Viessmann SM1 Quick guide

Please file in Service Binder
5774 469 v1.0 09/2013
SM1
SOLAR CONTROL MODULE
for use by heating contractor
Installation and Service
Instructions
Solar Control Module
for solar connections to the Vitotronic control
Product may not be exactly as shown
Read and save these instructions
for future reference.
IMPORTANT
Certified as a component
part for Viessmann boilers

Solar Control Module SM1, Installation and Service
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual can cause product/property damage, severe personal
injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
Product 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.
uFor a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
uPlease see section entitled Safety and
“Important Regulatory and Installation
Requirements”.
Advice 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, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Safety
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
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5774 469 v1.0

Table of Contents
Page
5774 469 v1.0
Solar Control Module SM1, Installation and Service
3
Safety
Important Precautions
General Information
Installation
Connections
Additional Information
Safety, Installation and Warranty Requirements..............2
Product documentation...........................................2
Licensed professional heating contractor...................2
Advice to owner....................................................2
Warranty...............................................................2
Important Regulatory and Installation Requirements........4
Approvals.............................................................4
Codes..................................................................4
Working on the equipment......................................4
Power supply........................................................4
About these Installation Instructions..............................5
Mounting on the Wall....................................................6
Overview of Electrical Connections...............................7
.System Example 1...................................................8
.System Example 2...................................................11
.System Example 3....................................................14
Power Supply...........................................................18
Connecting the KM Bus to the Extension Modules........19
Connection and Wiring Diagram.................................20
Function Description.................................................21
Specifications..........................................................23

Solar Control Module SM1, Installation and Service
5774 469 v1.0
4
Important Precautions
Important Regulatory and Installation Requirements
Approvals
Viessmann boilers, burners and controls are approved for
sale in North America by CSA International.
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
- CSA C22.1 Part 1 and/or local codes in Canada
- National Electrical Code ANSI/NFPA 70 in the U.S.
Always use latest editions of codes.
The heating contractor must comply with the Standard
for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1 where required by the
authority having jurisdiction.
Working on the equipment
The installation, adjustment, service, and maintenance
of this product must be done by a licensed professional
heating contractor who is qualified and experienced in the
installation, service, and maintenance of hot water boilers.
There are no user serviceable parts on the boiler, burner,
or control.
Power supply
Install power supply in accordance with the regulations
of the authorities having jurisdiction or, in absence of
such requirements, in accordance with National Codes.
Viessmann recommends the installation of a disconnect
switch to the 120V power supply outside of the boiler
room.
Ensure main power supply to equipment, the heating
system, and all external controls have been deactivated.
Close main oil or gas supply valve. Take precautions in
both instances to avoid accidental activation of power
during service work.
u Please carefully read this manual prior to attempting
installation. Any warranty is null and void if these
instructions are not followed.
For information regarding other Viessmann System
Technology componentry, please reference
documentation of the respective product.
We offer frequent installation and service seminars
to familiarize our partners with our products. Please
inquire.
u The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. These include low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
WARNING
Turn off electric power supply before
servicing. Contact with live electric
components can cause shock or loss
of life.

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5774 469 v1.0
Solar Control Module SM1, Installation and Service
About these Installation Instructions
General Information
Take note of all symbols and notations intended to draw attention to potential hazards or important
product information.
CAUTION
Cautions draw your attention to the presence of potential
hazards or important product information.
WARNING
Warnings draw your attention to the presence of potential
hazards or important product information.
u
IMPORTANT
u Indicates an imminently hazardous situation which,
if not avoided, could result in death, serious injury or
substantial product/property damage.
u Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product /
property damage.
u Helpful hints for installation, operation or maintenance
which pertain to the product.
u This symbol indicates to note additional information
u This symbol indicates that other instructions must be
referenced.

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Installation
Mounting on the Wall
Extension kit for installation on a wall
1. Loosen the retaining screws from the extension kit
enclosure (do not remove).
2. Remove cover and set aside.
3. Mount the extension module enclosure to the wall
using the supplied hardware.
4. Install the cover.
Components:
HSM1 module
HKM BUS plug aVG
HPower cord pre-wired to plug fÖ
HTemperature sensor %
HTemperature sensor &
HTemperature sensor / (accessory)
HTemperature sensor aÖ (accessory)
HPump plug sS
HPump plug sF
HSpeed control PWM plug

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Solar Control Module SM1, Installation and Service Connections
Overview of Electrical Connections
Note: Apply a strain relief to all on-site cables.
Close any unnecessary knock-outs with cable
grommets (not cut open).
CAUTION
Electronic modules can be damaged by electrostatic
charges.
Before commencing work, touch an grounded object,
e.g. heating or water pipes to discharge static loads.
Legend
A Solar control module
% DHW tank temperature sensor
& Collector temperature sensor
/ Temperature sensor (accessory)
aÖ Temperature sensor (accessory)
sS Transfer pump or 3-way diverter valve
sF Solar circuit pump
fÖ Power supply
aVG KM BUS to boiler control unit
PWM Speed control, solar circuit pump (if circulation
pump with PWM control installed)
A

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System Example 1
Connections
DHW heating with dual mode DHW tank
Function description
DHW heating with solar energy
If the temperature differential between collector
temperature sensor eQ and DHW tank temperature sensor
qQ is greater than the start temperature differential
(coding address 00), solar circuit pump eE is started and
DHW tank qP is heated.
Solar circuit pump eE stops if:
HActual temperature drops below stop temperature
differential (coding address 01)
HMaximum DHW tank temperature is exceeded (coding
address 08)
HThe temperature selected at high limit safety cut-out qW
(if installed) is reached
Additional function for DHW heating
The requirements for the additional function are achieved
through circulation pump qT.
Boiler installation and service instructions
Suppression of DHW tank reheating by the boiler
Reheating suppression takes place in two stages.
Required codes at the oil/gas boiler control unit
Reheating of DHW tank qP by boiler 1is suppressed
as soon as DHW tank qP is heated by collectors eP.
For this, the set DHW tank temperature for reheating
is reduced by boiler 1. After solar circuit pump eE
has been switched off, suppression remains active
for a certain time.
In the case of uninterrupted heating by the collectors eP
(> 2 h), boiler 1will only reheat if the set DHW
temperature selected at boiler control unit 2(coding
address “67”) is not achieved.
A third set DHW temperature can be specified via coding
address “67” [setting range 50 to 203° F (10 to 95° C)].
This value must be below the first set DHW temperature.
DHW tank qP will only be heated by boiler 1if this set
value cannot be achieved by the solar thermal system.
DHW heating without solar energy
The upper section of DHW tank qP is heated by
boiler 1. The DHW tank thermostat with DHW tank
temperature sensor qZ of boiler control unit 2regulates
DHW tank heating.
Note: Coding address 00 can be set to min. 0.9° F (0.5 K)
above coding address 01.
Coding address 01 can be set to max. 0.9° F (0.5 K)
below coding address 00.
Function/system components
Code in solar group
Adjust Factory set
condition
Start temperature differential for solar circuit pump at connection sF
Factory set condition 8 K (14.4° F)
00:... 00:8
Stop temperature differential for solar circuit pump at connection sF
Factory set condition 4 K (7.2° F)
01:... 01:4
Solar circuit pump type:
HSolar circuit pump is not speed-controlled
HSolar circuit pump is speed-controlled with wave pack control
HSolar circuit pump is speed-controlled with PWM control
--
02:1
02:2
02:0
02:0
02:0
Maximum DHW tank temperature (Factory set condition 140 F) 60° C) 08:... 08:60
Additional DHW heating function:
HWithout additional function for DHW heating
HWith additional function for DHW heating
--
20:1
20:0
20:0

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5774 469 v1.0
Solar Control Module SM1, Installation and Service Connections
System Example 1 (continued)
Hydraulic installation scheme
Equipment required
Legend
1 Wall mounted oil/gas boiler with
2 Boiler and heating circuit control unit
qP Dual mode DHW tank
qQ DHW tank temperature sensor % (solar control
module)
qW High limit safety cut-out (accessory)
qE DHW circulation pump (on site) (accessories may be
required for connection)
qR Thermostatic mixing valve (accessory)
qT Circulation pump sS (transfer of heat, on site)
qZ DHW tank temperature sensor % (boiler)
eP Solar collectors
eQ Collector temperature sensor &
eW Solar-Divicon (accessory) with
eE Solar circuit pump sF
eZ Solar control module, type SM1
eU Junction box (on site)

Solar Control Module SM1, Installation and Service
5774 469 v1.0
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Connections
System Example 1 (continued)
Electrical installation scheme
Solar control module, type SM1

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5774 469 v1.0
Solar Control Module SM1, Installation and Service Connections
DHW heating with two mono mode DHW tanks
Function description
DHW heating with solar energy
If the temperature differential between collector
temperature sensor eQ and DHW tank temperature sensor
qQ is greater than the start temperature differential
(coding address 00), solar circuit pump eE starts and
DHW tank 1 qP is heated.
Solar circuit pump eE stops if:
HActual temperature drops below stop temperature
differential (coding address 01)
HMaximum DHW tank temperature is exceeded (coding
address 08)
HThe temperature selected at high limit safety cut-out qW
(if installed) is reached
Transfer pump qT starts if the temperature at temperature
sensor qZ has reached the start temperature differential
of the differential temperature control 2 (code 22).
The water heated in DHW tank 1 qP is supplied to DHW
tank 2 qI. This means DHW tank 2 qI is also heated
by solar energy.
Transfer pump qT stops if the temperature at temperature
sensor qZ has fallen below the stop temperature differential
of the differential temperature control 2 (code 23).
System Example 2
Additional function for DHW heating
The requirements for the additional function are achieved
through circulation pump qT.
Suppression of DHW tank 2 heating by the boiler with
DHW heating Reheating suppression takes place in two
stages.
Heating DHW tank 2 qI by boiler 1is suppressed
as soon as DHW tank 1 qP is heated by collectors eP.
For this, the set DHW tank temperature for reheating
is reduced by boiler 1. After solar circuit pump eE
has been switched off, suppression remains active
for a certain time.
Boiler installation and service instructions
In the case of uninterrupted heating by the collectors
eP (> 2 h), boiler 1will only heat if the set DHW
temperature selected at boiler control unit 2(coding
address “67”) is not achieved.
A third set DHW temperature can be specified via coding
address “67” [setting range 50 to 203° F (10 to 95° C)].
This value must be below the first set DHW temperature.
DHW tank 2 qI will only be heated by boiler 1, if this
set value is not achieved by the solar thermal system.
DHW heating without solar energy
DHW tank 2 qI is heated by boiler 1.
The DHW tank thermostat with DHW tank temperature
sensor qO of boiler control unit 2starts the internal
circulation pump and changes the 3-way diverter valve
to DHW heating.
Note: Coding address 00 can be set to min. 0.9° F
(0.5 K) above coding address 01.
Coding address 01 can be set to max. 0.9° F
(0.5 K) below coding address 00.
Function/system components
Code in solar group
Adjust Factory set condition
Start temperature differential for solar circuit pump at
connection sF. Factory set condition 8 K (14.4° F)
00:... 00:8
Stop temperature differential for solar circuit pump at
connection sF. Factory set condition 4 K (7.2° F)
01:... 01:4
Solar circuit pump type:
HSolar circuit pump is not speed-controlled
HSolar circuit pump is speed-controlled with wave pack control
HSolar circuit pump is speed-controlled with PWM control
--
02:1
02:2
02:0
02:0
02:0
Maximum DHW tank temperature (Factory set condition 60° C) 08:... 08:60
Start temperature differential with central heating
backup. Factory set condition 8 K (14.4° F)
22:... 22:8
Stop temperature differential with central heating
backup. Factory set condition 4 K (7.2° F)
23:... 23:4
Required codes at the oil/gas boiler control unit

Solar Control Module SM1, Installation and Service
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System Example 2 (continued)
Connections
Hydraulic installation scheme
Equipment required
Legend
1Wall mounted oil/gas boiler with
2Boiler and heating circuit control unit
qP DHW tank 1, mono mode
qQ DHW tank temperature sensor %(solar control
module)
qW High limit safety cut-out (accessory)
qE DHW circulation pump (on site) (accessories may
be required for connection)
qR Thermostatic mixing valve (accessory)
qT Transfer pump (on site)
qZ Temperature sensor /(accessory)
qU Temperature sensor aÖ (accessory)
qI DHW tank 2, mono mode
qO DHW tank temperature sensor %(boiler)
eP Solar collectors
eQ Collector temperature sensor &
eW Solar-Divicon (accessory)
eE Solar circuit pump sF (standard delivery, Solar-Divicon)
eZ Solar control module, type SM1
eU Junction box

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5774 469 v1.0
Solar Control Module SM1, Installation and Service
System Example 2 (continued)
Electrical installation scheme
Solar control module, type SM1
A KM BUS to boiler control unit
Connections

Solar Control Module SM1, Installation and Service
5774 469 v1.0
14
System Example 3
DHW heating with mono mode DHW tank and central
heating backup with multi mode heating water buffer
DHW tank with differential temperature control
Function description
DHW heating with solar energy
If the temperature differential between collector
temperature sensor eQ and DHW tank temperature sensor
rQ is greater than the start temperature differential
(coding address 00), solar circuit pump eE starts and
heating water buffer DHW tank rP is heated.
Solar circuit pump eE stops if:
HActual temperature drops below stop temperature
differential (coding address 01)
HMaximum DHW tank temperature is exceeded (coding
address 08)
HThe temperature selected at high limit safety cut-out rR
(if installed) is reached
Entire heating water buffer DHW tank rP is heated by the
solar thermal system if the insolation is adequate.
If there is insufficient solar energy, the DHW is preheated
by the solar energy available in heating water buffer DHW
tank rP, and is brought up to the required temperature
in DHW tank qP via boiler 1.
The burner and circulation pump for DHW tank heating 7
are started via DHW tank temperature sensor qQ of the
boiler control unit.
Suppression of heating water buffer DHW tank reheating
by the boiler with DHW heating
Reheating suppression takes place in two stages.
Heating of DHW tank qP by boiler 1is suppressed
as soon as heating water buffer DHW tank rP is heated
by collectors eP. For this, the set DHW tank temperature
for reheating is reduced by boiler 1. After solar circuit
pump eE has been switched off, suppression remains
active for a certain time.
In the case of uninterrupted heating by the collectors
eP (> 2 h), boiler 1will only reheat if the set DHW
temperature selected at boiler control unit 2(coding
address “67”) is not achieved.
A third set DHW temperature can be specified via coding
address “67” [setting range 50 to 203° F (10 to 95° C)].
This value must be below the first set DHW temperature.
DHW tank qP will only be heated by boiler 1if this set
value cannot be achieved by the solar thermal system.
DHW heating without solar energy
DHW tank qP is heated by boiler 1.
The DHW tank thermostat with DHW tank temperature
sensor qQ of boiler control unit 2controls circulation
pump for DHW tank heating 7.
Connections

15
5774 469 v1.0
Solar Control Module SM1, Installation and Service
System Example 3 (continued)
Central heating with solar energy
If the temperature differential between sensor rW and
sensor rT is greater than the temperature differential
of coding address 22, 3-way diverter valve rZ is switched
to direction “AB-A”. The heating circuit return water
is routed through heating water buffer DHW tank rP
and heated by solar energy.
Suppression of reheating by the boiler in the case of
central heating backup with solar energy
If a sufficiently high temperature is available in heating
water buffer DHW tank rP to heat the heating circuits,
reheating by boiler 1can be suppressed.
Boiler installation and service instructions
Function/system components
Code in solar group
Adjust Factory set condition
Start temperature differential for solar circuit pump at connection sF
Factory set condition 8 K (14.4° F)
00:... 00:8
Stop temperature differential for solar circuit pump at connection sF
Factory set condition 4 K (7.2° F)
01:... 01:4
Solar circuit pump type:
HSolar circuit pump is not speed-controlled
HSolar circuit pump is speed-controlled with wave pack control
HSolar circuit pump is speed-controlled with PWM control
--
02:1
02:0
02:0
02:0
02:0
Maximum DHW tank temperature (Factory set condition 60° C) 08:... 08:60
Differential temperature control 2 with central heating backup 20:4 20:0
Start temperature differential with central heating backup
Factory set condition 8 K (14.4° F)
22:... 22:8
Stop temperature differential with central heating backup
Factory set condition 4 K (7.2° F)
23:... 23:4
Central heating without solar energy
If the temperature differential between sensor rW
and sensor rT is less than the temperature differential
of coding address 23, 3-way diverter valve rZ is switched
to direction “AB-B”. The heating circuit return water
is routed directly into low loss header tP and only heated
by the boiler.
Required codes at the oil/gas boiler control unit
Connections
Note: Coding address 00 can be set to min. 0.9° F
(0.5 K) above coding address 01.
Coding address 01 can be set to max. 0.9° F
(0.5 K) below coding address 00.

Solar Control Module SM1, Installation and Service
5774 469 v1.0
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System Example 3 (continued)
Hydraulic installation scheme
Equipment required
Legend
1Wall mounted oil/gas boiler with
2Boiler and heating circuit control unit
7 Circulation pump for DHW tank heating (on site)
(accessories may be required for connection)
qP Mono mode DHW tank
qQ DHW tank temperature sensor %(boiler)
qE DHW circulation pump (on site) (accessories may be
required for connection)
qR Thermostatic mixing valve (accessory)
eP Solar collectors
eQ Collector temperature sensor &
eW Solar-Divicon (accessory)
eE Solar circuit pump sF (standard delivery, Solar-Divicon)
eZ Solar control module, type SM1
eU Junction box (on site)
rP Heating water buffer DHW tank
rQ DHW tank temperature sensor %(solar control module)
rW Temperature sensor /(flow temperature sensor
in heating water buffer DHW tank, accessory)
rR High limit safety cut-out (accessory)
rT Temperature sensor aÖ (return temperature sensor
in heating circuit, accessory)
rZ 3-way diverter valve sS (accessory)
tP Low loss header (accessory)
tQ Flow temperature sensor, low loss header ?
(accessory)
Connections

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5774 469 v1.0
Solar Control Module SM1, Installation and Service
System Example 3 (continued)
Electrical installation scheme
Solar control module, type SM1
A KM BUS to boiler control unit
Connections

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5774 469 v1.0
18
Power Supply
Connect accessories with a total wattage above 400 W
directly to the mains power supply.
WARNING
Incorrect core termination can cause severe injuries
and damage to the equipment.
Never interchange cores “L1” and “N”.
CAUTION
An incorrect phase sequence can cause damage
to the unit.
Check for phase equality with the power supply
connection of the control unit.
HThe main isolator (if installed) must simultaneously
isolate all non-grounded conductors from the mains
with a minimum contact separation of 3 mm.
We additionally recommend installing an AC/DC-
sensitive (RCD class B ) for DC (fault) currents
that can occur with energy efficient equipment.
HIf no main isolator is installed, all nongrounded cables
must be isolated from the mains by the upstream
breaker with at least 3 mm contact separation.
The absence of component grounding in the system
can lead to serious injury from electrical current
if an electrical fault occurs.
The equipment and the pipework must be connected
to the ground bonding of the house in question.
WARNING
WARNING
Incorrectly executed electrical installations can result in
injuries from electrical current and in equipment damage.
Connect the power supply and implement all grounding
measures (e.g. RCD circuit) in accordance with the
following regulations:
HIn Canada all electrical wiring is to be done in
accordance with the latest edition of CSA C22.1 Part 1
and/or local codes. In the U.S. use the National
Electrical Code ANSI/NFPA 70. The heating contractor
must also comply with both the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1, and the Installation Code for
Hydronic Heating Systems, CSA B214-01, where
required by the authority having jurisdiction.
HConnection requirements specified by your local power
supply utility
HProtect the power cable with max. 15A
Connections
Isolators for non-grounded conductors
Legend
A SM1 module

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Solar Control Module SM1, Installation and Service
Connecting the KM BUS to the Extension Modules
Legend
A Boiler control unit
B Extension kit for heating circuit with mixing valve M2
C Extension kit for heating circuit with mixing valve M3
D Extension AM1, EA1 and/or solar control module,
type SM1
Connections

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Connection and Wiring Diagram
Legend
A1 Main PCB
PWM Speed control, solar circuit pump (if circulation
pump with PWM control installed)
TW Maximum temperature limiter
X... Electrical interfaces
% DHW tank temperature sensor
& Collector temperature sensor
/ Temperature sensor (if installed)
aÖ Temperature sensor (if installed)
sS Transfer pump or 3-way diverter valve
sF Solar circuit pump
fÖ Power supply 120V/60Hz
aVG KM BUS to boiler control unit
Connections