Viessmann Cascade control unit Service manual

Cascade control unit
Installation, operating
and service instructions
for heating engineers
Cascade control unit
Weather-compensated cascade control for up to four
gas fired wall-mounted boilers
5862Ă 7 ĂGBăăă3/2003 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety regulations
Installation, initial start-up, inspection,
maintenance and repairs must only
be carried out by a competent person
(heating engineer/installation
contractor).
Observe all current safety regulations
as defined by DIN, EN, DVGW, TRGI,
TRF and VDE or locally applicable
standards.
See also the safety instructions sheet
in the Vitotec technical documentation
folder.
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
Close the main gas shut-off valve
and safeguard against unauthorised
reopening.
Electrical components provided by
the customer must be type-tested.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations
acc. to TRGI or TRF and all local
regulations.
Please observe all commissioning
work specified for gas systems.
Repair work
It is not permitted to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start-up
The initial start-up must be carried
out by the system installer or a
designated commissioning engineer;
all actual values should be recorded
in a commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
¨This symbol denotes important
information which must be
observed to prevent material
losses.
Product information
Cascade control unit, part no.Ă7170Ă857, weather-compensated cascade
control for multi-boiler systems with up to four gas fired wall-mounted
boilers and one distribution pump.
5862Ă 7 ĂGB

Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product informationĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and connections
Installation conditionsĂ
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit installationĂ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical connectionsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relieving cable strainĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control
Operating controls and indicatorsĂ 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating level selectionĂ 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up/configurationĂ 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General details (general control units)Ă 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System details (multi-boiler control unit)Ă 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functions
Operating conditionsĂ 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set room temperatureĂ 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set flow temperatureĂ 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-boiler control unitĂ 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor pumpĂ 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and monitoring equipmentĂ 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
General faultsĂ 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel faultsĂ 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faults indicated in the "Faults" menuĂ 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor resistance tableĂ 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listĂ35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SpecificationĂ36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5862Ă 7 ĂGB

4
Installation and connections
Installation conditions
HInstall the control unit at eye level
and as close to the connected
system components as possible.
HMax. ambient temperature
see "Specification".
HDo not install the control unit near
water sprays.
Control unit installation
1. Drill three holes in accordance
with the installation template
(inside the packaging).
2. Insert the upper screw far enough
for the control unit to be hooked
into place.
. Remove the cover from the
termination chamber.
4. Hook the control unit into position
and insert the lower screws.
5862Ă 7 ĂGB
2.
1.
.
.
3.

5
Installation and connections
Electrical connections
Connection and wiring diagram
ACascade control unit
BMains connection 230ĂV~ă50ĂHz
CDistribution pump
DFault message (zero volt)
ESeparator (as delivered condition)
FViessmann 2ĆwireĂBUS for
connection to VitotronicĂ050,
VitotronicĂ050 accessory
GOutside temperature sensor
HFlow temperature sensor
KParty key
LExternal demand
MKM BUS interface
to VitodensĂ200
KĂ1 to KĂ Connection for
boilers 1 to
Sensors
Install sensors in their appropriate
positions and connect in accordance
with the diagram.
External switching contacts
Connect the external switching
contacts, the party key and the
"External demand" switching
contact (if installed) in accordance
with the diagram.
Boiler
Connect via the KM BUS interface in
accordance with the diagram.
5862Ă 7 ĂGB
1817
X5. X5.3
FT A
X5. X5.3 X5.3 X5. X5.3 X5.
161511312111098765321
NL
1 ~
M
BD
CGHKL
M
KF
K1 K2 K3 K
EA
K

6
Installation and connections
Electrical connections (cont.)
VitotronicĂ050 heating circuit control
unit
Connect via Viessmann 2ĆwireĂBUS
in accordance with the diagram
(see page 5).
ACascade control unit
BVitotronicĂ050 with communications
module Viessmann 2ĆwireĂBUS,
part no.Ă71 3Ă710
CConnection cable Viessmann
2ĆwireĂBUS, part no.Ă717 Ă99 , for
connecting the cascade control
unit with the first VitotronicĂ050
DConnection cable Viessmann
2ĆwireĂBUS, part no.Ă781 Ă62 , for
connecting the first VitotronicĂ050
with the further VitotronicĂ050
Set the differential temperature
between the boiler water and the set
flow temperature at VitotronicĂ050.
Code "9F:8" (as delivered condition)
must be set.
If the outside temperature for
VitotronicĂ050 is to be adopted from
the cascade control unit, set code
"97:1".
Distribution pump
Connect acc. to diagram (see
pageĂ5).
Connection load capacity:
max. ĂAă230ĂV~.
Fault indication
HFault message contact (volt-free)
at mains voltage potential
230ĂV~, 1Ă(0.5)ĂA
Plug the separator in (see pageĂ5)
to the right of terminal blockĂ"17/18".
HFault message contact (volt-free) at
safety low voltage 2 ĂVć/~, 2ĂA
Plug the separator in (see pageĂ5)
to the left of terminal blockĂ"17/18".
¨Strip a minimum length of
insulation off the cable.
Connect in accordance with the
diagram (see pageĂ5).
Mains electrical connection
Connect the supplied mains cable in
accordance with the diagram (see
pageĂ5).
5862Ă 7 ĂGB
S1
A
S1
5
BB
CDD

7
Installation and connections
Relieving cable strain
1. Fit a strain relief (supplied) to all
cables.
2. Fit the cover to the termination
chamber.
5862Ă 7 ĂGB
2.
1.

8
Control
Operating controls and indicators
ADisplay
BPush buttons
CSystem diagram
DFunction displays
5862Ă 7 ĂGB
3
2
1
1
2
3
A B DC

9
Control
Operating controls and indicators (cont.)
Push buttons
Subject to configuration and operating level, keysĂ , , and can be used
to display and/or amend the various details in the main and sub-menus. The
key function is subject to the respective menu item that is displayed when the
key is pressed.
Function in standard mode:
Scroll up the menu and/or increase the set value
Scroll down the menu and/or reduce the set value
Back to the previous menu and/or reinstate the previous set value
Menu selection and/or activation of the set value to change or confirm the
set value
Function during the configuration process (limited function):
Change the menu selection or increase the set value
Change the menu selection or reduce the set value
No function
Confirm the set value and scroll to the next configuration menu item.
Function display
"9":Hflashes if the control unit has been connected to the
mains supply but has not yet been configured,
Hilluminates permanently after configuration
"1 to " and " ": illuminate if the corresponding system component is
operational.
"U": illuminates in case of faults
5862Ă 7 ĂGB

10
Control
Operating level selection
The control unit has three operating levels.
Operating levelĂ1
Display of simple parameters, such as operating mode and software version.
Operating levelĂ2
Display of the most important operating details (e.g. actual and set flow
temperature, switching periods and settings, such as set room temperature,
set flow temperature) and modification of set values.
Operating levelĂ
System and device configuration.
Access to the operating levels
Press , "General control unit" will be
displayed.
When "Multi-boiler control unit" is displayed,
select "General control unit" with and confirm
with .
Select "Operating level" with and confirm
with ; operating levelĂ1, 2 or 3 will then be
displayed.
Press , figureĂ"1"or "2" will then flash.
Enter the following access code for the required
operating level:
for operating levelĂ2
for operating levelĂ3
Press , "Operating level" is then displayed.
This confirms the selection of the required
operating level.
Press to return to "General control unit".
Please note:
The control unit automatically reverts to operating levelĂ , if no key is pressed
within an hour.
5862Ă 7 ĂGB
Control unit 001ĆA
General
Operating level
Operating level 1
[ ]
Operating level
Control unit 001ĆA
General

11
Control
Initial start-up/configuration
The control unit covers two setting ranges, which must be configured
separately:
HGeneral control unit (described in the menu as "Control unitĂ001ĆA") for
general details, such as date and time
HMulti-boiler control unit (described in the menu as "Control unitĂ001ĆB") for
the control of multi-boiler systems, where boilers are enabled subject to
temperature.
¨Both configurations must be completed. The control unit will not function
properly if the configuration is prematurely terminated.
First, switch ON the gas fired wall-mounted boilers, then the cascade
control.
General control unit
Preconditions: Operating levelĂ3 must be selected (see pageĂ10).
Select "General control unit" with , if "General
control unit" is not already displayed; confirm
with .
Select "Configuration" with ; confirm with .
Select "Yes" with / ; confirm with .
Select the required language with / ;
confirm with .
Select "Yes" with / , if you wish the time to
change automatically between summer and
wintertime; confirm with .
Press to return to "General control unit".
The "General control unit" configuration is now
completed.
5862Ă 7 ĂGB
Control unit 001ĆA
General
Configuration
Configuration Yes
German
Summer/wintertime
auto Yes

12
Control
Initial start-up/configuration (cont.)
Multi-boiler control unit
Preconditions: Operating levelĂ3 must be selected (see pageĂ10).
Select "Multi-boiler control unit" with , if
"Multi-boiler control unit" is not already
displayed; confirm with .
Select "Configuration" with ; confirm with .
Select "Yes" with / ; confirm with .
Outside temperature sensor
Select "Yes" if an outside temperature sensor is
connected to the control unit.
Frost protection
Preconditions: "Outside sensor Yes" must be
configured.
Select "Yes" if the flow temperature should not fall
below an adjustable minimum temperature from a
certain outside temperature on.
Time switch
Preconditions: "Outside sensor Yes" must be
configured.
Select "Yes" if the control unit should be
operated with the integral time switch, i.e.
switching periods can be set up (see pageĂ18).
Holiday program
Preconditions: "Time switch Yes" must be
configured.
Select "Yes", if operation with a holiday program is
required (see pageĂ18).
5862Ă 7 ĂGB
Control unit 001ĆB
multi- oiler system
Configuration
Configuration Yes
Outside sensor Yes
Frost protection
outside temp. Yes
Time switch Yes
Holiday program Yes

1
Control
Initial start-up/configuration (cont.)
Pump
Select "Yes" if a distribution pump is to be
connected to the control unit.
Number of boilers
Enter the number of boilers in the multi-boiler
system.
Flue gas cascade
Select "Yes" if a pressure flue gas cascade is
installed.
The lag boiler will only be started if the operational
boiler has reached at least 80Ă% of its rated
output.
Boiler sequence change
"Yes": The start-up sequence is determined
once per week subject to the number of
hours run.
"No": The start-up sequence is permanently set
(subject to the connection sequence)
Pump protection control
Select "Yes" if the connected distribution pump
should be started at least once a day for a few
minutes to prevent it from seizing.
Resetting the hours run counter
Select "Yes" to set all operating and impulse
counters to zero, e.g. during commissioning.
The current date is automatically defaulted as
start date.
5862Ă 7 ĂGB
Pump Yes
Num er of oilers 2
Flue gas cascade
Yes
Boiler sequence
change Yes
Pump protection
control Yes
Counter
clear Yes

14
Control
General details
Activating operating levelĂ3 (see pageĂ10).
to confirm
Operating level
Please note:
If in the following you wish to
jump to the next menu item,
continue with .
Operating details
confirm; operating details
appropriate for the relevant
system can be selected with
or , e.g. type version
back to previous menu
Set values
confirm;
/ for selecting summertime
start or summertime end
confirm
/ for selecting the month
confirm
Please note:
If "Summer/wintertime auto"
was configured (see p.Ă ), the
system will change over
during these months.
back to previous menu
Relay test
confirm;
display pump
display flashes
for selecting relay
back to previous menu
Configuration
confirm; "No" flashes; if you
want to configure, select
"Yes"
confirm; language flashes
for language selection
confirm;
Display Summer/wintertime
auto
"Yes" or No" flashes
for selection;
confirm;
Display Configuration
Date and time
Date flashes
/ for selection of required value
confirm
General control unit
5862Ă 7 ĂGB

15
Control
System details
Activating operating levelĂ3 (see pageĂ10).
Multi-boiler control unit
confirm
Fault status display,
display only if faults exist
or
flow determined
Operating details
confirm;
/ Operating data can be
displayed subject to the
relevant system:
HSoftware version
HTime program standard
mode
HParty key standard mode
HHeating up
HTime program red. mode
HTime program holiday
mode
HStandby mode
HFault
HAutomatic summer mode
HExternal demand
HHeat demand via
Viessmann 2Ăwire BUS
HFrost protection
HSet flow temperature
HSet room temperature
HOutside temperature
HBoilersĂ1 to
(boiler-specific details):
ć Boiler off
ć Standard boiler op.
ć Boiler DHW
ć Boiler set flow temp.
ć Relative boiler output
HBoiler sequence
back to previous menu
5862Ă 7 ĂGB

16
Control
System details (cont.)
Set values
confirm
/ for selecting following
parameters:
HSet room temperature
Standard/reduced mode/
holiday mode
HOutside temp. low end
HFlow temp. low end
HDesign temp. outside/flow
HHeating curve slope
HFlow temperature
minimum/maximum
HMinimum flow temperature
frost protection
HRoom influencing factor
HTime constant summer mode
HDifference summer mode
HHeat-up time min./max.
HHeat up room factor
HHeat up outside factor
HExternal demand flow
temperature
HBoiler switch-on delay
HParty key time
HBuilding type
HDiff. flow temperature fault
HTime flow temperature fault
confirm; value flashes
/ change value
confirm value
back to previous menu
Time switch
confirm
/ for selecting weekday
confirm; switching time flashes
/ change time
confirm
back to previous menu
Holiday program
confirm
/ for selecting start and end
confirm;
back to previous menu
Hours run starts
Scanning individual boilers
back to previous menu
Faults
confirm
/ for scanning faults
back to previous menu
Configuration
confirm
/ for "Yes" or "No"*1
confirm
Multi-boiler control unit
* Configuration is required if a pressure flue gas cascade has been connected
(see pageĂ 3).
5862Ă 7 ĂGB

17
Functions
Operating conditions
You can scan the operating conditions from the "Operating details" menu in
the "Multi-boiler control unit" function area (see pageĂ15).
The following operating conditions may apply:
HStandard mode (standard room temperature, e.g. day)
HReduced mode (reduced room temperature, e.g. night)
HHoliday mode (reduced room temperature, e.g. holiday periods)
HStandby mode (the system is not operational)
HFault
Subject to the current operating state, certain components are either
operational or not, and those set values which control the various functions
therefore change.
Set room temperatures can be adjusted in the "Set values" menu (see
pageĂ16).
In some cases, the reason for the prevailing operating condition will be
displayed, e.g.
"External demand": The control unit is in standard mode, as the
"External demand" function is active.
Displaying the control state (Status display)
The following status indications can be displayed:
Multi-boiler control unit
Display of set flow and actual flow temperatures.
This is displayed if there is a fault.
5862Ă 7 ĂGB
Flow 20ºC
Actual 20ºC
Status display
fault

18
Functions
Operating conditions (cont.)
Time switch
Preconditions: "Time switch Yes" must be configured (see pageĂ12).
In the time switch program, two different switching periods can be set for
each weekday.
Each switching period requires the input of a switch-on and a switch-off point.
Within the switching period, the control unit operates in standard mode;
outside the period it operates in reduced mode.
Time switch (multi-boiler control unit)
Example:
For Tuesday, the switching periods 8 to 16 and 20
to 22Ăhrs standard mode have been set up.
In the "Operating details" menu (see pageĂ15) you can scan whether the
control unit is set to "Standard mode" or "Reduced mode" on account of the
time switch program.
Holiday program
Preconditions: "Holiday mode Yes" must be configured (see pageĂ12).
Eight different holiday periods with start and end times may be set up in the
holiday program.
Holiday program (multi-boiler control unit)
The holiday period begins on 16.07.03 and ends
on 15.08.03.
Please note:
Set room temperatures during the holiday period
can be adjusted in the "Set values" menu (see
pageĂ 6).
In the "Operating details" menu (see pageĂ15) you can scan whether the
control unit is set to "Time program holiday mode".
5862Ă 7 ĂGB
Tu 08:00 Ć 16:00
20:00 Ć 22:00
1: 16Ć07Ć2003
up to 15Ć08Ć2003

19
Functions
Operating conditions (cont.)
Party mode
A switching contact at the party key input enables the control unit to be
changed over to standard mode. The control unit will operate in standard
mode as long as the switching contact is closed.
Set value (multi-boiler control unit)
The impulse at the party key input lets the
control unit operate in standard mode for the set
period.
Please note:
The course of the set standard mode cannot be
terminated prematurely.
The control unit can be changed to standard mode for an adjustable period by
connecting a pushbutton to the party key input. After the set period has
expired, the control unit will automatically change back to its previous setting.
In the "Operating details" menu (see pageĂ15), you can scan whether the
control unit is set to party mode.
5862Ă 7 ĂGB
Party key
time 0h

20
Functions
Operating conditions (cont.)
Start-up optimisation (early heat-up)
The start-up optimisation ensures that the boiler is heated up before the
standard mode commences, subject to room and outside temperature.
This ensures that the set room temperature is achieved before the standard
mode commences. A minimum and maximum temperature can be set for the
heat-up period. The greater the difference between the set room temperature
in standard mode and the outside temperature, the longer the heat-up period.
Set value (multi-boiler control unit)
The control unit activates at least the minimum
set period earlier.
The control unit will be activated in advance by
no more than the minimum set period.
Earlier start-up time, to raise the room
temperature by 1ĂK.
The outside temperature has no influence here.
Room factor correction subject to outside
temperature.
In the "Operating details" menu (see pageĂ15) you can scan whether the
control unit is set to "Standard mode" on account of the heat-up function.
5862Ă 7 ĂGB
Heat-up time
minimum 15 min
Heat-up time
maximum 360 min
Room factor
heat-up 30 min/K
Outside factor
heat-up 0.02 K