Bosch FM441/CMM 910 User manual

FM441/CMM 910 FM455/CMC 900
FM442/CMM 920 FM457/CMC 920
FM443/CMS 910 FM458/CMC 930
FM444/CMG 910
FM448/CMB 900-0-10V
6 720 803 029 (2011/08) GB/IE/AU
Mounting Instructions
Modules for control units
CSM 7x0, CFB 8x0 and CFB 9x0

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
2 |
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Definition of the various modules . . . . . . . . . . . . . . . . . . . 3
1.2 Modules and their designation. . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 About these instructions . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Determined use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Standards and directives . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Explanation of the symbols used . . . . . . . . . . . . . . . . . . . 6
2.5 Observe this information . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Module assembly for control units CSM 7x0 . . . . . . . . . . 8
3.1 Possible module installations for control units CSM 7x0 . . . . 8
3.2 Arrangement of the modules in the control unit (CSM 7x0) . . 9
3.3 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.4 Removing and replacing the function module
FM455/CMC 900 (only for CSM 750). . . . . . . . . . . . . . . . . 19
4 Module mounting for control unit CFB 840 . . . . . . . . . . . 21
4.1 Possible module installations for control unit CFB 840 . . . . .21
4.2 Arrangement of modules in the control unit . . . . . . . . . . . .22
4.3 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5 Module assembly for control units CFB 9x0 . . . . . . . . . . 27
5.1 Possible module installations for control units CFB 9x0 . . . . 27
5.2 Arrangement of modules in the control unit . . . . . . . . . . . .28
5.3 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Introduction | 3
1 Introduction
These mounting instructions explain installation of the function modules
CMx in the control unit series CSM 7x0, CFB 8x0 and CFB 9x0.
1.1 Definition of the various modules
Tab. 1 Definition of modules
USER INFORMATION
Generally, these installation instructions can also be used for installing
other modules, as the procedure is similar.
Definitions
CM = Controller module
CMx = Function module
NM = Power supply module
ZM = Central or auxiliary module

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
4| Introduction
1.2 Modules and their designation
Tab. 2 Module designations
Designation Name
Controller
module CM431 Controller module
Power
supply
module
NM482 Power supply module
Central
module
ZM422 Burner control + 1 heating circuit
+ 1 DHW circuit
ZM424 Boiler control + 2 heating circuits
+ 1 DHW circuit
ZM432 Burner + boiler circuit functions
ZM433 External heat generation +
1 heating circuit
ZM434 Burner + boiler circuit functions +
0 - 10 % burner control
ZM425 Display module
Function
module
FM441/CMM 910 1 heating circuit + 1 DHW circuit
FM442/CMM 920 2 heating circuits
FM443/CMS 910 Solar circuit
FM444/CMG 910 Alternative heat generator
FM448/CMB 900-0-10V Central fault message
FM455/CMC 900 KSE 1 (only with ZM424)
with EMS
FM456/CMC 910 KSE 2 (cascade –
2 wall mounted boilers) with EMS
FM457/CMC 920 KSE 4 (cascade –
4 wall mounted boilers) with EMS
FM458/CMC 930 Strategy + EMS
Auxiliary
module ZM427/CME 930 Boiler operating module

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Safety | 5
2Safety
2.1 About these instructions
This chapter contains general safety instructions which must be observed
when installing the function modules CMx in the control units CSM 7x0,
CFB 8x0 and CFB 9x.
Also closely observe further safety instructions in other chapters of these
installation instructions. Please read the safety instructions carefully before
starting the installation.
If safety instructions are ignored, severe or even fatal injuries may result,
as well as material losses and environmental damage.
2.2 Determined use
You can integrate the function modules CMx into the control units
CSM 7x0, CFB 8x0 and CFB 9x0.
2.3 Standards and directives
The design and operation of this product conforms to the
European Directives and the supplementary national
requirements. Its conformity is confirmed by the CE
designation.
You may request the declaration of conformity for the
product. See rear page for contact details of your local
branch or from the relevant Bosch Thermotechnology
branch.

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
6| Safety
2.4 Explanation of the symbols used
Two levels of danger are identified and signalled by the following terms:
2.5 Observe this information
The function modules CMx were designed and built according to the state
of the art and the recognised safety-related standards.
However, material losses resulting from incorrect installation cannot be
completely excluded.
Before installing the CM function modules, read these mounting
instructions carefully.
WARNING!
RISK OF FATAL INJURY
Identifies possible risks associated with a product that might lead to
serious injury or even death if appropriate care is not taken.
CAUTION!
RISK OF INJURY / SYSTEM DAMAGE
Identifies potentially dangerous situations, which might lead to
medium or slight injuries or to material damage
USER INFORMATION
User tips for the optimum utilisation and adjustment of the appliance
plus other useful information.
WARNING!
RISK TO LIFE
from electricity.
zThe installation, electrical wiring, commissioning, electrical
connection, as well as maintenance and repairs must only be
carried out by a competent contractor who adheres to all current
technical regulations and requirements.
zRegional regulations should be observed in this regard!

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Safety | 7
Observe the following safety instructions during the installation of the
function modules.
2.6 Disposal
zElectronic components must not be disposed of with general domestic
waste.
Dispose of old modules correctly through an authorised disposal site.
WARNING!
RISK TO LIFE
from electricity.
zEnsure that all electrical work is only carried out by an authorised
electrician.
zBefore opening the control unit: Isolate all poles of the power
supply and secure against unintentional reconnection.
WARNING!
RISK TO LIFE
from electricity.
The risk of voltage flashes through unintentional loosening of the cores
at the terminals between the 230 V and the LV1)
must be prevented.
zTherefore fix the wires from each cable away from each other
(e.g. with cable ties) or only strip the wire for a very short section.
1) LV-terminal - extra low voltage connection for sensors, volt free connections and BUS.
CAUTION!
DAMAGE TO THE APPLIANCE
through electrostatic discharge (ESD).
zBefore unpacking the modules touch a radiator or a earthed metal
water pipe to discharge any electrostatic charge in your body.
USER INFORMATION
Ensure that a regulation isolator is available to disconnect all poles
from the mains power supply. Install an isolator if none is available.
USER INFORMATION
Only use original replacement parts from Bosch Thermotechnology.
Bosch Thermotechnology cannot take responsibility for losses caused
by the use of parts not supplied by Bosch Thermotechniology.

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
8| Module assembly for control units CSM 7x0
3 Module assembly for control units CSM 7x0
This section describes the installation of the function modules CMx in
the control units CSM 710 and CSM 750.
3.1 Possible module installations for control units CSM 7x0
Tab. 3 Standard equipment of control units and extension options
O = Standard equipment
X = Accessories
– = Combination/installation not possible
USER INFORMATION
zCheck that all parts have been delivered.
If this is not the case, contact a Bosch Thermotechnology branch.
Designation CMS 7x0
CSM 750 CSM 710
Modules
CM431 O O
NM482 O O
ZM424 O –
FM441/CMM 910 – X
FM442/CMM 920 X X
FM443/CMS 910 X X
FM444/CMG 910 X X
FM448/CMB 900-0-10V X X
FM455/CMC 900 O –
FM457/CMC 920 X X

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Module assembly for control units CSM 7x0 | 9
3.2 Arrangement of the modules in the control unit (CSM 7x0)
ZM424 and FM455/CMC 900 (only for CSM 750)
The module FM455/CMC 900 always occupies slot A (ÆFig. 1, [4]) and the
module ZM424 slot 1 (ÆFig. 1, [1]).
FM457/CMC 920
Control units which contain the function module FM457/CMC 920 should
be set as master. (Set as 0 if only one CSM 7x0 used, set as 1 if more than
1 CSM 7x0 used). Make this setting at the CM431 controller module.
Fig 1 Slot assignment
1Slot 1
2Slot 2
3Slot B behind the programming unit
4Slot A for function module FM455/CMC 900 (only for CSM 750)
1
3
4
2

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
10 | Module assembly for control units CSM 7x0
3.3 Fitting
zUnscrew 2 screws on the upper housing cover (ÆFig. 2, [1] and [2]).
zRemove top casing cover.
zUnscrew 2 screws on the cable cover (ÆFig. 2, [3] and [4]).
zRemove cable cover.
Fig 2 Removing covers
2
1
3
4
WARNING!
RISK OF FATAL INJURY
due to electrical current when the control unit is open.
zBefore opening the control unit:
Isolate all poles of the power supply and secure against
unintentional reconnection.

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Module assembly for control units CSM 7x0 | 11
zPress in upper nubs (ÆFig. 3, [1] and [2]) on both sides.
zFold out forwards the device front with the Programmer (ÆFig. 3, [3]).
Fig 3 Pivoting down device front
1
2
3
USER INFORMATION
Ensure that the cable cover has been removed, otherwise you will not
be able to pivot the device front forward.

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
12 | Module assembly for control units CSM 7x0
You will need a screwdriver to remove the crossbar (ÆFig. 4, [1]).
zUndo the crossbar on one side. For this push one of the two clips
(ÆFig. 4, [3]) outwards with the screwdriver.
zLift the crossbar on one tab (ÆFig. 4, [2]).
zPush the second clip outwards with the screwdriver.
zLift crossbar at the second tab.
zLift crossbar on this side off its retainer.
zAlso undo crossbar on the other side.
zRemove crossbar (ÆFig. 4, [1]).
Fig 4 Removing the cross brace
1
2
3

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Module assembly for control units CSM 7x0 | 13
When fitting a new module
zRemove blanking plate from slot 1 (ÆFig. 5) in the control unit.
zConnection cables for sensors and pumps must be laid and provided
with terminals before installation of the module (more detailed
information can be found in the technical documentation for control
units CSM 7x0).
zPush new module from above into the free slot by pressing on the
sensor strip (ÆFig. 6, page 14) until it clicks audibly into place.
Fig 5 Removing blanking plate
WARNING!
RISK TO LIFE
through metal jumpers.
zWhen stripping insulation or cutting cables, ensure that pieces of
cable do not fall into the electrical or electronic system.

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
14 | Module assembly for control units CSM 7x0
When removing and replacing a module
zDisconnect leads for the respective module and fix in standby position
(more detailed information can be found in the mounting instructions
for control units CSM 7x0).
zPull module out of the control unit.
zPush new module from above into the free slot by pressing on the
sensor strip (ÆFig. 6) until it clicks audibly into place.
Fig 6 Inserting a module

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Module assembly for control units CSM 7x0 | 15
Connecting module power supply to slot 1
zPlug in sensor leads and pump connections at the designated points on
the module.
zPlug 230 V module connector into the correct position in the terminal
strip (ÆFig. 7).
Fig 7 Connect power supply to slot 1
Netz
LN

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
16 | Module assembly for control units CSM 7x0
Connecting module power supply to slot 2
zRemove dummy plug (ÆFig. 8, [1]) of the three-pole plug (cable loom).
zPlug in 230 V module connecting plug to the three-pole plug
(ÆFig. 8, [2]).
Fig 8 Connecting power to slot 2

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Module assembly for control units CSM 7x0 | 17
After module installation
zPosition crossbar (ÆFig. 9, [1]) in the recesses and click into place.
zPivot the device front (ÆFig. 9, [2]) back and click into place.
Fig 9 Positioning crossbar
1
2

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
18 | Module assembly for control units CSM 7x0
zPosition top casing cover.
zReplace both screws on the upper housing cover (ÆFig. 10, [1]
and [2]).
zIf additional cables were routed out of the device, the cable cover
may need to be cut out in the lower section.
zPosition cable cover.
zReplace both cable cover screws (ÆFig. 10, [3] and [4]).
zTest the module function.
More detailed information can be found in the operating and servicing
instructions for control units CSM 7x0.
Fig 10 Fitting casing cover and cable cover
2
1
3
4

6 720 803 029 (2011/08)Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
Module assembly for control units CSM 7x0 | 19
3.4 Removing and replacing the function module FM455/CMC 900
(only for CSM 750)
If it is necessary to replace the FM455/CMC 900 module, first remove the
ZM424 module from slot 1.
zRemove 230 V module connecting plug (ÆFig. 7, page 15) and all the
connecting cables of the module ZM424 and fix in standby position.
zPull out the ZM424 module.
zPull out the PCB below – the FM455/CMC 900 module (ÆFig. 11).
zInsert new FM455/CMC 900 module.
zReinsert the ZM424 module by pressing on the sensor strip.
zReconnect all connecting cables in their original positions.
zReconnect the 230 V module power supply of the ZM424.
Fig 11 Replacing the module FM455/ CMC 900

6 720 803 029 (2011/08) Modules for control units CSM 7x0, CFB 8x0 and CFB 9x0
20 | Module assembly for control units CSM 7x0
Jumper switch
The jumper switch is used to configure the module:
Position Function
open
(factory
setting)
The module logs on as a new
module FM455/CMC 900 or
FM457/CMC 920.
USER INFORMATION
The jumper switch must be open if EMS is in use.
Fig 12 Jumper switch (e.g. FM457/CMC 920)
USER INFORMATION
If there is no 230 V power supply for the module or one of its 230 V
components (e.g. plug-in connection has not been made), the relevant
components (e.g. pumps) will not be activated.
You cannot recognise this error on the module in question since the
LED and the control functions work independently of this power
supply. Check cable connections thoroughly before re-fitting controller
casings.