Viessmann VITOCAL 242-G Installation And Service Instructions Manual
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Viessmann VITOCAL 242-G Installation And Service Instructions Manual

Compact energy tower for low energy houses
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VIESMANN
Installation and service
instructions
for contractors
Vitocal 242-G/222-G
Type CHE
Compact Energy Tower for low energy houses
For applicability, see the last page
VITOCAL 242-G/222-G
Please keep safe.
5592 969 GB
9/2007

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitocal 242-G/222-G Type CHE Compact Energy Tower for low energy houses For applicability, see the last page VITOCAL 242-G/222-G Please keep safe. 5592 969 GB 9/2007...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of relevant trade associations, Danger all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 Instal- charge static loads. ling non-authorised compo- nents and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Transport....................Positioning ....................Overview of available system versions ............13 Function description of systems ..............14 System version on the primary side ............. 18 System version 1 ..................19 System version 2 ..................27 System version 3 ..................
  • Page 5 Index Index (cont.) Control settings Menu structure overview Main menu ............133 Menu structure overview information ............134 Menu structure overview Programming............. 135 Menu structure overview Contractor level ..........138 Control settings by contractors..............142 Activating the technical service level ............142 Adjusting sensor temperatures..............
  • Page 6 Index Index (cont.) Internal pump run-on................... 160 Max. steps; three-way valve................ 160 Solar collector control settings (only for the Vitocal 242) Solar collector .................... 162 Maximum temperature ................162 Solar pump hysteresis ON/solar pump hysteresis OFF ........ 162 Pump kick hysteresis .................. 163 Pump kick runtime ..................
  • Page 7 Safety chain, 230 V units................197 Left part of the main PCB ................198 Upper and lower part of the main PCB ............200 R.h. part of the main PCB................202 Parts lists Parts list Vitocal 242-G ................204 Parts list Vitocal 222-G ................210...
  • Page 8 Index Index (cont.) Commissioning/service reports Hydraulic parameter report ................. 216 Control parameter report................217 Specification for 400 V devices ..............222 Specification for 230 V devices ..............226 Appendix Order to commission the Vitocal 242/222 ............ 229 Certificates Declaration of conformity ................230 Declaration of conformity ................

  • Page 9: Transport

    Never support the equipment We recommend you transport the on its front or side panels. equipment on a Viessmann trolley. Secure the unit with tension straps. Standard dimensions when tilted The max. permitted tilting angle for Equipment on pal-...
  • Page 10 Preparing for installation Positioning (cont.) Top panel dimensions (plan view) A Cable entry (length of cables in unit approx. 1300 mm) B Primary outlet C Primary inlet D Hydraulic connection array...
  • Page 11 Preparing for installation Positioning (cont.) Clearance dimensions (plan view) A min. 1000 mm B Vitocal 242: The required clearance for the removal of the front panels is 20 mm. Also maintain this dimen- sion when using decorative frames. Vitocal 222: Maintain a clearance of 140 mm to the left or right for the blow-off line of the heating circuit safety valve.
  • Page 12 Preparing for installation Positioning (cont.) On-site connection requirements A Appliance dimensions C Only Vitocal 242: B Recommended outlet area of on- Possible position (pipe centre) of site hydraulic connections (com- the on-site drain connection pulsory when installing with a con- DN 32 for condensate with a wall nection panel) clearance of >...

  • Page 13: Overview Of Available System Versions

    Preparing for installation Positioning (cont.) D Only Vitocal 242: F Top edge finished floor Position (centre pipe) of the on- G Only Vitocal 222: site drain connection DN 32 for Possible position (pipe centre) of condensate with a wall clearance the on-site drain connection from 15 to 45 mm DN 40 for the blow-off line of the...

  • Page 14: Function Description Of Systems

    Preparing for installation Function description of systems Note Never operate 230 V units in A pre-requisite for operating 230 V units in some countries is that starting cur- rents of up to 45 A are permissible in the power grid of the country concerned (observe other country-specific regulations, if necessary).
  • Page 15 Preparing for installation Function description of systems (cont.) Heating water buffer cylinder operated in parallel Heating water buffer cylinders provide Bridging power-OFF periods a hydraulic separation of the flow in Constant flow rate through the heat the heat pump and heating circuits. pump For example, the flow rate in the heat Longer heat pump operating times...
  • Page 16 Preparing for installation Function description of systems (cont.) The cooling capacity depends on the Underfloor heating systems and con- heat source temperature, which itself crete core tempering are available for is subject to seasonal fluctuations. cooling the building; radiator heating Experience has shown that the cool- systems are unsuitable for this pur- ing capacity is higher at the beginning...
  • Page 17 Preparing for installation Function description of systems (cont.) Overview of the internal components HR Heating return Upper cylinder temperature sen- HV Heating flow KW Cold water (connections, see Return temperature sensor of from page 94) the solar circuit (only Solar return (only Vitocal 242) Vitocal 242) Solar flow (only Vitocal 242) Solar circuit pump (only...

  • Page 18: System Version On The Primary Side

    Preparing for installation System version on the primary side Hydraulic diagram A Heat pump interface (see from 4 Geothermal probes/geothermal page 19) collectors 2 Brine accessory pack qQ Brine circuit pressure switch 3 Brine distributor for geothermal probes/collectors Electrical connection Pressure switch connection for brine circuit, qQ see page 21.

  • Page 19: System Version 1

    Preparing for installation System version 1 One directly connected heating circuit, DHW heating with solar boost (option) and natural cooling function (option) Note Solar boosted DHW heating is only possible with the Vitocal 242. To achieve this system version, select system design 2 at the control unit. Hydraulic diagram...
  • Page 20 Preparing for installation System version 1 (cont.) A Primary side interface (see from wI Heating circuit extension page 18) wO Connection panel B Min. 500 mm (for hydraulic eP Contact humidistat separation) eQ Circulation pump (secondary 1 Compact Energy Tower cooling circuit pump) 5 Overflow valve eW Three-way diverter valve heating/...
  • Page 21 Preparing for installation System version 1 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS (230 V) qQ Brine circuit pressure switch (if G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 22 Preparing for installation System version 1 (cont.) qR Natural cooling extension kit qO Room temperature sensor (if no qT Central fault message (230 V) remote control is installed), see qZ Power-OFF also page 67 qI KM BUS: Vitotrol 200 remote con- wP KM BUS: Cooling circuit exten- trol (with room temperature sen- sion kit...
  • Page 23 Preparing for installation System version 1 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Only with natural cooling:...
  • Page 24 Preparing for installation System version 1 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit ter power cable (circuit breakers K KM BUS must be blocked) Never operate 230 V units in...
  • Page 25 Preparing for installation System version 1 (cont.) qQ Brine circuit pressure switch (if qO Room temperature sensor (if no the pressure switch is not remote control is installed), see installed, use the jumper pro- also page 67 vided) wP KM BUS: Cooling circuit exten- qE DHW circulation pump sion kit qR Natural cooling extension kit...
  • Page 26 Preparing for installation System version 1 (cont.) Components to be connected Connection descrip- tion Connect capacitor to full wave soft starter see page 89 Only with natural cooling: See separate installa- Connect the required components to extension kit wP tion instructions and natural cooling qR extension kit Only when using an underfloor heating system: see page 68...

  • Page 27: System Version 2

    Preparing for installation System version 1 (cont.) Pos. Description Number Cooling circuit flow temperature sensor Cooling circuit mixer motor System version 2 One directly connected heating circuit with heating water buffer cylinder, DHW heating with solar boost (option) and natural cooling function (option) Note Solar boosted DHW heating is only possible with the Vitocal 242.
  • Page 28 Preparing for installation System version 2 (cont.) Hydraulic diagram A Primary side interface (see from 8 Plate-type heat exchanger page 18) 9 Heating water buffer cylinder B Min. 500 mm (for hydraulic qP Underfloor heating circuit separation) qW Heating circuit pump, direct heat- 1 Compact Energy Tower ing circuit 6 Diaphragm expansion vessel...
  • Page 29 Preparing for installation System version 2 (cont.) qO Room temperature sensor eT Circulation pump (primary cooling wP Extension kit for cooling circuit circuit pump) with mixer rQ Cooling circuit flow temperature wQ Outside temperature sensor sensor wW Heating water buffer cylinder tem- rW Cooling circuit mixer motor perature sensor wU DHW circulation extension...
  • Page 30 Preparing for installation System version 2 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS (230 V) qQ Brine circuit pressure switch (if G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 31 Preparing for installation System version 2 (cont.) qW Heating circuit pump, direct heat- qO Room temperature sensor (if no ing circuit remote control is installed), see qE DHW circulation pump also page 67 qR Natural cooling extension kit wP KM BUS: Cooling circuit exten- qT Central fault message (230 V) sion kit qZ Power-OFF...
  • Page 32 Preparing for installation System version 2 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Only with natural cooling:...
  • Page 33 Preparing for installation System version 2 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit ter power cable (circuit breakers K KM BUS must be blocked) Never operate 230 V units in...
  • Page 34 Preparing for installation System version 2 (cont.) qQ Brine circuit pressure switch (if qO Room temperature sensor (if no the pressure switch is not remote control is installed), see installed, use the jumper pro- also page 67 vided) wP KM BUS: Cooling circuit exten- qW Heating circuit pump, direct heat- sion kit ing circuit...
  • Page 35 Preparing for installation System version 2 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect capacitor to full wave soft starter...

  • Page 36: System Version 3

    Preparing for installation System version 2 (cont.) Pos. Description Number Natural cooling extension kit Extension kit for cooling circuit with mixer Natural cooling contact humidistat Three-way diverter valve heating/cooling Motorised two-way ball valve (for the brine circuit) Frost stat Circulation pump (primary cooling circuit pump) Cooling circuit flow temperature sensor Cooling circuit mixer motor System version 3...
  • Page 37 Preparing for installation System version 3 (cont.) Hydraulic diagram A Primary side interface (see from 8 Plate-type heat exchanger page 18) 9 Heating water buffer cylinder B Min. 500 mm (for hydraulic qP Underfloor heating circuit separation) qE DHW circulation pump 1 Compact Energy Tower qR Natural cooling extension kit 6 Diaphragm expansion vessel...
  • Page 38 Preparing for installation System version 3 (cont.) wP Extension kit for cooling circuit rP Heating circuit pump, mixer circuit with mixer rQ Flow temperature sensor, mixer wQ Outside temperature sensor circuit wW Heating water buffer cylinder tem- rW Three-way mixer - mixer motor perature sensor tP Extension kit for one heating cir- wU DHW circulation extension...
  • Page 39 Preparing for installation System version 3 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS (230 V) qQ Brine circuit pressure switch (if G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 40 Preparing for installation System version 3 (cont.) qR Natural cooling extension kit wP KM BUS: Cooling circuit exten- qT Central fault message (230 V) sion kit qZ Power-OFF wQ Outside temperature sensor qI KM BUS: Vitotrol 200 remote con- wW Heating water buffer cylinder tem- trol (with room temperature sen- perature sensor sor), see also page 67...
  • Page 41 Preparing for installation System version 3 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect components for heating circuit with mixer to...
  • Page 42 Preparing for installation System version 3 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit ter power cable (circuit breakers K KM BUS must be blocked) Never operate 230 V units in...
  • Page 43 Preparing for installation System version 3 (cont.) qQ Brine circuit pressure switch (if qO Room temperature sensor (if no the pressure switch is not remote control is installed), see installed, use the jumper pro- also page 67 vided) wP KM BUS: Cooling circuit exten- qE DHW circulation pump sion kit qR Natural cooling extension kit...
  • Page 44 Preparing for installation System version 3 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect components for heating circuit with mixer to...

  • Page 45: System Version 4

    Preparing for installation System version 3 (cont.) Pos. Description Number Solar collectors as required Collector temperature sensor Diaphragm expansion vessel for the solar circuit Solar circuit extension Option "Natural cooling" function Vitotrans 100, plate-type heat exchanger Natural cooling extension kit Extension kit for cooling circuit with mixer Natural cooling contact humidistat 3-way diverter valve...
  • Page 46 Preparing for installation System version 4 (cont.) Hydraulic diagram A Primary side interface (see from 1 Compact Energy Tower page 18) 6 Diaphragm expansion vessel B Min. 500 mm (for hydraulic heating circuit separation)
  • Page 47 Preparing for installation System version 4 (cont.) 7 Underfloor heating circuit tem- eW Three-way diverter valve heating/ perature limiter cooling 8 Plate-type heat exchanger eE 2-way motorised ball valve 9 Heating water buffer cylinder eR Frost stat qP Underfloor heating circuit eT Circulation pump (primary cooling qW Heating circuit pump, direct heat- circuit pump)
  • Page 48 Preparing for installation System version 4 (cont.) Electrical connection (400 V versions) Connections at the main connection area X60 F Control unit power connection K KM BUS (230 V) qQ Brine circuit pressure switch (if G Instantaneous heating water hea- the pressure switch is not ter power cable installed, use the jumper pro-...
  • Page 49 Preparing for installation System version 4 (cont.) qW Heating circuit pump, direct heat- wP KM BUS: Cooling circuit exten- ing circuit sion kit qE DHW circulation pump wQ Outside temperature sensor qR Natural cooling extension kit wW Heating water buffer cylinder tem- qT Central fault message (230 V) perature sensor qZ Power-OFF...
  • Page 50 Preparing for installation System version 4 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect components for heating circuit with mixer to...
  • Page 51 Preparing for installation System version 4 (cont.) Electrical connection (230 V versions) Connections at the main connection area X60 F Control unit power supply H External connections at natural G Instantaneous heating water hea- cooling extension kit ter power cable (circuit breakers K KM BUS must be blocked) Never operate 230 V units in...
  • Page 52 Preparing for installation System version 4 (cont.) qQ Brine circuit pressure switch (if qO Room temperature sensor (if no the pressure switch is not remote control is installed), see installed, use the jumper pro- also page 67 vided) wP KM BUS: Cooling circuit exten- qW Heating circuit pump, direct heat- sion kit ing circuit...
  • Page 53 Preparing for installation System version 4 (cont.) Information regarding other connections The primary pump, the secondary pump, the instantaneous heating water hea- ter and the central heating/DHW three-way diverter valve have already been connected in the factory. Components to be connected Connection descrip- tion Connect components for heating circuit with mixer to...
  • Page 54 Preparing for installation System version 4 (cont.) Pos. Description Number DHW circulation extension Option solar heating circuit (only with Vitocal 242) Solar collectors as required Collector temperature sensor Diaphragm expansion vessel for the solar circuit Solar circuit extension Option "Natural cooling" function Vitotrans 100, plate-type heat exchanger Natural cooling extension kit Extension kit for cooling circuit with mixer...
  • Page 55 Installation sequence Summary of electrical connections The following table provides an overview of all electrical connecting areas. A Full wave soft starter, 400 V or C Control module with X80 connect- 230 V version ing area B Junction box with X60 main con- D Main PCB with X16 connecting necting area and X50 additional area...

  • Page 56: Preparing The Installation

    Installation sequence Preparing the installation A Clearance from the wall or front edge of the recess. Note 1. Pull the front panel at its upper Position the back of the unit tempora- edge forward and lift out upwards. rily approx. 500 mm from the on-site drain connection.

  • Page 57: Fitting The Water Drain (Vitocal 242)

    Installation sequence Preparing the installation (cont.) 3. Pull the upper front panel at its 4. Release the front top panel. lower edge forward and lift out upwards. Fitting the water drain (Vitocal 242) Note 3. Note To prevent damage to the connecting Check the drain connection for cables with wall clearances of >...
  • Page 58 Installation sequence Fitting the water drain (Vitocal 242) (cont.) 4. Note Min. clearance between the wall and the back of the equipment when the drain connection is located behind the equipment: 15 mm, and when the drain connec- tion is located adjacent to the equipment: 45 mm.

  • Page 59: Fitting The Water Drain (Vitocal 222)

    Installation sequence Fitting the water drain (Vitocal 222) 1. Fit the threaded ferrule at the back of the equipment 2. Push the drain hose onto the threaded ferrule and secure with a hose clip. 3. Connect the drain outlet kit with the on-site drain connection DN 40.
  • Page 60 Installation sequence Heat pump preparation (cont.) 1. Remove the front part of the ther- 4. Check the floor area, valves and all mal insulation. visible solder joints of the heat pump for traces of oil. 2. Remove the top part of the thermal insulation.

  • Page 61: Installing The Control Module

    Installation sequence Heat pump preparation (cont.) 5. Lead the thermal insulation A of the primary inlets and outlets through the openings in the top part of the thermal insulation B. Position the top part of the thermal insulation. Note Do not push the thermal insulation together when doing this.

  • Page 62: Inserting The Heat Pump

    Installation sequence Installing the control module (cont.) 2. Suspend control module (with type 3. Tighten the screws. plate at the front) over the undone screws. 4. Fit the control panel connecting cable (7-pin) to pos. C at the con- Note trol unit (see page 22).
  • Page 63 Installation sequence Inserting the heat pump (cont.) 1. Remove the control panel and put it 3. Lift the edge protector and remove on top of the heat exchanger. the l.h. retaining panel with special stud. 2. Remove the crossbar. 4. Note Position the heat pump feet in the four indentations A provided for this purpose in the intermediate...

  • Page 64: Inserting The Cables

    Installation sequence Inserting the heat pump (cont.) 5. Note 6. Fit the l.h. retaining panel with the Observe information regarding the special stud. brine connection on page 98. 7. Fit the crossbar. Insert the corrugated pipes of the connection set for the brine circuit 8.
  • Page 65 Installation sequence Inserting the cables (cont.) Please note Please note Damaged cable insulation Condensate in the control can cause damage to the panel can damage the unit. equipment. Route cables so that they Route the cable harness as cannot touch very hot, described in the following vibrating or sharp-edged steps (with a bend so that...

  • Page 66: Connecting The External Electrical Components

    Installation sequence Inserting the cables (cont.) 3. Fit the control panel. 4. Make all external electrical connec- tions in accordance with the instructions starting on page 66. Connecting the external electrical components Note The unit's external electrical connections are located together in the control panel in the top right-hand area of the unit (see B on page 55).
  • Page 67 Installation sequence Connecting the external electrical components (cont.) Information regarding the use of room temperature sensors and remote controls If a room temperature sensor is being installed for a heating circuit without a remote control, the room temperature sensor must be connected as shown in the illustration above.
  • Page 68 Installation sequence Connecting the external electrical components (cont.) Collector temperature sensor (type Pt 500, only for the Vitocal 242) Solar collector installation instructions A Terminals in the control panel B Collector temperature sensor Connect temperature limiter to underfloor heating system When using the integral secondary circuit pump as a heating circuit pump 1.
  • Page 69 Installation sequence Connecting the external electrical components (cont.) When using a separate heating circuit pump Temperature limiter installation instructions Central fault message Breaking capacity: 230 V~, 0.7 A Note This contact is not at zero volt. 230 V~ will be present if there is a fault.
  • Page 70 Installation sequence Connecting the external electrical components (cont.) Extension kit for a mixer circuit and/or Vitotrol 200 remote control (via KM BUS) Note General information regarding the room temperature sensors and remote con- trols, see page 66. Connection via KM BUS data cable. Connect the mixer circuit pump to the extension kit.
  • Page 71 Installation sequence Connecting the external electrical components (cont.) Natural cooling with NC-Box The NC-Box is a fully assembled unit Power is connected via terminals for the implementation of the natural X60.19 and X60.21 inside the Com- cooling function, subject to version pact Energy Tower control panel.
  • Page 72 Installation sequence Connecting the external electrical components (cont.) Version 1 "Hard" shut-off of power supply for compressor and/or instantaneous heating water heater and OFF contact to control unit. Power-OFF with 400 V power connection (version 1) A No power-OFF in this position E Power-OFF contact for control B Control contact ripple control unit...
  • Page 73 Installation sequence Connecting the external electrical components (cont.) Power-OFF with 230 V power connection (version 1) Instantaneous heating water heater A No power-OFF in this position E Power-OFF contact for control B Control contact ripple control unit receiver "power-OFF" F Terminals in the control panel C Contactor (part no.

  • Page 74: Power Supply

    Installation sequence Connecting the external electrical components (cont.) B Control contact ripple control E Power-OFF contact for control receiver "power-OFF" unit C Contactor F Terminals in the control panel D The air and creepage gap must G Compressor (230 V) power sup- exceed 8 mm, since the control ply connection input is a low voltage input...
  • Page 75 Installation sequence Power supply (cont.) Main isolator requirements (if necessary) If a main isolator is set, it must isolate If no main isolator is set, all non- the power circuit with at least 3 mm earthed cables must be isolated by contact separation.
  • Page 76 Installation sequence Power supply (cont.) In negotiations with your power sup- The allocation of the power-OFF (for ply utility, different feed tariffs for the compressor and/or instantaneous main power circuits may be offered. heating water heater) is made via the The control unit/electronics feed control unit settings (see pages 150 must be implemented without possi-...
  • Page 77 Installation sequence Power supply (cont.) Control unit power supply Note This supply must never be blocked Max. fuse rating 16 A A Terminals in the control panel Compressor power supply Recommended core cross-section: 1.5 mm Note The upstream fuses must have Z characteristics.
  • Page 78 Installation sequence Power supply (cont.) Power supply 400 V~, one tariff One common power cable with a large cross-section up to the vicinity of the heat pump. The common power cable cannot be blocked. Selective blocking of the indivi- dual power cable must take place downstream of the sub-distribution, result- ing in additional sub-distribution cost.
  • Page 79 Installation sequence Power supply (cont.) Control unit power supply Note This supply must never be blocked. Max. protection 16 A. A Terminals in the control panel Compressor power supply Recommended core cross-section: 1.5 mm Note The upstream fuses must have Z characteristics.
  • Page 80 Installation sequence Power supply (cont.) 230 V~ power supply, various tariffs Three separate power cables Selective power-OFF for compressor and instantaneous heating water heater possible The cross-section of the power cables must be appropriate for the connected load of the relevant unit. A Control unit Recommended power cable: 3 x 1.5 mm...
  • Page 81 Installation sequence Power supply (cont.) Compressor power supply Recommended power cable: 3 x 4 Note The upstream fuses must have Z characteristics. A Terminals at the control module Instantaneous heating water heater power supply Each heater winding requires its own neutral conductor.
  • Page 82 Installation sequence Power supply (cont.) Adapt the cross-section of common power cable to the connected load of the instantaneous heating water heater and the compressor. The connected load of the control unit does not have to be taken into consideration. A Common heat pump power cable C Instantaneous heating water hea- Recommended power cable: 3 x...
  • Page 83 Installation sequence Power supply (cont.) Compressor power supply Recommended power cable: 3 x 4 Note The upstream fuses must have Z characteristics. A Terminals at the control module Instantaneous heating water heater power supply Each heater winding requires its own neutral conductor.
  • Page 84 Installation sequence Power supply (cont.) Over/undervoltage 15 % If the values are within the tolerance Phase asymmetry 15 % range again, the phase monitor auto- Switching delay matically re-enables the power sup- ply. The phase monitor shuts off if these tolerance ranges are exceeded.
  • Page 85 Installation sequence Power supply (cont.) Version 1 LEDs explained LED "Rel" illuminates green: All voltages and the rotating field (clockwise) are healthy. LED "Ph" illuminates red: The relay has responded; the rotat- ing field is anti-clockwise. All LED's off: One or several phases have dropped out.
  • Page 86 Installation sequence Power supply (cont.) Version 2 LEDs explained LED "R" illuminates green: All voltages and the rotating field (clockwise) are healthy. LED "Ph" flashes yellow: The relay has responded; the rotat- ing field is anti-clockwise. All LED's off: One or several phases have dropped out.

  • Page 87: Checking The Rotating Field Of The Power Supply

    Installation sequence Power supply (cont.) Relay switch contacts for activat- ing signalling equipment or for blocking the heat pump: A Contact used in the safety chain (N/O) Checking the rotating field of the power supply 1. Switch ON the power. 2.
  • Page 88 Installation sequence Installing a 400 V full wave soft starter (as of BWT . . . (cont.) Danger The absence of component earthing can transfer dan- gerous body currents, should an electrical fault occur. It is important to connect the earth strap from the cross- bar to the full wave soft star- ter.

  • Page 89: Installing A 230 V Full Wave Soft Starter (All Models)

    Installation sequence Installing a 230 V full wave soft starter (all models) Note In accordance with the previously described installation procedure, the heat pump module must already be installed. The heat pump module cannot be installed after the full wave soft starter has been installed. 1.
  • Page 90 Installation sequence Installing a 230 V full wave soft starter (all . . . (cont.) Danger 5. Plug connector from compressor The absence of component (6-pin plug with designation PE, N, earthing can transfer dan- L, S, 230, 231) to mating plug F gerous body currents, on the right side of the full wave should an electrical fault...

  • Page 91: Making The Electrical Heat Pump Connections

    Installation sequence Making the electrical heat pump connections 1. Only with model BWT 106 in 3. Push the primary temperature sen- 400 V version: sor connection (2-pole, LV) into the Push the compressor connection mating plug on the control panel. into pos.

  • Page 92: Connecting The Brine Pressure Switch Or A Jumper

    Installation sequence Connecting the brine pressure switch or a jumper 1. The brine pressure switch is con- nected across terminals X60.11 and X60.12 at the top of the control panel (see also page 69). If no brine pressure switch is con- nected, always connect the jumper (in the pack) across these term- inals.

  • Page 93: Connecting The Secondary Circuit

    Installation sequence Connecting the secondary circuit VL Secondary circuit flow RL Secondary circuit return 1. Route the corrugated stainless 2. Secure the corrugated pipes to the steel pipes of the secondary flow connectors with the clips provided. and return through both apertures in the thermal insulation, and push them onto the heat pump connec- tors behind the insulation.

  • Page 94: Connection Panel

    Installation sequence Connection panel We recommend the use of the con- nection panel (accessories) and asso- ciated connecting lines, fittings (accessories) and extensions for the DHW circulation, the solar and the heating circuit to make the hydraulic connections (see page 26). Installation location, see page 12.
  • Page 95 Installation sequence Connecting the DHW (cont.) Connection of the Vitocal 242 on the DHW side For the DHW connection, observe DIN 1988 and DIN 4753. A Domestic hot water G Drain valve B DHW circulation pump H Shut-off valve C Spring-loaded check valve K Cold water D Hydraulic connection array of the L Drinking water filter...

  • Page 96: Connecting The Heating Circuit

    Installation sequence Connecting the DHW (cont.) A DHW H Shut-off valve B DHW circulation pump K Flow regulating valve C Spring-loaded check valve L Pressure gauge connection D Hydraulic connection array of the M Non-return valve/pipe separator Compact Energy Tower (top view) N Drain valve E Diaphragm expansion vessel O Cold water...

  • Page 97: Connecting The Solar Circuit (Option, Only For The Vitocal 242)

    Installation sequence Connecting the heating circuit (cont.) Note Design the heating circuit as a single line heating circuit or with an overflow valve (minimum flow rate 700 l/h) and fill via boiler fill & drain valve C (see page 108). Equip the heating circuit on site with a diaphragm expansion vessel.

  • Page 98: Connecting The Brine Side

    (never use galvanised medium. pipes for the brine circuit or the Fill the solar circuit with Viessmann solar circuit). "Tyfocor" heat transfer medium To ensure the perfect operation of (ethylene glycol: water mixture with the brine circuit, route pipes so that frost protection down to 15 °C).
  • Page 99 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. Removing the front panels ..........2.
  • Page 100 Commissioning, inspection, maintenance Steps - commissioning, inspection and . . . (cont.) Commissioning steps Inspection steps Maintenance steps Page 19. Checking the secondary pump ........20.

  • Page 101: Removing The Front Panels

    Commissioning, inspection, maintenance Further details regarding the individual steps Removing the front panels Danger Please note Touching 'live' components can To prevent equipment damage, result in the transfer of danger- wait at least 30 min between ous body currents. the installation and the com- Never touch the connections missioning of the equipment.

  • Page 102: Filling The Primary Circuit, Venting It And Checking Its Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling the primary circuit, venting it and checking its pres- sure Please note 2. Only for commissioning: To prevent equipment damage, Fill the primary circuit with heat it is vital to prevent the com- transfer medium "Tyfocor 15 °C"...

  • Page 103: Filling And Venting The Heating Side Of The Equipment

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling and venting the heating side of the equipment Vitocal 242 Vitocal 222 A Electrical component cover B Non-return valve (only with Vitocal 242) C Boiler fill & drain valve heating circuit D Heating circuit pressure gauge...
  • Page 104 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) G Sight hose, Tyfocor drip container 10. Note (only with Vitocal 242) Pay attention to information con- H Three-way diverter valve (manual) cerning control operation (from (only with Vitocal 242) page 123), select language if necessary (see page 109, default 1.

  • Page 105: Filling And Venting The Solar Side Of The System (Only For The Vitocal 242)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Filling and venting the solar side of the system (only for the Vitocal 242) Danger 7. Set the operating mode selector Overheated collector areas (see page 123) to "9". and overheated heat transfer medium can cause burns and 8.

  • Page 106: Checking The Diaphragm Expansion Vessel Of The Heating Circuit And Its Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel of the heating cir- cuit and its pressure Carry out this test on a cold system. Note Only use anti-corrosion agents offered by the heating trade that have been approved for heat pumps with DHW heating via single-walled heat exchangers (DHW cylinders).

  • Page 107: Checking The Tyfocor Drip Container (Only For The Vitocal 242, If Required)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Commissioning Observe the static head of the solar Note circuit. Mark this calculated fill pressure on Pre-charge pressure of the diaphragm pressure gauge F (see page 108) as expansion vessel for the solar circuit: minimum fill value.

  • Page 108: Checking The Safety Valve And Siphon Function

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the safety valve and siphon function Vitocal 222 Vitocal 242: Check the function of the safety valves on the solar A, heating water B and DHW side C. Vitocal 222: Check the function of the safety valve on the heating water side B (external).

  • Page 109: System Configuration

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) System configuration Enable the system design used (see from page 13) and any optional compo- nents and functions at the control unit. Only required outside German-speaking countries: Setting the display lan- guage 1.
  • Page 110 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Press the following keys one after the other: " " and " " Enter the code for heating con- tractors ("SERVICE"; for details see page 142). Press the following keys one after the other: "...
  • Page 111 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Only if the code request is dis- played: Enter the code for heating contrac- tors ("SERVICE"; for details see page 142). 3. Select the required system design (2, 4 or 6) with >. Note The selected system design is shown in the display area marked...

  • Page 112: Checking The Antifreeze Concentration In The Brine Circuit

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Select or deselect the component Pressing "CONTINUE" in the example displayed above the keys (area C, shown will lead to the natural cooling see diagram) with "YES"/"NO". function being excluded from the sys- tem design.

  • Page 113: Checking The Secondary Pump

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the secondary pump 1. Start the test program: 2. "Sensor temperatures" Observe the temperatures at the Menu item "Secondary flow" and the "Sec- "Device settings" ondary return". The temperatures "Contractor level"...

  • Page 114: Checking The Solar Circuit Pump (Only For The Vitocal 242)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the solar circuit pump (only for the Vitocal 242) 1. Start the test program: 2. Observe the solar circuit return temperature. Menu item After a few seconds, the tempera- "Device settings"...

  • Page 115: Checking The Primary Pump

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Start the test program: 3. Determine and enter the actual values and test conditions in accor- Menu item dance with the commissioning/ser- "Device settings" vice report from page 216. "Contractor level"...

  • Page 116: Checking Mixers, Heat Pump And Cylinder Heating

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Start the compressor by pressing 5. Record the results in the service "ON". report from page 216. If the set values are not achieved: Note Vent the primary circuit The compressor will start automati- Check the pump connections cally after expiry of the 250 s long...

  • Page 117: Checking The High Pressure Switch

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Check the following temperature 5. Check the following temperature and record it in the service report and record it in the service record from page 216: sheet from page 216: The temperature at the "Sec- The spread between the secondary ondary flow"...

  • Page 118: Checking The Compressor Casing Temperature

    60 strap to the crossbar and the °C (otherwise consult the Technical top panel. Service department at Viessmann). Fit the front top panel. Cleaning the interior of the DHW cylinder Danger An uncontrolled exit of DHW or heat transfer medium can lead to scald- ing and building damage.
  • Page 119 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Vitocal 242 Vitocal 222 5. Remove loose deposits with a 1. Drain the DHW cylinder from the high pressure cleaner. DHW side. For this, close shut-off valve A (only for the Vitocal 242 Please note internal) and open drain valve B.
  • Page 120 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Use a chemical cleaning agent to 10. Fit flange lid F with impressed remove hard deposits that cannot current anode H and earth strap be removed with a high pressure K of the impressed current cleaner.

  • Page 121: Replacing The Impressed Current Anode

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 16. Record the work carried out in the commissioning/service report from 216. Replacing the impressed current anode 1. Dismantle the flange lid in accor- 3. Bend the impressed current anode dance with the steps described in accordance with the pattern of from page 118.

  • Page 122: Setting The Control Parameters

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. If required, change over the three- 2. Change the control settings (see way valve (see Fig.). page 169, section "Cylinder volume for heat pump"). Setting the control parameters 1. Activate the "Contractor level". 3.

  • Page 123: Fault Messages

    Troubleshooting Control unit diagnostics Programming unit overview A Display D Operating mode selector B Rotary selector "Reduced room E Menu keys temperature" F Programming unit flap C Rotary selector "Standard room temperature" Fault messages Internal faults are captured, displayed A maximum of eight faults can be and saved by the device.

  • Page 124: Acknowledging Fault Messages

    Troubleshooting Control unit diagnostics (cont.) If more faults than that have occurred, Active faults are displayed in accor- the control unit acts as follows: dance with their respective priority. Messages with lower priority will be deleted if there are messages with higher priority (than those already stored).

  • Page 125: Skipping Fault Messages

    Troubleshooting Control unit diagnostics (cont.) Scanning all stored ("historic") fault messages Menu item "BACK" "Information" "Statistics" Note "Fault history" The fault messages cannot be Press "TIME", to display the time acknowledged in the fault history. of the fault occurrence Press "FAULT" to return to the fault description.
  • Page 126 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures Primary in Lead broken Check the terminals and re- sensor place the sensor, if required Heating circuit Short circuit Check the sensor and re- 2 flow sensor place, if required (mixer circuit) Natural cool- ing flow sen- Heating circuit...
  • Page 127 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures Secondary Secondary pump faulty Check the secondary pump pump (see page 113); replace the pump, if required Solar heating The solar circuit has no cir- Check the solar circuit circuit culation pump (see page 114) and replace it, if required Pump HC 1...
  • Page 128 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures KM BUS mixer Communication fault mixer Check the extension kit HC 2 HC 2 connections; start the ex- tension kit KM BUS NC Communication fault nat- mixer ural cooling mixer KM BUS FB Fault KM BUS remote con- Check connections and HC 1...
  • Page 129 Troubleshooting Control unit diagnostics (cont.) Fault messages Cause Measures Safety chain Fault at one of the con- External safety chain; nected components check connected compo- nents and circuits (e.g. brine pressure or jumper) DHW SHC Break in jumper X 6.5 Check any possibly con- nected switching contact or bridge (connection on the...

  • Page 130: Diagnosis

    Troubleshooting Control unit diagnostics (cont.) The illustration shows the position of the high limit safety cut-out (A: K6, B: K7, K8) on the heater rods. For the location of the heater rods, see page 209. Diagnosis Measures in case the room temperature is constantly too low Carry out the following steps to troubleshoot the problem.
  • Page 131 Troubleshooting Diagnosis (cont.) 3. Check whether there is voltage at 5. Replace the power supply unit. the power feed to the control unit/ electronics; provide power if 6. Replace the programming unit. required. 7. Replace the main PCB. 4. Check the plug-in and threaded connections.
  • Page 132 Troubleshooting Diagnosis (cont.) Closing the service valve Use a new copper seal B. When refitting the sealing cap A, counterhold the hexagon C with a spanner. Required torque: 11 Nm...

  • Page 133: Main Menu

    Control settings Menu structure overview Main menu A see page 134 B see pages 135, 136 and 137 C see pages 138, 139, 140 and 141...

  • Page 134: Information

    Control settings Menu structure overview information Main menu > Information A only for the Vitocal 242...

  • Page 135: Programming

    Control settings Menu structure overview Programming Main menu > Equipment settings > Programming A see page 136 B see page 137 C only for the Vitocal 242...
  • Page 136 Control settings Menu structure overview Programming (cont.) Main menu > Equipment settings > Programming A see page 135 B see page 137 C only for the Vitocal 242...
  • Page 137 Control settings Menu structure overview Programming (cont.) Main menu > Equipment settings > Programming A see pages 135 and 136 B only for the Vitocal 242...

  • Page 138: Contractor Level

    Control settings Menu structure overview Contractor level Main menu > Equipment settings > Technical service level A see pages 140 and 141 B see page 139 C only for the Vitocal 242...
  • Page 139 Control settings Menu structure overview Contractor level (cont.) Main menu > Equipment settings > Technical service level A see page 138 B see pages 140 and 141 C only for the Vitocal 242...
  • Page 140 Control settings Menu structure overview Contractor level (cont.) Main menu > Equipment settings > Technical service level A see pages 138 and 139 B see page 141 C only for the Vitocal 242...
  • Page 141 Control settings Menu structure overview Contractor level (cont.) Main menu > Equipment settings > Technical service level A see page 138 B see page 140...

  • Page 142: Control Settings By Contractors

    Control settings Menu structure overview Contractor level (cont.) C see pages 135 to 137 D only for the Vitocal 242 Control settings by contractors Only those settings are described on The description of the control settings the following pages that are the is structured as follows: exclusive domain of specialists oper- Descriptions of the "Technical ser-...

  • Page 143: Adjusting Sensor Temperatures

    Control settings Activating the technical service level (cont.) 2. Enter code: Menu item "Device settings" "Access rights" Enter code: SERVICE press each 1 x 2 x "OK" Note Access to the technical service level is blocked if the programming unit flap is closed or the standard display key is pressed.

  • Page 144: Checking Signal Inputs

    Control settings Checking signal inputs The system can be checked using this menu. For example, in case of a fault, you can check whether the cause has been removed. This check can only be carried out with the relay switched OFF. In standard mode, all monitoring inputs are "OFF".
  • Page 145 Control settings Manual control of relays and mixers (cont.) "Relay" sub-menu Note Here, the relays can be activated at random. Some actuators may still be switched ON when this menu is called up. Please note Unintentional conflicting operating situations can be created using "manual control"...
  • Page 146 Control settings Manual control of relays and mixers (cont.) "Mixer" and y, then select the required Select a mixer by pressing x mixer position in % using the keys V/W. Key c puts the mixer in its zero position. "OK"...

  • Page 147: Power-Off Contact: 1S

    Control unit settings system definition System design As well as the procedure described in "system configuration" (see page 109), the system design can be modified at this point or additional components and/or functions selected or deselected. Access "System definition" "Device settings" "System scheme"...

  • Page 148: Heating Limit < T Room (Heating Limit Temperature)

    Control unit settings system definition Heating limit < T room (heating limit temperature) The heating limit temperature defines the value of the outside temperature below which central heating commences. The heating limit temperature is the result of the selected set room temperature less the value entered under "Heating limit <...

  • Page 149: Frost Protection Temperature

    Control unit settings system definition Temperature limit for reduced temperature mode (cont.) Standard setting -30 K Access Setting range -30 to +30 K "Device settings" "Programming" "System definition" "Temperature limit for red. BA" (1/!) Frost protection temperature The equipment enters reduced mode to protect itself against frost, as soon as the average outside temperature drops below this value.

  • Page 150: Heat Pump Control Settings Power-Off Compressor

    Heat pump control settings Power-OFF compressor With activated power-OFF ("power-OFF: YES") the power supply utility can switch off the heat that is being generated by the heat pump. This requires that the power-OFF contact has been connected (see page 71). The heat distribution by the heating circuit pump and the circulation pump for cylinder heating are not affected by the power interruption.

  • Page 151: Hysteresis T Primary/Min. T Primary In

    Heat pump control settings Minimum return temperature (cont.) Note If the minimum return temperature has been set too low, there is more compres- sor wear due to the increase in the number of low-pressure shutdowns. If the minimum return temperature is set too high, the proportion of electrical heating increases and the degree of efficiency drops.

  • Page 152: Minimum Runtime

    Heat pump control settings Minimum runtime Setting the minimum heat pump runtime. The heat pump only switches off when this time has elapsed. This setting is designed to reach long heat pump runtimes to achieve high effi- ciency and low wear. Access Standard setting 2:00 min...

  • Page 153: Optimum Runtime

    Heat pump control settings Flow; primary/secondary pump (cont.) Access "Device settings" "Programming" "Heat pump" "Primary pump flow" "Flow sec. pump" (P/Q) Standard setting 2:00 min Setting range 00:10 to 16:40 A Heating command B Primary pump C Secondary pump D Compressor E Start delay F Secondary pump flow G Primary pump flow...
  • Page 154 Heat pump control settings Optimum runtime (cont.) Access "Device settings" "Programming" "Heat pump" "Optimum runtime" (P/Q) Standard setting 2:00 h Setting range 00:20 to 24:00 A Optimum operating range B Primary temperature drop C Optimum runtime...

  • Page 155: Power-Off; Instantaneous Heating Water Heater

    Electric heater control settings E heating This parameter informs the equipment as to whether an instantaneous heating water heater is installed. Note Never modify this parameter. The use of the electric immersion heater for DHW heating and central heating can only be enabled or disabled via parameter "WW with electric heater"...

  • Page 156: Dhw With Electric Power

    Electric heater control settings Electric heating (cont.) Standard setting Access Setting range YES/NO "Device settings" "Programming" "Electric heater" "Heating with electric power" ("YES"/"NO") DHW with electric power This function makes it possible to deactivate DHW heating by the integral instantaneous heating water heater (e.g. if the water is subsequently heated by an on-site instantaneous heating water heater).

  • Page 157: Heater Rod Delay

    Electric heater control settings Heater rod delay Adjustment of the time during which the electric heating is not switched ON after changing the operating mode (reduced/standard). Access Standard setting 0:30 h "Device settings" Setting range 0:00 to 5:00 h "Programming" "Electric heater"...

  • Page 158: Maximum Stage; Electric Heater

    Electric heater control settings Maximum stage; electric heater This setting determines, with what output (stage 1, 2 or 3, see from page 222) DHW and heating water will be boosted. Access Standard setting "Device settings" Setting range 1 to 3 "Programming"...

  • Page 159: Time For Drying Buildings

    Internal hydraulics control settings Heat pump for drying buildings This setting determines whether the heat pump is used to dry the building as well as the instantaneous heating water heater. This function must be set to "NO" if the heat pump is not ready for operation because the heat pump primary circuit is not ready when building drying takes place.

  • Page 160: Flow Hysteresis

    Internal hydraulics control settings Flow hysteresis The set flow temperature of the secondary circuit is determined by the control unit in accordance with the current heat demand. The "Flow hysteresis" setting defines the difference from an internally calcu- lated set flow temperature at which one of the heat generators (heat pump, solar collector, instantaneous heating water heater) is switched ON and OFF.
  • Page 161 Internal hydraulics control settings Max. steps; three-way valve (cont.) Standard setting Access Setting range do not change "Device settings" "Programming" "Heat pump" "Max. step 3-way valve" (l/...

  • Page 162: Solar Collector Control Settings (Only For The Vitocal

    Solar collector control settings (only for the Vitocal 242) Solar collector Any installed solar collector must be enabled in the control unit. A number of other parameters that must be defined to make the integral solar control unit operate accurately can be retrieved at this point. Note If the solar collector has already been enabled under "System configuration"...

  • Page 163: Pump Kick Hysteresis

    Solar collector control settings (only for the Vitocal 242) Solar pump hysteresis ON/solar pump hysteresis . . . (cont.) Access "Device settings" "Programming" "Solar collector" "Hyst. solar circuit pump ON" "Hyst. solar circuit pump OFF" (0/=) A Temperature differential solar col- lector/cylinder (cylinder colder) B Start hysteresis C Stop hysteresis...

  • Page 164: Pump Kick Runtime

    Solar collector control settings (only for the Vitocal 242) Pump kick hysteresis (cont.) At 1, the solar circuit pump is started for the time defined as pump kick run- time (see page 164). If the tempera- ture continues to increase to the 2 ("Hyst.

  • Page 165: Pump Kick Dead Time

    Solar collector control settings (only for the Vitocal 242) Pump kick runtime (cont.) "Solar collector" "Pump kick runtime" (l/m) Setting range 00:01 to 00:20 Standard setting 00:02 min Pump kick dead time Time, inside of which the solar circuit pump cannot start after a pump kick (see page 163).

  • Page 166: Dhw Control Settings Dhw Cylinder Temperature

    DHW control settings DHW cylinder temperature Operating instructions DHW program temperature Operating instructions DHW circulation pump program Operating instructions Operating mode Determining the DHW cylinder operating mode. Setting Function Standby Equipment frost protection Reduced The control only responds to the upper cylinder temperature sen- sor;...

  • Page 167: Dhw Cylinder Maximum

    DHW control settings DHW cylinder maximum Setting of the maximum temperature inside the DHW cylinder. Renewed heating will be prevented after this temperature has been reached, until the temperature has dropped at least by 5 K. Note Increase this value to 70 °C when using solar collectors. Danger DHW temperatures >...
  • Page 168 DHW control settings Hysteresis; DHW instantaneous heating water . . . (cont.) Note The value selected for "Hysteresis" should be higher than the expected temperature drop due to heat losses in a single night (approx. 5 K). A lower value for "Hysteresis DHW E heating"...

  • Page 169: Start Optimisation

    DHW control settings Start optimisation Operating instructions Stop optimisation Operating instructions DHW auxiliary function Operating instructions Set DHW temperature 2 Operating instructions Heat pump cylinder volume The available cylinder volume can be varied via a manually controlled three- way valve (see page 121). Only this adjustment provides a feedback to the control unit via the setting of the manual valve and therefore the cylinder volume, which can be heated.

  • Page 170: Excess Reaction

    DHW control settings Excess reaction Coordination of the heat drawn off in the secondary circuit when the heat pump produces an excess of heat or the heat drawn by the secondary circuit is sud- denly choked off. Settings: No heat drawn off Heat will be drawn off only in case of a critical excess, i.e.
  • Page 171 DHW control settings Maximum DHW interruption (cont.) Access Standard setting 01:30 h "Device settings" Setting range 00:10 to "Programming" 24:00 h "DHW" "Max. DHW interruption" (P/Q)

  • Page 172: Heating Circuit Control Settings Standard Temperature

    Heating circuit control settings Standard temperature Operating instructions Reduced temperature Operating instructions Temperature program, heating circuit Operating instructions Remote control If a remote control is installed, it must be activated for the relevant heating cir- cuit. Note If a remote control is used, set the "Operating mode" parameter (see page 172) to "Remote control".

  • Page 173: Maximum Flow Temperature

    Heating circuit control settings Operating mode (cont.) Setting Function Standby Equipment frost protection Reduced Constant reduced room temperature Standard Constant standard room temperature Fixed value Operation as fixed value controller Rotary se- The operating mode is selected via the operating mode selector lector (standard setting) External...

  • Page 174: Dhw During Party Mode

    Heating circuit control settings Minimum flow temperature (cont.) Note This setting influences the natural cooling function. If the setting is too low, the dew point monitor switches the cooling function off prematurely, subject to the cooling curve (see page 173). Access "Heating circuit 1/2"...

  • Page 175: Room Temperature Sensor

    Heating circuit control settings Excess reaction (cont.) Access "Heating circuit 1/2" "Device settings" "Excess reaction" "Programming" (l/m) "Heating circuit" Standard setting Setting range 0 to 2 Room temperature sensor If a room temperature sensor is installed, it must be activated for the relevant heating circuit.

  • Page 176: Room Temperature Hook-Up

    Heating circuit control settings Room temperature hook-up Preconditions: Room temperature sensor installed and enabled. This setting determines when the room temperature hook-up should be enabled in addition to the weather-compensated control. Settings: No room temperature hook-up Room temperature hook-up only in reduced mode Room temperature hook-up only in standard mode Room temperature hook-up in standard and in reduced mode Access...

  • Page 177: Room Temperature Control

    Heating circuit control settings Maximum flow temperature correction (cont.) Access "Device settings" "Programming" "Heating circuit" "Heating circuit 1/2" "Max. flow corr." (0/=) Standard setting 10.0 K Setting range 0.1 to 10.0 K A Flow temperature B Differential between set room temperature and outside tempera- ture C Heating curve...

  • Page 178: Adjusting The Heating Curve Level And Slope

    Heating circuit control settings Adjusting the heating curve level and slope Operating instructions Integral room temperature controller Precondition: "Room temperature control" set to "Yes". Integral proportion of the room temperature control circuit. A high value results in a rapid response. Access "Heating circuit 1/2"...

  • Page 179: Mixer Runtime

    Heating circuit control settings Mixer runtime Note This setting is only used if parameter set "1" (free parameters) has been selected under "Mixer parameters". Setting of the time required by the servomotor of the external heating circuit mixer for a complete changeover from one operating state into another (90 degree movement).

  • Page 180: Screed Function

    Heating circuit control settings Screed function Note Observe the requirements of DIN 1264-4. The report to be provided by the heat- ing contractor must contain the following heat-up details: Heat-up data with respective flow temperatures Actual maximum flow temperature Operating condition and outside temperature during handover The function continues after a power failure or after the control unit has been switched OFF.

  • Page 181: Mixer Active Zone/Dead Zone

    Heating circuit control settings Screed function (cont.) Temperature/time profile 3 (to Temperature/time profile 4 ÖNORM) A Flow temperature A Flow temperature B Days B Days Access "Heating circuit 2" "Device settings" "Screed function" (l/m) "Programming" "Heating circuit" Standard setting Setting range 0 to 15 Mixer active zone/dead zone Note...

  • Page 182: Natural Cooling

    Heating circuit control settings Mixer active zone/dead zone (cont.) Access "Device settings" "Programming" "Heating circuit" "Heating circuit 1/2" "Mixer active zone" (5/%) "Mixer dead zone" (=/0) Mixer permanently closed Mixer closes (modulating) Mixer motor at zero volt Mixer opens Mixer permanently open Flow temperature Set flow temperature Active zone...

  • Page 183: Cooling Limit > T Room (Cooling Limit Temperature)

    Heating circuit control settings Cooling limit > T room (cooling limit temperature) Precondition: The natural cooling function is enabled. The cooling limit temperature defines the outside temperature, exceeding of which triggers the natural cooling function. The cooling limit temperature is the result of the selected set room temperature and the temperature entered under "cooling limit >...

  • Page 184: Natural Cooling With Mixer

    Heating circuit control settings Cooling curve level/slope (cont.) Access "Device settings" "Programming" "Heating circuit" "Heating circuit 1/2" "Cooling curve level" ("+LEV"/" LEV") "Heat. cooling curve" ("+SLOPE"/" SLOPE") A Flow temperature B Outside temperature C Cooling curve D Cooling curve with a higher level (C offset) E Cooling curve with a greater slope Standard setting...

  • Page 185: Active Zone/Dead Zone Natural Cooling Mixer

    Heating circuit control settings Active zone/dead zone natural cooling mixer Note This setting is only used if parameter set "1" (free parameters) has been selected under "Cooling mixer parameters". For function description see page 181. Access "Heating circuit 1/2" "Device settings" "NC mixer active zone"...

  • Page 186: Cooling Mixer Parameters

    Heating circuit control settings Cooling mixer parameters Precondition: The "NC mixer" function is enabled. At setting "0", the heat pump control unit utilises the function of the KM BUS mixer; the mixer only receives the required flow temperature. At the setting "1", the mixer parameters of the heat pump control unit (e.g. "Mixer runtime") are used to determine the mixer position.

  • Page 187: Buffer Cylinder Control Settings Buffer Cylinder

    Buffer cylinder control settings Buffer cylinder Note This function is only available for system design 2. When selecting system designs 4 and 6, the buffer cylinder will be defined auto- matically as a system component. Should a heating water buffer cylinder be part of a system in accordance with design 2, either set it by selecting option "Yes", or via the system configuration (see page 109) or system definition.

  • Page 188: Hysteresis Temperature

    Buffer cylinder control settings Fixed temperature (cont.) Access "Buffer cylinder" "Device settings" "Fixed temperature" (1/!) "Programming" "Further menu items" Standard setting 50 °C Setting range 1 to 60 °C Hysteresis temperature Note This function is only available in case of system design 2, if the option "Yes" was selected under "Buffer cylinder"...

  • Page 189: Stop Optimisation

    Buffer cylinder control settings Maximum temperature (cont.) Access "Buffer cylinder" "Device settings" "Max. temperature" (1/!) "Programming" "Further menu items" Standard setting 60 °C Setting range 1 to 70 °C Stop optimisation Note This function is only available in case of system design 2, if the option "Yes" was selected under "Buffer cylinder"...
  • Page 190 Buffer cylinder control settings Excess reaction (cont.) Heat will be drawn off, even if the excess heat being created is not critical for the heat pump. Access "Buffer cylinder" "Device settings" "Excess reaction" "Programming" (l/m) "Further menu items" Standard setting Setting range 0 to 2...

  • Page 191: Sensor Resistance Curves

    Components Sensor resistance curves Room temperature sensor (Ni 500) Internal sensors, temperature sen- sor in the heating water buffer cylinder and collector temperature sensor (Pt500) Outside temperature sensor (Ni500)

  • Page 192: Fuse

    Components Fuse The only replaceable fuse is located inside the fuse holder next to the system ON/OFF switch inside the programming unit. Fuse: 6.3 A (slow), 250 V max. power loss 2.5 W Danger Touching 'live' components can result in the transfer of danger- ous body currents.
  • Page 193 Connection and wiring diagrams Overview of the PCBs and connection options Note No physical layout is shown. A Main PCB P Solar circuit pump (only for the B Programming unit Vitocal 242) C Optolink interface R Cylinder primary pump D Sensors S Safety chain E Stepper motor (internal) T Main connecting area in control...

  • Page 194: Main Connection Area

    Connection and wiring diagrams Main connection area X50.109 Control unit power supply con- X50.108 nection X90.109 X90.108...
  • Page 195 Connection and wiring diagrams Main connection area (cont.) Instantaneous heating water Signal from refrigerant circuit heater (400 V) power supply Safety chain, for detailed connection description see A on Instantaneous heating water pages 196 and 197 heater (230 V) power supply Signal from phase monitor (only connection with 400 V units)

  • Page 196: Safety Chain, 400 V Units

    Connection and wiring diagrams Safety chain, 400 V units B Corresponds to area 5 and wW in fig. on page 194 C From the ON/OFF switch (see page 194) D Phase monitor E Compressor protective motor switch F Optional thermal contact G Feedback, three phase power monitor to main PCB H Control high pressure...

  • Page 197: Safety Chain, 230 V Units

    Connection and wiring diagrams Safety chain, 230 V units B Corresponds to area 5 and wW in fig. on page 194 C From the ON/OFF switch (see page 194) D Compressor protective motor switch E Full wave soft starter thermal fuse F Feedback, safety chain to main G Control high pressure H Hot gas temperature limiter...

  • Page 198: Left Part Of The Main Pcb

    Connection and wiring diagrams Left part of the main PCB Secondary return temperature to the power supply unit (see the sensor lower part of the main PCB on Cylinder primary pump for inte- page 200) gral cylinder loading system at C on the top of the main To X50., X60.
  • Page 199 Connection and wiring diagrams Left part of the main PCB (cont.) X50. Terminals on the inner top hat profile rail in the control panel X60. Main connection area for exter- nal connections on the control panel...

  • Page 200: Upper And Lower Part Of The Main Pcb

    Connection and wiring diagrams Upper and lower part of the main PCB A Programming unit E Power supply to the power supply B Optolink interface unit 230 V~ C on H (impressed current anode F Heating element 4 to K8 PCB) on page 198 G Heating element 3 to K7 D Power supply unit...
  • Page 201 Connection and wiring diagrams Upper and lower part of the main PCB (cont.) K Heating element 1 to K6 M Supply (L1) heating elements 1 L Neutral conductor, instantaneous and 2 heating water heater with sepa- N Supply (L2) heating element 3 rate RCD circuits O Supply (L3) heating element 4 Central PE conductor point inside the electronics enclosure...

  • Page 202: R.h. Part Of The Main Pcb

    Connection and wiring diagrams R.h. part of the main PCB Flow temperature sensor, sec- Return temperature sensor; ondary circuit solar circuit Lower cylinder temperature sen- Upper cylinder temperature sen- to the auxiliary PCB...
  • Page 203 Connection and wiring diagrams R.h. part of the main PCB (cont.) alternatively with an internal Safety chain jumper (DHW jumper SHC) Stepper motor mixer heating/ X60. Main connection area for exter- nal connections on the control Flow temperature sensor, pri- panel mary circuit...

  • Page 204: Parts Lists Parts List Vitocal 242-G

    Parts lists Parts list Vitocal 242-G When ordering spare parts 034 Solar circuit pressure gauge Quote the part and serial no. (see 035 Instantaneous heating water type plate) and the item number of the heater 6 kW required part (as per this parts list).
  • Page 205 Parts lists Parts list Vitocal 242-G (cont.) 072 Full wave soft starter for 084 Control unit AS9 for BWT 110, BWT 108/110, 400 V 230 V 073 Phase monitor 400 V 085 Full wave soft starter for 074 Phase monitor strapping plug...
  • Page 206 Parts lists Parts list Vitocal 242-G (cont.)
  • Page 207 Parts lists Parts list Vitocal 242-G (cont.)
  • Page 208 Parts lists Parts list Vitocal 242-G (cont.)
  • Page 209 Parts lists Parts list Vitocal 242-G (cont.)

  • Page 210: Parts List Vitocal 222-G

    Parts lists Parts list Vitocal 222-G When ordering spare parts 041 Gasket set Quote the part and serial no. (see 042 Gasket set type plate) and the item number of the 044 Fixing elements required part (as per this parts list). 047 Heat pump module 200/106, 400 Obtain standard parts from your local supplier.
  • Page 211 Parts lists Parts list Vitocal 222-G (cont.) 079 Heat pump module 200/108, 086 Full wave soft starter capacitor 230 V for BWT 106, 230 V 080 Heat pump module 200/110, 087 Full wave soft starter capacitor 230 V for BWT 108, 230 V 081 Brine circulation pump motor, 088 Full wave soft starter capacitor BWT 108/110, 230 V...
  • Page 212 Parts lists Parts list Vitocal 222-G (cont.)
  • Page 213 Parts lists Parts list Vitocal 222-G (cont.)
  • Page 214 Parts lists Parts list Vitocal 222-G (cont.)
  • Page 215 Parts lists Parts list Vitocal 222-G (cont.)

  • Page 216: Hydraulic Parameter Report

    Commissioning/service reports Hydraulic parameter report Setting and test values Set value Commis- sioning DHW cylinder interior cleaning Antifreeze concentration (brine med- °C ium) Testing the secondary pump Temperature "Secondary flow" in- creased? Temperature "Secondary return" in- creased? Temperature differential T Solar circuit pump test (only for Vitocal 242) Temperature "Solar return"...

  • Page 217: Control Parameter Report

    Commissioning/service reports Hydraulic parameter report (cont.) Setting and test values Set value Commis- sioning Temperature "DHW cylinder top" con- Yes (±1 K) stant? Temperature "Secondary flow" °C from: Heat pump cylinder heating Temperature "Secondary flow" °C from: Temperature "DHW cylinder top" °C from: Control parameter report...
  • Page 218 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting Primary pump flow 00:10 to 16:40 min 2:00 min Secondary pump flow 00:10 to 16:40 min 2:00 min Optimum runtime 00:20 to 24:00 h 2:00 h Instantaneous heating water heater E heater No/Yes Power-OFF...
  • Page 219 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting DHW circulation pump 7-day program program Operating mode 0 to 6 DHW cylinder max. 20 to 80 °C 60 °C Electric DHW heating 2 to 30 K 10 K hysteresis Hysteresis...
  • Page 220 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting Room temperature 0 to 3 hook-up Start optimisation No/Yes Max. flow correction 0.1 to 10.0 K 10.0 K Room temperature No/Yes control Heating curve level 15 to 40 K Heating curve slope 0.0 to 3.5 Integral room tempera-...
  • Page 221 Commissioning/service reports Control parameter report (cont.) Setting parameters Setting range Standard Commission- setting Excess reaction 0 to 2 0: No reaction; 1: Draw-off only in case of critical excess; 2: Always draw-off.

  • Page 222: Specification For 400 V Devices

    Specification for 400 V devices Specification for 400 V devices Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Heat pump performance data Heat pump module Type 200/106 200/108 200/110 Rated output Refrigerating capacity Power consumption Coefficient of performance (COP)
  • Page 223 Specification for 400 V devices Specification for 400 V devices (cont.) Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Rated voltage (instanta- 3/N/PE 400 V/50 Hz neous heating water hea- ter) Rated voltage (control cir- 230 V/50 Hz cuit)
  • Page 224 Specification for 400 V devices Specification for 400 V devices (cont.) Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Weight, standard device Weight, heat pump Weights Vitocal 222 Total weight Weight, standard device Weight, heat pump Permissible operating pressure...
  • Page 225 Specification for 400 V devices Specification for 400 V devices (cont.) Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Connections Primary flow and return optionally Rp ¾" or Multi-connect system (brine) DN 20 Heating flow and return Multi-connect system DN 20...

  • Page 226: Specification For 230 V Devices

    Specification for 230 V devices Specification for 230 V devices Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Heat pump performance data Heat pump module Type 200/106 200/108 200/110 Rated output Refrigerating capacity Power consumption Coefficient of performance (COP)
  • Page 227 Specification for 230 V devices Specification for 230 V devices (cont.) Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Rated voltage (instanta- 1/N/PE 230 V/50 Hz neous heating water hea- ter) Rated voltage (control cir- 230 V/50 Hz cuit)
  • Page 228 Specification for 230 V devices Specification for 230 V devices (cont.) Vitocal 242-G/222-G Type BWT 106 BWT 108 BWT 110 Weight, standard device Weight, heat pump Weights Vitocal 222 Total weight Weight, standard device Weight, heat pump Permissible operating pressure...

  • Page 229: Appendix Order To Commission The Vitocal 242/222

    Appendix Order to commission the Vitocal 242/222 Please fax this order, together with the enclosed system layout, to your local Viessmann sales office. We would ask that a competent employee of yours be present during the com- missioning.

  • Page 230: Certificates Declaration Of Conformity

    Declaration of conformity for Vitocal 242-G We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitocal 242-G incl. CD 70 heat pump con- trol unit complies with the following standards: AD Codes of Practice...

  • Page 231: Declaration Of Conformity

    Certificates Declaration of conformity Declaration of conformity for Vitocal 222-G We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitocal 222-G incl. CD 70 heat pump con- trol unit complies with the following standards:...

  • Page 232: Keyword Index

    Keyword index Keyword index Adjusting sensor temperatures Central fault message ..... . Antifreeze concentration in the brine Checking mixers ......circuit Checking pumps 113, 114, 115...
  • Page 233 Keyword index Keyword index (cont.) Connections Brine side E heating ........
  • Page 234 Keyword index Keyword index (cont.) Heat pump start delay Main connection area ........Heating circuit connection Main PCB .
  • Page 235 Keyword index Keyword index (cont.) Remote control Safety chain ............Repair work Screed function .
  • Page 236 Applicability Applicable for heat pumps: Brine/water heat pump Vitocal 242-G/222-G, type BWT 106, 108 and 110 400 V and 230 V With the standard equipment from serial no: 7288 308 7 01000 ... (Vitocal 242-G) 7286 654 7 01000 ... (Vitocal 222-G) With the heat pump module from serial no: 7278 656 6 01000 ...

This manual is also suitable for:

Vitocal 222-g

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