Viessmann Vitocal 242-S Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitocal 242-S
Type AWT-AC 241.A04 to A13
Compact heat pumps, split version for heating and cooling opera-
tion
For applicability, see the last page
VITOCAL 242-S
5623 661 GB 10/2012 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
5623 661 GB

3
!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.)
5623 661 GB

4
Installation instructions
Preparing for installation
Application............................................................................................................ 6
Requirements regarding on-site connections....................................................... 7
Overview of possible system schemes................................................................ 9
Designations in the system examples.................................................................. 11
System example, ID: 4605415_1202_02............................................................. 11
Installation sequence
Installing the external unit..................................................................................... 18
Installing the internal unit...................................................................................... 23
Connecting refrigerant lines................................................................................. 33
Connecting the secondary circuit......................................................................... 41
Connections on the DHW side............................................................................. 44
Connecting the solar circuit.................................................................................. 45
Connecting a cooling circuit if required................................................................ 45
Electrical connection............................................................................................ 45
Power supply........................................................................................................ 61
Closing the heat pump......................................................................................... 68
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 69
Further details regarding the individual steps....................................................... 71
Troubleshooting
Repairs................................................................................................................. 94
Parts lists, internal unit
Parts lists, internal unit......................................................................................... 107
Overview of assemblies, internal unit................................................................... 108
Parts not shown, internal unit............................................................................... 109
Internal unit casing............................................................................................... 109
Internal unit electrical equipment.......................................................................... 111
Internal unit hydraulics......................................................................................... 113
Internal unit cylinder............................................................................................. 115
Parts lists, external unit
Parts lists, external unit........................................................................................ 117
External unit type AWT-AC 241.A04.................................................................... 117
External unit type AWT-AC 241.A07.................................................................... 119
Overview of external unit assemblies, type AWT-AC 241.A10, A13.................... 121
Index
Index
5623 661 GB

5
External unit casing, type AWT-AC 241.A10, A13............................................... 122
External unit electrical equipment, type AWT-AC 241.A10, A13.......................... 124
External unit hydraulics, type AWT-AC 241.A10, A13......................................... 126
Commissioning/service reports
Hydraulic parameter report................................................................................... 128
Control parameter report...................................................................................... 128
Specification....................................................................................................... 136
Appendix
Heat pump commissioning order.......................................................................... 141
Declaration of conformity.................................................................................. 142
Keyword index.................................................................................................... 143
Index
Index (cont.)
5623 661 GB

6
The compact heat pumps Vitocal 242-S,
type AWT-AC 241.A04 to A13, can be
used for the following purposes:
■ Central heating and cooling via a heat-
ing system.
■ DHW heating with the integral DHW
cylinder; also through the utilisation of
solar energy.
Any other use is considered inappropri-
ate.
Note
Vitocal 242-S is intended exclusively for
domestic use, i.e. even people who have
not had any instruction are able to oper-
ate the appliance safely.
Preparing for installation
Application
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7
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
5623 661 GB
Installation

8
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 10 mm is necessary 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.)
5623 661 GB

9
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~) – 1.5 m
Other connecting cables:
230 V~, e.g. for 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
Vitocal 242-S, type AWT-AC 241.A04 241.A07 241.A10 241.A13
External unit (compressor)
230 V~
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
Heat pump control unit (inter-
nal unit) 230 V~
Cable cross-section
■ Without power-OFF contact 3 x 1.5 mm23 x 1.5 mm23 x 1.5 mm23 x 1.5 mm2
■ With power-OFF contact 5 x 1.5 mm25 x 1.5 mm25 x 1.5 mm25 x 1.5 mm2
Instantaneous heating water
heater
Cable cross-section
■ 400 V~ 5 x 2.5 mm25 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 mm27 x 2.5 mm2
Max. cable length 25 m 25 m 25 m 25 m
Overview of possible system schemes
The following table provides an overview
of all possible system schemes.
Preparing for installation
Requirements regarding on-site connections (cont.)
5623 661 GB
Installation

10
System schemes
Component System scheme
0 1 2 3 4 5 6 11
Heating circuit
A1/HC1 — X X — — X X —
M2/HC2 — — — X X X X —
DHW cylinder
X — X — X — X —
Heating water buffer cylinder
— 0 0 X X X X —
Instantaneous heating water heater
X X X X X X X —
Swimming pool
— 0 0 0 0 0 0 —
Solar thermal system
(with integral solar control function)
0—0—0—0—
Cooling
A1/HC1 — 0 0 — — 0 0 —
M2/HC2 — — — 0 0 0 0 —
SKK 0 0 0 0 0 0 0 —
Electricity meter 1-phase/3-phase
0 0 0 0 0 0 0 0
Vitovent
0 0 0 0 0 0 0 0
X Component selected.
0Component may be added.
Preparing for installation
Overview of possible system schemes (cont.)
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11
--230V-- -KM BUS-
--F6-- --F0-- --F8-- --F14--
--212.3-- --211.2-- --211.4--
-2/X3.8;3.9-
2
2
[H
F
[YF
F
--2/F14--
--2/211.2--
-2/145-
A1
--2/X3.8;3.9--
oR
iE
oE oP
oQ
oW
oE
--2/F14--
oEoE
System example, ID: 4605415_1202_02
Note
This scheme is a general example with-
out shut-off valves or safety equipment.
This does not replace the need for local
engineering.
Preparing for installation
Designations in the system examples
5623 661 GB
Installation

12
Hydraulic installation scheme
60
61
71
70
73
74
76
77
91
90
96
62
2
--2/F13--
--2/F4--
--2/212.2--
--212.3--
--212.4--
--212.2--
--F21--
--F0--
--F13--
--F4--
--105/52--
--74/20--
-105/20--76-
--105/2--
-KM BUS-
--230 V--
89
--2/211.5-----
--211.5--
-2/X3.8;3.9-
83
--52--
--2--
-KM BUS-
--20--
-230 V-
105
8
--145-- --145--
--145--
--145--
-8/145- -8/145-
--
--X3.8;3.9--
A1 M2
1
29
3
--2/F0--
6
54
CW
DHW
43
42
44
45
49
--2/F21--
----2/212.4--
28
27
-2/212.3-
-2/X3.8;3.9-
18
37
30
12
13
41
-2/212.4-
--F6--
--2/211.5--
89
15
-2/X3.3;3.4-
Note
In cooling mode, safeguard the minimum flow rate in the secondary circuit. Open
valves on the heating circuit distributor fully and permanently or install an overflow
valve.
Preparing for installation
System example, ID: 4605415_1202_02 (cont.)
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Pos. Designation
Heat source
1Internal unit, heat pump, Vitocal 242-S, type AWT-AC 241.A
2Heat pump control unit Vitotronic 200, type WO1C
3Outside temperature sensor ATS
4Instantaneous heating water heater with switching module (integral)
53-way diverter valve "Heating/DHW heating" (integral)
6Secondary pump (integral)
8KM BUS distributor (accessories)
qW Safety assembly
qE Heating circuit expansion vessel
qT Flow switch
Primary circuit
wU Hot gas line
wI Liquid line
wO External unit of the heat pump Vitocal 242-S
DHW heating with heat pump
eP DHW cylinder (integral)
eQ Cylinder temperature sensor STS (integral)
eU DHW circulation pump ZP (accessories)
DHW heating with a solar thermal system
rQ High limit safety cut-out (accessories)
rW Solar Divicon
rE Solar circuit pump
rR Collector temperature sensor KOL
rT Solar collector
rO Solar circuit expansion vessel
zP Heating water buffer cylinder
zQ Buffer temperature sensor PTS
zW System flow temperature sensor VTS
Preparing for installation
System example, ID: 4605415_1202_02 (cont.)
5623 661 GB
Installation

14
Pos. Designation
Heating circuit with mixer M2/HC2 (KM BUS)
uP Underfloor heating circuit/cooling circuit
uQ Vitotrol remote control
uE Flow temperature sensor
uR Temperature limiter to restrict the maximum temperature of underfloor
heating systems
■ as immersion thermostat
or
■ as contact thermostat
uZ Heating circuit pump
uU 3-way mixer, heating circuit
Mixer motor of the 3-way mixer
q-T Mixer extension kit
Active cooling function AC
qI Frost stat 230 V
iE Contact humidistat 230 V
iO 3-way diverter valve for "heating/cooling"
Heating circuit without mixer A1/HC1
oP Radiator heating circuit
oQ Vitotrol remote control
oZ Heating circuit pump
Electrical installation scheme
For an overview of the electrical connec-
tions and more detailed information
regarding the PCBs, see from
page 49 and the service instructions
for the Vitotronic 200 heat pump control
unit.
For information regarding the power sup-
ply, see page 61.
Preparing for installation
System example, ID: 4605415_1202_02 (cont.)
5623 661 GB

15
230 V/50 Hz
2
212.3
X2.N
X1.
212.2
X2.N
X1. HK A1 96
ZP 37
X2.N
X1.
X2.N
X1.
1
2
145
8
145
145
145
145
40
145
52
21
2
N
L
UP M2
77
73
M
1~
74
76
M2
VTS M2
20
230 V/50 Hz
105
2
1
HK A1
HK M2
91
71
Low voltage
1/N/PE
1
2
1
2
2
50 W
100 W
L
N
20
41
STB
212.4
UP 43
130 W
95 °C
211.5
89
89
HK M2
X1.
X3.8
X3.9
8318
KM BUS distributor
UV
UV
NTC 10 kΩ
X3.4
X3.3
15
M
1~
M
1~
1
3
2
1
3
2
1
3
2
L
N
N
M
1~
1
3
2
M
1~
M
1~
M
1~
Preparing for installation
System example, ID: 4605415_1202_02 (cont.)
5623 661 GB
Installation

16
Low voltage
PTS
KOL
VTS
NTC, 20 kΩ
NTC, 10 kΩ
NTC, 10 kΩ
ATS
NTC, 10 kΩ
1
2
F0
F13
F21
F4 zQ
rR
zW
3
2
Power supply, internal unit with
instantaneous heating water heater
4 for 400 V~ or 230 V~
2
1 / N / PE
230 V / 50 Hz
F1T6.3AH
L1
N
N1
1 / N / PE
230 V/50 Hz
N1
N1
L1
4
L1
L1
3 / N / PE
400 V/50 Hz
N
L2
4
L3
L1
X3.18
X1.1
X2.1
230 V
400 V
Instantaneous heating water heater power supply
Heat pump control unit power supply
External unit connections
C N L
29
4 kW
COM
43 V
> 42 V
2
L1
N
1 / N / PE
230 V/ 50 Hz
COM
29
7 kW
COM
43 V
> 42 V
2
L1
N1 / N / PE
230 V/ 50 Hz
Li No Lo
Ni
29
COM
12 V
2
L1
N1 / N / PE
230 V/ 50 Hz
NL
L
N
C1
C2
10 / 13 kW
< 42 V
Preparing for installation
System example, ID: 4605415_1202_02 (cont.)
5623 661 GB

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Required parameter settings
To call up "Coding level 1" for setting
the parameters, see the commissioning
assistant on page 83 and page 86.
Parameter Setting
"System definition"
■"System scheme 7000" "6"
DHW heating:
"Time program DHW heating" Set time program (see op-
erating instructions)
"Time program DHW circulation"
(if a DHW circulation pump is installed)
Set time program (see op-
erating instructions)
"DHW"
■"Enable booster heaters for DHW heating 6014" "1"
■"Enable electric heaters for DHW heating 6015" "1"
"Solar"
■"Solar control unit type" "4"
Instantaneous heating water heater:
"Electr booster heater"
■"Enable instantaneous heating water heater
7900"
"1"
■"Enable instant. heating water heater for central
heating 7902"
"0"
■"Time prog elec heater" Set time program (see op-
erating instructions)
"Cooling"
■"Cooling function 7100" "3"
■"Cooling circuit 7101" "2"
Remote controls (if installed):
"Heating circuit 1"
■"Remote control 2003" "1"
"Heating circuit 2"
■"Remote control 3003" "1"
Preparing for installation
System example, ID: 4605415_1202_02 (cont.)
5623 661 GB
Installation

18
!Please note
Avoid damaging the appliance
during transportation.
Never put weight on top of the
appliance.
!Please note
If the compressor in the external
unit is steeply angled, lubricant
will enter the refrigerant circuit
and damage the appliance.
Compliance is required with the
max. tilt angle according to the
following table.
Type AWT-AC Max. tilting angle
241.A04 45°
241.A07 45°
241.A10 30°
241.A13 30°
Installation requirements
Installation location
■ Select a site with good air circulation,
so that the cooled air can dissipate and
be replenished by warm air.
■ Avoid direct insolation.
■ When installing the unit where it is
exposed to wind, ensure that the wind
cannot influence the fan area. This
could result in an "air short circuit"
between the discharged and the
inrushing air. Strong wind can have a
negative influence on the evaporator
ventilation.
!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.
Installation sequence
Installing the external unit
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19
Avoid "air short circuits".
■ Take the lengths of the refrigerant
lines into account (see "Connecting
refrigerant lines").
■ Select the installation site so that the
evaporator cannot be blocked by
leaves, snow etc.
■ Select the installation site with due
consideration of the statutory regula-
tions on sound dissipation and reflec-
tions.
Technical guide "Heat pump
principles"
■ Never site in corners of rooms,
recesses or between walls.
■ Never install next to or below bedroom
windows.
■ 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
there are outside temperatures below
10 °C.
■ The installation site should be easily
accessible, for example for mainte-
nance work (see "Minimum clearan-
ces").
Type of installation
■ Floorstanding installation with cable
entry above ground level
■ Floorstanding installation with cable
entry below ground level
■ Wall mounting
Technical guide
Installation information
■ Installation on a floor:
Use supports (accessories) for floor-
standing installation.
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 account of the weight of the
external unit (see following table).
■ Wall mounting:
Use the wall mounting bracket set
(accessory).
■ Never install with the discharge side
facing the main wind direction.
■ Observe wind loads when installing
the unit on sites exposed to the wind.
■ When mounting the unit on a wall, the
wall must offer sufficient load-bearing
capacity.
■ Design wall outlets and protective
pipes for the refrigerant lines and elec-
trical cables without moulded parts
and changes of direction.
■ Incorporate the external unit into the
lightning protection system.
■ Consider the heat emitted by the unit
when planning your weatherproofing
measures or an enclosure.
■ Ensure the condensate can drain
freely, and create a permanent gravel
bed below the external unit as a soak-
away.
Installation sequence
Installing the external unit (cont.)
5623 661 GB
Installation

20
■ In regions with prolonged cold sea-
sons (e.g. in Germany), provide an
electric supplementary heating facility
(accessory) for the condensate pan.
■ For insulation of structure-borne noise
and vibrations between the building
and the external unit, consider the fol-
lowing measures:
– When cable entry is above ground
level, fit pipe bends as anti-vibration
mounts in refrigerant lines (see
"Connecting 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 structure etc.
– When installing the unit on the floor,
use only the rubber mounts sup-
plied; for wall mounting use the anti-
vibration mounts supplied with the
wall mounting bracket set; never use
additional anti-vibration mounts,
springs, rubber buffers etc.
Weight of external units
Type AWT-AC Weight in kg
241.A04 43
241.A07 66
241.A10 110
241.A13 110
Installation sequence
Installing the external unit (cont.)
5623 661 GB