Opop Biopel CS-503 User manual

Cascade controller
CS-503
OPOP cascade controller is device connecting up to 4 boilers in one line and provides automatic operation of each of
them on temperature or weather control basis. This allows installers to install more than one boiler inside one boiler
room and still have all features of automatic operation. You operate your boilers as it would be just one boiler room.
Power of all boiler is summarized together and used only if needed in consideration of output temperature or outside
weather temperature. Boilers are stopped and started only if there is a real need for heat. If all hydraulic system
circuits are heated up, boilers are turned off one by one to reduce heat production when not needed.
Cascade controller decreases fuel consumption, extends cleaning intervals for not running boilers and makes whole
hydraulic system more efficient and reactive to real time needs of end users. It also saves customer’s time and money
by all of mentioned features.
Connection and activation of OPOP’s cascade controller is easy and quick. However it should be still provided by
certificated installer company only. Follow this manual to install and activate CS-503 Cascade controller properly. Read
all instructions and make setup of controller the way as you expect your hydraulic system should work. Exact setup
must be handled by professional certificated installation company to be sure that all connected boilers works in proper
way of operation considering exact hydraulic system connection.

CONTENT
1. PACKAGING ............................................................................................................................................................... 2
2. BASIC DESCRIPTION .................................................................................................................................................. 2
3. TECHNICAL SPECIFICATION ....................................................................................................................................... 2
4. SAFETY REQUAREMENTS .......................................................................................................................................... 2
5. CONNECTION AND COMMUNICATION..................................................................................................................... 3
6. OPERATION MODES .................................................................................................................................................. 3
6.1. Equithermal mode ............................................................................................................................................ 3
6.2. Modulation mode ............................................................................................................................................. 4
7. INSTALATION EXAMPLE ............................................................................................................................................ 4
8. WARRANTY................................................................................................................................................................ 5

1. PACKAGING
Following list of parts is included inside CS-503
package:
1. CS-503 cascade controller
2. 4 pcs of RS connection cable (5m)
3. 230V power supply cord
4. User manual
2. BASIC DESCRIPTION
1. CS-503 controller
2. 4pcs of RS connectors,
for connection of each boiler enabling multi-
structural communication provided by cascade
controller.
3. Indication diodes,
which indicates real time boiler operation.
Light indicates that boiler is in operation, no
light indicates that boiler is turned off by
cascade controller.
4. Power supply cord,
to connect controller to the electricity.
Main box
Indication diodes
No light –boiler off
Light –boiler on
RS outputs for boiler connection
Power supply cable
CS-503 cascade controller should be connected close
to the boilers to connect each of them with 5m RS cable
supplied in standard delivery.
Position all cables in a way to protect them against
physical and heat damage.
Device should not be installed close to other
electromagnetic devices such as motors, fans of the
boiler. Safe distance is at least 50cm.
3. TECHNICAL SPECIFICATION
Following list is specification of basic electrical and
other technical values.
Power supply 230V
Power consumption 1W
Maximal current 250mA
CS-503 diameters:
oHeight 20mm
oLength 100mm
oDepth 40mm
RS connection cable:
oLength 5m
oConnector RS
Max operational temp. -20 to 45°C
Package weight 35g
4. SAFETY REQUAREMENTS
Read these instructions carefully to make sure CS-503
will work without any problem in all conditions.
Do not install any kind of cascade controller
equipment directly on boiler or boiler
equipment surface to protect device and
cables against high temperatures.
Cables connecting each boiler should be
covered and positioned in a safe way, so no
heat ash or dust will damage them in long term
use.
Prevent installation of electronical
components in boiler rooms with high
humidity.
CS-503 cascade controller shouldn’t be
installed close to any kind of wireless or
electromagnetically operated device. Safe
distance is 50cm or more.
Update boiler control unit to the latest
firmware version to make sure cascade
operation is included in controller’s submenu.
Communicate the exact way of operation with
your installer to be sure cascade controller
operates all boilers in a way you need.
Consider both possible operations with CH
boiler temperature sensor and outside
Weather sensor.
Weather sensor is included in 431N module
packaging which is part of each burner box. To
make weather cascade operation work, also
431N module must be installed into the boiler
connected in 1st RS output of cascade
controller.

5. CONNECTION AND COMMUNICATION
Before activation and any kind of setup or change of parameters make sure that all boilers are connected into CS-503
cascade controller by RC communication cable.
In next step make communication configuration as follows: Installer settings (v8) or Main settings (v9) –Cascade –
Connected. Communication is now active.
Important! This process must be repeated separately on each connected boiler to the cascade controller.
Next step is to select how many boilers has been connected into the cascade controller RS outputs. Go to Installer
settings (v8) or main settings (v9) –Cascade –Number of boilers. Select number of connected boilers (4 is max).
Important! You always have to connect boilers to the outputs from 1 to 4, not the opposite. Number of boilers also
determinates how many options you have inside the menu from which you can change parameters of cascade
operation. Factory settings is 1 boiler. Select the “Number of boilers” function on boiler which is connected into the
1st cascade controller output.
6. OPERATION MODES
Setup of cascade operation is done by v8 or v9 control unit of Biopel boiler. So first ting to enable this feature is to
update your boiler control unit firmware. Ask your installer or OPOP representative to explain you which is the
required firmware version and how to successfully update your v8 or v9 control unit. When firmware is updated
proceed to Installer settings and open Cascade control submenu. Following chapter is describing main functions inside
this submenu. Read it carefully and then proceed to Installation examples chapter for examples of exact installations.
CS-503 controller has 2 types of operation –eqithermal and modulation. These modes are responsible for boiler
operation if Cascade control is turned Active in Installer settings of your v8 or v9 boiler control unit. Cascade controller
uses both outside and CH boiler temperature sensor for cascade operation.
Important! Values of CH temperature and Weather temperature are red only by the boiler connected to the socket
no.1 which is first from the left end of cascade controller.
6.1. Equithermal mode
Cascade operation is based on outside weather sensor. You can select from which outside temperature level your
boilers starts to operate. To change these temperatures you have to do the following. Installer (v8) or Main
settings (v9) –Cascade –and change temperature parameters:
Temp of 3 boilers
Temp of 2 boilers
Temperature of 1 boiler
Hysteresis
4 boilers are in function if:
external temperature is lower than “Temp of 3 boilers” minus “Hysteresis”.
3 boilers are in function if:
external temperature is lower than “Temp of 2 boilers” minus “Hysteresis”.
external temperature is higher or the same as “Temp of 3 boilers” minus “Hysteresis”.
2 boilers are in function if:
external temperature is lower than “Temp of 1 boiler” minus “Hysteresis”.
external temperature is higher or the same as “Temp of 2 boilers” minus “Hysteresis”.
1 boiler is in function if:
external temperature is lower than “Temp of 1 boiler” minus “Hysteresis”.

6.2. Modulation mode
Cascade controller operates the boiler to achieve selected boiler temperature. Only 1st boiler connected to 1st RS
output is active in the beginning of operation. When boiler reaches maximum power, counter starts to measure
time selected in Installer settings (v8) or Main Settings (v9) –Cascade - Waiting time. If set boiler temperature has
not been reached during this time period, second boiler will be activated and counter starts to measure “Waiting
time” again. This procedure is repeated until set boiler temperature (of boiler connected into the 1st RS output) is
reached or until all boilers are activated (Installer settings (v8) or Main settings (v9) –Cascade –Number of boilers).
When boiler temperature is reached (of boiler connected into the 1st RS output), boilers will be selectively
deactivated one by one if their summarized output power is lower than parameter: “Lower limit of effectivity”
(factory settings is 60%). This parameter is adjusted as follows:
Installer settings (v8) or Main settings (v9) –Cascade –Installer settings (v8) or Main settings (v9) –Cascade –
Lower limit of effectivity. Next boiler will be deactivated after 20min from time when boiler before was
deactivated. This process is repeated until:
CH boiler temperature (of the 1st boiler in 1st RS output) is lower than set CH temperature minus Hysteresis.
Or last boiler is in operation.
CS-503 cascade controller measures operation time of each boiler and selectively deactivates each boiler to
achieve equal operation during full heating season. So each boiler will work approximately the same time during
heating season interval.
7. INSTALATION EXAMPLE
Eqithermal mode:
CH boiler1 temperature = 70°C
Temp of 2 boilers = 0°C
Temp of 1 boiler = 10°C
Hysteresis = 10°C
Modulation mode:
CH boiler1 temperature = 70°C
Waiting time = 20min
Hysteresis = 10°C
Eqithermal mode:
1st boiler will start at +10°C of outside temperature. 2nd
boiler will be turned on when outside temperature
drops below 0°C of outside temp.
Modulation mode:
First boiler will be started accordingly CH boiler temp.
If the temperature is not reached during 20min of
operation, 2nd boiler will be started.
Boilers will stop at 70°C and 1st boiler starts when CH
temperature drops below Hysteresis.
Boiler
1
Boiler
2
431N +
weather
sensor

8. WARRANTY
CS-503 Cascade controller for Biopel v8 and v9 controllers
Manufacturer: OPOP spol. s r.o., Valašské Meziříčí, Czech republic
Tel.: [phone], fax.: [phone]
Warranty conditions:
This warranty certificate includes a certificate of quality and completeness. The manufacturer certifies that the product
is inspected and meets its design specifications and EN 303-5. For quality, function and we guarantee the boiler for 24
months from the date of sale to the consumer, no longer than 30 months after expedition from the factory and in a
way that demonstrably result of defects due to faulty materials, faulty design, faulty design or removed as soon as at
our expense, provided that the device:
•it is in normal condition according to the Instruction manual
•is not damaged mechanically (no unauthorized interference with the exception of interference allowed in the
instructions)
•consumer complaints submitted with the application of this warranty certificate duly completed
•When a fault occurs it is always necessary to submit the warranty certificate, give the exact address and the
circumstances under which the defect occurred. The manner and place of repair will be decided in our
company.
•Device was installed only by a firm authorized to mount OPOP equipment.
•Date and installer stamp must be included with warranty list.
Date and stamp of manufacturer:
Date of sale and stamp of installer:

OPOP, spol. s r. o.
Zašovská 750
757 01 Valašské Meziříčí
Bank details:
Komerční banka a.s., account no.:1608851/0100
Reg. no.: 47674105, VAT no.: CZ 47674105
Phone: Sales Dept: 571 675 589, Secretariat: 571 611 250, Production: 571 675 405
Sourcing: 571 675 114, Finance: 571 675 472, Fax. [phone]