Viessmann Vitocal 242-S Installation And Service Instructions Manual
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Viessmann Vitocal 242-S Installation And Service Instructions Manual

Compact heat pumps, split version for heating and cooling operation
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VIESMANN
Installation and service
instructions
for contractors
Vitocal 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
Please keep safe.
5623 661 GB
10/2012

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Summary of Contents for Viessmann Vitocal 242-S

  • Page 1 VIESMANN Installation and service instructions for contractors 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 Please keep safe. 5623 661 GB 10/2012...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ Codes of practice of the relevant trade associations. Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, VDE and risk of injury.
  • Page 3 Repairing components that fulfil a safety function can compromise the safe operation of your sys- tem. Defective components must be replaced with genuine Viessmann spare parts. Auxiliary components, spare and wearing parts Please note Spare and wearing parts that have not been tested together with the system can compromise its function.

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Application......................Requirements regarding on-site connections............Overview of possible system schemes..............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.................
  • Page 5 Index Index (cont.) 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................
  • Page 6 Preparing for installation Application The compact heat pumps Vitocal 242-S, Any other use is considered inappropri- type AWT-AC 241.A04 to A13, can be ate. used for the following purposes: ■ Central heating and cooling via a heat- Note ing system.
  • Page 7 Preparing for installation Requirements regarding on-site connections Internal unit A Opening for LV leads <42 V B DHW...
  • Page 8 Preparing for installation Requirements regarding on-site connections (cont.) C DHW circulation H Heating water flow D Opening for 230 V cables K Heating water return E Cold water L Solar circuit return F Liquid line M Solar circuit flow G Hot gas line Connection sizes for hydraulic connections Pos.

  • Page 9: Overview Of Possible System Schemes

    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 mm 3 x 2.5 mm...
  • Page 10 Preparing for installation Overview of possible system schemes (cont.) System schemes Component System scheme Heating circuit A1/HC1 — — — — M2/HC2 — — — — DHW cylinder — — — — Heating water buffer cylinder — — Instantaneous heating water heater —...

  • Page 11: Designations In The System Examples

    Preparing for installation Designations in the system examples -2/145- --2/F14-- --2/F14-- --2/X3.8;3.9-- --2/211.2-- 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.
  • Page 12 Preparing for installation System example, ID: 4605415_1202_02 (cont.) Hydraulic installation scheme -8/145- -8/145- -2/X3.8;3.9- --105/2-- -105/20--76- --2/212.2-- --74/20-- --105/52-- ----2/212.4-- --2/F13-- -2/X3.8;3.9- -2/212.3- -2/212.4- -2/X3.3;3.4- --2/211.5-- 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.
  • Page 13 (cont.) Pos. Designation Heat source Internal unit, heat pump, Vitocal 242-S, type AWT-AC 241.A Heat pump control unit Vitotronic 200, type WO1C Outside temperature sensor ATS Instantaneous heating water heater with switching module (integral) 3-way diverter valve "Heating/DHW heating" (integral)
  • Page 14 Preparing for installation System example, ID: 4605415_1202_02 (cont.) Pos. Designation Heating circuit with mixer M2/HC2 (KM BUS) Underfloor heating circuit/cooling circuit Vitotrol remote control Flow temperature sensor Temperature limiter to restrict the maximum temperature of underfloor heating systems ■ as immersion thermostat ■...
  • Page 15 Preparing for installation System example, ID: 4605415_1202_02 (cont.) X3.8 X3.9 50 W 212.3 X2.N 100 W 212.2 HK A1 X2.N 95 °C 130 W 212.4 X2.N 211.5 X2.N X3.3 X3.4 KM BUS distributor HK A1 HK M2 HK M2 230 V/50 Hz 1/N/PE UP M2 NTC 10 kΩ...

  • Page 16: Instantaneous Heating Water Heater

    Preparing for installation System example, ID: 4605415_1202_02 (cont.) NTC, 10 kΩ NTC, 20 kΩ NTC, 10 kΩ NTC, 10 kΩ Power supply, internal unit with External unit connections instantaneous heating water heater 4 for 400 V~ or 230 V~ 4 kW Heat pump control unit power supply X1.1 1 / N / PE...
  • Page 17 Preparing for installation System example, ID: 4605415_1202_02 (cont.) 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"...

  • Page 18: Installing The External Unit

    Installation sequence Installing the external unit Please note Type AWT-AC Max. tilting angle Avoid damaging the appliance 241.A04 45° during transportation. 241.A07 45° Never put weight on top of the 241.A10 30° appliance. 241.A13 30° Please note If the compressor in the external unit is steeply angled, lubricant will enter the refrigerant circuit and damage the appliance.
  • Page 19 Installation sequence Installing the external unit (cont.) Avoid "air short circuits". Installation information ■ Take the lengths of the refrigerant ■ Installation on a floor: lines into account (see "Connecting Use supports (accessories) for floor- refrigerant lines"). standing installation. ■ Select the installation site so that the Where such supports cannot be used, evaporator cannot be blocked by install the external unit freestanding on...
  • Page 20 Installation sequence Installing the external unit (cont.) ■ In regions with prolonged cold sea- Weight of external units sons (e.g. in Germany), provide an Type AWT-AC Weight in kg electric supplementary heating facility 241.A04 (accessory) for the condensate pan. 241.A07 ■...

  • Page 21: Minimum Clearances

    Installation sequence Installing the external unit (cont.) Minimum clearances Example: type AWT-AC 241.A04 A Air intake B Air discharge Type AWT-AC Dimensions in mm Cable entry above below ground ground level level 241.A04 ≥ 100 ≥ 100 ≥ 400 ≥ 300 ≥...
  • Page 22 Installation sequence Installing the external unit (cont.) Floor mounting A Support for floorstanding installation (accessory)

  • Page 23: Installing The Internal Unit

    Installation sequence Installing the external unit (cont.) B Gravel bed as condensate soak- E Rubber mounts (supplied) away C Concrete foundations (see technical guide) D Drainage pipe DN 100 (only with entries below ground level) Note We recommend letting condensate drain away freely (without condensate pipe).
  • Page 24 Installation sequence Installing the internal unit (cont.) Total weight with filled DHW cylinder Minimum room volume (to Type AWT-AC Weight in kg DIN EN 378): 241.A04 Type AWT-AC Minimum room 241.A07 volume in m 241.A10 241.A04 241.A13 241.A07 241.A10 241.A13 Minimum clearances Minimum room height h Installation...
  • Page 25 Installation sequence Installing the internal unit (cont.) Removing the cylinder module...
  • Page 26 Installation sequence Installing the internal unit (cont.) P501 P303 P302 P301...
  • Page 27 Installation sequence Installing the internal unit (cont.)
  • Page 28 Installation sequence Installing the internal unit (cont.)
  • Page 29 Installation sequence Installing the internal unit (cont.)
  • Page 30 Installation sequence Installing the internal unit (cont.) Note Do not damage sealing tape A when removing the cylinder module.
  • Page 31 Installation sequence Installing the internal unit (cont.) Assembly and sealing faces to note 2. Fit the cylinder module in reverse order to that described on page 25. Please note Make tight hydraulic connec- tions between the heat pump module and cylinder module. With pipe knock-outs, ensure diaphragm grommets C are seated correctly (see follow-...
  • Page 32 Installation sequence Installing the internal unit (cont.)

  • Page 33: Connecting Refrigerant Lines

    – In cooling mode, if the internal unit is cases: installed lower than the external unit. Routing refrigerant lines Vitocal 242-S, type AWT-AC 241.A04 241.A07 241.A10 241.A13 Refrigerant lines Min. line length Max.
  • Page 34 Installation sequence Connecting refrigerant lines (cont.) Hot gas line Oil lift bends Flow direction for heating mode Flow direction for cooling mode Insulation against noise and vibrations with entry points above ground level Note Route connecting cables and refrigerant lines separately. A Pipe bends as vibration compensa- D Electrical cables/leads, internal/ tors...
  • Page 35 Installation sequence Connecting refrigerant lines (cont.) Connection to the external unit 1. Type AWT-AC 241.A04 and A07: Remove the side cover, see page 59. Example: type AWT-AC 241.A04 C Liquid line D Hot gas line...
  • Page 36 Installation sequence Connecting refrigerant lines (cont.) Please note 3. Flare the pipe ends. Contamination (e.g. metal swarf) or moisture must not 4. Secure the pipes. enter the copper pipes. Therefore, hold the pipe open- ings downwards or tempora- rily plug them. Undo the nuts from connections C and D on the refrigerant lines (liquid line and hot gas line).
  • Page 37 Installation sequence Connecting refrigerant lines (cont.) C Liquid line D Hot gas line Please note Note Contamination (e.g. metal swarf) ■ The refrigerant lines of the internal unit or moisture must not enter the are filled with nitrogen, overpressure copper pipes. 2 bar.
  • Page 38 Installation sequence Connecting refrigerant lines (cont.) 1. Remove nuts from refrigerant con- nections C and D and slide onto the supplied pipe bends. 2. Flare the pipe ends of the supplied pipe bends on the short side. Note Flare the pipe end of the hot gas line by approx.
  • Page 39 Installation sequence Connecting refrigerant lines (cont.) 5. Flare the pipe bends on their open end and secure connection piece (twin nipple) with union nuts. Note ■ Flare the pipe end of the hot gas line by approx. 0.5 mm. ■ Connection pieces must not be positioned diagonally.
  • Page 40 Installation sequence Connecting refrigerant lines (cont.) 6. Type AWT-AC 241.A04: ■ Slide the supplied union nuts (⁷⁄₁₆ UNF for liquid line, ¾ UNF for hot gas line) over the refrigerant lines from the external unit. ■ Flare the refrigerant lines from the external unit.
  • Page 41 Installation sequence Connecting refrigerant lines (cont.) Type AWT-AC Line Connection Torque in Nm to internal unit 241.A13 Liquid line 7 10 mm ⅝ UNF 33–42 Hot gas line 7 16 mm ⅞ UNF 63–77 Connecting the secondary circuit Opening the casing door...
  • Page 42 Installation sequence Connecting the secondary circuit (cont.) A Straight pipe sections supplied B Pipe bends from secondary circuit connection set (accessories, see separate installation instructions) Symbol Meaning Connection Heating water return Cu 28 x 1 mm Heating water flow Cu 28 x 1 mm...
  • Page 43 Installation sequence Connecting the secondary circuit (cont.) 2. Install the supplied safety assembly: Either to the on-site line in the heating water return to the secondary circuit connection set (accessory) Connection set installation instructions 3. Fill and vent the secondary circuit. 4.

  • Page 44: Safety Valve

    Installation sequence Connections on the DHW side For connecting the DHW side, observe DIN 1988 and DIN 4753 . P R H M O A DHW H Shut-off valve B DHW circulation pump K Flow regulating valve C Spring-loaded check valve L Pressure gauge connection D Heat pump connecting chamber M Non-return valve/pipe separator...

  • Page 45: Connecting A Cooling Circuit If Required

    Installation sequence Connections on the DHW side (cont.) Recommendation: Install the safety valve higher than the top edge of the cyl- inder. This protects the valve against contamination, scaling and high temper- atures. The DHW cylinder does not then need to be drained when working on the safety valve.
  • Page 46 Installation sequence Electrical connection (cont.) ■ Route LV leads < 42 V and Note cables > 42 V/230 V~/400 V~ If two components are connected to the separately. same terminal, both cores must be ■ Strip the insulation from the pressed together into a single wire fer- cables as close to the terminals rule.
  • Page 47 Installation sequence Electrical connection (cont.) Internal unit: Routing electric cables to the wiring chamber 400/230 V > 42 V < 42 V...
  • Page 48 Installation sequence Electrical connection (cont.) A Power cables to switching module E Type AWT-AC 241.A04 and A07: for instantaneous heating water 43 V BUS cable: Routing in the heater 230 V~/400 V~ 230 V~ voltage range (connection, B Connecting cables for 230 V~ func- see page 60) tion components F Heat pump control unit power cable...
  • Page 49 Installation sequence Electrical connection (cont.) Internal unit: Overview of connections F21 F13 F23 F14 12 V P202 P203 43 V F101...
  • Page 50 Installation sequence Electrical connection (cont.) A Expansion PCB on main PCB (con- nect nothing on site) B Main PCB (see page 50) F3 Fuse 6.3 A (slow) C Controller and sensor PCB (see page 55) D AVI PCB (see page 58) F101 Fuse 1.0 A (slow) E Luster terminals (see page 53) F1 Fuse 6.3 A (slow)
  • Page 51 Installation sequence Electrical connection (cont.) Plug sYA Terminals Function Explanation 211.2 Secondary pump ■ In systems without a heating water buffer cylinder, no other heating circuit pump is required (see terminal 212.2). ■ Connect temperature limiter as maxi- mum temperature limiter for underfloor heating circuit (if installed) in series.
  • Page 52 Installation sequence Electrical connection (cont.) Plug sYS Terminals Function Explanation 212.3 DHW circulation pump Connection values ■ Output: 50 W ■ Voltage: 230 V~ ■ Max. switching current: 4(2) A 212.4 Solar circuit pump with high Connection values limit safety cut-out (max. 95 ■...
  • Page 53 Installation sequence Electrical connection (cont.) Heating circuit without mixer A1/ Connection Circulation pump C A to control unit ■ Without heating water buffer cylin- 211.2 Secondary pump ■ With heating water buffer cylinder 212.2 Heating circuit pump A1/ Connecting the temperature limiter, part no.

  • Page 54: Electrical Connection

    Installation sequence Electrical connection (cont.) Terminals Function Explanation X3.1 Switched phase. Via control unit ON/OFF switch. Note Observe the total load (1000 W) of all con- nected components. X3.3 Flow limiter Requires zero volt N/O contact: X3.4 ■ Closed: Heat pump in operation ■...
  • Page 55 Installation sequence Electrical connection (cont.) Terminals Function Explanation X3.8 Frost stat and/or contact Requires zero volt N/C contact: X3.9 humidistat ■ Closed: Continuous safety chain ■ Open: Safety chain interrupted; heat Jumper pump shut down ■ Breaking capacity 230 V~, 0.15 A ■...
  • Page 56 Installation sequence Electrical connection (cont.) Plug Sensor Type KM BUS (wires interchangeable) Use the KM BUS distributor (accessories) if several de- vices are connected. KM BUS subscriber (examples): ■ Extension kit for one heating circuit with mixer M2/HC2 ■ Remote control for Vitotrol 200A or Vitotrol 300B (set the heating circuit assignment at the remote control) ■...
  • Page 57 Installation sequence Electrical connection (cont.) L1 N A Extension EA1 G Circulation pump for swimming pool B Power supply 1/N/PE 230 V/50 Hz heating (accessory) H Temperature controller for regulat- C Junction box (on site) ing the swimming pool temperature D Fuses and contactor for circulation (floating contact, 230 V~;...
  • Page 58 Installation sequence Electrical connection (cont.) Internal unit: AVI PCB Interface internal unit – external unit Plug Component F101 Fuse 1.0 AL (slow) P202 BUS connection (12 V to external unit for type AWT-AC 241.A10 and A13) P203 BUS connection (43 V to external unit for type AWT-AC 241.A04 and A07) Note ■...
  • Page 59 Installation sequence Electrical connection (cont.) External unit: Overview of connections Vitocal 242-S, type AWT-AC 241.A04 241.A07 241.A10 and A13 A Wiring chamber: ■ BUS connection to the internal unit Note Do not interchange the BUS con- nection wires between the internal and external units.
  • Page 60 Installation sequence Electrical connection (cont.) Connecting internal and external unit Vitocal 242-S, type AWT-AC 241.A04 241.A07 241.A10 and A13 C N L ? C2 C1 ? N L 12V COM COM 43V 12V COM COM 43V 12V COM COM 43V...

  • Page 61: Power Supply

    Installation sequence Power supply Isolators for non-earthed conductors Danger ■ The mains isolator (if installed) must The absence of component simultaneously isolate from the mains earthing can lead to serious injury all non-earthed conductors with a min- from electric current if an electri- imum contact separation of 3 mm.
  • Page 62 Installation sequence Power supply (cont.) ■ The heat pump control unit/PCB ■ Protect the power supply to the heat must be supplied without power-OFF; pump control unit with a fuse of 16 A tariffs that are subject to possible shut- (max.).
  • Page 63 Installation sequence Power supply (cont.) Power supply, external unit (230 V~) Vitocal 242-S, type AWT-AC 241.A04 241.A07 241.A10 and A13 C N L ? C2 C1 ? N L ? N L1 ? N L1 A Wiring chamber, external unit (see...
  • Page 64 Installation sequence Power supply (cont.) Connecting instantaneous heating water heater power cable Internal unit ■ Recommended power cable: 400 V~: 5 x 2.5 mm 1/N/PE 230 V~: 7 x 2.5 mm 230 V/50 Hz ■ Max. fuse protection 16 A ■...
  • Page 65 Installation sequence Power supply (cont.) Power supply with power-OFF Power-OFF without on-site load disconnection The power-OFF signal is connected Note directly to the heat pump control unit. Observe the technical connection condi- The compressor is "forced" off when tions of the relevant power supply util- power-OFF is enabled.
  • Page 66 Installation sequence Power supply (cont.) Power-OFF with on-site load disconnection The power-OFF signal is connected to Note the on-site contactor of the economy tar- Observe the technical connection condi- iff power supply and in the heat pump tions of the relevant power supply util- control unit.
  • Page 67 Installation sequence Power supply (cont.) G Ripple control receiver (contact H Economy tariff meter open: power-OFF enabled) with K Feed: TNC system backup fuse L Mains isolator Power supply in conjunction with own energy consumption Without power-OFF E1E2 D /D L1 L1 L2 L2 L3 L3 A Heat pump C Electricity meter...

  • Page 68: Closing The Heat Pump

    Installation sequence Power supply (cont.) G Double-tariff meter (for special tariff K Meter with reverse block: for heat pump) For energy generated by PV sys- Not permissible in conjunction with L Isolator for the domestic power sup- PV systems for own energy con- sumption.

  • Page 69: Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Opening the heat pump..........71 • 2. Compiling reports............71 •...
  • Page 70 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • • 19. Closing the heat pump; resetting the circuit breaker/ main fuse • • • 20. Starting the heat pump........... 83 • 21.

  • Page 71: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Opening the heat pump Danger Please note Touching 'live' components can Wait at least 30 min between the result in severe injury due to elec- installation and commissioning of tric shock. the appliance to prevent equip- ■...

  • Page 72: Evacuating Refrigerant Lines And Internal Unit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Evacuating refrigerant lines and internal unit Please note Please note Commissioning is weather- Before evacuating the refrigerant dependent. lines and the internal unit, check all connections for tightness with In the case of high relative humid- leak detection spray.
  • Page 73 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Example: type AWT-AC 241.A07 A Internal unit E Service valve (Schrader valve) B External unit For type AWT-AC, type 241.A07, the service valve is located at the C Liquid line connection of the liquid line.
  • Page 74 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) G Fill hose between pressure gauge L Vacuum pump set and external unit M Connection hose between pressure H Pressure gauge set gauge set and vacuum gauge K Connection hose between pressure N Valve for vacuum gauge gauge set and vacuum pump O Vacuum gauge...

  • Page 75: Filling Refrigerant Lines And The Internal Unit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling refrigerant lines and the internal unit Note 3. Unscrew the caps on the external unit ■ The external unit is pre-filled with fill valves, open both fill valves and refrigerant R410A.

  • Page 76: Checking The Refrigerant Circuit For Tightness

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Unscrew the caps on the external unit Refrigerant filling capacity per metre fill valves, open both fill valves and line length (for line lengths from 12 to refit the caps. 30 m) Type AWT-AC R410A in g/m...

  • Page 77: Filling And Venting The Secondary Side

    ■ Soften fill water with a hardness above 16.8 °dH (3.0 mol/m ), e.g. with the small softening system for heating water (see the Viessmann Vitoset pricelist). 1. Open any non-return valves installed on site. 2. Check the pre-charge pressure of the expansion vessel.
  • Page 78 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Fill (flush) and vent the secondary cir- cuit: ■ Slightly open the quick-action air vent valve (see safety assembly, chapter "Connecting the secon- dary circuit"); it remains open. ■ To vent, move the 3-way diverter valve for "Heating/DHW heating"...

  • Page 79: Filling And Venting The Solar Circuit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling and venting the solar circuit Danger Please note Overheated collector areas and To prevent equipment dam- overheated heat transfer medium age, can cause burns/scalding and only fill the solar circuit with equipment damage.
  • Page 80 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note A short circuit between the mag- nesium anode and internal indi- rect coil increases the protective effect of the magnesium anode and leads to corrosion damage on the DHW cylinder. Before inserting the electrical cables, measure the resistance between terminals A and B.

  • Page 81: Replacing The Magnesium Anode

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Replacing the magnesium anode Note Please note If the magnesium anode needs to be A short circuit between the mag- replaced, a maintenance-free impressed nesium anode and internal indi- current anode (accessory) can be used. rect coil increases the protective effect of the magnesium anode For removal of the magnesium anode,...

  • Page 82: Checking Thermal Insulation Of Flared Connections 18. Checking Electrical Connections Of The External Unit For Firm Seating

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note 3. Check the aluminium fins of the heat Excessive air pressure from exchanger for deformation and the front and sides can result scratches; if necessary, repair with a in the deformation of the alu- suitable tool (e.g.

  • Page 83: Starting The Heat Pump

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Starting the heat pump Please note 2. Wait 2 min. Operation of the heat pump with insufficient refrigerant results in 3. Switch ON internal unit voltage. damage to the appliance. ■...
  • Page 84 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning with the commissioning wizard The commissioning wizard guides you Switch on the ON/OFF switch on the automatically through all the menus heat pump control unit. where settings have to be made. For ■...
  • Page 85 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Language Date Time Date/time Start commissioning? Parameter group Parameter Coding level 1 select Sensor values Temperature sensors display Signal inputs Signal inputs display Actuator test Actuator test carry out Subscriber check Subscriber check carry out Function check...
  • Page 86 Required heat pump parameters "Output compressor stage 5030" During commissioning, the heating out- put of the heat pump must be selected subject to type. Vitocal 242-S, type AWT-AC 241.A04 241.A07 241.A10 241.A13 "Output compressor stage 4 kW...
  • Page 87 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Required parameters for components connected on site Detailed explanations regard- ing parameters Service instructions for Vitotronic 200 heat pump control unit Pumps and other components Pump/component Parameter Setting Heating circuit pump "System definition"...
  • Page 88 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Pump/component Parameter Setting For a separate cooling cir- "1" cuit: "Cooling" Ó "Remote control cooling circ 7116" "Cooling" Ó ■ "0" F16 "Ranking room temp ■ "1" A1/HC1 sensor separate cooling ■...
  • Page 89 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) External functions Parameter Setting External changeover of the "System definition" Ó "0" to "55" operating state of various sys- "System components for tem components external changeover 7011" "System definition" Ó "0"...
  • Page 90 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cooling function Cooling function parameters Setting "Cooling" Ó "3" "Cooling function 7100" "Cooling" Ó ■ "1" (heating circuit A1/HC1) "Cooling circuit 7101" ■ "2" (heating circuit M2/HC2) ■ "4" (separate cooling circuit SKK) Instantaneous heating water heater Parameters for...
  • Page 91 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Vitovent 300-F Parameters for Vitovent 300-F Setting "Ventilation" Ó "1" "Vitovent enable 7D00" Other enabling settings, if applicable: "Ventilation" Ó ■ "Enable preheater bank electric 7D01" "1" ■ "Enable reheater bank hydraulic 7D02" "1"...

  • Page 92: Checking The System Function

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

  • Page 93: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct him/her in the operation of the system.
  • Page 94 Troubleshooting Repairs Overview of electrical components See from page 49. Opening programming unit...
  • Page 95 Troubleshooting Repairs (cont.) Removing cover from programming unit, if necessary...
  • Page 96 Troubleshooting Repairs (cont.) Overview of internal components: Internal unit a:C] a:C]...
  • Page 97 Troubleshooting Repairs (cont.) Secondary circuit flow tempera- Secondary circuit drain & fill ture sensor (alternative posi- valve tions) Internal unit service valve Return temperature sensor, (Schrader valve; can be used in solar circuit place of the external unit service Secondary circuit, return tem- valve for checking pressure and perature sensor evacuating the refrigerant cir-...
  • Page 98 Troubleshooting Repairs (cont.) Cylinder drain & fill valve positions A Closed C Open for draining or filling the cylin- B Open for draining internal DHW line Overview of internal components: External unit Danger Contact with 'live' components can result in severe injuries. Capacitors remain 'live' after the power supply has been switched OFF.
  • Page 99 Troubleshooting Repairs (cont.) External unit, type AWT-AC 241.A04 A Fan F Electronic expansion valve (EEV) B Heat exchanger (evaporator) G Compressor head temperature sen- C Evaporator air intake temperature sor (CTT) sensor (OAT) H Liquid separator D Evaporator temperature sensor K Evaporator refrigerant inlet temper- (OMT) ature sensor (OCT)
  • Page 100 Troubleshooting Repairs (cont.) External unit, type AWT-AC 241.A07 A Fan F Electronic expansion valve (EEV) B Heat exchanger (evaporator) G Compressor head temperature sen- C Evaporator air intake temperature sor (CTT) sensor (OAT) H Liquid separator D Evaporator temperature sensor K Evaporator refrigerant inlet temper- (OMT) ature sensor (OCT)
  • Page 101 Troubleshooting Repairs (cont.) External unit, type AWT-AC 241.A10 and A13 A Fan G Compressor head temperature sen- B Heat exchanger (evaporator) sor (CTT) C Evaporator air intake temperature H Liquid separator sensor (OAT) K Evaporator refrigerant inlet temper- D Evaporator temperature sensor ature sensor (OCT) (OMT) L Compressor...
  • Page 102 Troubleshooting Repairs (cont.) Draining secondary side heat pump 1. Close the on-site boiler drain & fill 2. Drain the heat pump at the secondary valve. circuit fill & drain valve (see chapter "Overview of internal components: Internal unit"). Checking the sensors Sensor Captur- Installed loca-...
  • Page 103 (see page 98) control (observe label on the exter- nal unit) Temperature sensors in the internal unit (with marking) Viessmann NTC 10 KΩ (blue marking) Further sensors Outside temperature sensor 10 30 50 70 90 110 -20 -10 10 20 30 Temperature in °C...
  • Page 104 Troubleshooting Repairs (cont.) Viessmann Pt 500A (green marking) 140 180 Temperature in °C Viessmann NTC 20 kΩ (orange marking) Temperature in °C...
  • Page 105 Troubleshooting Repairs (cont.) Temperature sensors in external unit (no marking) Type NTC 10 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C Type NTC 50 kΩ 1000 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 Temperature in °C Checking fuses For fuse locations, see from page 49.
  • Page 106 Troubleshooting Repairs (cont.) Danger Removing the fuse does not switch the power circuit to zero volt. Contact with 'live' compo- nents can lead to serious injury from electric current. Before working on the equip- ment, always ensure that the power circuit is also at zero volt.

  • Page 107: Parts Lists, Internal Unit

    Parts lists, internal unit Parts lists, internal unit Ordering individual parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local dealer. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list)
  • Page 108 Parts lists, internal unit Overview of assemblies, internal unit A Type plate C Electrical equipment assembly, B Casing assembly, internal unit internal unit...

  • Page 109: Parts Not Shown, Internal Unit

    Internal unit casing 0001 Front panel, top 0006 Top panel, back 0002 Front panel, bottom 0007 Viessmann logo 0003 Side panel, left 0008 Support, heat pump control unit 0004 Side panel, right 0009 Screws (set) 0005 Top panel, front...
  • Page 110 Parts lists, internal unit Internal unit casing (cont.) 0006 0003 0005 0001 0008 0007 0009 0002 0010 0004...

  • Page 111: Internal Unit Electrical Equipment

    Parts lists, internal unit Internal unit electrical equipment 0001 Programming unit 0039 Service instructions 0002 Controller and sensor PCB with Vitotronic 200, type WO1C cover (CU401) 0040 Operating instructions 0005 Main PCB with cover (MB761) Vitotronic 200, type WO1C 0006 Expansion PCB with cover (SA135) Parts not shown 0007 Coding card...
  • Page 112 Parts lists, internal unit Internal unit electrical equipment (cont.) 0018 0020 0033 0017 0019 0001 0032 0007 0006 0005 0010 0002 0009 0037 0011 0008 0030 0013 0023 0025 0024 0034 0035 0039 0040...

  • Page 113: Internal Unit Hydraulics

    Parts lists, internal unit Internal unit hydraulics 0001 Back panel, lower casing 0024 Fastening ⅞ UNF for hot gas line 0002 Bottom panel 0025 Fastening ⅝ UNF for liquid line 0003 Top panel, lower casing 0026 Pressure sensor (ICT) 0027 Valve body ⁷⁄₁₆ 0004 Angle profile, lower casing, left 0005 Angle profile, lower casing, right 0028 Schrader valve...
  • Page 114 Parts lists, internal unit Internal unit hydraulics (cont.) 0038 0003 0034 0035 0027 0042 0028 0014 0026 0041 0026 0027 0039 0041 0028 0038 0015 0044 0030 0030 0029 0033 0030 0044 0039 0034 0027 0041 0009 0035 0044 0028 0039 0048 0029...

  • Page 115: Internal Unit Cylinder

    Parts lists, internal unit Internal unit cylinder 0001 Primary store, 220 litres 0019 Locking cap G¾ with retaining 0002 Back panel, casing top loop 0003 Retaining bracket, cylinder 0020 Magnesium chain anode 0004 Connection line, cylinder primary 0021 Heating lance pump–check valve 0022 Non-return valve 30 mbar, con- 0005 Return line, solar...
  • Page 116 Parts lists, internal unit Internal unit cylinder (cont.) 0032 0034 0011 0007 0017 0035 0035 0008 0012 0015 0035 0013 0017 0035 0003 0030 0029 0035 0014 0014 0013 0028 0001 0026 0021 0002 0033 0016 0018 0035 0009 0015 0027 0035 0035...

  • Page 117: Parts Lists, External Unit

    Parts lists, external unit Parts lists, external unit Ordering individual parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local dealer. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) External unit type AWT-AC 241.A04...
  • Page 118 Parts lists, external unit External unit type AWT-AC 241.A04 (cont.) 0024 0022 0026 0010 0021 0020 0031 0028 0023 0027 0009 0014 0006 0005 0004 0030 0025 0002 0008 0019 0015 0017 0016 0001 0003 0032 0018 0013 0029 0007 0012 0011...
  • Page 119 Parts lists, external unit External unit type AWT-AC 241.A07 0001 Air discharge grille 0026 Heat exchanger (evaporator) 0002 Side panel, left 0027 Grille 0003 M8 nut 0028 Retainer, temperature sensor 0004 Axial fan 0029 Transformer 0005 4-way diverter valve, complete 0030 Partition 0007 DC motor 0031 ODU control unit...
  • Page 120 Parts lists, external unit External unit type AWT-AC 241.A07 (cont.) 0033 0032 0031 0036 0027 0036 0028 0030 0026 0035 0029 0034 0004 0007 0038 0003 0012 0020 0022 0021 0025 0043 0005 0042 0024 0037 0023 0013 0014 0011 0017 0015 0016...
  • Page 121 Parts lists, external unit Overview of external unit assemblies, type AWT-AC 241.A10, A13 A Type plate B Casing assembly, external unit...
  • Page 122 Parts lists, external unit Overview of external unit assemblies, type… (cont.) C Electrical equipment assembly, external unit D Hydraulic assembly, external unit External unit casing, type AWT-AC 241.A10, A13 0001 Top panel 0013 Transport handle, left 0002 Side panel, r.h. 0014 Motor support 0003 Cover, power supply 0015 Air inlet ring...
  • Page 123 Parts lists, external unit External unit casing, type AWT-AC 241.A10, A13 (cont.) 0012 0001 0019 0018 0013 0014 0009 0021 0010 0015 0011 0004 0008 0006 0020 0021 0010 0003 0015 0017 0016 0006 0007 0002 0016 0005...

  • Page 124: External Unit Electrical Equipment, Type Awt-Ac 241.A10, A

    Parts lists, external unit External unit electrical equipment, type AWT-AC 241.A10, A13 0001 Main PCB 0020 Communication cable, drivers 0002 Driver PCB 0021 Communication cable, IDU 0003 Capacitor PCB 0022 Power cable, controller PCB, 0004 PCB, mains filter 0005 Coils 0023 Communication cable, starter 0006 Terminal controller...
  • Page 125 Parts lists, external unit External unit electrical equipment, type AWT-AC… (cont.) 0002 0004 0003 0006 0005 0011 0009 0012 0010 0001 0013 0007 0008...

  • Page 126: External Unit Hydraulics, Type Awt-Ac 241.A10, A

    Parts lists, external unit External unit hydraulics, type AWT-AC 241.A10, A13 0001 Compressor 0009 Compressor thermal insulation 0002 EEV pipework, complete 0010 Temperature sensor NTC 50 kΩ 0003 4-way diverter valve pipework, (CTT) complete 0011 Shut-off valve, liquid line 0004 Liquid separator 0012 Compressor power supply cover 0005 High pressure switch 0006 Shut-off valve, hot gas line...
  • Page 127 Parts lists, external unit External unit hydraulics, type AWT-AC 241.A10,… (cont.) 0002 0005 0008 0004 0010 0007 0006 0003 0009 0001 0011 0012...

  • Page 128: Hydraulic Parameter Report

    Commissioning/service reports Hydraulic parameter report Setting and test values Set value Commission- Testing the external heating circuit pumps Circulation pump type Circulation pump stage Overflow valve setting Commissioning, primary circuit Air intake temperature ("Diagnosis" Ó °C "System overview") Air discharge temperature ("Diagnosis" Ó °C "System overview") Temperature differential (air intake/dis-...
  • Page 129 Commissioning/service reports Control parameter report (cont.) System definition Parameter Code Delivered condi- Commis- tion sioning "System scheme" (see chapter "Over- 7000 view of possible system schemes") "Temperature differential for calculat- 7003 40 (≙ 4 K) ing the heating limit" "Temperature differential for calculat- 7004 40 (≙...
  • Page 130 Commissioning/service reports Control parameter report (cont.) Parameter Code Delivered condi- Commis- tion sioning "Set DHW temperature" 6000 500 (≙ 50 °C) "Min. DHW temperature" 6005 100 (≙ 10 °C) "Max. DHW temperature" 6006 600 (≙ 60 °C) "Hysteresis DHW temperature heat 6007 50 (≙...
  • Page 131 Commissioning/service reports Control parameter report (cont.) Electric booster heater Parameter Code Delivered condi- Commis- tion sioning "Enable instantaneous heating water 7900 heater" "Enable instant. heating water heater 7902 for central heating" "Max. output instantaneous heating 7907 water heater" "Output for instant. heating water 790A heater at power-OFF"...
  • Page 132 Commissioning/service reports Control parameter report (cont.) Heating circuit 1 Parameter Code Delivered condi- Commis- tion sioning "Standard room temperature" 2000 200 (≙ 20 °C) "Reduced room temperature" 2001 160 (≙ 16 °C) "Remote control" 2003 "Heating curve level" 2006 0 (≙ 0 K) "Heating curve slope"...
  • Page 133 Commissioning/service reports Control parameter report (cont.) Cooling Parameter Code Delivered condi- Commis- tion sioning "Cooling function" 7100 "Cooling circuit" 7101 "Set room temperature separate cool- 7102 200 (≙ 20 °C) ing circuit" "Min. flow temperature cooling" 7103 100 (≙ 10 °C) "Influence room temperature hook-up 7104 cooling circuit"...
  • Page 134 Commissioning/service reports Control parameter report (cont.) Parameter Code Delivered condi- Commis- tion sioning "Control voltage matching" 7D27 0 (≙ 0 V) "Fan for control voltage matching" 7D28 Photovoltaics Parameter Code Delivered condi- Commis- tion sioning "Enable own energy consumption 7E00 PV"...
  • Page 135 Commissioning/service reports Control parameter report (cont.) Communication Parameter Code Delivered condi- Commis- tion sioning "Enable LON communication mod- 7710 ule" "LON subscriber number" 7777 "LON fault manager" 7779 "LON system number" 7798 "Interval for data transfer via LON" 779C 20 min "Source outside temperature"...
  • Page 136 Specification Specification Vitocal 242-S, Type AWT-AC (230 V~) Type AWT-AC 241.A04 241.A07 241.A10 241.A13 Heating output data At 100 % according to EN 14511 (A2/W35 °C, spread 5 K) Rated heating output 10.6 Compressor frequency Fan speed Power consumption 0.91 1.73...
  • Page 137 Specification Specification (cont.) Type AWT-AC 241.A04 241.A07 241.A10 241.A13 Cooling performance data At 100 % according to EN 14511 (A35/W18 °C, spread 5 K) Rated cooling capacity 10.0 12.6 Compressor frequency Fan speed Power consumption 1.13 2.63 2.80 4.20 Energy efficiency ratio 3.72 3.35 3.57...
  • Page 138 Specification Specification (cont.) Type AWT-AC 241.A04 241.A07 241.A10 241.A13 Electrical values Internal unit Heat pump control unit/PCB ■ Rated voltage, con- 1/N/PE 230 V/50 Hz trol unit/PCB ■ Fuse protection, 1xB16A power supply ■ Internal fuse 6.3A (slow)/250 V Instantaneous heat- ing water heater ■...
  • Page 139 Specification Specification (cont.) Type AWT-AC 241.A04 241.A07 241.A10 241.A13 Integral cylinder Capacity Continuous output when heating DHW from 10 to 60 °C Performance factor N to DIN 4708 Max. draw-off rate at l/min 16.8 16.8 17.3 17.3 the stated performance factor N and DHW heating from 10 to...
  • Page 140 Specification Specification (cont.) Type AWT-AC 241.A04 241.A07 241.A10 241.A13 Connections Heating water flow Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Heating water return Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cu 28 x 1 Cold water...

  • Page 141: Heat Pump Commissioning Order

    Components for ventilation fully installed (optional) Components for PV system fully installed (optional) Preferred appointment: Date Time Date Time The work that is requested to be carried out by Viessmann will be billed in accordance with the latest Viessmann pricelist. Place/date Signature...

  • Page 142: Declaration Of Conformity

    A The product characteristics determined as system values for the product Vitocal 242-S (see technical guide) can be utilised to assess the energy consumption of heating and ventilation systems to DIN V 4701-10 specified by the EnEV [Ger- many].

  • Page 143: Keyword Index

    Keyword index Keyword index Checking the sensors......102 Adjustable feet........23 Checking the system pressure...78 Air discharge........21 Checking threaded fittings....76 Air discharge grille removal....81 Check valve........44 Air intake..........21 Chilled ceiling........45 Air short circuit........18 Cleaning Air vent valve, secondary circuit..97 ■ Cylinder..........79 Aligning the appliance......23 Closing the heat pump.......68 Ambient temperatures......23 Coding level 1........84...
  • Page 144 Keyword index Keyword index (cont.) Connection Cylinder, cleaning......79 ■ BUS cable........58 Cylinder assembly ■ Cooling circuit.........45 ■ Internal unit........115 ■ DHW..........44 Cylinder drain & fill valve....97 ■ Electrical components....45 Cylinder module, fitting......31 ■ Overview...........7 Cylinder module removal....25 ■ Preparing..........8 ■ Refrigerant lines......33 ■...
  • Page 145 Keyword index Keyword index (cont.) Electrical equipment assembly External unit ■ External unit type AWT-AC 241.A10 ■ Cable lengths........9 and A13........124 ■ Checking electrical connections..82 ■ Internal unit........111 ■ Cleaning.........81 Electrical installation scheme.....14 ■ Closing..........68 Electrical power consumption..138 ■ Dimensions........139 Electrical values ■...
  • Page 146 Keyword index Keyword index (cont.) Floor load...........23 Heating circuit without mixer A1..14 Floor mounting Heating output, compressor....86 ■ External unit........22 Heating water buffer cylinder.....13 Floor unevenness......23 Heating water flow...8, 41, 42, 140 Flow, DHW cylinder/heating water..41 Heating water return..8, 41, 42, 140 Flow limiter.........54 Heat pump, starting......83 Flow regulating valve......44...
  • Page 147 Keyword index Keyword index (cont.) Installation scheme......12, 14 Instantaneous heating water Magnesium anode.......80, 81 heater.......13, 65, 66, 97 Magnesium anode, replacing.....81 ■ High limit safety cut-out reset..92 Main PCB...........50 ■ Parameter settings......90 Mains isolator........67 ■ Power cable........9 Maintenance........71 ■ Power supply........64 Maximum temperature limiter....52 ■...
  • Page 148 Keyword index Keyword index (cont.) Overflow valve........43 Power cable........9, 62 Overview ■ External unit........63 ■ Electrical connections.....94 ■ Heat pump control unit....48 ■ Internal components....96, 98 ■ Instantaneous heating water heater64 ■ Pumps........96, 98 ■ Switching module for instantaneous ■ Sensors........96, 98 heating water heater.......48 ■...
  • Page 149 Keyword index Keyword index (cont.) Return temperature sensor, secondary Radiator heating circuit......14 circuit..........102 RCD...........65 Ripple control receiver....65, 66 Recommended power cables....9 Room height........23 Reducer, connecting......40 Room temperature sensor....102 Refrigerant ........33, 75 Room volume........24 ■ Filling capacity........75 Rubber mounts........23 ■ Properties........76 ■...
  • Page 150 Keyword index Keyword index (cont.) Side cover System pressure, checking....79 ■ External unit........68 System schemes Side panels........31 ■ Overview...........9 Siting ■ Parameter settings......17 ■ Between walls.........19 System user, instructing.....93 ■ Conditions........19 ■ External unit........22 ■ Freestanding........19 Temperature limiter......14, 52 ■ In recesses........19 Temperature sensor......102 Solar circuit connection......45 ■...
  • Page 151 Keyword index Keyword index (cont.) Warranty..........84 Underfloor heating......52 Water quality........77 Underfloor heating circuit.....14, 52 Weatherproofing........19 Union nuts, replacing......40 Weight..........20 ■ External unit........139 ■ Internal unit........139 Vacuum gauge........74 Well circuit..........54 Vacuum pump........74 Wind direction........19 Ventilation..........91 Wind loads.........19 Venting Working on the refrigerant circuit..76 ■...
  • Page 152 7424690 7424691 7424692 7497344 7497345 7502081 7502082 7514941 7514942 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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