Viessmann PM1 Quick guide

Installation and service instructions
for contractors
VIESMANN
Pump module PM1
Function extension for wall mounting to control a circulation pump:
■Single boiler systems: Boiler circuit pump
■Multi boiler systems: Feed pump
Pump module PM1
5812530 GB/en 12/2017 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5812530

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5812530

4
1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
System examples .................................................................................. 6
2. Installation sequence Wall mounting ........................................................................................ 7
Inserting cables and providing strain relief ............................................ 7
Overview of electrical connections ........................................................ 7
Connecting the circulation pump ........................................................... 8
■Enable contact hH ............................................................................... 8
■Connecting circulation pumps without enable contact ........................ 8
■Connecting circulation pumps with enable contact ............................. 11
Temperature sensors ............................................................................. 13
Fault message input .............................................................................. 14
Power supply ......................................................................................... 14
■Separate power supply ....................................................................... 15
■Power supply via Vitotronic control unit .............................................. 15
3. Commissioning and
adjustment
Starting the pump module ...................................................................... 16
Setting parameters ................................................................................ 16
■Calling up parameters ........................................................................ 16
■Parameters in the "General" group ................................................... 16
■Parameters in the "Pump module" group ......................................... 16
Adjusting an individual circulation pump curve ...................................... 32
■Calculating pairs of values for the circulation pump control range ..... 34
■Configuring an individual circulation pump curve ............................... 35
Checking pump module outputs (actuator test) ..................................... 36
4. Diagnosis and fault mes-
sages
Brief scan ............................................................................................... 37
Fault messages ..................................................................................... 37
■74 Short circuit sensor 1 pump module .............................................. 37
■75 Short circuit sensor 2 pump module .............................................. 37
■76 Short circuit sensor 3 pump module .............................................. 38
■77 Short circuit sensor 4 pump module .............................................. 38
■7C Lead break sensor 1 pump module .............................................. 38
■7D Lead break sensor 2 pump module .............................................. 38
■7E Lead break sensor 3 pump module ............................................... 39
■7F Lead break sensor 4 pump module ............................................... 39
■A5 Fault message at pump module digital input ................................. 39
■A6 Internal pump module error ........................................................... 39
■C4 Pump module comm error ............................................................ 39
Checking the temperature sensors ........................................................ 40
Checking the fuses ................................................................................ 40
5. Parts lists Overview of assemblies ......................................................................... 41
Pump module ......................................................................................... 42
6. Connection and wiring dia-
gram
................................................................................................................ 44
7. Specification ................................................................................................................ 45
8. Certificates Declaration of conformity ....................................................................... 46
9. Keyword index ................................................................................................................ 47
Index
Index
5812530

5
Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is designed exclusively for the control of boiler circuit
pumps.
Commercial or industrial use for a purpose other than
the heating of heating water shall be deemed inappro-
priate.
Intended use presupposes that a permanent installa-
tion in conjunction with permissible components
designed for this purpose has been carried out.
Information
Disposal of packaging
5812530
Information

6
All other use is deemed inappropriate. Any resulting
losses are excluded from the manufacturer's liability.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Intended use also includes adherence to maintenance
and inspection intervals.
Product information
Pump module PM1 contains the inputs, outputs, and
functions required for control of and signal acquisition
from the following circulation pumps:
■Single boiler systems: Boiler circuit pump
■Multi boiler systems: Feed pump
On systems with a heating water buffer cylinder or low
loss header, the power demand of the connected circu-
lation pump and the heat recovery and energy effi-
ciency of the system can be optimised with the pump
module. This function is set and the circulation pump
configured subject to the system configuration.
Pump module PM1 is available as an accessory for the
following Vitotronic control units for medium sized and
industrial/commercial boilers:
■Vitotronic 100, types CC1E and CC1I
■Vitotronic 200, types CO1E and CO1I
■Vitotronic 300, types CM1E and CM1I
For more information, see www.vitotronic.info
System examples
For available system examples, see www.viessmann-
schemes.com
Information
Intended use (cont.)
5812530
Information

7
1.
2.
Fig. 1
Inserting cables and providing strain relief
■Provide strain relief for on-site cables.
■Seal any unnecessary apertures with cable grom-
mets (not cut open).
Fig. 2
Overview of electrical connections
!Please note
Electrostatic charge can damage electronic
assemblies.
Before beginning work, touch an earthed object
such as a heating or water pipe to discharge any
static.
F4
? ?
fÖ
?
sL f-]
A
0 - 10 V
OUT
S3 S4S1 S2
DE1
aVG aVG hH
SP Ö
Fig. 3
sL Circulation pump power supply
fÖ Power supply 230 V/50 Hz
fÖAMains connection for accessories
Installation sequence
Wall mounting
5812530
Installation

8
hH Floating output for circulation pump with enable
contact
DE1 Circulation pump fault message input
aVG KM-BUS to Vitotronic control unit
F4 Fuse 4 A (slow), 250 V~
0 - 10 V OUT 0 to 10 V output for control voltage for
speed control
S1 to S4 Temperature sensors for functions 1 to 7
according to setting in parameter "03"
(see chapter "Setting parameters")
Viessmann NTC 10 kΩ (blue marking)
Connecting the circulation pump
Enable contact hH
Floating output for circulation pump enable
hH
SP Ö
X2 hH
SP Ö
X2
A B
Fig. 4
AFloating contact as N/C contact:
P — Ö opens when demand present.
BFloating contact as N/O contact:
P — S closes when demand present.
■Switching voltage: 24 to 230 V~
■Switching current: 0.01 to 1 A
Note
Safety and protective equipment of the connected con-
sumer must be switched on.
Connecting circulation pumps without enable contact
Circulation pumps 230 V~
?
sL
aVG aVG
12
+-
U
-
+
hH
SP Ö
N
PE
L
145 0-10 V
A
BC
0-10 V
OUT
+-
145
Fig. 5
APump module PM1
BVitotronic control unit
CCirculation pump
sL Circulation pump power supply
aVG KM-BUS cable between pump module and
Vitotronic control unit
0 - 10 V OUT 0 to 10 V output for control voltage for
speed control
Installation sequence
Overview of electrical connections (cont.)
5812530
Installation

9
Separate power supply or 230 V~ circulation pump with power consumption greater than 2 A
?
sL
aVG aVG
12
+-
U
-
+
hH
SP Ö
145
0 - 10 V
A
B
C
0 - 10 V
OUT
LN LN
N PE
L
E
D
145
+-
Fig. 6
APump module PM1
BVitotronic control unit
CCirculation pump
DContactor
ECirculation pump power supply 230 V/50 Hz
sL Power supply for on-site contactor D for switch-
ing the circulation pump power supply
aVG KM-BUS cable between pump module and
Vitotronic control unit
0 - 10 V OUT 0 to 10 V output for control voltage for
speed control
Installation sequence
Connecting the circulation pump (cont.)
5812530
Installation

10
Circulation pump 400 V~
L1 L2 L3 N PE
?
sL
aVG aVG
12
+-
U
-
+
hH
SP Ö
145
0-10 V
A
B
C
0-10 V
OUT
LN
D
NPE
L3
L1 L2
145
+-
E
Fig. 7
APump module PM1
BVitotronic control unit
CCirculation pump
DContactor
ECirculation pump power supply 400 V/50 Hz
sL Power supply for on-site contactor D for switch-
ing the power supply to the circulation pump
aVG KM-BUS cable from pump module to Vitotronic
control unit
0 - 10 V OUT 0 to 10 V output for control voltage to
the speed controller
Installation sequence
Connecting the circulation pump (cont.)
5812530
Installation

11
Connecting circulation pumps with enable contact
Circulation pumps 230 V~
?
sL
aVG aVG
12
+-
U
-
+
hH
SP Ö
External
ON/OFF
N
PE
L
145 0-10 V
A
BC
0-10 V
OUT
+-
145
Fig. 8
APump module PM1
BVitotronic control unit
CCirculation pump
sL Circulation pump power supply
hH Floating switching contact for enabling the circu-
lation pump
Enable contact can be connected as N/C or N/O
contact: See fig. 4, page 8
aVG KM-BUS cable between pump module and
Vitotronic control unit
0 - 10 V OUT 0 to 10 V output for control voltage for
speed control
Installation sequence
Connecting the circulation pump (cont.)
5812530
Installation

12
Separate power supply or 230 V~ circulation pump with power consumption greater than 2 A
?
sL
aVG aVG
12
+-
U
-
+
hH
SP Ö
External
ON/OFF
145
0 - 10 V
A
B
C
0 - 10 V
OUT
LN LN
N PE
L
E
D
+-
145
Fig. 9
APump module PM1
BVitotronic control unit
CCirculation pump
DContactor
ECirculation pump power supply 230 V/50 Hz
sL Power supply for on-site contactor D for switch-
ing the circulation pump power supply
hH Floating switching contact for enabling the circu-
lation pump
Enable contact can be connected as N/C or N/O
contact: See fig. 4, page 8
aVG KM-BUS cable between pump module and
Vitotronic control unit
0 - 10 V OUT 0 to 10 V output for control voltage for
speed control
Installation sequence
Connecting the circulation pump (cont.)
5812530
Installation

13
Circulation pump 400 V~
L1 L2 L3 N PE
?
sL
aVG aVG
12
+-
U
-
+
hH
SP Ö
External
ON/OFF
145
0-10 V
A
B
C
0-10 V
OUT
LN
D
NPE
L3
L1 L2
145
+-
E
Fig. 10
APump module PM1
BVitotronic control unit
CCirculation pump
DContactor
ECirculation pump power supply 400 V/50 Hz
sL Power supply for on-site contactor D for switch-
ing the circulation pump power supply
hH Floating switching contact for enabling the circu-
lation pump
Enable contact can be connected as N/C or N/O
contact: See fig. 4, page 8
aVG KM-BUS cable between pump module and
Vitotronic control unit
0 - 10 V OUT 0 to 10 V output for control voltage for
speed control
Temperature sensors
S3 S4S1 S2
DE1
aVG aVG
Fig. 11
S1 to S4 Temperature sensors for functions 1 to 7
according to setting in parameter "03" (see
chapter "Setting parameters")
Viessmann NTC 10 kΩ (blue marking)
Installation sequence
Connecting the circulation pump (cont.)
5812530
Installation

14
S3 S4S1 S2
aVG aVG DE1
Fig. 12
DE1 Floating contact
External contacts must be floating. When connecting,
observe the requirements of protection class II, i.e.
8.0 mm air and creep path or 2.0 mm insulation thick-
ness to live parts.
Function uses setting in parameter "04" (see chapter "Setting parameters"):
Setting Function
04:1 ■Contact open:
Fault message "A5" is displayed on the Vitotronic control unit.
■Contact closes:
No fault
04:2 ■Contact closed:
Fault message "A5" is displayed on the Vitotronic control unit.
■Contact opens:
No fault
Power supply
Connecting heat generator accessories to a power
supply
■Oil or gas boiler:
Plug aBH on Vitotronic control unit:
Observe max. connected load of all accessories
(400 W). If required, connect pump module PM1
directly to the mains supply: See boiler or Vitotronic
control unit installation and service instructions.
Danger
Incorrectly executed electrical installations can
result in injuries from electrical current and dam-
age to the appliance.
Connect the power supply and implement all
safety measures (e.g. RCD circuit) in accord-
ance with the following regulations:
■IEC 60364-4-41
■VDE regulations
■Technical connection requirements specified
by the local power supply utility
■Protect the power cable on site with a fuse of
up to 16 A.
Danger
The absence of system component earthing can
lead to serious injury from electric current if an
electrical fault occurs.
The appliance and pipework must be connected
to the equipotential bonding of the building.
Isolators for non-earthed conductors
■Install an isolator in the power cable to provide
omnipolar separation from the mains for all active
conductors, corresponding to overvoltage category
III (3 mm) for full isolation. The isolator must be fitted
in the permanent electrical installation, in line with
installation requirements.
■We additionally recommend installing an AC/DC-
sensitive RCD, type B , for DC (fault) currents
that can occur with energy efficient equipment.
Power supply for accessories and external compo-
nents
■Recommendation: For accessories and external
components that are not connected to the control
unit, make the power connection to the same fuse.
At the very least, connect them in phase with the
control unit.
■Connection to the same fuse provides additional
safety in the event of the power being switched off.
Observe the power consumption of the connected
consumers.
Installation sequence
Fault message input
5812530
Installation

15
Danger
Incorrect core assignment can result in serious
injury and damage to the appliance.
Never interchange cores "L" and "N".
!Please note
Incorrect phase sequence can cause damage to
the appliance.
Ensure phase equality with the Vitotronic control
unit power supply.
Power cable
■If the mains connection is made with a flexible power
cable, it must be ensured that the live conductors get
pulled taut before the earth conductor in the event of
strain relief failure. The length of the earth conductor
wire will depend on the design.
Separate power supply
? ?
fÖf-]
A
230 V~
B
L1
N
?
sL
F4
A
Fig. 13
APump module PM1
BMains isolator (if required)
Power supply via Vitotronic control unit
? ?
fÖf-]
A
?
sL
F4
B
A
156
Fig. 14
APump module PM1
BPlug aBH to Vitotronic control unit
Installation sequence
Power supply (cont.)
5812530
Installation

16
1. Switch ON the power supply at the separate fuse
or the mains isolator.
2. Turn on the ON/OFF switch on the Vitotronic con-
trol unit.
Vitotronic control unit installation and service
instructions
The Vitotronic control unit automatically detects the
pump module as a KM-BUS subscriber (parameter
"1B:1" in the "General" group).
Note
All pump module settings and scans are carried out on
the Vitotronic control unit.
Setting parameters
Calling up parameters
Tap the following buttons:
01.
02. "Service"
03. Enter the password "viservice".
04. "System configuration"
05. "Parameter level 2"
Enter the password "viexpert".
06. Select "Pump module" group.
07. Use or to select the parameter.
08.
09. Use or for the required value in line with
the tables below.
10. Confirm with .
Note
■Parameter level:
At "Parameter level 1", not all parameters are avail-
able. In the "Pump module" group, only parameters
"00" and "03" are available.
All pump module setting parameters available in
"Parameter level 2" are listed below.
■Pump module enable:
Parameter "1B:1" in the "General" group is used to
enable the pump module.
The pump module is detected automatically. The
parameter is set automatically.
■Parameter values:
Parameter values in bold are factory settings.
The parameters that can be adjusted depend on the
function selected in parameter "03".
Parameters in the "General" group
1B Pump module PM1
Display Value Explanations
Without 1B:0 No pump module available
With 1B:1 Recognised automatically. Pump module is enabled.
Parameters in the "Pump module" group
00 Pump type
The circulation pump is controlled according to the
curve set here. This curve can be configured individu-
ally using parameters "20" to "26", which match it to
the existing circulation pump type.
Parameters "20" to "26" can alternatively be set in the
"Individual pump type" menu (see chapter "Configur-
ing an individual circulation pump curve").
You can determine the required settings using a relay
test (see chapter "Determining an individual circulation
pump control range").
Commissioning and adjustment
Starting the pump module
5812530
Commissioning

17
Display Value Explanations
Individual pump type 00:0 The circulation pump is controlled according to the
following default curve:
%
100
25
10
1.0 3.9 10.0 V
Example of circulation pump with enable contact
Wilo 00:1 Wilo Stratos circulation pumps are controlled accord-
ing to the following curve:
%
100
50
25
3.0 5.3 10.0 V
Circulation pump without enable contact
GRUNDFOS 00:2 Grundfos Magna circulation pumps are controlled ac-
cording to the following curve:
%
100
65
30
2.0 4.6 10.0 V
Circulation pump with enable contact
01 Feed pump in multi boiler system
Display Value Explanations
Activation via butterfly valve status 01:0 As soon as at least one butterfly valve opens, the
feed pump is enabled.
Activation via distribution pump switching
signal
01:1 As soon as the distribution pump runs, the feed pump
is enabled.
Commissioning and adjustment
Setting parameters (cont.)
5812530
Commissioning

18
03 Function selec. pump
Display Value Explanations
None 03:0 Function 0:
No speed control
The boiler circuit pump is switched on via the
Vitotronic control unit when a heat demand exists.
The control voltage corresponds to the control volt-
age for the max. flow rate, and depends on the boiler
circuit pump used (see parameter "25").
Function 1: Speed output-controlled 03:1 Function 1:
Only in conjunction with a heating water buffer cylin-
der
M
C
D
A
B
E
ABoiler water temperature sensor § or 3A/3B
BOil/gas boiler
CHeating water buffer cylinder
DHeating circuit
EBoiler circuit pump
In function 1, the speed of the boiler circuit pump is
controlled subject to the current burner output.
The higher the burner output, the higher the speed of
the boiler circuit pump.
■The flow rates at minimum and maximum burner
output are set in parameters "05" and "06".
■No additional temperature sensors need to be con-
nected to the pump module.
Commissioning and adjustment
Setting parameters (cont.)
5812530
Commissioning

19
Display Value Explanations
Function 2: Target temp control 03:2 Function 2:
Only in conjunction with a heating water buffer cylin-
der
M
C
D
A
B
E
ABoiler water temperature sensor § or 3A/3B
BOil/gas boiler
CHeating water buffer cylinder
DHeating circuit
EBoiler circuit pump
In function 2, the speed of the boiler circuit pump is
controlled subject to the set boiler water temperature.
The smaller the temperature differential between the
actual and set boiler water temperature, the higher
the speed of the boiler circuit pump.
This allows the boiler water temperature to rise more
quickly. It also prevents the system from being cooled
down by high flow rates with low boiler water temper-
atures.
Temperature sensor used for function 2:
■Boiler water temperature sensor at plug § of the
Vitotronic control unit
or
Boiler water temperature sensor at plug 3A/3B of
the burner control unit
■If the target temperature needs to be controlled dif-
ferently, e.g. through the flow temperature in the
boiler circuit, an additional temperature sensor can
be connected to plug S3 of the pump module. In
this case, parameter "2B:1" should be set.
Note
For further setting options for function 2, see parame-
ters "07", "08" and "09".
Commissioning and adjustment
Setting parameters (cont.)
5812530
Commissioning

20
Display Value Explanations
Function 3: Differential temp ctrl, return
(single boiler system)
03:3 Function 3:
In conjunction with low loss header only
M
D
A
B
C
E
GF
H
ABoiler water temperature sensor § or 3A/3B
BOil/gas boiler
CTemperature sensor, low loss header )
DHeating circuit
ELow loss header
FSystem return temperature sensor S2
GBoiler return temperature sensor S1
HBoiler circuit pump
In function 3, the boiler circuit pump speed is control-
led according to the temperature differential between
the return temperatures upstream and downstream of
the low loss header (boiler return temperature and
system return temperature). This maintains a con-
stant temperature differential.
The greater the temperature differential, the lower the
boiler circuit pump speed.
This prevents an imbalance between the boiler and
system circuit flow rates. Balancing the two flow rates
increases the degree of condensing technology uti-
lisation, and reduces the boiler circuit pump power
consumption.
Temperature sensors required for function 3:
■Boiler return temperature sensor at plug S1 of the
pump module
■System return temperature sensor at plug S2 of the
pump module
The temperature sensors are recognised automati-
cally.
Note
For further setting options for function 3, see parame-
ters "0A", "0B" and "0C".
Commissioning and adjustment
Setting parameters (cont.)
5812530
Commissioning