Robur Cascade controller Guide

for the centralized control of Caldaria systems and their
distribution circuits
Cascade controller
Installation and use manual

This Installation and use manual has been drawn up and printed by Robur S.p.A.; whole or partial reproduction of
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The original is led at Robur S.p.A.
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aected.
With the aim of continuously improving the quality of its products, Robur S.p.A. reserves the right to modify the
data and contents of this Installation and use manual without prior notice.
Revision: D
Code: D-LBR874EN
DISPOSAL
The appliance and all its accessories must be disposed of separately in accordance with the regulations in force.
Use of theWEEE symbol (Waste Electrical and Electronic Equipment) indicates that this product cannot be disposed of as house-
hold waste. Proper disposal of this product helps to prevent potential negative consequences for the environment and human
health.

Installation and use manual – Cascade controller ODSP039 3
INDEX OF CONTENTS
I Introduction.......................................................................... p.4
I.1 Recipients................................................................ p.4
I.2 Available languages ............................................ p.4
II Symbols and denitions......................................... p.4
II.1 Key to symbols ...................................................... p.4
II.2 Terms and denitions ......................................... p.4
III Warnings ................................................................................... p.4
III.1 General and safety warnings............................ p.4
III.2 Compliance............................................................. p.5
III.3 Exclusions of liability and warranty ............... p.5
1 General information.................................................... p.6
2 Technical data ..................................................................... p.6
3 Mounting and installation.................................... p.7
3.1 Mounting and connecting the OT/Modbus
interface................................................................... p.7
3.2 Electrical hookup.................................................. p.9
4 Preliminary operations for
programming..................................................................... p.11
5 Control panel...................................................................... p.12
6 Menus and parameters........................................... p.13
6.1 Access to menus and parameters................. p.13
6.2 Basic parameter programming ..................... p.13
6.3 Complete parameter programming............ p.15
7 System examples........................................................... p.30
7.1 1 boiler, DHW with diverter valve, 3 circuits
of which 2 mixed................................................ p.30
7.2 1 boiler, DHW with delivery, 3 circuits of
which 2 mixed ..................................................... p.31
7.3 1 boiler, DHW with diverter valve, heat
exchanger, 2 circuits of which 1 mixed....... p.32
7.4 1 boiler, DHW with delivery, heat
exchanger, 3 circuits of which 1 mixed....... p.33
7.5 3 boilers, DHW with diverter valve, 2
circuits of which 1 mixed................................. p.34
7.6 3 boilers, DHW with delivery, 3 circuits of
which 1 mixed ..................................................... p.35
7.7 3 boilers, DHW with diverter valve, heat
exchanger, 2 circuits of which 1 mixed....... p.36
7.8 3 boilers, DHW with delivery, heat
exchanger, 3 circuits of which 2 mixed....... p.37
7.9 2 boilers, DHW with delivery, heat
exchanger, 3 circuits of which 1 mixed....... p.38
7.10 3 boilers, DHW with 2 diverter valves, 2
circuits of which 1 mixed................................. p.39
7.11 3 boilers, DHW with 2 deliveries, 4 circuits
of which 1 mixed................................................ p.40
7.12 3 boilers, DHW with diverter valve and
delivery, 3 circuits of which 1 mixed............ p.41
7.13 3 boilers, heating only, 0-10 V external
input, 2 circuits of which 1 mixed................. p.42
8 Fault codes............................................................................ p.43
9 Menus and parameters table........................... p.44

Introduction
4
I
I INTRODUCTION
Installation and use manual
This Installation and use manual contains all the
information needed to install and congure the
Cascade controller ODSP039, which can only be
used in conjunction with one or more Caldaria
systems, each of which must be equipped with
its own OT/Modbus interface (optional ODSP040),
with the exception of Caldaria 100.2 units that are
already equipped with it.
The controller is a programmable digital controller,
suitable for DIN rail mounting and capable of per-
forming sophisticated temperature control func-
tions. The large display allows easy entry of system
parameters.
I.1 RECIPIENTS
This Manual is intended for:
▶ Electrical installers for proper installation of the con-
trol equipment.
▶ Installers and authorised Robur Technical Assistance
Centres (TAC) for conguration.
I.2 AVAILABLE LANGUAGES
For versions of this Installation and use manual in other
languages, see Robur website.
II SYMBOLS AND DEFINITIONS
II.1 KEY TO SYMBOLS
DANGER
WARNING
NOTE
PROCEDURE
REFERENCE (to other document)
II.2 TERMS AND DEFINITIONS
Boiler = condensing boiler series Caldaria.
controller = control unit for cascade and any second-
ary circuits management for condensing boilers series
Caldaria, available as optional ODSP039.
OT/Modbus interface = OT/Modbus interface board for
connection between boiler board and controller, availa-
ble as optional ODSP040.
TAC = Technical Assistance Centre authorised by Robur.
III WARNINGS
III.1 GENERAL AND SAFETY WARNINGS
Installer's qualications
Installation must exclusively be performed by a
qualied rm and by skilled personnel, with specif-
ic knowledge of electrical systems, in compliance
with the laws in force in the Country of installation.
Declaration of conformity
Upon completing installation, the installing rm
shall issue to the owner/client the appliance's
workmanlike conformity declaration, according to
national/local regulations in force and the manu-
facturer's instructions/provisions.
Misuse
The appliance must only be used for the purpos-
es for which it has been designed. Any other use
is deemed hazardous. Incorrect use may aect
operation, duration and safety of the appliance.
Adhere to the manufacturer's instructions.
Electrocution hazard
Disconnect the electrical power supply before any
operation on appliance components.
For electrical connections exclusively use compli-
ant components and according to the specica-
tions provided by the manufacturer.
Ensure the appliance cannot be accidentally
switched back on.
Earthing
Electrical safety depends on eective earthing sys-
tem, correctly connected to the appliance and in-
stalled according to the regulations in force.
In the event of failure
Operations on internal components and repairs
may exclusively be carried out by a TAC, using only

Warnings
Installation and use manual – Cascade controller ODSP039 5
III
original spare parts.
In the event of fault of the appliance, do not at-
tempt to repair and/or restore and immediately
contact the TAC.
Keep the Manual
This Installation and use manual must always ac-
company the appliance and must be handed to
the new owner or installer in the event of sale or
removal.
The equipment must be installed indoors and out
of the weather. For its positioning, refer to the pro-
tection rating given in Paragraph 2 p.6 .
III.2 COMPLIANCE
The appliance is CE certied and conforms with all essen-
tial requirements of the following Directives:
▶ 2014/30/EC "Electromagnetic Compatibility Directive"
as amended and added.
Furthermore, they comply with the requirements of the
following standards:
▶ EN 55022 "Information technology equipment - Radio
disturbance characteristics - Limits and methods of
measurement"
▶ EN 55024 "Information technology equipment -
Immunity characteristics - Limits and methods of
measurement"
▶ EN 61000-6-1 "Immunity for residential, commercial
and light-industrial environments".
▶ EN 61000-6-2 "Immunity for industrial environments".
▶ EN 61000-6-3 "Emission standard for residential, com-
mercial and light-industrial environments".
▶ EN 61000-6-4 "Emission standard for industrial envi-
ronments".
III.3 EXCLUSIONS OF LIABILITY AND
WARRANTY
Any contractual or extra-contractual liability of the
manufacturer for any damage caused by incorrect
installation and/or improper use and/or failure to
comply with regulations and with the manufactur-
er's directions/instructions shall be disclaimed.
In particular, the warranty on the appliance may be
rendered void by the following conditions:
Incorrect installation/cabling.
Misuse.
Failure to comply with the manufacturer's indica-
tions on installation, use and maintenance.
Alteration or modication of the product or any
part thereof.
Extreme operational conditions or however out-
side of the operational ranges set forth by the man-
ufacturer.
Abnormal actions transmitted to the appliance by
the system or installation (mechanical stresses,
pressure, vibrations, thermal expansion, electrical
surges...).
Accidental damages or due to force majeure.

General information
6
1
1 GENERAL INFORMATION
The controller is a programmable digital controller with
a display that allows the centralised management of
Caldaria boilers, up to a maximum of 8 boilers connect-
ed to the same controller. The controller also allows the
control of up to two mixed circuits and DHW production,
including the corresponding temperature probes.
Each of the boilers connected to the controller must be
equipped with its own OT/Modbus interface, available
as ODSP040 optional, with the exception of the Caldaria
100.2 appliances, which are already equipped with it.
The controller also allows any errors on the boilers to be
reported and reset.
The main functions are:
▶ Programmed on/o switching of the generation sys-
tem for space heating and DHW production.
▶ Cascade management up to a maximum of 8 boilers
connected to the same controller, with dierent pri-
ority logics.
▶ Outdoor temperature measurement by NTC probe.
▶ Manifold temperature measurement by NTC probe.
▶ Management of up to two mixed circuits.
▶ Management of a modulating pump downstream of
any heat exchanger or hydraulic separator.
▶ Buer tank DHW production management with di-
verter valve or through delivery from the heating
manifold, also split between two DHW buer tanks,
with relevant temperature probes and recirculation
management.
▶ Diagnostics with reporting of boiler errors and reset-
ting directly from the controller.
2 TECHNICAL DATA
Table2.1Technical data
Power supply
Supply voltage 24 V AC (±10%)
Frequency 50 / 60 Hz
Absorption max 450 mA
Power supply protection 4 A delayed fuse
Function Software class A
Inputs 6 congurable universal inputs
NTC 10 kΩ
0-10 V DC
PT1000
KTY 81
Digital input
Digital inputs
• Open contact voltage
• Closed contact current
Safety Extra Low Voltage (SELV) for voltage-free contacts
3,3 V
< 1 mA
Outputs
8 relay outputs 8 relays 5 A 220 V AC, potential-free contacts with common pole
Relay outputs
• Relay rated current
• Voltage range
Mechanical relay without switching ON current
5 A
0 ÷ 277 V AC
2 analog outputs 2 analog outputs for modulating commands 0-10 V DC
Analog outputs
• Voltage
• Current
• Ripple
• Zero level accuracy
• Error over rest of range
max 10 V DC
max 20 mA
80 mV @ 1 MHz
250 mV
≤ 3%
Outdoor probes measuring
range
NTC 10 kΩ
PT1000 and NI1000
KTY 81
-20 ÷ 90 °C (depending on the value of β)
-60 ÷ 250 °C
-50 ÷ 150 °C
Communication bus
Modbus RTU 2 RS485 Modbus connections (master/slave)
Total cable length max 1200 m
Cable type to use EIA RS485 (type Belden 9841)
Connections Screw terminals 6 removable screw terminals
Cabling
Maximum lower terminals cable cross-sec-
tion 16 AWG - 1,5 mm²
Maximum upper terminals cable cross-sec-
tion 12 AWG - 3 mm²
Maximum input/ouput cables length 30 m
Climatic conditions Storage
Operation
-20 ÷ 50 °C
0 ÷ 50 °C, humidity 10 ÷ 95 % (non condensing)
Protection rating Enclosure protection rating IP 20
Degree of contamination per EN60730 2
Mounting DIN rail 4 DIN modules

Assembly and installation
Installation and use manual – Cascade controller ODSP039 7
3
Dimensions With packing 130 x 75 x 130 mm
Weight With packing 300 g
3 MOUNTING AND INSTALLATION
The controller is designed for DIN rail mounting and occu-
pies the space equivalent to 4 DIN modules.
Before installing the unit, check that the equip-
ment is not connected to its power supply.
The controller and any other equipment and acces-
sories must be powered up only when the installa-
tion is complete. Failure to observe this instruction
incurs a risk of electrocution and short-circuit.
The controller must not be exposed to water.
The unit's ambient operating temperature range is
0 °C - 50 °C.
3.1 MOUNTING AND CONNECTING THE
OT/MODBUS INTERFACE
Mounting and connecting the
OT/Modbus interface
1. Secure the OT/Modbus interface inside the control
panel of the boiler, using the screw provided (Figure
3.1 p.7 ).
2. Connect the OT/Modbus interface to the boiler
board using the connection cable provided (Figure
3.2 p.7 ).
3. Check that jumper B is open and jumper A is closed
(Figure 3.3 p.8 ).
4. Only for Caldaria 35 and Caldaria 55.1: check, through
the interface of the boiler control panel, that the boil-
er parameter P28 is set to 0 (see the boiler Manual for
setting the board parameters).
5. Only for the slave module of Caldaria 100.2: open
jumper A (Figure 3.4 p.8 ).
Figure3.1OT/Modbus interface mounting
Figure3.2Connection of OT/Modbus interface to boiler board
A Boiler board
B Connection cable (supplied)
C Jumper
D OT/Modbus interface ODSP040
E Modbus connection
11
10
98
7
12
13
14
15
16
17
M12 M9 M7 M5
M2
M4
M8
M10
M15
M16
1
2
3
4
57
61
60
59
58
44 43 42 41 40
39 38
37 36 35 34 33 32
31 30
29 28
27 26
62
63
64
65
66
67
68
51
52
53
54
55
56
56
M13
M14
M6
12
6
5
TXOUTRXIN
GND +24V
BA
B
C
A
D
E

Assembly and installation
8
3
Figure3.3ODSP040 board jumper position for Caldaria 35 and
55.1
A Jumper open B Jumper closed
A B
Figure3.4ODSP040 board jumper position for Caldaria 100.2
slave module
A Jumper open B Jumper open
A B
For further details refer to the OT/Modbus interface
instruction sheet.

Assembly and installation
Installation and use manual – Cascade controller ODSP039 9
3
3.2 ELECTRICAL HOOKUP
Figure3.5Electrical connections to the rst boiler
A Connection to the following boiler of the cascade
Required components
BO01 First boiler of the cascade (P26 = 1)
CCA controller (optional ODSP039)
CON OT/Modbus interface (optional ODSP040, except
Caldaria 100.2)
FUS Delayed 4 A fuse
IB Two-pole magnetothermal breaker
IG General two-pole magnetothermal breaker
MA BO01 Terminal block of the rst boiler of the cascade
QLT BO01 Electrical panel of the rst boiler of the cascade
S1 Manifold/separator/inertial buer probe (optional
OSND010)
Optionals
0-10 V External temperature or power request signal
CB Charging circuit pump from the manifold for DHW
buer tank 1
CB2 Charging circuit pump from the manifold for DHW
buer tank 2
CR1 Heating circuit 1 pump
CR2 Heating circuit 2 pump
CRC DHW recirculation pump
PWM Modulating pump post heat exchanger/hydraulic
separator
S2 HC2 ow probe (optional OSND010)
S3 HC1 ow probe (optional OSND010)
S4 Post heat exchanger/hydraulic separator probe (optional
OSND010)
SB1 DHW buer tank 1 probe (optional OSND011)
SE Outdoor probe (optional OSND009)
SRB Remote lockout lamp
TA1 External heating request for heating circuit 1
TA2 External heating request for heating circuit 2
TS1 DHW buer tank 1 thermostat (alternative to SB1 probe)
VD Buer tank 1 diverter valve for DHW charging
VMixCR1 0-10 V mixing valve for heating circuit 1
VMixCR2 Mixing valve for heating circuit 2
- RS485
+ RS485
230 V
L
N
-
24 Vac
SE
SB1
SR
TR
CR1
CR2
CB
CRC
IB
2x16A
12 34
VMixCR1
FUS 0 - 10 V
IG
230 V
50 Hz
L N
2x16A
12 34
TS1
CCA
K1 K2 KC K3 K4 KC K5 K6 KC K7 K8 KC
P- P+ B1 A1 B2 A2 CC U1 U2 U3 U4 U5 U6 Y1 Y2 CC
M1
M2
C
A
VMixCR2
CON
BO01 (P26 = 1)
M1
531
M3
M4
LNSeSe
TaTa
MA BO01
QLT BO01
VD
C
24 Vac
S1
S2
S3
TA1
IB
2x16A
4 3
2 1
+
CB2
SRB
S4
PWM
38 39 40 41 42 43 44
32 33 34 35 36 37
7 8 9 10 11
TA2
0-10 V
M12 M9
M4
A
A

Assembly and installation
10
3
Figure3.6Electrical connections to following boilers
A Connection to the previous boiler of the cascade B Connection to the following boiler of the cascade
Required components
CON OT/Modbus interface (optional ODSP040, except Caldaria
100.2)
IB Two-pole magnetothermal breaker
Optionals
BO02 Second boiler of the cascade (P26 = 2)
MA BO02 Terminal block of the second boiler of the cascade
QLT BO02 Electrical panel of the second boiler of the
cascade
SB2 DHW buer tank 2 probe (optional OSND011)
TS2 DHW buer tank 2 thermostat (alternative to SB2 probe)
VD Buer tank diverter valve for DHW charging
B
B
A
A
SB2
BO02 (P26 = 2)
M1
531
M3
LNSeSe
TaTa
MA BO02
QLT BO02
VD
IB
2x16A
4 3
2 1
38 39 40 41 42 43 44
32 33 34 35 36 37
7 8 9 10 11
SR
CON
M4
C
M12 M9
M4
Remove the bridge on the TA-TA contacts of all
boilers.
Remove any digital control connected to each
of the boilers.
In the presence of several boilers provided for
DHW service with 3-way diverter valve, it is
mandatory to have one valve for each boiler
and the individual valves must each be con-
nected to its own boiler.