Buderus FM443 Quick guide

For heating
contractors
Read carefully prior to
commissioning and
service work
Installation and Service
Instructions
Function module
FM443
Solar Module
6 720 618 623 - 11/2008 US/CA

Contents
FM443 Function module - We reserve the right to make technical modifications.
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1Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Standards, regulations and directives . . . . . . . . . . . . . . . . . 4
1.4 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Please observe these notes. . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Inputs and outputs, connections . . . . . . . . . . . . . . . . . . . . 9
2.2 Installation in the Logamatic 4000 control panels . . . . . . . . . . 11
2.3 Positions of manual switches . . . . . . . . . . . . . . . . . . . . . .12
3 The functions of the FM443 . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Integrating the FM443 function module in the control panel . . . . 15
3.2 Changing the operating mode . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Solar consumer "1" – solar circuit 1 . . . . . . . . . . . . . . . . . .20
3.4 Buffer integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.5 Solar circuit heat meter . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Pump function – secondary circuit pump . . . . . . . . . . . . . . . 30
3.7 Heat-up of the pre-heat stage. . . . . . . . . . . . . . . . . . . . . . . 36
3.8 Solar consumer "2" – solar circuit 2 . . . . . . . . . . . . . . . . . .38
4 Relay test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5 Fault log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
7 Monitor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7.1 Solar consumer "1" – solar circuit 1 . . . . . . . . . . . . . . . . . .48
7.2 Buffer bypass circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
7.3 Solar circuit heat meter . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.4 Solar consumer "2" – solar circuit 2 . . . . . . . . . . . . . . . . . .51
8 Sensor curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Safety 1
1 Safety
1.1 About this manual
This section contains general safety instructions that you must
observe when servicing the FM443 function module.
The other sections of the service instructions contain additional
safety instructions that must also be observed. Read the safety
instructions carefully before carrying out the activities described
below.
If the safety instructions are not observed, serious or even fatal
personal injury and damage to property and the environment may
be caused.
1.2 Intended use
The FM443 function module can be installed in the control panels
of the Logamatic 4000 control system.
For the system to operate perfectly you will require control panel
software version 4.17 or higher.

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Safety1
1.3 Standards, regulations and directives
1.4 Key to symbols
Two levels of danger are identified and signified by the following
terms:
USER NOTE
Observe all regulations and standards applicable to installation
and operation of the system in your country.
USER NOTE
All electrical components must be approved for the USA and
Canada!
This product has been tested and certified and meets
applicable standards for the US and Canadian markets.
WARNING!
RISK OF LIFE
Identifies possible dangers emanating from a product that might
cause serious injury or death if appropriate care is not taken.
CAUTION!
RISK OF INJURY/
SYSTEM DAMAGE
Indicates a potentially dangerous situation that could cause minor
or moderately serious injuries or damage to property.
USER NOTE
Tip for optimum use of equipment and adjustment as well as
useful information.

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Safety 1
1.5 Please observe these notes
The FM443 function module has been designed and built in
accordance with currently recognized standards and safety
requirements.
However, damage resulting from improper service work cannot be
completely prevented.
Before starting service work on the FM443 function module read
these service instructions carefully.
WARNING!
RISK OF LIFE
due to electric shock!
zThe installation, electrical wiring, commissioning, electrical
connection, as well as maintenance and repairs must only be
carried out by a trained contractor who adheres to all current
technical regulations and requirements.
zThe local regulations must be observed.
WARNING!
RISK OF LIFE
due to electric shock!
zMake sure that all electrical work is carried out by a trained
contractor.
zBefore opening the control panel: isolate all poles of the power
supply and secure against accidental reconnection.
WARNING!
RISK OF LIFE
due to electric shock!
The risk of voltage transfers between the line voltage (120 V) and
the low voltage wiring through accidental loosening of the wires at
the terminals must be prevented.
zTherefore secure individual cables together in bundles (e.g.
with cable ties) or strip off only a minimum of the outer
insulation.

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Safety1
1.6 Disposal
zElectronic components do not belong in household waste.
Dispose of defunct modules correctly through an authorized
disposal site.
CAUTION!
RISK OF INJURY/
SYSTEM DAMAGE
due to operator error!
Operator errors can cause injury and damage to property.
zEnsure that children never operate the appliance
unsupervised or play with it.
zEnsure that only personnel trained to operate the appliance
correctly have access to it.
CAUTION!
DEVICE DAMAGE
through electrostatic discharge (ESD).
zBefore unpacking the module, touch a radiator or a grounded
metal water pipe to discharge any electrostatic charge in your
body.
USER NOTE
Ensure that a circuit breaker is available to disconnect all poles
from the mains power supply. If there is no circuit breaker, you will
need to install one.
USER NOTE
Only use original Buderus spare parts. Damage caused by the use
of parts not supplied by Buderus is excluded from the Buderus
warranty.

FM443 Function module - We reserve the right to make technical modifications. 7
Product description 2
2 Product description
You can install only one of the FM443 function modules into one
control panel of the Logamatic 4000 control system.
The main function of the FM443 function module is to integrate a
solar system with one or two solar consumers (e.g. tanks) into an
existing control panel.
Installing the FM443 function module makes the following
functions or connection options available:
–Change the operating mode.
–Integrate a solar consumer "1" (e.g. storage tank).
–Buffer bypass circuit for central heating.
–Tank series circuit.
–Integrate a solar heat meter (WMZ), available as an accessory
from Buderus.
–Integrate a solar consumer "2" (e.g. swimming pool).
–Thermal disinfection of the pre-heat stage.
USER NOTE
Before installing the FM443 function module, check the software
version of the controller module (CM431) and MEC2 remote
control (version 4.17 or higher).
For more information, contact your Buderus wholesaler.

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Product description2
Fig. 1 Front panel of FM443 function module
1Manual switch (solar circuit 1)
2LED "Three-way valve" in case of buffer bypass circuit (central heating
via tank)
3LED "Three-way valve" in case of buffer bypass circuit (no central
heating via tank)
4Solar circuit pump 1*
5Maximum temperature storage tank 1
6"Module Fault" LED (red) – general module fault
7Maximum temperature of collector
8Secondary solar circuit pump 2 or transfer pump enabled*
9Solar circuit pump 2 or 3-way valve 2 in solar circuit 2 position*
10 3-way switching valve in solar circuit 1 position
11 Manual switch (solar circuit selection)
* LED constantly ON: Pump running (100 %)
LED "flickers": Pump modulates
LED OFF: Pump OFF
3
1
7
4
5
8
9
11
10
6
2

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Product description 2
2.1 Inputs and outputs, connections
The low-voltage terminals and the 120 V outputs are on the top
rear of the FM443 function module.
Colored labels with inscriptions matching the appropriate plugs are
attached to the strips.
Plugs are color-coded.
Tab. 1 Connections 120 V
Designation Description
Netz Power supply
PSS2 Solar circuit pump 2
SU 3-way switching valve (tank 1/tank 2)
PS2 Solar circuit 2 secondary pump
SPB Buffer bypass circuit:
3-way switching valve
PSS1 Solar circuit pump 1

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Product description2
Tab. 2 Low-voltage connections
USER NOTE
Ensure that you connect the FPB sensors correctly and install
them in their correct positions depending on the type of system
circuits (buffer bypass or storage tanks in series).
Name Description
FPB
FR Buffer bypass circuit:
return temperature sensor
FP Buffer bypass circuit:
buffer storage tank temperature sensor
WMZ
Ground terminal
FR Return temperature sensor from solar
circuit for heat metering
FV Supply temperature sensor from solar
circuit for heat metering
ZV Flow meter from solar circuit for heat
metering
Sensor
FSS2 Temperature sensor for solar consumer 2
FSS Temperature sensor for solar consumer 1
FSK Collector temperature sensor

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Product description 2
2.2 Installation in the Logamatic 4000 control panels
The FM443 function module can be installed in any free slot in the
4000 series control panels (e.g. slot 1 – 4 in Logamatic 43xx).
Tab. 3 Possible slot assignments
USER NOTE
Position the FM443 function module as far to the right as possible
in the control panel. This ensures that the heating zones are in a
logical order. The heating zone modules should be installed in the
control panel starting from the left side.
Possible slot assignments in the various control panels
43xx
1, 2, 3, 4

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Product description2
2.3 Positions of manual switches
The various positions of the manual switch have different effects
on the solar circuits or the two solar consumers.
CAUTION!
SYSTEM DAMAGE
if the manual switch is set to "Manual" for an extended period the
solar system may be damaged or parts may be damaged.
zUse the "Manual" position for short periods only.
USER NOTE
In normal operation the manual switches should be in the AUT
position.

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Product description 2
2.3.1 Manual switch (solar circuit 1)
Tab. 4 Manual switch positions
If manual mode is activated:
–the warm medium of the solar thermal system (e.g. glycol:
water mixture) can flow from the storage tank to the collector
array.
–the cold medium (< 32 °F (0 °C)) of the solar thermal system
(e.g. glycol: water mixture) can flow from the collector to the
storage tank – the storage tank temperature drops, so that
reheating may start, for example.
–the collector protection is disabled.
–the tank protection is disabled.
–the collector frost protection is disabled.
USER NOTE
If the manual switch is not in automatic mode, a message to that
effect appears on the MEC2 remote control, and the "Module fault"
LED on the module lights up.
Position Effect
Solar circuit 1 (solar circuit pump 1) and the bypass
(3-way valve) are switched off.
Use this setting only for commissioning or for
maintenance or service work.
Solar circuit 1 and the bypass are in automatic mode
– this is the standard setting.
Manual mode is activated.
Solar circuit pump 1 is switched on. The bypass is
not being controlled.

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Product description2
2.3.2 Manual switch (solar circuit selection)
Tab. 5 Manual switch positions
USER NOTE
If the manual switch is not in automatic mode, a message to that
effect appears on the MEC2 remote control, and the "Module fault"
LED on the module lights up.
Position Effect
The selection of the solar circuit is switched off.
Use this setting only for commissioning or for
maintenance or service work.
Automatic changeover to charging of the solar
consumers on the FM443 function module (solar
module) is active – this is the standard setting.
If the corresponding solar yield is available, only
solar consumer "2" (solar circuit 2) is loaded.
The automatic changeover is disabled.
If the corresponding solar yield is available, only
solar consumer "1" (solar circuit 1) is loaded.
The automatic changeover is disabled.

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The functions of the FM443 3
3 The functions of the FM443
The following sections explain how to use and set the various
functions via the MEC2 remote control.
3.1 Integrating the FM443 function module in the control panel
Calling up the service level
The service instructions for your Logamatic 4xxx control panel
explain in detail how you operate the MEC2 remote control. The
following provides a brief overview of the MEC2 operation.
The MEC2 remote control offers two operating levels (level 1 with
closed flap and level 2 with open flap) plus one service level
(accessible via password). The service level has various main
menus and submenus for set up of the controls.
Fig. 2 MEC2 remote control
1Display
2Dial
3Function keys
To enter the service level press this key combination (key code)
until "service level – general data" is displayed.
service level
general data
1
2
3

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The functions of the FM4433
Integration of FM443 function module at the MEC2 level
After you have installed the FM443 function module (Æsee
installation instructions "Modules for 4xxx control panels"), your
control panel will detect it automatically when it is switched on.
Manual integration of FM443 function module at the MEC2
level
Call up the service level.
Turn the dial until "service level – module selection" appears on the
display.
Press "Display" to select the main menu "module selection"
"module selection – Slot A" is shown on the display.
USER NOTE
If the FM443 function module is not recognized automatically, you
will need to install it manually once via the MEC2 remote control.
service level
module selection
module selection
Slot A
boiler module
ZM434

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The functions of the FM443 3
Turn the dial to the position (slot) where the FM443 function
module is installed.
For example, the FM443 function module is to be installed in slot 2.
Hold "Display" down (the text on the bottom line begins to flash),
and turn the dial until the FM443 function module appears on the
display.
Release the "Display" button.
Press "Back".
The FM443 function module (solar panel) is installed in slot 2.
Press "Back" three times or close the operating flap to reach
operating level 1.
module selection
Slot 2
solar module
FM443

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The functions of the FM4433
3.2 Changing the operating mode
You can change the operating mode of the solar control. The
operating modes are as follows:
–Manual ON ("day mode" button)
–Manual OFF ("night mode" button)
–Automatic operation ("AUT" button)
Open the flap of the MEC2 remote control.
Press and hold the "heating zone" button.
Turn the dial until "select heat zone – solar" appears on the display.
Release the "heating zone" button.
USER NOTE
With the operating mode "Manual ON" ("day mode" button), the
collector protection function is switched on.
USER NOTE
When the flap on the MEC2 remote control is closed, it generally
indicates the heating zone to which the MEC2 remote control is
assigned. If the MEC2 remote control is not assigned to any
heating zone, then the lowest installed heating zone is always
indicated.
For more information see the technical documentation for your
control panel.

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The functions of the FM443 3
Different operating modes
Press manual ON ("day mode" button) to set the solar control unit
to "permanent on".
Press the "AUT" button to set the solar control to automatic.
Press manual OFF ("night mode" button) to switch off the solar
control.
Manual ON
This operating mode has no control function, but it switches the
solar system off if the collector field or the tank(s) have exceeded
the maximum allowable temperature.
This way, the collector is protected against overheating.
If this operating mode is activated:
–the hot medium in the solar system (e.g. glycol water) can flow
from the tank to the collector field.
–The cold medium (32 °F (< 0 °C)) of the solar thermal system
(e.g. glycol: water mixture) can flow from the collector to the
storage tank – the storage tank temperature drops, so that
reheating may start, for example.
Input range Factory setting
Operating mode automatic
OFF
ON
automatic

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The functions of the FM4433
3.3 Solar consumer "1" – solar circuit 1
You can integrate a first consumer (e.g. storage tank) into the
controls using the FM443 function module.
3.3.1 Set the maximum storage tank temperature
Call up the service level.
Turn the dial until "service level – solar" appears on the display.
Press "Display" to open the main "SOLAR DATA" menu.
Turn the dial until "SOLAR DATA – max temperature tank 1"
appears on the display.
Press and hold the "Display" button and turn the dial.
The maximum tank temperature can now be set.
USER NOTE
Only integrate a storage tank water heater for DHW heating as
solar consumer "1".
SOLAR DATA
max temperature
tank 1
140°F
Input range Factory setting
max temperature tank 1 86 °F – 194 °F (30 °C – 90 °C) 140 °F (60 °C)