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