Viessmann Vitocal 242-S Guida rapida

Installation and service

instructions

for contractors

VIESMANN

Vitocal 242-S

Type AWT-AC 241.A04 to A13, B10, B13

Compact heat pumps, split version for heating and cooling opera-

tion

For applicability, see the last page

VITOCAL 242-S

5546 699 GB 7/2014 Please keep safe.

Please follow these safety instructions closely to prevent accidents and mate-

rial losses.

Safety instructions explained

Danger

This symbol warns against the

risk of injury.

!Please note

This symbol warns against the

risk of material losses and envi-

ronmental pollution.

Note

Details identified by the word "Note" con-

tain additional information.

Target group

These instructions are exclusively inten-

ded for qualified contractors.

■ Work on the refrigerant circuit may

only be carried out by authorised

refrigeration engineers.

■ Work on electrical equipment must

only be carried out by a qualified elec-

trician.

■ The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations

Observe the following when working on

this system:

■ National installation regulations

■ Statutory regulations regarding the

prevention of accidents

■ Statutory regulations regarding envi-

ronmental protection

■ Codes of practice of the relevant trade

associations.

■ All current safety regulations as

defined by DIN, EN, DVGW, VDE and

all locally applicable standards

aÖNORM, EN and ÖVE

cSEV, SUVA, SVTI, SWKI and

SVGW

Working on the system

■ Isolate the system from the power sup-

ply (e.g. by removing the separate fuse

or by means of a mains isolator) and

check that it is no longer 'live'.

Note

In addition to the control circuit, there

may be several power circuits.

Danger

Contact with 'live' components

can result in severe injuries.

Some components on the

PCBs will remain 'live' even

after the power supply has

been switched off.

Prior to removing equipment

covers, wait at least 4 min. to

allow the voltage to dissipate.

■ Safeguard the system against recon-

nection.

Safety instructions

5546 699 GB

!Please note

Electronic assemblies can be

damaged by electrostatic dis-

charge.

Before beginning work, touch

earthed objects, such as heating

or water pipes, to discharge static

loads.

Repair work

!Please note

Repairing components that fulfil a

safety function can compromise

the safe operation of your sys-

tem.

Defective components must be

replaced with genuine

Viessmann spare parts.

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that

have not been tested together

with the system can compromise

its function. Installing non-author-

ised components and making

non-approved modifications or

conversions can compromise

safety and may invalidate our

warranty.

For replacements, use only spare

parts supplied or approved by

Viessmann.

Safety instructions

Safety instructions (cont.)

5546 699 GB

Installation instructions

Preparing for installation

Intended use......................................................................................................... 6

Requirements regarding on-site connections....................................................... 7

Installation sequence

Installing the external unit..................................................................................... 10

Installing the internal unit...................................................................................... 15

Connecting refrigerant lines................................................................................. 24

Connecting the secondary circuit......................................................................... 34

Connecting the DHW side.................................................................................... 37

Connecting the solar circuit.................................................................................. 38

Connecting a cooling circuit if required................................................................ 38

Electrical connection............................................................................................ 38

Power supply........................................................................................................ 54

Closing the heat pump......................................................................................... 62

Service instructions

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 63

Further details regarding the individual steps....................................................... 65

Troubleshooting

Repairs................................................................................................................. 88

Parts lists, internal unit

Ordering parts...................................................................................................... 101

Overview of assemblies, internal unit................................................................... 102

Parts not shown, internal unit............................................................................... 103

Casing, internal unit.............................................................................................. 103

Electrical equipment, internal unit........................................................................ 105

Hydraulics, internal unit........................................................................................ 108

Cylinder, internal unit............................................................................................ 111

Parts lists, external unit 230 V~, type AWT-AC 241.A04

Ordering parts...................................................................................................... 113

External unit 230 V~............................................................................................. 113

Parts lists, external unit 230 V~, type AWT-AC 241.A07

Ordering parts...................................................................................................... 116

External unit 230 V~............................................................................................. 116

Index

5546 699 GB

Parts lists, external unit 230 V~, type AWT-AC 241.A10, A13

Ordering parts...................................................................................................... 119

Overview of assemblies 230 V~........................................................................... 120

Casing, external unit 230 V~................................................................................ 121

Electrical equipment, external unit 230 V~........................................................... 123

Hydraulics, external unit 230 V~.......................................................................... 125

Parts lists, external unit 400 V~, type AWT-AC 241.B10, B13

Ordering parts...................................................................................................... 127

Overview of assemblies 400 V~........................................................................... 128

Casing, external unit 400 V~................................................................................ 129

Electrical equipment, external unit 400 V~........................................................... 131

Hydraulics, external unit 400 V~.......................................................................... 133

Commissioning/service reports

Hydraulic parameter report................................................................................... 135

Control parameters report.................................................................................... 135

Specification....................................................................................................... 145

Appendix

Heat pump commissioning order.......................................................................... 154

Declaration of conformity.................................................................................. 155

Keyword index.................................................................................................... 156

Index

Index (cont.)

5546 699 GB

The appliance is only intended to be

installed and operated in sealed unven-

ted heating systems that comply with

EN 12828, with due attention paid to the

associated installation, service and

operating instructions.

Depending on the version, the appliance

can only be used for the following pur-

poses:

■ Central heating

■ Central cooling

■ DHW heating

The range of functions can be extended

with additional components and acces-

sories.

Intended use presupposes that a fixed

installation in conjunction with permissi-

ble, system-specific components has

been carried out.

Commercial or industrial usage for a pur-

pose other than central heating/cooling

or DHW heating shall be deemed inap-

propriate.

Any usage beyond this must be

approved by the manufacturer for the

individual case.

Incorrect usage or operation of the appli-

ance (e.g. the appliance being opened

by the system user) is prohibited and

results in an exclusion of liability. Incor-

rect usage also occurs if the components

in the heating system are modified from

their intended function.

Note

The appliance is intended exclusively for

domestic use, i.e. even users who have

not had any instruction are able to oper-

ate the appliance safely.

Preparing for installation

Intended use

5546 699 GB

Internal unit

405

147

134

159

62 300

387

475

29 2051

2075

2047

600 680

111

454

564

666

506

AOpening for LV leads < 42 V BDHW

Preparing for installation

Requirements regarding on-site connections

5546 699 GB

Installation

CDHW circulation

DOpening for 230 V cables

ECold water

FLiquid line

GHot gas line

HHeating water flow

KHeating water return

LSolar circuit return

MSolar circuit flow

Connection sizes for hydraulic connections

Pos. Sym-

bol

Meaning Connection

B– DHW Rp ¾

C– DHW circulation G 1

E– Cold water Rp ¾

FRefrigerant lines from/to

the external unit:

■ Liquid line 7 connection pipe:

(supplied pipe bends)

10 mm

UNF thread: ⅝

For type AWT-AC 241.A04, a reduction

from 10 to 6 mm is necessary down-

stream of the pipe bend (reducer ⅝ to ⁷⁄₁₆

supplied).

G■ Hot gas line 7 connection pipe:

(supplied pipe bends)

16 mm

UNF thread: ⅞

For type AWT-AC 241.A04, a reduction

from 16 to 12 mm is required down-

stream of the pipe bend (reducer ⅞ to

¾ supplied).

HHeating water flow Cu 28 x 1 mm

KHeating water return Cu 28 x 1 mm

L– Solar circuit return DN 20 pipe sleeve for multi connect sys-

tem

M– Solar circuit flow

1. Prepare the connections on the heat-

ing water and the DHW side.

Flush the heating system.

2. Prepare the electrical connections.

Preparing for installation

Requirements regarding on-site connections (cont.)

5546 699 GB

Cable lengths in the internal/external unit plus wall clearance

Cables Internal unit External unit

Power cables:

■ Heat pump control unit (230 V~) 2.0 m –

■ Compressor (230 V~/400 V~) – 1.5 m

Other connecting cables:

■ 230 V~, e.g. for circulation pumps 2.0 m –

■ < 42 V, e.g. for sensors 2.0 m –

Internal/external unit connecting cable:

■ 12 V BUS 2.5 m 1.5 m

■ 43 V BUS 2.5 m 1.5 m

Recommended power cables

Type AWT-AC 241.A04 to A13, B10, B13

Heat pump control unit (internal unit) 230 V~

Cable cross-section

■ Without power-OFF 3 x 1.5 mm2

■ With power-OFF 5 x 1.5 mm2

Instantaneous heating water heater

Cable cross-section

■ 400 V~ 5 x 2.5 mm2

■ 230 V~ 7 x 2.5 mm2

Max. cable length 25 m

Type AWT-AC 241.A04 241.A07 241.A10 241.A13

External unit 230 V~ (compres-

sor)

Cable cross-section 3 x 2.5 mm23 x 2.5 mm23 x 2.5 mm23 x 4.0 mm2

Max. cable length 29 m 25 m 20 m 20 m

or or

Cable cross-section – – 3 x 4.0 mm23 x 6.0 mm2

Max. cable length – – 32 m 30 m

Type AWT-AC 241.B10 241.B13

External unit 400 V~ (compressor)

Cable cross-section 5 x 2.5 mm25 x 2.5 mm2

Max. cable length 30 m 30 m

Preparing for installation

Requirements regarding on-site connections (cont.)

5546 699 GB

Installation

Installation information

Types of installation:

■ Floorstanding installation with line

entry above ground level

■ Floorstanding installation with line

entry below ground level

■ Wall mounting

Technical guide

Floorstanding installation:

■ Use supports for floorstanding instal-

lation (accessories).

■ Where such supports cannot be used,

install the external unit freestanding on

a solid base of at least 100 mm height.

■ In difficult climatic circumstances

(temperatures below zero, snow,

humidity) install the appliance on a

plinth of approx. 300 mm height.

■ Take into account the weight of the

external unit: See the following table.

Wall mounting:

■ Use the wall mounting bracket set

(accessories).

■ The wall must meet the structural

requirements.

Positioning:

■ Never install with the discharge side

facing the main wind direction.

■ Provide wall ducts and protective

pipes for the refrigerant lines and elec-

trical cables without moulded parts

and change of direction.

Weather influences:

■ Observe wind loads when installing

the unit on sites exposed to the wind.

■ Incorporate the external unit into the

lightning protection system.

■ Consider the heat emitted by the unit

when planning your weatherproofing

or an enclosure.

Condensate:

■ Ensure the condensate can drain

freely, and create a permanent gravel

bed below the external unit as a soak-

away.

■ In regions with prolonged cold sea-

sons (such as Sweden for example),

provide an electric ribbon heater

(accessory) for the condensate pan.

Insulation against structure-borne

noise and vibrations between build-

ing and external unit:

■ When line entry is above ground level,

fit pipe bends in the refrigerant lines for

vibration compensation: See "Con-

necting refrigerant lines".

■ Route electrical cables/leads between

the internal and external units free of

stress.

■ Installation only on walls with high

weight per area (> 250 kg/m2), in other

words not on lightweight walls, roof

structures etc.

■ For floorstanding installation, only use

the rubber mounts supplied.

■ For wall mounting, only use the anti-

vibration mounts from the bracket set.

■ Never use additional anti-vibration

mounts, springs, rubber mounts, etc.

Installation sequence

Installing the external unit

5546 699 GB

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