Viessmann VITOCAL 242-G Instructions d'exploitation

Installation and serviceinstructionsfor contractorsVIESMANNVitocal 242-GCompact heat pump with electric drive, 400 V~ and 230 V~For applicability, see

10Pos. Description Heat source1Compact heat pump2Heat pump control unit3Outside temperature sensor4Instantaneous heating water heater, 9 kW (accessor

100 The screed programme affects all ena-bled heating circuits in parallel. The selected "Screed program" iscontinued after a power failur

101ValueTemperature:time profileAFlow temperatureBDays"4" Temperature/time profile 4AB1 5 10 15 20 25 301020304050"5" Temperature/

102"Set flow temperature, external demand 730C"Set flow temperature in case of externaldemand, e.g. from the swimming pool(see page 85).In c

103ValueExplanation"2" Operation at a fixed speed, con-trol via PWM signal"3" Variable speed operation of thesecondary pump via PW

104Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Buffer cylinder"4. Select parameter.7200 Heat

105The set value determines the deviationfrom the set temperature of the heatingwater buffer cylinder (subject to operat-ing mode) at which heating is

106Note For system schemes 1 and 2, thisfunction is only available if option "1"was selected under "Buffer cylinder7200". If the

107Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Heating circuit 1"or"Heating circuit 2&q

108Delivered condition 0Setting 1 / 02006/2007 Heating curve slope/level"Heating curve slope 2006""Heating curve level 2007"Heatin

109This parameter determines the condi-tions under which the set flow tempera-ture with weather-compensated controlshould be corrected by the room inf

11Required parametersParameter Setting"System definition" "System scheme 7000" "2""Cooling" "Coolin

110Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Cooling"4. Select parameter.7100 Cooling mode

111"Room temperature 7102"With this parameter a different set roomtemperature than for the heating circuitscan be specified for the separate

112Delivered condition 0Setting range 0 to 507110/7111 Cooling curve (cooling circuit/separate cooling cir-cuit)"Cooling curve level 7110"&q

113Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Time"4. Select parameter.7C00 - 7C06 Summerti

114Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Communication"4. Select parameter.7710 LON co

115 Subscriber number System numberDelivered condition 1 1Setting range 1 to 99 1 to 57779 Fault manager"Fault manager 7779"Device is fault

116"Outside temperature 7797"If several subscribers use the currentoutside temperature value, this can bemade available centrally by one dev

117This parameter determines the sourcefrom which the control unit receives thetime and whether it is to be transmittedvia LON to other subscribers.No

118Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Control"4. Select parameter.8800 Lock out con

119Overview of electrical connectionsVitocal 242-G, 400 V~FDGBCBBBHLMKAConnection and wiring diagramsOverview of the PCBs and connection options5441 6

12During handling, the cylinder module canbe removed (see page 13 onwards). Inaddition, the heat pump module can beremoved (see page 18).!Please noteA

120ACompressor contactorBCable trunkingC3 rows of luster terminalsDController and sensor PCBFProgramming unitGMain PCBHCompressor power supply (belowc

121Vitocal 242-G, 230 V~FDGBCBBBHLKANOMConnection and wiring diagramsOverview of the PCBs and connection options (cont.)5441 603 GBService

122ACompressor contactorBCable trunkingC3 rows of luster terminalsDController and sensor PCBFProgramming unitGMain PCBHCompressor power supply (belowc

123Main PCB (operational components 230 V~)1 2 3 4 5 1 2 3 4sYH sYG sYFsYÖ sYA sYS sYD fÖF36.3 A (slow)N?N?NrN?MN?A1N?N?1 2NF3 Fuse 6.3 A (slow)fÖFact

124Operational components 230 V~Plug Terminals Function ExplanationfÖ Power supply PCB Factory connectionsYÖ210.1210.2Compressor controlvia EEV contr

1253 rows of luster terminals (message and safety connections)X31123467891616F1 6.3 A (slow)NX2?X1NNNNNNNNN31??????????1 PEL1?NL1230V/ 50 Hz1/N/PE18P+

126Message and safety connectionsTerminals Function ExplanationX3.1 Phase switched X3.3X3.4Flow switch, well circuit Zero volt contact required: Clo

127Controller and sensor PCBF6F7F0F2F3F4LONX31aVGF21F23F18F20F16F17F13F14F11F12F8F9193dF.. Plug for sensorLON Slot for LON module"X31" Codin

128Plug Sensor TypeF6 Cylinder temperature sensor, topFactory connectionPt 500F8 Flow temperature sensor, secondary circuitFactory connectionPt 500F9

129Information for ordering spare parts.Quote the part and serial no. (see typeplate) and the position no. of the requiredpart (as per this parts list

13Removing the cylinder module3.1.5.4.2.2xInstallation sequenceOpening and separating the heat pump (cont.)5441 603 GBInstallation

130770 Return temperature sensor PT500solar771 Terminal appliance fuse772 Fuse holder773 Appliance fuse 6.3A105106107 109113112114775Parts listsParts

131315002613333103119316600615614007008009011010301336336611610612321317339315320Parts listsParts list (cont.)5441 603 GBService

132774121317310306101308100111104110330102001311400402122337004015319318303323323322774300325326016402123405014Parts listsParts list (cont.)5441 603 G

133205204006409214228212202116126203232231774732774311311774207311210227229233230230218217219218219217221226209225318127408324338215213222234731332Par

134Vitocal 242-G, 400 V~727700776712702711701735743745767765757118115748763307307758704729729728728Parts listsParts list (cont.)5441 603 GB

135Vitocal 242-G, 230 V~745307307758701704764727700776729729728728712702711736767766757118115748737738743Parts listsParts list (cont.)5441 603 GBServi

136759313 314 327 332 500 501504502506 507 509650 651 652317 318 319Parts listsParts list (cont.)5441 603 GB

137Setting and test values Set value Commission-ingAntifreeze concentrate primary circuit(brine)°C -15 Overflow valve setting After 10 min

138Parameter Code Delivered condi-tionCommis-sioningCompressorEnable 5000 1 Output compressor stage 5030 Rated heating out-put in accordancewith the

139Parameter Code Delivered condi-tionCommis-sioningInternal hydraulicsHeat pump for drying a building 7300 0 Screed program 7303 0 Heating/DHW dive

1410.6.8.sXF9.4x2x400 V 230 V2x11.X3sGsHlJaYH7.Installation sequenceOpening and separating the heat pump (cont.)5441 603 GB

140Parameter Code Delivered condi-tionCommis-sioningCoolingCooling 7100 0 Cooling circuit 7101 1 Room temperature 7102200 (≙ 20 °C) Minimum flow tem

141Connection values of operational componentsComponents Connec-tionConnectedload [W]Voltage [V] Max.switchingcurrent [A]Primary pump/well pump 211.1

142Vitocal 242-G Type BWT 106 BWT 108 BWT 110Secondary circuit (heating water) Content, heat pump l 3.3 3.5 3.8Content, total l 6.2 6.4 6.7Minimum

143Vitocal 242-G Type BWT 106 BWT 108 BWT 110Refrigerant circuit Refrigerant R410A R410A R410AFill volume kg 2.1 2.1 2.4Compressor Type Hermetica

144Vitocal 242-G, 230 VVitocal 242-G Type BWT 106 BWT 108 BWT 110Heating output data at 5 K spread(to EN 14511, B0/W35 °C) Rated output kW 6.0 7.8 1

145Vitocal 242-G Type BWT 106 BWT 108 BWT 110Electrical values – heat pump Rated voltage compressor 1/N/PE 230 V/50 HzRated current, compressor A

146Vitocal 242-G Type BWT 106 BWT 108 BWT 110Permiss. operating pressure Primary circuit (brine) bar 3.0 3.0 3.0Secondary circuit heating water bar

147Service menu: Diagnosis Diagnosis System over-view System Adjusted outs

148 Diagnosis(cont.) Heating circuit1/2 Operating program Operating pro-gram/Operating statusHeating time prog.Time prog htg coo

149 Diagnosis(cont.) Heat pump CompressorPrimary sourceSecondary pumpValve heating/DHWCompr. hours runCompressor startsFlow tem

1513.2x14.2x16.17.12.15.18.Installation sequenceOpening and separating the heat pump (cont.)5441 603 GBInstallation

150 Diagnosis(cont.) Signal inputs Ext. demandExt. blockingReheat suppressionPower-OFF contactPrimary sourceSafety high pressur

151 Coding level 1NoteMenu content incoding level 1 andsequence corre-sponds to thedetails in table"Control parame-ters report"; seepage 13

152We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole respon-sible body that the product Vitocal 242-G, incl. Vitotronic 200, ty

153AAcknowledging messages...47Activating, service menu...76Actuator test...68A-D c

154Connection values of operationalcomponents...141Contact protector...120, 122Contractor...

155Dimensions...8Diverter valve...101Drain & fill valve...

156Heating water buffer cylinder...104 Dual mode temperature...106 Hysteresis...104 Maximum

157Low pressure...61Luster terminals...125MMain PCB...

158Parameter group Buffer cylinder...104 Communication...114 Compressor...

159Room temperature Hook-up...108 Normal...107 Reduced...

164x4x6x2x22.19.21.20.Installation sequenceOpening and separating the heat pump (cont.)5441 603 GB

160System definition Changing the heating circuit operatingmode...81 Common system sensor...

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164ApplicabilityCompact heat pump with electric drive, 400 V~ and 230 V~Output Serial number: Vitocal 242-G, 400 V~ Vitocal 242-G, 230 V~6 kW 7418 03

174x23.2x26.25.24.Installation sequenceOpening and separating the heat pump (cont.)5441 603 GBInstallation

18Removing the heat pump module6.1.4.kKaYHsH3.1.5.2.Installation sequenceOpening and separating the heat pump (cont.)5441 603 GB

198.sHkKaYH7.9.4x2x12.11.4x?aJ10.Installation sequenceOpening and separating the heat pump (cont.)5441 603 GBInstallation

2Please follow these safety instructions closely to prevent accidents and mate-rial losses.Safety instructions explainedDangerThis symbol warns agains

20Assembly and sealing faces to noteA1. Install the heat pump module inreverse order to that described onpage 18.With pipe outlets, ensure pipe gland

21CBBInstalling the heat pumpInstall the heat pump according to thedetails on page 8.Installation sequenceOpening and separating the heat pump (cont.)

22Removing the transport brackets!Please noteIf transport brackets are notremoved, they cause vibrationsand excessive development ofnoise.4.1.3.2.2x2x

23Overview of connectionsMLFGHKEDCBAAEntry for low voltage cables < 42 VBDHWCDHW circulationDEntry for 230 V cablesECold waterFPrimary circuit retu

24Connecting the primary/secondary circuit4x4x2.1.ABAStraight pipe sections suppliedBPipe bends from connection set pri-mary/secondary circuit (access

25Note Expansion vessel must beapproved to DIN 4807. Dia-phragms of expansion vessel andsafety valve must be suitable forthe heat transfer medium. B

262. Install the safety assembly provided:Either to the on-site line in the heatingwater returnorTo the connection set primary circuit/secondary circ

27Required cable lengths:400/230 V~ 1700 mm plus wall clear-ance< 42 V 1500 mm plus wall clear-anceNoteThe 400/230 V~ compressor power sup-ply is p

28DangerIncorrectly executed electricalinstallations can lead to injuryfrom electrical current and resultin equipment damage.Make the power supply con

29General information regarding the power supplyInformation regarding the compres-sor power supply !Please noteAn incorrect phase sequencecan cause

3Ancillary components, spare andwearing parts!Please noteSpare and wearing parts thathave not been tested togetherwith the heating system can com-prom

30Power cablesThe power supply is separated into threeareas with three power cables:Vitocal 242-G, 400 V~BCA400 V~ 3/PE400 V~ 3/N/PE230 V~ 1/N/PEACont

31Compressor power supply (400/230 V~)Vitocal 242-G, 400 V~L1A?3/PE400 V, 50 Hz?L2L3NL1L2L3ACompressor mains terminalsbehind contact shield (seepage 1

32Vitocal 242-G, 400 V~X3.7X3.6CBAHDFE5 4334433/N3/N≈4GkWhkWhDiagram excluding fuses and RCD.AControl unit (for connection to lusterterminals, see pag

33Vitocal 242-G, 230 V~X3.7X3.6CBAHDFE7 331/N1/N≈GkWhkWhDiagram excluding fuses and RCD.AControl unit (for connection to lusterterminals, see page 125

34Power-OFF with on-site load discon-nectionThe power-OFF signal is connected tothe on-site contactor of the low tariffpower supply and in the control

35GRipple control receiver (contactopen: power-OFF enabled)HLow tariff meterKTNC system feedVitocal 242-G, 230 V~X3.7X3.6CBA≈F H731/N1/NGKkWhkWh3EDDia

36Phase monitor (accessory, 400 V~)The phase monitor is used to monitor themains power supply to the compressor.The following power supply deviationsa

37After connecting the power supply, aconnection must be made at terminalsX3.8 and X3.9: Primary circuit pressure switch and/orfrost stator Jumper f

38For further information regarding the individual steps, see the page indicatedCommissioning stepsInspection stepsMaintenance steps Page•1. Writing r

39Writing reportsEnter measurements taken during com-missioning (described in the following)into the reports from page 137onwards.Checking the refrige

4Installation instructionsPreparing for installationInstallation...

402. Check the pre-charge pressure of theexpansion vessel (see page 41).3. Fill (flush) and vent secondary cir-cuit: Slightly open quick-action air

413. Vent the solar circuit.Minimum system pressure: 1.7 barPermissible operating pressure:6 barChecking the expansion vessel and the heating circuit

421.8xBA2.!Please noteA short circuit between magne-sium anode and internal indirectcoil increases the protectiveeffect of the magnesium anodeand lead

43Replacing the magnesium anodeFor removing the magnesium anode,see page 41.!Please noteA short circuit between magne-sium anode and internal indirect

44SpracheCeskyCZDeutschDEDanskEnglishDKGBWählen mit Øç Messages are displayed by manuallycontrolling some components duringcommissioning. These do n

45Start functioncheckSelectfunctionCarry out a subscribercheckCarry out anactuator testDisplay signalinputsDisplaysensor valuesSetparameters"Time

46Instructing the system userThe system installer must hand the operating instructions to the system user andinstruct him/her in the operation of the

47Scanning messagesAFlow temperatureDHWSolar energyInformationSelect with 40℃Heating/coolingiBCDAON/OFF switchBProgramming unitCON indicator (green)DF

48Calling up messages from the mes-sage history Messages cannot be acknowledged inthe message history. The messages are listed in order ofoccurrence

49Message System characteristics Cause Measures10 Outside temp sensor Operation with outsidetemperature -40 °CShort circuit, outsidetemperature

57015 External blocking mixer "CLOSED"... 857017 Vitocom 100...

50Message System characteristics Cause Measures29 Return sensor sec. Operation with tempera-ture value of flow temper-ature sensor in secon-dary

51Message System characteristics Cause Measures39 Return sensor primary Operation with tempera-ture value of flow temper-ature sensor in primary

52Message System characteristics Cause Measures4C Flow sensor cooling Break, flow temperaturesensor, cooling circuitCheck resistance (Ni 500)a

53Message System characteristics Cause Measures68 Buffer cylinder sensor Buffer cylinder is heatedonce every hour. Heatingstops according to set

54Message System characteristics Cause Measures79 Room sensor HC2 No frost protectionmode via room temper-ature sensor No room temperaturehoo

55Message System characteristics Cause Measures9A Collector sensor Collector temperaturesensor lead brokenCheck resistance (Pt 500)at plug-in

56Message System characteristics Cause MeasuresA9 Heat pump Heat pump fault Heat pump faulty Safety high pressureswitch has responded High

57Message System characteristics Cause Measures Check power supply,power cable and plug tothe instantaneous heat-ing water heater Test in

58Message System characteristics Cause MeasuresBA KM BUS mixer HC Communication fault,KM BUS or internal faultin extension set for oneheating

59Message System characteristics Cause MeasuresC9 Refrigerant circuit Refrigerant circuit fault: Safety high pressureswitch has activated Co

67303 Screed program ... 99730D Operation with three-way divert

60Message System characteristics Cause MeasuresCB Primary temperature Heat pump stops Min. primary flow tem-perature (brine inlet) notachieved

61Message System characteristics Cause MeasuresD1 Compressor Compressor fault:Thermal compressorrelay or safety element offull wave soft start

62Message System characteristics Cause MeasuresD6 Flow switch Well circuit flow switchcannot detect a flow Check well pump. Check primary ci

63Calling up diagnosisService menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Diagnosis"3. Select required area, e.g. "Heatpump&

64System overviewÜ21 2238443832414510 73è2è11A50 45B D E F G H K5150C LGNBack with ä2010153321 22 1845Ç29A to LFor an explanation of the con-tents of

65B1 Refrigerant circuit (compressorstage 1)1Instantaneous heating waterheater (at stage 1)45 Secondary circuit flow tempera-ture41 Secondary circuit

66Heat pump module diagnosisAs part of the heat pump module diagnosis, the compressor hours run can be scan-ned for different load classes.A load clas

67For an explanation of the relevant values in the individual lines, see the fol-lowing table:Line (briefscan)Field 1 2 3 4 5 61 Control unit:Softwar

68Line (briefscan)Field 1 2 3 4 5 69 0 0 0 0 0 010 Control unit:Software versionHighControl unit:Software versionLowProgramming unit:Software version

69"Function check" menuFunction System characteristicsHeating circuit 1 Secondary pump and heating circuit pump A1 arestarted.Heating circui

777FF Time via LON... 116Parameter group operationParameter

702. Check throughput of affected heatingcircuits. Recommended temperaturedifferential between heating flow andreturn approx. 8 K.3. Hydraulically b

71Overview of internal componentsMKGDCBAaSsHkK?aJsGlJ%HaYNAaYNSaYNGaYNHaYNDaYNFFg]aa:C]cTroubleshootingRepairs5441 603 GBService

72?Secondary circuit flow tempera-ture sensor (alternative positions)%Cylinder temperature sensor%aSolar circuit return temperaturesensoraSPrimary cir

73Positions cylinder drain & fill valveABCADrain & fill valve, cylinder, closedBDrain & fill valve, cylinder, open todrain the internal DH

74Temperature sensors type Ni 500400-40 -20 0Resistance inTemperature in °C440480520560600204060640Capturing element: "Ni 500" Outside temp

75DangerContact with 'live' componentscan lead to severe injury fromelectric current.Before working on the equip-ment, always ensure that th

76The following pages only describe thoseparameters that can only be adjusted byspecialists operating in the service menuat "Coding level 1"

77Alternatively, if the service menu wasalready activated:Extended menu1. å2. "Service"3. Select "Coding level 1".4. Select parame

78Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "System definition"4. Select parameter.7000 Sys

79"Temperature differential heating 7003"Temperature differential for calculatingthe heating limit.Heating limit: Set room temperatureminus

8!Please noteThe installation room must be dryand free from the risk of frost.Ensure ambient temperatures of0 to 35 ºC.!Please noteObserve the permiss

80Room cooling stops if the average out-side temperature falls below 23 °C(because of the specified hysteresis of1 K).NoteThis parameter is only avail

81Swimming pool heatingValueExplanation"1" Swimming pool is connected andwill be heated."0" Swimming pool will not beheated.NoteTh

82Setting Heating circuitwithout mixerA1Heating circuitwith mixer M2DHW heating Heating waterbuffer cylinder17 X — X —18 — X X —19 X X X —20-31 Do not

83Value Operating mode (see operating instructions)Heating DHW"2" "Normal" "Normal""3" "Fixed value"

84Example:8 h8 h8 hABABABThe diagram shows the duration of exter-nal operating mode changeover B,subject to signal duration A, withparameter "Dur

85"External demand mixer "OPEN" 7014"NoteOnly in conjunction with external exten-sion H1.Setting for the way the signal "Exte

86Setting Heating circuit with mixerM2Heat pump blocking0 Control mode No1 Mixer "Close" No2-3 Do not adjust.4 Control mode Yes5 Mixer "

87Delivered condition 1Setting 1 / 0Parameter group system definition701B Common system temperature sensor (cont.)5441 603 GBService

88Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Compressor"4. Select parameter.5000 Enable com

89Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "DHW"4. Select parameter.6000 Set cylinder temp

9211.2F0F14F21X3.8/9X4.1/2211.3211.5212.3212.4P2/X3.82/X3.92/F0P2/F212/212.4P2/212.42/145A12/X4.1/22/211.12/F14MPM2/211.5145WW2/212.32/211.3Explanatio

90ValueExplanation"1" Instantaneous heating waterheater (accessory) is connectedand enabled for DHW reheating."0" Instantaneous he

91"DHW hysteresis 6007""Booster heater hysteresis 6008"Cylinder temperature hysteresis forstarting and stopping DHW heating.The se

92"Start optimisation 6009"Comfort function for DHW cylinder heat-ing.Operating instructionsDelivered condition 0Setting range 1 / 0600A DHW

93"Combi cylinder 6016"No function.6017 DHW at control high pressure"No. of attempts DHW 6017"High set cylinder temperatures canre

94Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Solar"4. Select parameter.7A00 Solar control u

95The set value determines the tempera-ture differential between the collectortemperature and the temperature of theDHW cylinder at which the solar ci

96Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Electric heater"4. Select parameter.7900 Insta

97"Heating with electro 7902"Enabling heating mode with the instan-taneous heating water heater (acces-sory).If the set flow temperature can

98ValueExplanation"0" Instantaneous heating waterheater remains off during power-OFF, except for frost protection."1" Max. output

99Service menu:1. Press OK + å simultaneously forapprox. 4 s.2. "Coding level 1"3. "Internal hydraulics"4. Select parameter.7300 H