHW (ac-
cessories)
2250
■With connection set for
pre-installation/DHW (ac-
cessories)
2350
Observe engineering informa-
tion.
Vitocal technical guide
Handling
The cylinder module can be removed
during transport. !Please note Avoid damaging the appliance
during handling.
Never put weight on the top, front
or side panels of the appliance.
Installation sequence
Installing the internal unit (cont.)
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Removing the cylinder module
2x
3.
1.
4.
5.
2.
Installation sequence
Installing the internal unit (cont.)
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Installation

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6.
8.
P301
P501
P303
P302
F23
F6
X25
193B
193C
7.
Installation sequence
Installing the internal unit (cont.)
5546 699 GB

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SLP
N
9.
11.
aCH
sG
lJ
10.
Installation sequence
Installing the internal unit (cont.)
5546 699 GB
Installation

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X20
2x
16. 17.
2x
12.
14. 18.
13.
15.
Installation sequence
Installing the internal unit (cont.)
5546 699 GB