Viessmann OpenTherm Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Mixer extension kit
OpenTherm mixer extension kit
For Vitodens 100-W, 111-W and 050-W
Mixer extension kit
5837721 GB 11/2018 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 envi-
ronmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
intended for qualified contractors.
■ Work on gas installations may only
be carried out by a registered gas fit-
ter.
■ 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 preven-
tion of accidents
■ Statutory regulations for environmen-
tal protection
■ Codes of practice of the relevant
trade associations
■ Relevant country-specific safety reg-
ulations
Safety instructions
Safety instructions
5837721

3
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 safe-
guard it against unintentional reopen-
ing.
■ 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 recon-
nection.
■ Wear suitable personal protective
equipment when carrying out any
work.
Danger
Hot surfaces and fluids can lead
to burns or scalding.
■ Before maintenance and serv-
ice 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 electrostatic dis-
charge.
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 function can compro-
mise the safe operation of the
system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compro-
mise its function. Installing non-
authorised components and
making non-approved modifica-
tions or conversions can com-
promise safety and may invalid-
ate our warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5837721

4
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in seri-
ous 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 threat-
ening poisoning.
■ Shut down the heating sys-
tem.
■ 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 appli-
ance there is a risk of electrocu-
tion.
Switch OFF the heating system
at the external isolator (e.g. fuse
box, domestic distribution
board).
Danger
If water escapes from the appli-
ance 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 condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building character-
istics are not permissible (e.g. cable/
pipework routing, cladding or parti-
tions).
Safety instructions
Safety instructions (cont.)
5837721

5
Danger
Leaking or blocked flue sys-
tems, or an inadequate supply
of combustion air can cause life
threatening poisoning from car-
bon 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, extrac-
tors, 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 poison-
ing due to a reverse flow of flue
gas.
Fit an interlock circuit or take
suitable steps to ensure an ade-
quate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5837721

6
Service instructions
Information
Disposal of packaging.......................................................................................... 7
Symbols................................................................................................................ 8
Intended use......................................................................................................... 9
Product information.............................................................................................. 9
Installation instructions
Installation sequence
Installing the extension kit.................................................................................... 10
Fitting the flow temperature sensor...................................................................... 10
Overview of electrical connections....................................................................... 12
Connecting the flow temperature sensor.............................................................. 13
Connecting the mixer motor................................................................................. 13
Connecting the heating circuit pump.................................................................... 14
OpenTherm connections...................................................................................... 17
Power supply........................................................................................................ 18
Service instructions
Commissioning and adjustment
Setting the mixer extension kit parameters.......................................................... 20
Fault messages.................................................................................................. 25
Connection and wiring diagram........................................................................ 26
Specification....................................................................................................... 27
Index
Index
5837721

7
Please dispose of packaging waste in
line with statutory regulations.
Information
Disposal of packaging
5837721
Service

8
Sym-
bol
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
environmental 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 surface.
Dispose of component correct-
ly.
Dispose of component at a
suitable collection point. Do
not dispose of component in
domestic waste.
Information
Symbols
5837721

9
The appliance is intended solely for
installation and operation in sealed
unvented heating systems that comply
with EN 12828, with due attention paid
to the associated installation, service
and operating instructions. It is only
designed for heating up heating water
that is of potable water quality.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a
purpose other than heating the building
or DHW shall be deemed inappropriate.
Any usage beyond this must be
approved by the manufacturer in each
individual case.
Incorrect usage or operation of the
appliance (e.g. the appliance being
opened by the system user) is prohibi-
ted and will result in an exclusion of lia-
bility. Incorrect usage also occurs if the
components in the heating system are
modified from their intended use (e.g. if
the flue gas and ventilation air paths
are sealed).
Product information
Extension kit for one heating circuit with
mixer and one heating circuit without
mixer. Operation via room temperature
controller.
For weather-compensated operation,
an outside temperature sensor (sepa-
rate accessory) must be connected to
the boiler control unit.
Boiler installation and service
instructions
Information
Intended use
5837721
Service

10
Install the device near the mixers and
heating circuit pumps in the installation
room.
1.
2.
Fitting the flow temperature sensor
■ Fit the flow temperature sensor to the
heating flow pipe immediately down-
stream of the heating circuit pump in
the flow direction.
■ If using plastic pipes, fit the sensor to
a metal intermediate pipe section.
■ Clean the flow pipe down to bare
metal.
■ Heat conducting paste is not
required.
■ Never thermally insulate the sensor.
Installation sequence
Installing the extension kit
5837721

11
1.
2.
3.
100
4.
Installation sequence
Fitting the flow temperature sensor (cont.)
5837721
Installation

12
??
M
1~
230 V~ M
1~
?
M
40 20A 20B 52
1 2 3 4 5 6 1 2 3 4
sÖ A Heating circuit pump for heating
circuit without mixer (on site)
sÖ B Heating circuit pump for heating
circuit with mixer (on site)
fÖ Power supply
gS Mixer motor
LV connections
X 3.1 - X 3.2 Flow temperature sen-
sor for heating circuit
without mixer (immer-
sion temperature sen-
sor)
X 3.3 - X 3.4 OpenTherm connec-
tion of boiler control
unit
X 12.1 - X 12.2 OpenTherm room tem-
perature controller for
heating circuit with
mixer
X 12.3 - X 12.4 OpenTherm room tem-
perature controller for
heating circuit without
mixer
X 12.5 - X 12.6 Flow temperature sen-
sor for heating circuit
with mixer (contact
temperature sensor)
X 21 No function
X 22 No function
!Please note
Electronic assemblies can be
damaged by electrostatic loads.
Before beginning work, touch an
earthed object such as heating
or water pipes to discharge any
static.
Installation sequence
Overview of electrical connections
5837721

13
Note
Apply strain relief to on-site cables.
Seal any unnecessary apertures with
cable grommets (not cut open).
Connecting the flow temperature sensor
Flow temperature sensor for heating circuit with mixer
Connect the flow temperature sensor to
X 12.5 and X 12.6 (see page 12).
Flow temperature sensor for heating circuit without mixer
Connect the temperature sensor to X
3.1 and X 3.2 (see page 12).
Connecting the mixer motor
Mixer motor, part no. 7450 657
A
23
1
gS
APlug on mixer motor
gS Plug on extension kit
|Mixer open
~Mixer close
Connect the mixer motor in accordance
with the diagram.
Never interchange wires.
Installation sequence
Overview of electrical connections (cont.)
5837721
Installation

14
Mixer motors without plug or on-site mixer motor
M
1~ A
gS
AMixer motor
gS Plug on extension kit
|Mixer open
~Mixer close
Connect the mixer motor in accordance
with the diagram.
Never interchange wires.
The mixer motor must meet the fol-
lowing criteria:
Rated voltage 230 V∼
Rated breaking capaci-
ty of the relay output
0.2 (0.1) A
Runtime for 90°∢120 s
Rotational direction Can be
changed
Connecting the heating circuit pump
Note
In underfloor heating circuits, install a
temperature limiter on site to restrict the
maximum temperature of the underfloor
heating system.
Installation sequence
Connecting the mixer motor (cont.)
5837721

15
Heating circuit pump 230 V~
sÖ
A1~
M
A/B
AHeating circuit pump
sÖ A/B Mains connection on extension
kit
For allocation of the heating circuit
pumps see page 12.
Specification
Rated current 2(1) A
Recommended
connecting cable
H05VV-F3G 0.75
mm2
or
H05RN-F3G 0.75
mm2
Heating circuit pump with power consumption greater than 2 A
LN
Ext.
ON/OFF
LN
N PE
NL
L
C
B
A
sÖ
sÖ A/B Plug on extension kit
AHeating circuit pump
BContactor
CSeparate power supply
(observe manufacturer's
instructions)
For allocation of the heating circuit
pumps see page 12.
Installation sequence
Connecting the heating circuit pump (cont.)
5837721
Installation

16
Heating circuit pump 400 V~
LN L1 L2 L3 N PE
A
B
3~
M
sÖ
AHeating circuit pump
BContactor
sÖ A/B Plug on extension kit
Specification for switching the con-
tactor:
Rated voltage 230 V∼
Rated current 2(1) A
Recommended
connecting cable
H05VV-F3G
0.75 mm2
or
H05RN-F3G
0.75 mm2
Installation sequence
Connecting the heating circuit pump (cont.)
5837721

17
L?
4 3 2 1
96
A
B
CDE
F
X12 X22 X3
1234 5 6 46
5
4
6
5
4
321
ABoiler control unit
BTerminals on the control unit
CMixer extension kit
DRoom temperature controller for
heating circuit without mixer
ERoom temperature controller for
heating circuit with mixer
FJumper
1. Connect the heat generator control
unit and the room temperature con-
troller.
2. Remove jumper F.
Installation sequence
OpenTherm connections
5837721
Installation

18
Danger
Incorrect electrical installations
can lead to serious injury from
electrical current and result in
appliance damage.
Connect the power supply and
implement all safety measures
(e.g. RCD circuit) in accordance
with the following regulations:
■ IEC 60364-4-41
■ VDE regulations
■ TAR medium voltage VDE-
AR-N-4110
Danger
The absence of system compo-
nent earthing can lead to seri-
ous injury from electric current if
an electrical fault occurs.
The appliance and pipework
must be connected to the equi-
potential bonding of the building.
Isolators for non-earthed conductors
■ The mains isolator (if installed) must
simultaneously isolate all non-
earthed conductors from the mains
with a minimum contact separation
of 3 mm.
■ If no mains isolator is installed, all
non-earthed conductors must be iso-
lated from the power supply by the
upstream circuit breaker with a mini-
mum contact separation of 3 mm.
Installation sequence
Power supply
5837721

19
L1
B
FE
D
D
N
C
A
40
APower supply for extension
BPower supply for heat generator
control unit
CPower supply 1/N/PE, 230 V/50 Hz
DFuse (max. 16 A)
EMains isolator, 2-pole, on site
FJunction box (on site)
Connect the power supply in accord-
ance with the diagram.
If the power supply to the appliance is
connected with a flexible cable, ensure
that the live conductors are 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.
Danger
Incorrect core assignment can
result in serious injury and dam-
age 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
power supply of the heat gener-
ator control unit.
Colour coding to IEC 60757
BN Brown
BU Blue
GNYE Green/yellow
Installation sequence
Power supply (cont.)
5837721
Installation

20
Calling up and changing parameters
Display and adjustments are made at
the room temperature controller.
01. Press MODE.
02. Use / to select "SETTINGS".
03. OK to confirm
04. Use / to select "SERVICE".
05. OK to confirm
06. Use / to select "TSP-PARAM-
ETER".
07. OK to confirm
08. Use / to select the required
parameter.
See the following chapter.
Note
Parameter 9 has no function.
09. OK to confirm
10. Set the required value with +/-.
11. OK to confirm
Parameters
Function of the room temperature controller
Parameter 0
Setting Explanations
0 Heating circuit without mixer
and heating circuit with mixer
Room temperature controller acts on
the connected heating circuit. See pa-
ges 12 and 17.
1 Heating circuit without mixer
and heating circuit with mixer
A room temperature controller acts on
both connected heating circuits. See
pages 12 and 17.
2 Heating circuit with mixer Room temperature controller only acts
on the heating circuit with mixer. See
pages 12 and 17
3 Heating circuit without mixer Switching input: On-site room tempera-
ture controller or time switch acts on
the heating circuit without mixer.
Contact closed: Circulation pump on
and flow temperature in accordance
with the setting of parameter 2
Contact open: Circulation pump with
run-on time off and set flow tempera-
ture 10 °C (frost protection)
Commissioning and adjustment
Setting the mixer extension kit parameters
5837721