Viessmann Dekamatik-HK1 User manual

Dekamatik-HK1
Installation Instructions
Dekamatik-HK1
Digital indoor/outdoor heating circuit control unit
for mounting on the mixing valve, Part No. 7450 107
for wall mounting, Part No. 7450 110
Please file in Service Binder
5167 137 1/99

Safety
2
Safety, Installation and Warranty Requirements
Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed below
and details printed in this manual can cause product/property damage, and/or severe personal injury. Ensure all requirements below are
understood and fulfilled (including detailed information found in manual subsections).
HLicensed professional heating
contractor
The installation, adjustment, service, and
maintenance of this equipment must be
performed by a licensed professional
heating contractor.
"Please see sections
entitled “Safety” and
“Important Installation
Requirements.”
HProduct documentation
Read all applicable documentation before
commencing installation. Store
documentation near boiler in a readily
accessible location for reference in the
future by service personnel.
"For a listing of applicable
literature, please see
section entitled “Important
Installation Requirements.”
HAdvice to owner
Once the installation work is complete, the
heating contractor must familiarize the
system operator/ultimate owner with all
equipment, as well as safety precautions/
requirements, shut-down procedure, and
the need for professional service annually
before the heating season begins.
HWarranty
Information contained in this and related
product documentation must be read and
followed. Failure to do so renders warranty
null and void.
Safety Terminology
The following terms are used throughout this manual to bring attention to the presence of potential hazards or important product information.
Please heed the advice given!
Helpful hints for installation, operation or
maintenance which pertain to the
product.
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Indicates an imminently hazardous
situation which, if not avoided, will
result in death, serious injury or
substantial product/property
damage.
DANGER
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property
damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT

Contents
3
Page
Important Precautions Safety 4...........................................................................................
Important Installation Requirements
Information Product Information 5................................................................
Heating System Types -Application Example 1 6...........................................................
- One heating circuit with mixing valve
- Dekamatik-HK 1 for mounting on the mixing valve or
-for wall mounting
Application Example 2 7
...........................................................
- One underfloor heating circuit with mixing valve
- Dekamatik-HK 1 for mounting on the mixing valve or
-for wall mounting
Installation Dekamatik-HK1 for Mounting on the Mixing Valve 8.......
Dekamatik-HK1 for Wall Mounting 9.....................................
Electrical Connections Overview 10.....................................................................................
Sensors 12.......................................................................................
Supply temperature sensor 12.....................................................
Outdoor temperature sensor 13...................................................
Accessories 14...............................................................................
Room temperature sensor 14.......................................................
Wall mounting fixture 14.................................................................
WS/RS remote control unit 15......................................................
Heating circuit pump 115 V 16.......................................................
Heating circuit pump with high current or 3-phase 17..............
Other Connection Facilities 18..................................................
External heat demand / External heat disable 18....................
Mixing valve motor 18.....................................................................
Compiled fault indication 19...........................................................
Power Supply 20............................................................................
Appendix Post-Installation Testing 21........................................................
Checklist 21......................................................................................
Service binder 21.............................................................................
Dimensions / Technical Data 22................................................
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Important Precautions
4
Safety
Take note of all symbols and notations intended to draw attention to potential hazards or important product information.
These include “DANGER,” “WARNING,” “CAUTION,” and “INFORMATION.” See page 2 for details.
Approvals
Viessmann boilers, burners and controls
are approved for sale in North America by
International Approval Services (IAS). All
electrical wiring is to be done in
accordance with the latest edition of the
National Electrical Code ANSI/NFPA 70.
In Canada use latest edition of CSA
C22.1 Part 1 and/or local codes.
Please carefully read this manual prior
to attempting installation. Any
warranty is null and void if these
instructions are not followed.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
Working on the equipment
The installation, adjustment, service, and
maintenance of this boiler must be done
by a licensed professional heating
contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water heating
equipment. There are no user-serviceable
parts on this equipment.
Power supply
Install power supply in accordance with
the regulations of the authorities having
jurisdiction or, in the absence of such
requirements, in accordance with National
Codes.
Viessmann recommends the installation
of a disconnect switch to the 120 V power
supply outside of the boiler room. The
installer must provide maximum 15 A
overcurrent protection for the 120 V
power supply (fuse or circuit breaker).
Ensure that all contacts have sufficient
insulation clearance to live parts and
are certified for these applications.
Proper consultation with Viessmann
Manufacturing Company Inc. should
occur when installing components not
included in the Viessmann product
line.
No static discharge to the internal
componentry must ever occur when
working with opened control
equipment.
Important Installation Requirements
Literature applicable to installation of the
Dekamatik-HK 1:
- Installation Instructions
- Start-up and Service Instructions
- Operating Instructions
- Installation codes mentioned in this
manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
5167 137
IMPORTANT
Turn off electric
power supply before
servicing. Contact
with live electric
components can
cause shock or loss
of life.
WARNING
IMPORTANT
IMPORTANT

Information
5
Product Information
Digital indoor/outdoor heating circuit control unit for one heating circuit with mixing valve,
either
with drive module for mounting on Viessmann mixing valve
or
for wall mounting and connection of a separate mixing valve motor.
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Heating System Types
6
Application Example 1
- One heating circuit with mixing valve
- Dekamatik-HK1
Instead of the Dekamatik-HK 1 for mounting on the mixing valve it is also possible to use a Dekamatik-HK 1 for wall mounting in
conjunction with a separate mixing valve motor.
Dekamatik-HK 1 for mounting on
the mixing valve
Heating circuit
Supply header
Return header
Outdoor temperature sensor*1
Supply temperature sensor
Heating circuit pump
Power supply
Remote control
*2 Viessmann 2-wire BUS
for communication with other
Dekamatik control units
External heat demand /
external heat disable
*1It is possible to connect a separate room temperature sensor (accessory) instead of the outdoor temperature sensor for the purpose of
*1a purely room temperature dependent control.
*1If the outdoor temperature value of the boiler or heating circuit control unit is used via the Viessmann 2-wire BUS, a room temperature
*1sensor can be connected for room temperature dependent control (only possible with communication module, accessory).
*2Only in conjunction with communication module (accessory).
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ATS = Outdoor temperature sensor
VTS = Supply temperature sensor

Heating System Types
7
Application Example 2
- One underfloor heating circuit with mixing valve
- Dekamatik-HK1
Instead of the Dekamatik-HK 1 for mounting on the mixing valve it is also possible to use a Dekamatik-HK 1 for wall mounting in
conjunction with a separate mixing valve motor.
Dekamatik-HK 1 for mounting on
the mixing valve
Underfloor heating circuit
Supply header
Return header
Outdoor temperature sensor*1
Supply temperature sensor
Return temperature sensor
(accessory) (see separate
instructions regarding installation
and electrical connections)
Heating circuit pump
Power supply
Remote control
*2 Viessmann 2-wire BUS for
communication with other
Dekamatik control units
External heat demand /
external heat disable
*1It is possible to connect a separate room temperature sensor (accessory) instead of the outdoor temperature sensor for the purpose of
*1a purely room temperature dependent control.
*1If the outdoor temperature value of the boiler or heating circuit control unit is used via the Viessmann 2-wire BUS, a room temperature
*1sensor can be connected for room temperature dependent control (only possible with communication module, accessory).
*2Only in conjunction with communication module (accessory).
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ATS = Outdoor temperature sensor
VTS = Supply temperature sensor
RLS = Return temperature sensor

Installation
8
Dekamatik-HK1 for Mounting on the Mixing Valve
1. Screw the threaded bolts (M6 or M8
female thread depending on size of
mixing valve) onto the threaded
bolts of the mixing valve.
2. Place the base plate in position and
screw on with the washers and nuts
provided.
3. Snap the control unit with drive
module onto the base plate ;
fasten with the screws provided.
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Fig. 1
Mounting the Dekamatik-HK 1 on the mixing valve

Installation
9
Dekamatik-HK1 for Wall Mounting
1. Pull the wall mounting fixture off the
control unit .
2. Fasten the wall mounting fixture to
the wall with three screws.
3. Carry out the electrical connections
(i.e. mixing valve motor and compiled
fault indication) (see page 18 and 19).
4. Pull off the cover .
5. Push the control unit in the
guideways onto the wall mounting
fixture ; fasten with the screws
provided.
6. Re-fit the cover .
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Fig. 2
Mounting the Dekamatik-HK 1 on the wall

Electrical Connections
10
Overview
Open up the terminal compartment by
unscrewing the screws in the cover
below the programming unit .
Mother board
for heating circuit pump
Connect via connector AC 120 V~
for power supply.
Cord and plug factory supplied;
AC 120 V~60 Hz;
15 A receptacle required (field
supplied).
Fuse F1
On/off switch
Strain relief clamp
Low voltage connections
X14 for outdoor temperature
sensor or room temperature
sensor (accessory)/
supply temperature sensor
X3 not used
or
X3 for return temperature
sensor (accessory) in
conjunction with underfloor
heating circuit
X1 for WS/RS remote control
unit (accessory)
or
X16 for wall mounting fixture
(assembly)
for using Comfortrol program-
ming unit as a remote control
X11 for external heat demand
(open mixing valve) / external
heat disable (close mixing
valve)
or
for external changeover of
the heating program
X16 not used
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Fig. 3
Electrical connections

Electrical Connections
11
Overview (continued)
Wall mounting fixture
Terminal strips for connection of
mixing valve motor or compiled fault
indication
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Fig. 4
Electrical connections in the wall mounting fixture;
Dekamatik-HK1 for wall mounting

Electrical Connections
12
Sensors
Supply temperature sensor (strap-on sensor)
Mount the supply temperature sensor
downstream from the heating circuit
pump on the heating supply pipe at a
distance of approx. 3 to 5 ft /
1 to 1.5 m from the mixing valve.
Where plastic pipes are used, mount the
sensor on an intermediate metal pipe
section. It is not necessary to use heat
conductive paste.
If a pressure-activated bypass valve is
installed, mount the sensor on the
supply pipe immediately after the bypass
valve.
1. Thoroughly clean the heating supply
pipe until metallically bright.
2. Open the case of the sensor with a
screwdriver.
3. Place the perforated mounting strap
(supplied inside the sensor case) on
the tensioning screw , run it around
the supply pipe and place back on
the tensioning screw; tighten the
tensioning screw.
4. Close the sensor case.
The sensor must not be insulated.
5. If the outdoor temperature sensor
or a room temperature sensor is
to be connected, go to page 13.
Otherwise, insert connector
in socket “X14” in the terminal
compartment (see page 10); install
strain relief clamp.
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Fig. 5
Supply temperature sensor
IMPORTANT
Fig. 6
Installing the supply temperature sensor downstream from the bypass valve
Fig. 7
Opening the case
Fig. 8
Opening the supply temperature sensor and fastening with perforated mounting strap
IMPORTANT

Electrical Connections
13
Sensors (continued)
Outdoor temperature sensor
If the outdoor temperature sensor of the boiler or heating circuit control unit is used via the Viessmann
2-wire BUS, it is not necessary to connect the outdoor temperature sensor provided. A room
temperature sensor can be connected instead of the outdoor temperature sensor (see page 14).
1. Remove the cap .
2. Mount the bottom part of the case
(cable entry must point
downwards).
The outdoor temperature sensor should
be mounted 6½ to 8¼ ft / 2 to 2.5 m above
ground level on the north or north-west
facing wall of the building. In the case of
multi-storey buildings, it should be
mounted in the upper half of the second
storey.
If different parts of the building are
controlled via separate heating circuits,
the outdoor temperature sensor should
be mounted on the corresponding side
of the building. For example, if the
heating circuit controls the south-facing
part of the building, the outdoor
temperature sensor must be mounted on
the south-facing wall.
Ensure that the outdoor temperature
sensor is not located over windows,
doors and air vents, nor immediately
beneath a balcony or guttering.
The outdoor temperature sensor must
not be plastered over. If mounting on an
unplastered wall, make allowances for
thickness of plaster or remove sensor
before plastering wall.
3. Connect the cable to the terminals
(the wires are interchangeable).
Cable:
AWG 16/2, copper; max. 115 ft / 35 m.
4. Place cap over base and snap on.
5. Connect the 2-wire cable from the
outdoor temperature sensor to
connector at terminals “1” and “2”
(the wires are interchangeable).
6. Break open the cable bushing; install
strain relief clamp.
7. Insert connector in socket “X14” in
the terminal compartment (see
page 10); install strain relief clamp.
5167 137
Fig. 9
Mounting the outdoor temperature sensor
IMPORTANT
Fig. 10
Connecting the outdoor temperature sensor to the Dekamatik-HK 1
Outdoor temperature sensor
Supply temperature sensor

Electrical Connections
14
Accessories
Room temperature sensor
Room temperature sensor
Supply temperature sensor
1. Mount the room temperature sensor in
accordance with the separate
installation instructions.
2. Connect the 2-wire cable from the
room temperature sensor to
connector at terminals “1” and “2”
(the wires are interchangeable).
3. Break open the cable bushing; install
strain relief clamp.
4. Insert connector in socket “X 14”
in the terminal compartment (see
page 10); install strain relief clamp.
Wall mounting fixture (for using the programming unit as a remote control)
The programming unit of the control unit
can be used as a remote control in the
wall mounting fixture (accessory).
1. Remove the cover .
2. Take the programming unit out of
the control unit.
3. Fit the blank cover of the wall
mounting fixture in the control unit.
5167 137
Fig. 11
Connecting the room temperature sensor to the Dekamatik-HK 1
Fig. 12
Taking the programming unit out of the control unit

Electrical Connections
15
Accessories (continued)
Wall mounting fixture
4. Mount the wall mounting fixture in
accordance with the separate
installation instructions.
5. Connect the 2-wire cable from the wall
mounting fixture to connector at
terminals “1” and “2” (the wires are
interchangeable).
6. Break open the cable bushing; install
strain relief clamp.
7. Insert connector in socket “X 16” in
the terminal compartment (see
page 10); install strain relief clamp.
8. Insert the programming unit in the wall
mounting fixture.
WS remote control unit
RS remote control unit
Remote control unit
1. Mount the remote control unit in
accordance with the separate
installation instructions.
2. Connect the 3-wire cable from the
remote control unit to connector .
3. Break open the cable bushing; install
strain relief clamp.
4. Insert connector in socket “X 1” in
the terminal compartment (see
page 10); install strain relief clamp.
5167 137
Fig. 13
Connecting the wall mounting fixture to the Dekamatik-HK1
Fig. 14
Connecting the remote control unit to the Dekamatik-HK 1

Electrical Connections
16
Accessories (continued)
Heating circuit pump 115 V
1. Install the heating circuit pump in
accordance with the manufacturer’s
specifications and instructions.
Rated current: AC 4 (2) A
2. Disconnect the connector from the
heating circuit pump (if connected);
connect the 3-wire cable from the
heating circuit pump to connector .
3. Insert connector in the socket for
the heating circuit pump.
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In the case of underfloor heating
systems, a high limit aquastat
(immersion or strap-on type)
must be installed in the heating
supply downstream from the mixing
valve and the heating circuit pump.
In this case connect the heating
circuit pump to the high limit
aquastat (see separate Installation
Instructions).
WARNING
Fig. 15
Connecting the 115 V pump

Electrical Connections
17
Accessories (continued)
Heating circuit pump with high current or 3-phase
1. Install the heating circuit pump in
accordance with the manufacturer’s
specifications and instructions.
2. Select contactor and connection wire
according to the rating of the pump to
be connected.
3. Connect the heating circuit pump to the
contactor.
3-Phase pumps require use of contactors
with overload protection.
4. Connect contactor to connector .
5. Insert connector in socket for
heating circuit pump in the terminal
compartment (see page 10); install
strain relief clamp.
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Fig. 16
Connecting the high current or 3-phase pump
Contactor
High current or 3-phase pump
IMPORTANT

Electrical Connections
18
Other Connection Facilities
External heat demand / External heat disable
When the “external heat demand” contact is activated, the mixing valve is opened.
When the “external heat disable” contact is activated, the mixing valve is closed.
1. In the plug-in connector
provided, connect a potential-
free contact for
- external heat demand
or
external changeover of the
heating program (see Service
Instructions for the coding
required) at terminals “3” and “2”
- external heat disable at terminals
“1” and “2.”
2. Break open the cable bushing; install
strain relief clamp.
3. Insert connector in socket “X 11” in
the terminal compartment (see
page 10); install strain relief clamp.
External heat demand
or
external changeover of the heating program
External heat disable
Mixing valve motor only with Dekamatik-HK 1 for wall mounting
HConnect the 4-wire cable from the
mixing valve motor to terminals “X3,”
“X4.1,” “X4.2” and “X4.3” in the wall
mounting fixture of the Dekamatik-HK 1
as shown in Fig. 18.
Mixing valve open
Mixing valve closed
The Dekamatik-HK 1 incorporates a
120 V mixing valve output.
5167 137
Fig. 17
Connecting external heat demand / external heat disable
Fig. 18
Connecting the mixing valve motor
Wall mounting fixture
IMPORTANT

Electrical Connections
19
Other Connection Facilities (continued)
Compiled fault indication only with Dekamatik-HK 1 for wall mounting
Data transfer and sensor faults are reported.
In conjunction with a Dekamatik boiler control unit, a compiled fault message is also
relayed to these via the Viessmann 2-wire BUS (accessory).
Wall mounting fixture
1. Select the signal device (provided by
the customer).
Rated voltage: AC 120 V~
Rated current: AC 4 (2) A
2. Carry out the connection to terminals
“X3,” “X4.4” and “X4.5” in the wall
mounting fixture of the Dekamatik-HK 1
as shown in Fig. 19.
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Fig. 19
Connecting the compiled fault indication

Electrical Connections
20
Power Supply
Safety requirements
Install power supply in accordance with the regulations of the authorities having
jurisdiction or, in the absence of such requirements, in accordance with National
Codes.
The Dekamatik-HK 1 is standard equipped with a 120 V power cord. A receptacle with
a max. 15 A circuit breaker or fuse is required (field supplied).
5167 137