Logamatic 4000 Modular Control System Control Units and Extended Functions

Transcription

1 Planning document Planning document Issue 05/2008 P I PI 4000 Modular Control System Control Units and Extended Functions Heat is our element

2 with FM MEC2 BFU remote control Buderus 4000 series (some controllers already contain modules for extended functions as supplementary equipment) Installation of a slot in module within a 4000 control unit

3 Contents Contents 4000 control unit Applications Features and key benefits System description controllers for boilers and burners with Buderus digital burner control units ( EMS) controllers for boilers with third-party burners for boilers with EMS control system, autonomous controllers and slave unit for floor-standing boilers in the medium to high output range Structure of a modular control system ECOCAN-BUS for data communication Control pads Communication-enabled MEC2 control pad for 4000 system digital controllers BFU remote control system digital controllers controller for Buderus EMS boilers and wall-mounted boilers with UBA.5 or used as autonomous heating system controller controllers as function expansion units or master controllers and 422 with FM445 as cylinder charging system controller controller for a floor-standing boiler controller for single floor-standing boiler or 432 and 4322 controllers for systems with multiple floor-standing boilers controller as autonomous heating circuit controller or slave unit incorporating control of a feed pump Function modules for expansion of digital controllers Function module FM44 for DHW heating with a cylinder system (e.g. Logalux indirect DHW cylinder*) and heating circuit control ( heating circuit with mixing valve) Function module FM442 for heating circuit control (2 heating circuits with mixing valve) Function module FM443 for controlling a solar thermal system for DHW heating or for DHW heating and space heat boosting Function module FM444 for incorporating an alternative heat source Function module FM445 for DHW heating using a cylinder charging system (e.g. Logalux LAP* or LSP* heat exchanger set) Function module FM448 for output of an electrically isolated centralised fault signal and external imposition and output of heat demand Function modules FM456 and FM457 for controlling multi-boiler cascade systems Function module FM458 as strategy module Interfaces and communication RS232 gateway as bus interface for LON gateway for communication with a higher-level control system for system analogue controllers controller for operating a floor-standing boiler with constant boiler water temperature without required operating conditions or in combination with a higher-level control system (e.g. BEMS)

4 Contents 8 Expansion modules for 4000 system controllers ZM426 expansion module as controller expansion module with (2nd) safety temperature limiter Expansion module ZM427 for maintaining required boiler operating conditions with 422 controller Overview of example systems Wall-mounted single-boiler systems with 42 or 4323 controller Wall-mounted multi-boiler cascade systems with 42 or 422 controller Wall-mounted and floor-standing boilers with EMS and 42/4323 controller Multi-boiler systems with 42/4323 controller Floor-standing single-boiler systems with 42 controller Floor-standing single-boiler systems with 432 controller Floor-standing multi-boiler systems with 432 or 4322 controllers /4323 controller as autonomous heating circuit controller or slave unit Installation notes Electrical installation Controller dimensions Appendix Notes, Glossary Index List of abbreviations

5 4000 control unit 4000 control unit. Applications The 4000 control system is the modern solution to diverse modulation and control tasks for single and multi-boiler systems with Buderus boilers of all types and sizes. And it goes without saying that it also caters for regenerative energy from sources such as the sun and wood, or cogeneration systems such as modular CHP plants. One control concept can operate and control not only floor-standing and wall-mounted Buderus boilers but also subordinate systems or autonomous heating circuits. The 4000 system is, of course, fully compatible with EMS, the Buderus energy management system. The EMS controls the combustion process and everything boiler-related on the EMS boiler, while the 4000 carries out the individual control functions. The 4000 is a modular system. The powerful basic system is fully capable of the standard control tasks for a single-boiler system ( 3/). Even if there is no Buderus boiler in use, the 4000 control system offers suitable solutions. The 4000 system offers autonomous controllers for controlling heating in an apartment block or commercial premises supplied with heat from an external source ( 3/2). In such situations, the 4000 system allows unlimited functionality and, of course, any number of heating circuits. When planning large building projects such as schools or district heating projects for commercial premises or large residential buildings, additional 4000 controllers can be installed long distances away in separate subordinate systems function modules can then take on specific localised tasks. Up to controllers can be connected via the ECOCAN-BUS. With the appropriate equipment and function modules, the system is capable of expansion for the control of complex multi-boiler systems in the medium to large size range ( 3/3). 3/ Controllers for operating boilers 3/2 Controllers for autonomous systems ECOCAN-BUS External heat source EMS-BUS ECOCAN- BUS 4323 EMS- BUS 432, FM44 + FM458 3/3 Controllers for heating systems with subordinate systems 3

6 4000 control unit.2 Features and key benefits Optimised control functions For certain control functions for boiler safety, all that is required is entry of the boiler type (e.g. low temperature, Ecostream) and the type of control device (e.g. boiler mixing valve). Ecologically sound and energy-efficient Special control functions such as the dynamic switching differential save energy and reduce harmful emissions. Straightforward control of multi-boiler systems With a strategy module for floor-standing boilers and a cascade module for wall-mounted boilers, the output levels can be controlled according to load and demand. Use of environmental energy With the solar module and the alternative heat source module, regenerative energy from sources such as the sun or wood, or cogeneration systems (e.g. modular CHP plants) can be incorporated. Subordinate systems and autonomous heating circuit controllers With accordingly extensive systems, widely distributed system configurations are possible. Modular design The equipment concept comprising function and expansion modules is easily manageable, flexible and requirements-focussed. Extensive capabilities The wide choice of function and expansion modules extends the capabilities of the individual controller. In addition, the combination of multiple controllers within an ECOCAN-BUS network (up to 5 addresses) offers a virtually limitless multiplicity of functions. Control functions are available for all EMS boilers via an EMS BUS interface. Forward looking Expandable at any time by the addition of new function modules. Standardised controls for convenience The simple "press and turn" controls concept and the menu-based user interface is standardised across all digital controllers. There is no need to constantly readjust to different systems. One for all All digital controllers in the 4000 system can be operated by the MEC2 control pad. Automatic module detection The MEC2 control pad "detects" which modules are installed so that the menu system then only shows the adjustment options that are available. That simplifies installation and prevents errors. Quick-assembly system with terminal connectors Sensor leads with ready-wired connectors and connectors with terminals for all components to be connected save time and money on installation, servicing and maintenance. Open standard system The 4000 control system uses openstandard communication interfaces that provide the capability for bidirectional communication with master control systems made by the majority of established BEMS producers. Interfaces with EIB and LON networks mean that the most widely used nonproprietary protocols are supported. Outstanding functional reliability Faults are detected and identified immediately, indicated by a "plain English" message on the MEC2 control pad and/or signalled on the module itself by LEDs. There is a separate manual control mode for every module function. Remote monitoring and programming The interfaces for connecting to the telecontrol system provide the ideal basis for heat supply concepts and round-the-clock system monitoring. Service software All digital controllers can be programmed and read using standardised service software on a PC. 4

7 System description 2 2 System description controllers for boilers and burners with Buderus digital burner control units ( EMS) Boiler with integral EMS energy management system with safety system and BC0 basic controller Burner with UBA universal burner control unit or SAFe safety burner control unit Boiler water temperature sensor (FK) Temperature control (TR) Safety temperature limiter (STB) EMS-BUS Function modules for implementation of control functions Controllers (e.g. 42) or controllers with function modules with digital BUS-communication link to EMS control system (e.g with FM456/FM457 or FM458) / 4000 controllers for boilers and burners with Buderus digital burner control units controllers for boilers with third-party burners Function modules for implementation of control functions (4322) Controllers (e.g. 42, 432) with safety system and burner control via standardised 7-pin burner interface Boiler water temperature sensor (FK) Temperature control (TR) Safety temperature limiter (STB) Burner interface level (7-pin) Burner interface level 2 (4-pin) Boiler for Burner with third-party burner control unit (e.g. GE35, GE55, GE65, S635, S735, SB65 or SB735) 5/ controllers for boilers with third-party burners 5

8 2 System description for boilers with EMS control system, autonomous controllers and slave unit Wall-mounted Logamax or Logamax plus boilers and multi-boiler cascade systems with outputs from to 800 kw Floor-standing Logano or Logano plus boilers and multi-boiler cascade systems with outputs from 9 to 920 kw Controller and central module (basic controller specifications) Controller module/central module Function modules present/available module slots Boiler controller Autonomous heating circuit controller/slave unit (extended function) in ECOCAN-BUS network Boiler type (control function) DHW heating controlled by EMS Number of heating circuits if DHW heating controlled by EMS Maximum possible number of heating circuits Maximum possible number of boilers telecontrol system FM44 function module FM442 function module Logamax gas space heating boiler Logamax plus gas condensing boiler with mixing valve (mixer) / without mixing valve with FM442 expansion modules basic specification / with FM457 expansion modules optional inc. hardware and software DHW system (cylinder system) with cylinder charging pump and DHW circulation pump One heating circuit with mixing valve (mixer) Two heating circuits with mixing valve (mixer) 4000 expansion modules (optional equipment) FM443 function module FM444 function module FM445 function module FM448 function module FM456 function module Solar thermal system with one or two heat consumers, i.e. solar domestic hot water (DHW) cylinder system or solar DHW (cylinder) system and space heating boost Alternative heat source (solid fuel boiler, pellet boiler, heat pump or CHP module) and/or thermal store DHW heating (cylinder charging system) with two cylinder charging pumps and DHW circulation pump or with two cylinder charging pumps, mixing valve and DHW circulation pump External imposition and output of heat demand or output of electrically isolated centralised fault signal and facility for connection of a heat meter Cascade system for two modulating control boilers with UBA.5 or EMS/UBA3 FM457 function module FM458 function module Cascade system for four modulating control boilers with UBA.5 or EMS/UBA3 Strategy module for four boilers with 4000 and/or EMS 6/ 4000 modular control system for wall-mounted and floor-standing boilers 6

9 System description 2 Specification options for controllers in the 4000 system Boilers from 9 to 920 kw CM43 / ZM424 CM43 / CM43 / ZM433 / / 2 / 4 FM455 (FM456 / FM457) (FM456 / FM457 / FM458) / / / (FM456 / FM457) (FM456 / FM457 / FM458) (FM456 / FM457) (FM456 / FM457 / FM458) / 5 / 8 / 8 7/ 4000 modular control system for wall-mounted and floor-standing boilers Key to symbols: Control function present; optional; Control function not present or module not usable 7

10 2 System description for floor-standing boilers in the medium to high output range Floor-standing Logano or Logano plus boilers and multi-boiler systems with outputs from 9 to kw Controller and central module (basic controller specifications) Controller module / central module Function modules present / available module slots Boiler type (control function) Safety systems DHW heating using cylinder charging pump Number of heating circuits Maximum possible number of heating circuits Multi-boiler systems telecontrol system FM44 function module FM442 function module Oil/Gas low temperature (LT) boiler Oil/Gas LT boiler with minimum return temperature Oil/Gas LT boiler with base temperature Oil/Gas Ecostream boiler Oil/gas condensing boilers Pellet combination boiler Control thermostat Safety temperature limiter using cylinder system with mixing valve (mixer) / without mixing valve with FM442 expansion modules with FM458 expansion module optional inc. hardware and software DHW system (cylinder system) with cylinder charging pump and DHW circulation pump One heating circuit with mixing valve (mixer) Two heating circuits with mixing valve (mixer) 4000 expansion modules (optional equipment) FM443 function module FM444 function module FM445 function module FM448 function module FM458 function module Solar thermal system with one or two heat consumers, i.e. solar domestic hot water (DHW) cylinder system or solar DHW (cylinder) system and space heating boost Alternative heat source (solid fuel boiler, pellet boiler, heat pump or CHP module) and/or thermal store DHW heating (cylinder charging system) with two cylinder charging pumps and DHW circulation pump or with two cylinder charging pumps, mixing valve and DHW circulation pump External imposition and output of heat demand or output of electrically isolated centralised fault signal and facility for connection of a heat meter Strategy module for four boilers with 4000 and/or EMS ZM426 function module Second safety temperature limiter (2nd STB) ZM427 option module Compliance with required boiler operating conditions 8/ 4000 modular control system for floor-standing boilers 8

11 System description 2 Specification options for controllers in the 4000 system Boilers from 9 to kw CM43 / ZM422 / ZM425 CM43 / ZM434 CM43 / ZM434 / 2 / 3 / 4 / 4 (ZM427) (ZM427) (FM442) (FM442) (ZM427) (ZM427) /0/20 00/0/20 00/0/20 00/0/20 0 / (BEMS) 9/ 4000 modular control system for floor-standing boilers Key to symbols: Control function present; optional; Control function not present or module not usable 9

12 2 System description 2.5 Structure of a modular control system 2.5. Extensive basic specifications with "future-proofing" as standard The 4000 is a modular system. The 42, 42, 42 P, 432, 4322 and 4323 digital controllers are factory-fitted with a CM43 controller module and an appliance-specific central module for controlling a boiler/feed pump ( 4323) plus other basic functions. There is also be a manual control mode for emergency operation according to module type. It can be used to directly control burners or pumps, for example. With those extensive basic specifications, the controllers have the functions for controlling single-stage, 2-stage or modulating control burners as well as specific boiler safety functions for controlling various boiler types. Optimum adaptation of the controller to the heating system is, of course, a feature provided, as are the functions for modulating boiler water temperature control and a variety of energy-saving operating modes. Every controller comes as standard with a central power supply unit for supplying all controller modules. Some controllers already incorporate space heating and DHW control functions as standard ( 0/). All controllers also have spare module slots as standard. They can be fitted with additional modules from the available choice for extending the range of functions to suit the particular project. The 4000 digital control system is operated by means of the MEC2 control pad. It can be used for complete control system installation and retrieving all controller information in plain English. FM442 A B FM442 0/ Example of maximum configuration of 42 digital controller for floor-standing boilers Key to illustration A Slot A with ZM422 central module for boiler/burner control and one heating circuit without mixing valve and one DHW system with cylinder charging pump (cylinder system), thermal disinfection and DHW circulation pump (with manual control mode) B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot for one function expansion module (example shows FM442 function module as optional equipment) 2 Slot 2 for one function expansion module (example shows FM442 function module as optional equipment) 3 Power switch 4 Burner emergency mode switch 5 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) 6 Fuse 7 Boiler water temperature control 8 Safety temperature limiter (adjustable) 0

13 System description The module system: clearly structured, flexible and requirements-focussed All controllers in the 4000 system have spaces for optional function expansion modules which can be used as required to suit the control system requirements. There are expansion modules available for specific control functions as determined by the system concept or the nature of the heat-consuming systems. With digital controllers, the MEC2 control pad "detects" every new module that is plugged in so that the plain English menu system then displays only the adjustment options available with the actual configuration installed. That simplifies installation and prevents errors. Every module also has a manual control mode for switching the burner or pumps on/off when servicing or repairing faults ( /). The modules are simply plugged into the controller from above once the top cover has been removed. Every expansion module is guaranteed compatible with the proven Buderus quick-assembly system. Two separate terminal blocks for low voltage circuits (e.g. for temperature sensors, remote controls and external switches) and for 230V control circuits (e.g. for mains power supply, mixing valves and circulation pumps) have colour-coded and specially keyed sockets with terminal pins ( /2). Consequently, it is virtually impossible to connect devices incorrectly and quick assembly is guaranteed. / Function expansion module Shown here: FM44 function module /2 Buderus quick-assembly system with terminal connectors Shown here: FM442 function module Key to illustration ( / and /2) Terminal connectors 2 Module fault indicator (LED) 3 Manual mode switch, heating circuit 4 Manual mode switch, DHW system 5 Circuit board 6 Module terminal block for low-voltage circuits (for temperature sensor, remote control and external switch connectors) 7 Module terminal block for control circuits (for 230 V AC mains supply, mixing valve and circulation pump connectors)

14 2 System description 2.6 ECOCAN-BUS for data communication 2.6. Structure of the ECOCAN-BUS All digital controllers in the 4000 system are equipped as standard with an ECOCAN-BUS interface for data communication. Up to 5 controllers can be connected to an ECOCAN-BUS network, thereby substantially increasing the number of control functions and corresponding heat consumers possible. ECOCAN-BUS system The CAN (Controller Area Network) protocol was originally developed for use in motor vehicles. Using that ultra-reliable CAN-BUS data transmission standard as the basis, the ECOCAN-BUS system with its own application-specific bus protocol was developed for Buderus. Connection to third-party BUS systems is possible but requires the use of appropriate interface converters (gateways) and object-related engineering. Further information on this subject is provided in Section 6 or can be obtained from your local Buderus agent ( back page). ECOCAN-BUS Addresses Every controller is a BUS device on the ECOCAN-BUS. A Service Key (for direct connection of a PC), an interface converter, such as a LON gateway or RS232 gateway, and a Easycom telecontrol modem are also a bus devices. Those devices have permanent ECOCAN-BUS addresses that are preset on the hardware but which do not affect the number of available controller addresses. ECOCAN-BUS cable There are fundamental requirements to be followed for routing the ECOCAN-BUS cable. The controllers (BUS devices) should be connected in series. A star or ring circuit arrangement is not possible. The distance to the furthest device on the BUS network must not be more than 000 m. The required cable-core cross-sectional area is between 0.4 and 0.75 mm 2 ; a shielded cable is required if the BUS cable is over 50 m long or is routed alongside a power cable (e.g. 230 V AC) in a shared cable conduit. Permissible cable length: 000 m max. (complete BUS system) ECO-BUS connector for 4000 control system 2 3 ECO-BUS connector supplied with controller Cable-core cross-sectional area: mm 2 (e.g. LiYCY (TP)) Connect cable shield (broken line) to Terminal at one end 2 3 ECO-BUS connector for 4000 control system 2/ Connector terminal assignment for ECOCAN-BUS cable between 4000 system digital controller 2

15 System description Examples of combining 4000 system digital controllers using ECOCAN- BUS Single-boiler system with floor-standing boiler Easycom PRO Address Adresse ECO-BUS 3 2 Address Adresse ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS max Adresse Fixed address fest ECO-BUS 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS Heizkessel Boiler Address (master) 42 Boiler controller with outside-temperature sensor for heating circuit function ( heating circuit without mixing valve) and DHW heating (cylinder system) 2 spare slots for function expansion modules Addresses 2 5 (choice and assignment unrestricted) 422 Function expansion (as slave unit without feed pump or outsidetemperature sensor) 2 spare slots for function expansion modules 4323 Slave unit with feed pump and outside-temperature sensor Heating circuit function ( heating circuit with mixing valve) 4 spare slots for function expansion modules 42 (not illustrated, for description page 26) 422 with FM445 (not illustrated, for description page 38) Fixed address (preset) Easycom PRO Telecontrol modem 3/ Example combination of 4000 system digital controllers for a single-boiler system with floor-standing boiler showing assignment of boiler and addresses on ECOCAN-BUS network 3

16 2 System description boiler system with floor-standing boilers 432 FM458 EMS-BUS LON-Gateway Address Adresse ECO-BUS 3 2 Address Adresse 2 ECO-BUS 3 2 Address Adresse 3 ECO-BUS 3 2 Adresse Fixed address fest ECO-BUS 3 2 ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS BC0 Heizkessel Boiler Heizkessel Boiler 2 2 Heizkessel Boiler 3 3 Heizkessel Boiler 4 4 Address (master) 432 Controller for master boiler () with FM458 function module (strategy module) with outside-temperature sensor 3 spare slots for function expansion modules Address Controller for sequential boiler (2) 4 spare slots for function expansion modules Address Controller for sequential boiler (3) 4 spare slots for function expansion modules Addresses 4 5 (choice and assignment unrestricted) 4323 (not illustrated, for description page 60) 42 (not illustrated, for description page 26) 422 (not illustrated, for description page 34) 422 with FM445 (not illustrated, for description page 38) Fixed address (preset) LON gateway Interface for communication with a higher-level control system for 4000 Other Boiler 4: connected to EMS BUS via FM458 function module 4/ Example combination of 4000 system digital controllers for a 4-boiler system with floor-standing boilers showing assignment of boilers and addresses on ECOCAN-BUS network 3-boiler cascade system with wall-mounted boilers FM FM Easycom Web Address Adresse ECO-BUS 3 2 Adresse Address ECO-BUS Adresse Address ECO-BUS Adresse Address max. 5 ECO-BUS 3 2 Adresse Fixed address fest ECO-BUS 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS BC0 BC0 BC0 Heizkessel Boiler Heizkessel Boiler 2 2 Heizkessel Boiler 3 3 Address (master) 42 Controller for cascade system control with FM455 function module ( boiler) and FM456 (2 boilers) with outside-temperature sensor Heating circuit function (2 heating circuits with mixing valve and heating circuit without) and DHW heating (cylinder system) via UBA burner control unit on st boiler No spare slots for function expansion modules Addresses 2 5 (choice and assignment unrestricted) 422 (for description page 34) 4323 (for description page 60) 42 (not illustrated, for description page 26) 422 with FM445 (not illustrated, for description page 38) Fixed address (preset) Easycom Telecontrol modem 4/2 Example combination of 4000 system digital controllers for a 3-boiler system with wall-mounted boilers showing assignment of boilers and addresses on ECOCAN-BUS network 4

17 System description 2 6-boiler cascade system with wall-mounted boilers FM FM Easycom Adresse Address ECO-BUS 3 2 Address Adresse 2 ECO-BUS 3 2 Adresse Address ECO-BUS Adresse Address ECO-BUS 3 2 max. 5 Adresse Fixed ECO-BUS address 3 2 fest TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS BC0 BC0 BC0 BC0 BC0 BC0 Heizkessel Boiler Heizkessel Boiler 2 2 Heizkessel Boiler 3 3 Heizkessel Boiler 4 4 Heizkessel Boiler 5 5 Heizkessel Boiler 6 6 Address (master) 422 Controller for all boilers with FM456 function module (2 boilers) and FM457 (4 boilers) with outside-temperature sensor No spare slots for function expansion modules Addresses 2 5 (choice and assignment unrestricted) 422 Function expansion (as slave unit without feed pump or outsidetemperature sensor) 2 spare slots for function expansion modules 4323 Slave unit with feed pump and outside-temperature sensor Heating circuit function ( heating circuit with mixing valve) 4 spare slots for function expansion modules 42 (not illustrated, for description page 26) 422 with FM445 (not illustrated, for description page 38) Fixed address (preset) Easycom Telecontrol modem 5/ Example combination of 4000 system digital controllers for a 6-boiler system with wall-mounted boilers showing assignment of boilers and addresses on ECOCAN-BUS network EMS-boiler system with floor-standing boiler Easycom Address Adresse EMS ECO-BUS Adresse Address ECO-BUS Adresse Address ECO-BUS 3 2 max. 5 5 Adresse Fixed ECO-BUS address 3 2 fest TAE UBA/ EMS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS BC0 Buderus Heizkessel Boiler Address (master) 42 Boiler controller with outside-temperature sensor for heating circuit function (2 heating circuits with mixing valve) and DHW heating (cylinder system) spare slot for function expansion module Addresses 2 5 (choice and assignment unrestricted) 422 Function expansion (as slave unit without feed pump or outsidetemperature sensor) 2 spare slots for function expansion modules 4323 Slave unit with feed pump and outside-temperature sensor Heating circuit function ( heating circuit with mixing valve) 4 spare slots for function expansion modules 42 (not illustrated, for description page 26) 422 with FM445 (not illustrated, for description page 38) Fixed address (preset) Easycom Telecontrol modem 5/2 Example combination of 4000 system digital controllers for an EMS-boiler system with floor-standing boiler showing assignment of boiler and addresses on ECOCAN-BUS network 5

18 3 Control pads 3 Control pads 3. Communication-enabled MEC2 control pad for 4000 system digital controllers Operating concept All parameter settings for a controller can be entered on the MEC2 control pad. Settings are entered using the simple and proven "press and turn" control concept. The user interface on the digital display is programmed in such a way that it only shows the parameters that are actually possible with the function and expansion modules that are installed. In so doing, the interactive, plain English user interface on the MEC2 control pad prevents conflicting parameter settings, thereby largely eliminating errors during commissioning. The MEC2 control pad also can also retrieve and display all available information from the controller such as temperature readings, specified settings, fault messages, etc. If multiple controllers are used, it is possible to unplug the MEC2 from one controller and plug it into another one. The "Retrieve/send data" function can be used to transfer the parameters from the controller concerned to the MEC2 control pad and save changed settings back to the controller Connection The MEC2 control pad can be connected to the 4000 system digital controllers in the following ways: Slot on the CM43 controller module Terminals on the BF socket on the appliance-specific central module, for example if connecting the wall socket for using the MEC2 control pad as a remote control ( page 7) SUB-D socket (5-pin) on the front of the controller, e.g. if connecting the MEC2 control pad via the Online cable for servicing work ( 0/) 6/ Communication-enabled MEC2 control pad for 4000 system digital controllers Key to illustration Digital display with user interface in plain English 2 Rotary control knob, e.g. for changing settings that are displayed by pressing a button (Item 5) 3 Indicator (LED) for showing the required room temperature setting 4 Button with LED for activating cylinder recharging (once-only charging page 70) or for entering the required DHW temperature 5 Second-level control set with function buttons 6 Cover flap for second-level controls 7 Button with LED for manually selecting night-time mode (constant low heating mode) 8 Button with LED for Automatic mode (daytime and night-time modes as programmed) 9 Button with LED for manually selecting daytime mode (constant heating mode) 6

19 Control pads BFU remote control Setting room temperature The BFU remote control enables separate control of a heating circuit from the living area. The rotary control is used to set the required room temperature ( 7/, Item ). Adjustment range for daytime mode: 0 to 30 C Minimum adjustment limit for night-time mode: 0 C Changing the operating mode The buttons on the remote control provide the facility for selecting the following operating modes: Daytime mode (manually set, constant heating mode) Automatic mode (daytime and night-time modes as programmed) Night-time mode (manually set, constant low heating mode) An indicator (LED) in the button concerned shows which mode is currently active. In Automatic mode, the configurable timer programme on the controller controls the changeovers between constant heating mode (daytime mode) and low heating mode (nighttime mode). Indication of summer mode An LED indicates whether the assigned heating circuit is in summer mode, i.e. not heating due to high outside temperatures ( page 73). In that case, only the DHW system is active. Summer mode can be cancelled by pressing the button for manually selecting daytime or night-time mode ( 7/, Items 4 and 2 respectively). Room temperature override The remote control has an integral room temperature sensor. If the measured room temperature differs from the required room temperature setting, the flow temperature of the heating circuit concerned is automatically adjusted accordingly. In that way, short-lived room temperature fluctuations, e.g. due to open windows, heating stoves, etc., can be balanced out. It is important to note that the remote control affects the entire heating circuit, in other words other rooms apart from the one in which it is situated. Therefore, this function only makes sense in a representative reference room ( page 72). Room temperature monitoring in low mode The room temperature sensor monitors the temperature in the reference room during low heating mode (night-time mode) if the low mode option "Room control" is set ( page 77). Once-only cylinder charging (recharging) An external electrically isolated input (externally connected button) can be used to initiate once-only heating of the DHW cylinder ( page 70) / BFU remote control with integral room temperature sensor Key to illustration Rotary control for setting required room temperature 2 Button with indicator (LED) for manually selecting night-time mode (constant low heating mode) 3 Button with LED for Automatic mode (daytime and night-time modes as programmed) 4 Button with LED for manually selecting daytime mode (constant heating mode) 5 LED for summer mode (DHW only) External room temperature sensor If the siting of the remote control is not suitable for recording the room temperature, there is the facility for connecting a separate, external room temperature sensor ( 7/2). 7/2 Separate room temperature sensor for external connection as alternative to integral room temperature sensor in BFU remote control 7

20 system digital controllers system digital controllers controller for Buderus EMS boilers and wall-mounted boilers with UBA.5 or used as autonomous heating system controller 4.. Brief description Possible applications The basic version of the 42 digital controller is suitable either for controlling single-boiler systems with EMS or UBA.5, as a function expansion unit for the 4000 control system, as a slave unit without feed pump or as a controller for autonomous heating systems (not connected to a Buderus boiler). As standard, the unit includes the DHW heating (cylinder system) and heating circuit control (one heating circuit with mixing valve and one without) functions. If DHW heating is controlled by the basic function incorporated in the boiler ( EMS), the 42 controller can control two heating circuits with mixing valves. The 42 controller may be expanded by the addition of a function/expansion module to suit the requirements of a particular heating system. For example, the 42 controller in combination with the FM456 function module can control up to three modulating-control boilers with EMS, and with the FM457 function module, up to five modulating-control boilers with EMS in series as a cascade system. With the FM443 function module, a solar thermal system can be integrated in the 4000 control system, while the FM444 function module allows incorporation of an alternative heat source. If the single spare module slot is insufficient, the controller can also be combined with other digital controllers (e.g. 422 or 4323) in an ECOCAN-BUS network (for function expansion options page 2). 2 A 8/ Basic version of 42 digital controller B Boiler control The following boiler types can be set on the Service menu of the MEC2 control pad: Low temperature boiler Condensing boiler In conjunction with the appropriate plumbing configuration and the correct settings, the EMS or UBA.5 guarantees that the required boiler operating conditions are maintained. Key to illustration ( 8/) A Slot A occupied by FM455 function module (KSE boiler control unit in inside) B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot with ZM424 central module 2 Slot 2 for one function expansion module 3 Power switch 4 Fuse 5 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) 8/2 ZM424 central module of 42 controller Key to illustration ( 8/2) Module fault indicator (LED) 2 Summer mode LED for heating circuit 2 3 Circulation pump LED for heating circuit 2 4 Actuator opening LED for heating circuit 2 5 Actuator closing LED for heating circuit 2 6 Manual mode switch for heating circuit 2 7 Manual mode switch for heating circuit and DHW 8 LED for circulation pump running or heating circuit mixing valve closing 9 LED for cylinder charging pump running or heating circuit mixing valve opening 0 Circulation pump LED for heating circuit Burner on LED (wall-mounted boiler control) 8

21 4000 system digital controllers 4 Autonomous heating system controller or slave unit Use as an autonomous heating system controller not controlling boiler or monitoring heat supply Use as a slave unit not controlling a feed pump but communicating via the ECOCAN-BUS with a 4000 master boiler controller Heating circuit and DHW control and control of DHW via 42 ( page 27) Outside-temperature driven control of a heating circuit without mixing valve via the space heating circulation pump and control of a heating circuit with mixing valve and circulation pump Alternatively: DHW heating controlled by EMS Outside-temperature driven control of two heating circuits with mixing valve and circulation pump Option of connecting a separate remote control for room-temperature override for each heating circuit Adjustable, automatic switching between summer/winter modes separately for each heating circuit Individually timer-controlled DHW heating using a cylinder charging pump (cylinder system), daily monitoring, thermal disinfection and control of a DHW circulation pump One external electrically isolated input (optional function terminal WF) either for an external heat demand override for a heating circuit function on the basic 42 controller or for activating the DHW function (once-only cylinder charging) or for thermal disinfection Choice of DHW priority or simultaneous with the space heating circuits depending on boiler and system configuration Standard specifications 42 digital controller with CM43 controller module, ZM424 central module, FM455 function module (KSE for controlling one EMS boiler or wall-mounted boiler with UBA.5), MEC2 control pad Outside temperature sensor FA Boiler water temperature sensor FK Flow temperature sensor FV/FZ 42: control of wall-mounted boiler and heating system (2 heating circuits with mixing valve); DHW system configuration "EMS motorised diverter valve" with DHW circulation pump and thermal disinfection function External switch (electrically isolated) connected to WF: Contact Heating circuit Domestic hot water 3 2 Manual daytime = Heat demand Manual night-time or pump fault Thermal disinfection or once-only cylinder charging Pump fault FA 42 Logamax plus BF HK 2BF HK2 23 WF PZ UBA/ EMS MAG BC0 SU 230 V AC 50 Hz VK SA ) FK FV PH SH 2FV 2PH 2SH KR RK VS RS SMF FB Logalux SU... ) Notes on calibrating can be found in planning document for wall-mounted boiler 9/ Control of wall-mounted boiler and heating system (2 heating circuits with mixing valve); DHW system configuration "EMS motorised diverter valve" with DHW circulation pump and thermal disinfection function (for key to abbreviations page 84) 9

22 system digital controllers 42: control of boiler with EMS and heating system (4 heating circuits with mixing valve); DHW system configuration "EMS charging pump" with DHW circulation pump and thermal disinfection function External switch (electrically isolated) connected to WF: Contact Heating circuit Domestic hot water 3 2 Manual daytime = Heat demand Manual night-time or pump fault Thermal disinfection or once-only cylinder charging Pump fault FA 42 (FM455) FM WF oder or BF 2) 2) 2 3 WF oder or 2BF 2 3 WF oder or BF 2 3 WF oder or 2BF HK HK2 HK3 HK4 UBA/ EMS FV 2FV 3FV 4FV PH 2PH 3PH 4PH MC0 VK SA ) SH 2SH 3SH 4SH RK Logano Logano plus SMF RS VS PZ KR PS KR 2) 23 WF FB Logalux SU... ) Notes on calibrating can be found in planning document for boiler 2) Optional function terminal on basic controller can be assigned by software settings to x external override switch 20/ Control of boiler with EMS and heating system (4 heating circuits with mixing valve); DHW system configuration "EMS chaging pump" with DHW circulation pump and thermal disinfection function (for key to abbreviations page 84) 20

23 4000 system digital controllers Expansion of 42 controller functions Additional modules ) for 42 Module FM442 function module 2 heating circuits with mixing valve (mixer) FM443 function module Solar thermal system with one or two heat consumers FM444 function module Alternative heat source and/or thermal store FM445 function module DHW (cylinder charging system) Module FM448 function module Heat demand or centralised fault signal and heat meter FM456 function module Cascade system for two modulating control boilers with EMS/UBA.5 FM457 function module Cascade system for four modulating control boilers with EMS/UBA.5 LON-Gateway LON BUS interface 2/ Expansion of 42 controller functions by additional modules ) One spare module slot on 42 controller 42 in ECOCAN-BUS network with other digital controllers Easycom Adresse Address ECO-BUS 3 2 Adresse Address ECO-BUS Address Adresse ECO-BUS Adresse Address max. 5 5 ECO-BUS 3 2 Adresse Fixed ECO-BUS address 3 2 fest TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS 2/2 Example of combination of 42 controller with other digital controllers in ECOCAN-BUS network 4..3 Technical data for 42 controller Controller 42 Controller 42 Power supply 230 V AC ± 0 % Boiler water temperature sensor FK ) 2/3 Specifications of 42 controller ) Max. lead length 00m (shielded upwards of 50 m) 2) Switch load 5 V DC / 0 ma 3) Max. lead length 0 m 4) Max. lead length 50 m NTC sensor, dia. 9 mm Frequency 50 Hz ± 4 % DHW temperature sensor AS.6 ) NTC sensor, dia. 6 mm Power consumption 5 VA DHW temperature sensor FB ) NTC sensor, dia. 9 mm Heating circuit mixing valve SH Max. switching current 5A DHW temperature sensor FB if DHW NTC sensor, dia. 6 mm Control 230 V; 3-point switching heated via motorised 3-way diverter valve (connected to UBA universal boiler control unit only) controller (PI characteristic) Flow temperature sensor FV/FZ ) NTC sensor, dia. 9 mm Recommended positioner motor running time 20 s (adj. betw s) Outside temperature sensor FA ) NTC sensor Space heating circulation pump PH Max. switching current 5 A External optional function WF )2) Electrically isolated input Cylinder charging pump PS Max. switching current 5 A MEC2 or BFU/F remote control ) BUS communication DHW circulation pump PZ Max. switching current 5 A 42 UBA.5 controller 3) BUS communication 42 EMS controller 4) BUS communication 2

24 system digital controllers controller function description This function description relates only to the basic version. The 42 controller has one spare module slot for additional function expansion modules. For details of the possible additional functions that can be incorporated in the 42 by means of expansion modules, please refer to the function description for the module concerned ( 2/). Boiler control using 42 controller in conjunction with energy management system ( EMS) A large number of Buderus boilers with ratings up to 00 kw are supplied as standard with the EMS energy management system. Condensing boilers and low-temperature boilers with EMS are supported by the 42 controller. The EMS and 42 jointly control the heating system. The EMS concept is based on a digital burner control unit which, in addition to controlling and monitoring the burner, also performs the safety-related tasks for the heat source. The BC0 basic controller the basic EMS boiler control panel EMS also incorporates a number of basic system control functions, such as for DHW heating. The EMS system combines high levels of efficiency, functionality, easy-to-use standardised controls and ease of servicing and maintenance. All boilers with EMS, regardless of whether they are oil or gas-fired, floor-standing or wall-mounted, have a standardised control panel the BC0 basic controller. The BC0 basic controller ( 22/) is the standardised basic control panel used on most boilers with the EMS control system. The BC0 includes all the necessary controls for operating the boiler ( 22/, Item 7) Key to illustration Power switch (On/Off) 2 LED "Hot water" indicator 3 Hot water temperature control 4 LCD screen for displaying status and system pressure and for fault diagnosis 5 LED "DHW and space heating heat demand" indicator 6 Maximum boiler water temperature control 7 RC35 control panel (optional instead of blanking plate) 8 LED "Burner On/Off" indicator 9 Connection bush for connecting diagnostic lead 0 "Show status" button "Chimney sweep" button for flue gas test and manual mode 2 "Reset" button / Display, indicators and controls on the BC0 basic controller Functions and controls on the BC0 basic controller Power switch for switching the boiler and all modules fitted in it on and off ( 22/, Item ) LED "Hot water" indicator ( Item 2) Hot water temperature control ( Item 3) At position "0", the required temperature for the DHW is set to 5 C. At the "Eco" position, the required temperature for the DHW is set to 60 C. If the temperature control is set to between 30 C and 60 C, a specified DHW temperature is limited by that control setting. In the "Aut" position, the DHW temperature is set by the 42 controller. If a specific DHW temperature is set, the 42 can not set a higher temperature. LCD screen for status display and fault diagnosis ( Item 4) Display of boiler water temperature, system pressure (filling mode) and, if applicable, a fault or service code LED "DHW and space heating heat demand" indicator ( Item 5) 22

25 4000 system digital controllers 4 Limitation of boiler water temperature to a maximum level ( Item 6) LED "Burner On/Off" indicator ( Item 8) Connection bush for diagnostic lead for connecting a laptop ( Item 9) "Show status" button for switching the display between various functions ( Item 0) "Chimney sweep" button for flue gas test and manual mode ( Item ) "Reset" button for resetting the burner in the event of lock-out faults ( Item 2) Emergency mode Boiler heating output limitation System parameter configuration using ECO-SOFT 4000/EMS software Wall-mounted EMS boilers with UBA3.x The 42 controller and the UBA3.x universal boiler control unit are used to control the Logamax plus series boilers. A 2-core connection to the FM455 function module in the 42 controller enables communication between the UBA3.x universal burner control unit and the 42 controller using an internal BUS protocol. The UBA3.x is the central control device for boiler and combustion control. It controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the connected components (e.g. 42). The UBA3.x also contains the BCM burner control module that provides the universal burner control unit with the boiler-specific and combustion-related data. In addition, the UBA3.x controls heating of the domestic hot water in response to external activation and specification of required settings, e.g. by the 42 controller. The BC0 basic controller serves as the basic control panel on the EMS boiler. Fault indicator lamp 23/ UBA3.x universal burner control unit Fixing screw Floor-standing EMS boilers with SAFe The 42 controller and the MC0 master controller with the SAFe safety control unit are used to control the Logano and Logano plus series boilers. The MC0 and FM455 function module in the 42 controller communicate via a 2-core connection. Buderus uses an internal BUS protocol. The SAFe burner safety control unit is the central control device for boiler and combustion control. It controls and monitors the combustion process and controls the required operating conditions as required by the connected components. The SAFe obtains the boiler-specific combustion-related data from the from the BIM burner identification module attached to the boiler. In addition, the MC0 controls heating of the domestic hot water in response to external activation and specification of required settings, e.g. by the 42 controller. The EMS boiler is operated by means of the BC0 basic controller, which is integrated in the MC0. BC0 23/2 MC0 master controller with BC0 basic controller Fault indicator lamp/reset button 23/3 SAFe digital safety burner control unit 23

26 system digital controllers Boiler control using 42 controller in conjunction with UBA.5 universal burner control unit Wall-mounted boilers with UBA.5 The Buderus wall-mounted boiler is controlled by the UBA.5 universal burner control unit and the 42 controller. The UBA.5 monitors all electrical and electronic components of a Buderus wallmounted boiler and controls the boiler output by modulation of the gas burner. The operating status and all faults that occur are indicated in code form on the UBA.5. A 2-core connection to the FM455 function module in the 42 controller enables communication between the UBA.5 universal burner control unit and the controller using an internal BUS protocol. The UBA.5 has two sets of controls. The firstlevel control set is directly accessible when the control panel cover on the Buderus wall-mounted boiler casing is open. The second-level control set is behind a second control panel cover ( 24/, Item 7) and should only be used by a heating engineer / First and second-level (outlined in blue) control sets on the UBA.5 universal burner control unit Key to illustration First-level control set Power switch 2 Reset button 3 Service button 4 Indicator (red LED) 5 DHW temperature control 6 Boiler water temperature control Second-level control set 7 Cover for second-level controls (shown open) 8 Jumper for limiting output to kw 9 "Chimney sweep" switch 0 Switch for pump run-on time Control for limiting output Switching of boiler on and off by 42 controller When there is a change in the required setting, the controller specifies the temperature and enables boiler heat output. The boiler is then controlled by the burner control unit so as to reach the required setting as quickly as possible. After a certain time, the 42 controller checks not only the difference between the specified boiler flow temperature and the actual temperature, but also the temperature gradient at the boiler-water temperature sensor on the boiler (e.g. if heating circuit is connected directly) or on the low-loss header. The boiler is switched off as soon as the actual boiler flow temperature exceeds the variable required setting by a permanently set hysteresis amount. If, in the case of small variations to the required setting, the heat demand decreases, e.g. as a result of individual heating circuits or the DHW system being switched off, the controller checks the rate of cooling at the boilerwater temperature sensor after a specified period. If the boiler output is still too great to reach the lower specified setting within the target time, the boiler modulates down to base-load output and is then switched off. Multi-stage boilers are switched off immediately by the hysteresis function. 24

27 4000 system digital controllers 4 Special features of boiler control using low-loss header with 42 controller Buderus wall-mounted boilers are distinguished by very small boiler water capacities so that they reach temperature very quickly. Isolation from the circulating flow by means of a lowloss header is required if The system volumetric flow rate is more than 2000 l/h (with boiler ratings up to 43 kw) or more than 3500 l/h (with 60 kw boiler rating) There is more than one heating circuit The boiler's internal pump is insufficient for supplying the system (with one heating circuit), or The boiler is part of a wall-mounted multi-boiler cascade system A heating system can only be controlled to optimum effect and energy-efficiently if it is correctly dimensioned and planned. Dimensioning should be in accordance with the technical guidance. The definitive figure for the correct choice of low-loss header is the maximum volumetric flow rate. That figure depends on the outputs and temperature spreads for which the heat exchangers and heat consumers are designed. The advantages of the low-loss header are Easy dimensioning of heating circulation pump and mixing valve No reciprocal effects between flow in boiler circuit and heating circuit(s) Heat sources/consumers are only subjected to the allocated water flow rates Usable for single-boiler systems and multi-boiler cascade systems regardless of heating circuit control Actuators on heating-circuit side of low-loss header function to optimum effect (assuming they are correctly dimensioned) If needed, the output of a Buderus wall-mounted boiler can be permanently limited on the 42 controller to as little as 50 % of the total output so as to be perfectly matched to the heat demand of a building. The operating status and faults can also be viewed on the 42 controller. D 2 3 Key to illustration Perforated divider 2 Connection for automatic air vent 3 Connection for 5" immersion sleeve 4 Fast shut-off valve D Diameter of low-loss header (For other abbreviations page 84) VK RK VH RH 5 D 3 4 D D 4 25/ Dimensions of low-loss header Special function for extraneous heat detection on 42 controller Where wall-mounted boilers are combined with solar thermal systems or solid-fuel boilers for heating backup, the aim is to use the regenerative energies to best effect. For such situations, the 42 controller has a special function for detecting extraneous heat. To that end, the controller's boiler-water temperature sensor FK is positioned either on the low-loss header or a thermal store depending on the system configuration. A temperature difference between the required and actual boiler flow temperatures is then defined on the MEC2 control pad. As soon as the actual boiler flow temperature exceeds the set figure by the specified temperature differential, the 42 controller switches off the boiler and the circulation pump because another heat source is providing sufficient energy. 25

28 system digital controllers 42 controller as autonomous heating circuit controller As well as controlling a boiler, the 42 controller can also be used as an autonomous heating circuit controller. The heat source is externally controlled. There is no connection to the heat source. In this application scenario, the basic version of the controller can control one heating circuit with an mixing valve and one without on the basis of outside temperature. In addition, individual timer-controlled heating of domestic hot water using a cylinder charging pump (cylinder system), thermal disinfection and control of a DHW circulation pump are also possible. There is the option of setting hot water priority or simultaneous operation with the heating circuits. A heat source monitoring function is not implemented. If such a function is desired, the 4323 controller should be specified as the autonomous heating circuit controller ( page 60). FA VK RK 42 FB PZ KR BF HK 26/ Example of system using basic version of 42 as autonomous heating circuit controller (for abbreviations page 84) KR PS KR PH 2BF HK2 2FV 2PH 2SH 42 controller as slave unit A controller is designated a slave unit if connected via the ECOCAN-BUS to a 4000 system master controller. When used as a slave unit, the 42 controller has the same range of functions as when acting as an autonomous heating circuit controller. As the outside temperature is also signalled via the ECOCAN-BUS, it is not absolutely imperative to connect an outside-temperature sensor. However, it is advisable in cases where parts of the building face in different directions (north/south) to connect a separate outside-temperature sensor to the slave unit. The heat demand from the heat consumers connected to the 42 controller is signalled via the ECOCAN-BUS to the heating centre and is subordinate to the operation demands of the heat source connected to the master controller. A feed pump is not controlled by the 42 controller. Therefore, the heating circuit circulation pumps should be dimensioned accordingly. A flow temperature monitoring function is not implemented either. If a feed pump and monitoring of the flow temperature are desired, the 4323 controller should be specified as the slave unit ( page 60). FA FA 42 ECOCAN-BUS ECOCAN-BUS SV 42 FB PZ KR FB KR PS PZ KR KR PS BF HK KR PH KR PH- HK0 2BF HK2 2FV 2PH 2SH BF HK0 FK VK RK MAG 26/2 Example of system using basic version of 42 as slave unit with separate outside-temperature sensor (for abbreviations page 84) 26

29 4000 system digital controllers 4 DHW heating controlled by 42 The 42 controller offers six different alternatives for implementing the DHW system (as cylinder system) according to boiler type and number of boilers. Separate timer programmes guarantee flexible adaptation to accommodate DHW heating DHW circulation pump Thermal disinfection Daily heating More information on the functions can be found in the section describing the functions of the FM44 function module starting on page 69 f. Alternative Used with DHW function, connected to EMS motorised diverter valve ( page 28) EMS cylinder charging pump ( page 28) EMS single-boiler systems EMS With mixing valve EMS single-boiler systems EMS With mixing valve EMS integral water heater ( page 29) EMS single-boiler systems EMS With mixing valve 4000 DHW cylinder ( page 29) UBA integral water heater ( page 30) UBA cylinder ( page 30) Single-boiler systems and multi-boiler cascade systems Wall-mounted boiler with UBA.5 Wall-mounted boiler with UBA.5 27/ DHW heating alternatives using 42 controller ) Without mixing valve if DHW circulation pump controlled by Heating circ. Heating circ. 2 Without mixing valve With mixing valve With mixing valve ) With mixing valve With mixing valve With mixing valve With mixing valve With mixing valve With mixing valve 27

30 system digital controllers 42: DHW heating via motorised diverter valve, "EMS motorised diverter valve" alternative DHW heating for wall-mounted/floor-standing EMS boilers via a motorised diverter valve SU DHW heating only with priority over space heating Electrical connections (motorised diverter valve SU, DHW circulation pump, sensor) on EMS (UBA3.x/MC0) Separate DHW cylinder larger than 50 l EMS, UBA3.x or MC0 (SAFe) control heating of domestic hot water with priority over the space heating by controlling the burner, the motorised diverter valve and the internal circulation pump in the wall-hanging/floor-standing EMS boiler EMS controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the 42 controller. The 42 controller's MEC2 control pad is used to make all settings, e.g. required temperature, timer programme, daily heating, thermal disinfection, once-only cylinder charging, etc. If the alternative "EMS motorised diverter valve" is used for DHW heating, the 42 controller can control two heating circuits with mixing valves. FA EK SMF PZ KR EZ AW FB Logamax plus BC0 ÜV 42 PH 28/ DHW heating via motorised diverter valve, "EMS motorised diverter valve" alternative (for abbreviations page 84) SU UBA/ EMS MAG VK RK FK BF HK FV SH 2BF HK2 2FV 2PH 2SH 42: DHW heating via cylinder charging pump, "EMS cylinder charging pump" alternative DHW heating for EMS boiler using cylinder charging pump PS Choice of DHW priority or simultaneous with space heating Electrical connections (cylinder charging pump, DHW circulation pump, sensor) on EMS (UBA3.x/MC0) Separate DHW cylinder larger than 50 l EMS, UBA3.x or MC0 (SAFe) control heating of domestic hot water, either with priority over or simultaneously with the space heating, by controlling the burner and the cylinder charging pump. EMS controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the 42 controller. The 42 controller's MEC2 control pad is used to make all settings, e.g. required temperature, timer programme, daily heating, thermal disinfection, once-only cylinder charging, etc. If the alternative "EMS cylinder charging pump" is used for DHW heating, the 42 controller can control two heating circuits with mixing valves. FA UBA/ EMS Logano BC0 Buderus FK SMF RS 42 28/2 DHW heating via cylinder charging pump, "EMS cylinder charging pump" alternative (for abbreviations page 84) VS PZ KR PS KR FB Logalux SU... BF HK FV PH SH 2BF HK2 2FV 2PH 2SH 28

31 4000 system digital controllers 4 42: DHW heating via motorised diverter valve, "EMS integral water heater" alternative DHW heating via motorised diverter valve SU for wall-mounted EMS boilers with integral indirect water heater DHW heating only with priority over space heating Electrical connections (cylinder charging pump, DHW circulation pump, sensor) on EMS (UBA3.x/MC0) Integral indirect water heater smaller than 50 l EMS, UBA3.x or MC0 (SAFe) control heating of domestic hot water with priority over the space heating by controlling the burner, the motorised diverter valve and the internal circulation pump in the wall-hanging EMS boiler EMS controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the 42 controller. The 42 controller's MEC2 control pad is used to make all settings, e.g. required temperature, timer programme, daily heating. If the alternative "EMS integral water" is used for DHW heating, the 42 controller can control two heating circuits with mixing valves. A thermal disinfection function is not possible. Furthermore, since control of a DHW circulation pump is not required, that option can not be selected. FA UBA/ EMS MAG AW EK Logamax plus MAG V AC 50 Hz SA SMF FK BF HK FV PH SH 2BF HK2 2FV 2PH 2SH 29/ DHW heating via motorised diverter valve, "EMS integral water heater" alternative (for abbreviations page 84) 42: DHW heating via cylinder charging pump, "4000 cylinder" alternative DHW heating for EMS boiler/wall-mounted boiler with UBA.5 using cylinder charging pump PS Choice of DHW priority or simultaneous with space heating Electrical connections (cylinder charging pump, DHW circulation pump, sensor) on 42 Separate DHW cylinder larger than 50 l 42 controls heating of domestic hot water, either with priority over or simultaneously with the space heating, by controlling the boiler and the cylinder charging pump. The 42 controller signals the DHW temperature requirement via the internal BUS link to the boiler, which then controls the boiler output accordingly. The boiler control unit controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the 42 controller. The 42 controller's MEC2 control pad is used to make all settings, e.g. required temperature, timer programme, daily heating, thermal disinfection, once-only cylinder charging, etc. If the alternative "4000 cylinder" is used for DHW heating, the 42 controller can control one heating circuit with mixing valve and one without. FA UBA/ EMS Logamax plus BC0 MAG 230 V AC 50 Hz FK VK SA RK SMF 42 RS 29/2 DHW heating via cylinder charging pump, "4000 cylinder" alternative (for abbreviations page 84) VS PZ KR PH PS KR FB Logalux SU... BF HK KR 2BF HK2 2FV 2PH 2SH 29

32 system digital controllers 42: DHW heating via motorised diverter valve, "UBA integral water heater" alternative DHW heating via motorised diverter valve SU for wall-mounted EMS boilers with UBA.5 and integral indirect water heater DHW heating only with priority over space heating Electrical connections (mixing valve, sensor) on UBA.5 universal burner control unit Integral indirect water heater smaller than 50 l DHW heating is controlled by the UBA.5 universal burner control unit by controlling the motorised diverter valve and the wall-mounted boiler's internal circulation pump. DHW heating is given priority over space heating. The UBA.5 universal burner control unit controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the 42 controller. The 42 controller's MEC2 control pad is used to make all settings, e.g. required temperature, timer programme, daily heating. If the alternative "UBA integral water" is used for DHW heating, the 42 controller can control two heating circuits with mixing valves. A thermal disinfection function is not possible. Furthermore, since control of a DHW circulation pump is not required, that option can not be selected. FA UBA MAG AW EK Logamax plus GB2-24 T25 SV 230 V AC 50 Hz SU FK VK SA RK SMF 42 BF HK FV PH SH 2BF HK2 2FV 2PH 2SH 30/ DHW heating via motorised diverter valve, "UBA integral water heater" alternative (for abbreviations page 84) 42: DHW heating via motorised diverter valve, "UBA cylinder" alternative DHW heating for wall-mounted boilers with UBA.5 via a motorised diverter valve SU DHW heating only with priority over space heating Electrical connections (mixing valve, sensor) on EMS Separate DHW cylinder larger than 50 l FA Logamax plus GB2-24, GB2-29 GB2-43, GB BF HK 2BF HK2 The UBA.5 universal burner control unit controls and monitors the combustion process and adjusts the boiler temperature to the specified setting as required by the 42 controller. The 42 controller's MEC2 control pad is used to make all settings, e.g. required temperature, timer programme, daily heating. If the alternative "UBA cylinder" is used, the 42 controller can control one heating circuit with mixing valve and one without. If no DHW circulation pump is specified, there is the option of configuring both heating circuits with mixing valve. UBA MAG SV SU VS RS VKRK 230 V AC 50 Hz FK VK SA RK PZ ) KR Logalux SU... SMF FB FV PH SH 2FV 2PH 2SH ) External control of DHW circulation pump w/o thermal disinfection function 30/2 DHW heating via motorised diverter valve, "UBA cylinder" alternative (for abbreviations page 84) 30

33 4000 system digital controllers 4 Control of heating circuit using 42 controller Using the basic version of the 42 controller in combination with Buderus boilers with EMS, it is always possible to control two heating circuits with mixing valves on the basis of outside temperature or room temperature. If the basic version of the 42 controller is used together with Buderus wall-mounted boilers with UBA.5, it can always control one heating circuit with mixing valve and, depending on the DHW alternative selected, another heating circuit with or without mixing valve on the basis of outside temperature or room temperature. The control functions control the circulation pumps via separate 2-point signals (230 V AC) and the heating circuit mixing valves via separate 3-point signals (230 V AC). The appropriate characteristic heating curves for the various standard heating system configurations are stored on the controller. Adaptation to the individual system layout is straightforward using the MEC2 control pad. Heating system options Radiator/convector or underfloor Automatic calculation of characteristic heating curve to suit heating system Base point Pre-control of ventilation systems; heating characteristic is a linear progression between two points, space heating flow temperature is dependent on outside temperature Constant Pre-control of ventilation systems or swimming pool heating; heating always based on a constant required space heating flow temperature regardless of outside temperature Room thermostat The required space heating flow temperature is dependent only on the measured room temperature Each heating circuit function can be adapted to the requirements of the system by means of the following additional functions: Adjustment of low-setting temperature to DIN EN 283 Various low-setting modes for night-time operation Various low-setting modes for the holiday function Adaptation of characteristic heating curve Room temperature override or Optimisation of cut-in and cut-out The standard DIN EN 283 is the European standard for calculating the heat requirement for buildings. According to DIN EN 283, dimensioning of heat sources and heating surfaces must take an additional allowance into account for rooms with intermittent heating. A new function is the option of cancelling the low-setting phase for each heating circuit if the outside temperature falls below a definable, corrected level. That prevents excessive cooling of the living areas. As a result, the additional allowance for a greater initial heating output can be dispensed with when dimensioning the boiler. For the holiday function, a separate low-setting mode can be selected from the familiar options Room control, Reduced, Off, and Outside control. Therefore, the 4000 controller can be adjusted to different user requirements in the holiday period. The optional function terminal can be allocated either to a heating circuit function or a DHW function. An optional function terminal provides the facility either for an external heat demand override for a heating circuit function on the basic 42 controller or for externally activating the DHW function (onceonly cylinder charging) or thermal disinfection. More information on the functions can be found in the section describing the functions of the FM442 function module ( page 73 ff.). 3

34 system digital controllers 42: special "Screed drying" function for an underfloor heating circuit without mixing valve The 4000 control system provides the Example ( 32/) facility of a separate heating programme for screed ➊ Starting temperature 25 C floor drying if an underfloor heating circuit is connected. The 42 controller has a ➋ Temperature rise 5 K per heating period special feature whereby a screed drying programme can be implemented not only for an underfloor heating circuit with mixing valve ( page 77) but also for a directly connected underfloor heating circuit ➌ Heating period day ➍ Maximum temperature 40 C during holding period ➎ Holding period 3 days without mixing valve. Control is effected by operation ➏ Temperature reduction 5 K per cooling period of the UBA.5 universal burner control unit and its modulating control of the gas condensing boiler ➐ Cooling period 2 days output. ➑ Finishing temperature 20 C The conditions for screed drying with a directly connected underfloor heating system are that 50 the boiler is a modulating-control gas condensing boiler and 40 the heat draw is guaranteed to be above the boiler's base modulation output (30 %). If the heat draw is lower or if the boiler is a lowtemperature boiler (gas circulating water heater), isolation from the circulating flow is required (e.g. by means of low-loss header). The screed drying programme starts with a flow 0 temperature of 25 C. The following parameters can be set on the MEC2 control pad: 0 Temperature rise This setting specifies the increment by which the space heating flow temperature should rise for the screed drying function Heating period This setting specifies the interval in days at which the temperature for screed drying should increase. The heating period is stored under the menu option "Rise". Maximum temperature This specifies the maximum temperature to be reached during the screed drying programme. Holding period The holding time is used to set the period for which the maximum screed drying temperature is maintained. Temperature reduction This setting specifies the increment by which the space heating flow temperature should decrease for the cooling phase of the screed drying function. The cooling phase ends at 20 C. Cooling period This setting specifies the interval in days at which the temperature should be reduced for the cooling phase of the screed drying programme. The cooling period is stored under the menu option "Reduction". 32/ Programme sequence for "Screed drying" function with the parameter settings in the example Key to illustration t Time Flow temperature for heating circuit ϑ VH 32

35 4000 system digital controllers Wiring diagram for 42 controller Netz Netz Operation Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. Ensure the mains power is correctly wired to the terminals. Do not use an earthed plug. Caution! Earth lead (yellow/green) must not be used as a control lead. ) The total current drawn by all electrical consumers must not exceed 0 A. It is imperative that the above figure is adhered to and checked after commissioning in order to prevent damage to equipment. Recommended connecting cable in cable trunking: H 05 V V-F3G.0 mm 2 or H 05 V V- F4G.0 mm 2. 2) Caution! Only one MEC2 may be allocated to each controller. The MEC2 can either be plugged directly into the controller module or connected to one of the ZM.. or FM.. modules using the room fitting kit (optional accessory page 7). 3) If several ECOCAN-BUS devices are connected, the switches S (terminal resistors on the NM482) on the two outermost ECOCAN-BUS devices must be closed. 4) Shielded wires are not required for standard applications. Only connect the shielding at one end. 5) See also servicing instructions 6) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): Heating circuit: -3 manual daytime mode = heat demand, -2 manual night-time mode or pump fault DHW: -3 thermal disinfection or once-only cylinder charging, -2 pump fault 7) Caution! The jumper across terminals 3/4 must be removed first. Incorrect connection inside the gas wall-mounted boiler can lead to equipment damage. Therefore, always check the connections on the UBA universal boiler control unit. 8) Automatic control input 9) Power supply for FM module in slot 2 33/ Wiring diagram for 42 controller (for abbreviations page 84) 33

36 system digital controllers controllers as function expansion units or master controllers and 422 with FM445 as cylinder charging system controller 4.2. Brief description of 422 controller as function expansion unit Possible applications The basic version of the 422 digital controller does not have any functions. It may be expanded by the addition of two function/expansion modules to suit the requirements of a particular heating system. If a particular heating system requires more function modules, the additional expansion slots can be provided by additional digital controllers (e.g. 422 and 4323). Those controllers then serve as function expansion units ( page 39) and are connected to the master controller via the ECOCAN- BUS. When acting as a function expansion unit with FM442 function expansion modules, the 422 controller can control heating circuits on the basis of outside temperature. It obtains the necessary outside temperature information from the master controller via the ECOCAN-BUS. Since an outside temperature sensor can not be connected, the 422 controller is not suitable for use as an autonomous heating system controller. Standard specifications 422 digital controller with CM43 controller module and MEC2 control pad ( 34/) or with boiler display 2 34/ Basic version of 422 digital controller Key to illustration B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot for one function expansion module 2 Slot 2 for one function expansion module 3 Power switch 4 Fuse 5 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) B

37 4000 system digital controllers 4 422: expansion of heating system function by control of heating circuit and domestic hot water Easycom Address ECO-BUS 3 2 Address 2 ECO-BUS 3 2 Address 3 ECO-BUS 3 2 Address max. 5 ECO-BUS 3 2 Fixed address adress ECO-BUS 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS FM44 FM WF 2PZ KR FV PH WF WF 2WF or or or or BF BF 2BF HK HK HK2 FV 2FV PH 2PH 2FW KR 2PS SH SH 2SH VK RK 35/ Possible connections to 422 controller serving as function expansion unit fitted with function modules FM44 and FM442 (for 422 wiring diagram page 40, for FM44 page 7, for FM442 page 78, for abbreviations page 84) 35

38 system digital controllers Brief description of 422 controller as master controller for a multi-boiler cascade system Possible applications The 422 digital controller fitted with FM456/FM457 function modules is suitable for use as a master controller for a multi-boiler cascade system with up to eight modulating-control EMS boilers. Depending on the options required, the 422 controller can be fitted with one function/expansion module. Boiler control The following boiler types can be set on the Service menu of the MEC2 control pad: Low temperature boiler Condensing boiler B In conjunction with the appropriate plumbing configuration and the correct settings, the EMS or UBA.5 guarantees that the required boiler operating conditions are maintained. In a multi-boiler cascade system, all the boilers must be modulating-control boilers of the same type (i.e. gas condensing boilers or low-temperature boilers) with EMS or UBA.5. However, the boilers may have different outputs. Multi-boiler cascade systems can include gas condensing boilers with EMS and with UBA.5. That means that existing systems can be extended. Standard specifications Equipment options (each with separate article number) 422 digital controller with CM43 controller module and MEC2 control pad FM456 function module for 2-boiler cascade system FM457 function module for 4-boiler cascade system One FM456 and one FM457 function module for 6-boiler cascade system or Two FM457 function modules for 8-boiler cascade system Boiler water temperature sensor FK for low-loss header Outside temperature sensor FA 36/ 422 digital controller as master controller for multi-boiler cascade systems Key to illustration B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot with FM456 or FM457 function module (for version with FM457 function module 5/) 2 Slot 2 for another FM456 or FM457 function module or an expansion module 3 Power switch 4 Fuse 5 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) 36

39 system digital controllers 4 422: master controller of a heating system with boiler control FM Easycom Address Adresse ECO-BUS 3 2 Adresse Address ECO-BUS Address Adresse 3 ECO-BUS 3 2 Adresse Address max. max. 5 5 ECO-BUS 3 2 Adresse Fixed address fest ECO-BUS 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS BC0 BC0 Heizkessel Boiler Heizkessel Boiler 2 2 Address (master) 42 Controller for cascade system control with FM455 function module ( boiler) and FM456 (2 boilers) with outside-temperature sensor Heating circuit function (2 heating circuits with mixing valve and heating circuit without) and DHW heating (cylinder system) via UBA burner control unit on st boiler No spare slots for function expansion modules Addresses 2 5 (choice and assignment unrestricted) 422 (for description page 34) 4323 (for description page 60) 42 (not illustrated, for description page 26) Fixed address (preset) Easycom Telecontrol modem 37/ Example combination of 4000 system digital controllers for a 2-boiler system with wall-mounted boilers showing assignment of boilers and addresses on ECOCAN-BUS network 37

40 system digital controllers Brief description of 422 with FM445 as cylinder charging system controller Possible applications The 422 digital control unit with FM445 function module is a controller for DHW heating using upright and horizontal stratified cylinders with a Buderus cylinder charging system with either the Logalux LAP* heat exchanger set (charging system with top-mounted heat exchanger) or Logalux LSP* heat exchanger set (charging system with sidemounted heat exchanger). DHW heating (function module FM445) Temperature control of a cylinder charging system by controlling volumetric flow rate of the primary and secondary circuit pumps (AC pumps only) or by controlling the primary circuit mixing valve with maximum volumetric flow rate from primary circuit pump and variable volumetric flow rate from secondary circuit pump. Separate timer programmes for DHW heating with cylinder charging pump, daily monitoring, thermal disinfection and DHW circulation pump operation Electrically isolated output for heat demand signal to externally controlled heating systems Electrically isolated external input for once-only charging of cylinder outside of set times or for activating thermal disinfection Electrically isolated external input for fault signal from cylinder charging pump or for an inert anode for display on the MEC2 control pad Thermal disinfection Daily monitoring Anti-scaling function Option of hot water priority or simultaneous operation with the heating circuits Facility for setting cut-in and cut-out hysteresis Standard specifications 422 digital controller with CM43 controller module, FM445 function module and MEC2 control pad DHW temperature sensor FSM (cylinder centre sensor) DHW temperature sensor FSU (cylinder bottom sensor) DHW temperature sensor FWS (heat exchanger secondary circuit sensor) 2 38/ Basic version of 422 digital controller with FM445 Key to illustration B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot for one function expansion module 2 Slot 2 with FM445 function module ( 05/) 3 Power switch 4 Fuse 5 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) B * In the UK & Ireland this product was unavailable at the time of printing. 38

41 4000 system digital controllers with FM445 heat demand in ECOCAN-BUS network or as stand-alone solution The 422 controller with FM445 function module is suitable for use as an autonomous controller for controlling the temperature of a cylinder charging system in externally controlled heating systems. The heat demand is signalled to the external controller via the electrically isolated switch (terminal WA page 07) on the FM445 function module. Alternatively, the 422 controller with FM445 function module can be connected to a 4000 system boiler controller (master controller) via the ECOCAN-BUS. In that case, the heat demand from the cylinder is forwarded by the 422 controller with FM445 function module via the ECOCAN-BUS to the 42, 42 or 432 master controller, which initiates the heat demand signal to the boiler. When used as a function expansion unit in conjunction with an FM442 function expansion module, the 422 controller with FM445 function module can also control heating circuits on the basis of outside temperature. It obtains the necessary outside emperature information from the master controller via the ECOCAN-BUS. 422 VH RH SK PS FM445 WT FWS FSM FSU PZ KR 39/ 422 digital controller with FM445 function module as stand-alone solution (for abbreviations page 84) PS2 External switch (electrically isolated) connected to WF: /2 (break switch) = pump fault /3 (make switch) = once-only cyl. charge AW WA KR EK 23 WF EZ Expansion of 422 controller functions Additional modules ) for 422 Module FM44 function module DHW (cylinder system) heating circuit with mixing valve (mixer) FM442 function module 2 heating circuits with mixing valve (mixer) FM443 function module Solar thermal system with one or two heat consumers FM444 function module Alternative heat source and/or thermal store FM445 function module DHW (cylinder charging system) Module FM448 function module Heat demand or centralised fault signal and heat meter FM456 function module Cascade system for two modulating control boilers with EMS/UBA.5 FM457 function module Cascade system for four modulating control boilers with EMS/UBA.5 LON-Gateway LON BUSinterface 39/2 Possibilities for expansion of 422 controller functions by additional modules ) Maximum of two spare expansion slots on 422 controller Technical data for 422 Controller 422 Controller 422 Power supply 230 V AC ± 0 % Power consumption 5 VA Frequency 50 Hz ± 4 % 39/3 Technical data for 422 controllers (for FM445 function module technical data page 07; for FM456/FM457 function module technical data page 7) 39

42 system digital controllers controller function description The basic version of the 422 controller does not include any function modules but has two spare module slots. The configuration-specific functions provided by the 422 controller with FM456 and/or FM457 function module and used as master controller for modulating-control EMS-boiler cascade systems are the same as the functions provided by the FM456/FM457 function module ( page 7 ff.). If fitted with only one FM456/FM457 function module, the 422 controller has one spare module slot for additional function/expansion modules. For details of the possible additional functions of the 422 controller, please refer to the function description for the particular module fitted ( 39/2) Wiring diagram for 422 controller 422 BUS (internal) B Power supply module NM482 CM43 controller module 3) S ) L N ECO-BUS 3 2 L2 N N L Netz L N 2) L L N N b a Mode I 0 0,4 0,75 mm 2 4) Fuse 0 AT L N PE / ECOCAN-BUS ) Mains 230 V 50 Hz ~ Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. Ensure the mains power is correctly wired to the terminals. Do not use an earthed plug. Caution! The earth lead (yellow/green) must not be used as a control lead. The total current drawn by all electrical consumers must not exceed 0 A. It is imperative that the above figure is adhered to and checked after commissioning in order to prevent damage to equipment! Recommended connecting cable in cable trunking: H0 5 V V-F3G.0 mm 2 or H 0 5 V V-F4G.0 mm 2. Caution! Only one MEC2 may be allocated to each controller. The MEC2 may be either plugged into the controller module or connected to one of the FM.. modules using the room fitting kit (optional accessory page 7). ) If several ECOCAN-BUS devices are connected, the switches S (terminal resistors on the NM482) on the two outermost ECOCAN-BUS devices must be closed. 2) Shielded wires are not required for standard applications. Only connect the shielding at one end! 3) Power supply for function module in slot 4) Power supply for function module in slot 2 40/ Wiring diagram for 422 controller (for abbreviations page 84) 40

43 4000 system digital controllers 4 M 422 with FM445 BUS (internal) B BUS (internal) 2 LAP-module FM445 7) S 2) 4) 4) 4) 4) 4) 4) 0 0 AUT AUT P S k6a k5 k4 k3a k2 k L N ECO-BUS 3 2 L2 N N L Netz L N 0,4 0,75 mm 2 3) Netz L N Fuse 0 AT b Operation I 0 a PS SK 43 4 PS PZ 4 3 WA 4 2 5) WF U FBS FVF FSM FSU FWS ECOCAN-BUS 2) 3,5 2 4,5 2 3,5 2 3,5 2 max. 2 A max. 5 A max. 2 A max. 5 A ) ) ) ) hotter colder 0,4 0,75 mm 2 L N PE / Mains 230 V 50 Hz L N M N Cylinder charging pump primary circuit (PS) Servomotor primary circuit Runtime 2 min. (SK) L N M Cylinder charging pump secondary circuit (PS2) L N M DHW circulation pump (PZ) 2 6) 3 Selection function (zero volt) (WF) 2 FB Connection to DHW temperature sensor terminal on Series 2000 and HS/HW 420 controllers DHW temperature cylinder sensor centre (FSM) DHW temperature cylinder sensor bottom (FSU) DHW temperature cylinder sensor Heat exchanger (FWS) Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. Ensure the mains power is correctly wired to the terminals. Do not use an earthed plug. Caution! The earth lead (yellow/green) must not be used as a control lead. ) The total current drawn by all electrical consumers must not exceed 0 A. It is imperative that the above figure is adhered to and checked after commissioning in order to prevent damage to equipment! Recommended connecting cable in cable trunking: H0 5 V V-F3G.0 mm 2 or H 0 5 V V-F4G.0 mm 2. 2) If several ECOCAN-BUS devices are connected, the switches S (terminal resistors on the NM482) on the two outermost ECOCAN-BUS devices must be closed. 3) Shielded wires are not required for standard applications. Only connect the shielding at one end! 4) Automatic control input 5) Heat demand signal to external device (electrically isolated): +2 break switch; +4 make switch. 6) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): DHW: -3 thermal disinfection or once-only cylinder charging, -2 pump fault 7) Power supply for expansion/function module in slot Switch position 0 AUT P primary circuit (PS) k6a Control mode (SK) k5 k4 Control mode colder Switching states Control mode hotter Switch position 0 AUT secondary circuit WA (PS2) (PZ) k3a k2 k Control mode Control Control mode mode colder hotter 4/ Wiring diagram for 422 controller with FM445 function module (for abbreviations page 84) 4

44 system digital controllers controller for a floor-standing boiler 4.3. Brief description Possible applications The 42 digital controller is suitable for controlling a Buderus floor-standing oil/gas boiler with single-stage, 2-stage or modulating-control burner. As standard, the unit includes the DHW heating (cylinder system) and heating circuit control (one heating circuit without mixing valve) functions. It can be expanded by the addition of two function modules to suit the requirements of the heating system. A B 2 Boiler safety functions The following boiler types and the corresponding boiler safety function options for ensuring required operating conditions can be set on the Service menu of the MEC2 control pad: Low-temperature boiler (required boiler operating conditions ensured by pump control logic) Ecostream boiler (required boiler operating conditions ensured by superimposition of heating circuit mixing valves) Low-temperature boiler with raised minimum boiler water temperature/base temperature (required boiler operating conditions ensured by superimposition of heating circuit mixing valves) Gas-fired condensing boiler The correct settings in conjunction with the appropriate plumbing configuration guarantee that the required boiler operating conditions are maintained. Depending on the plumbing configuration, the circulation pump for "Heating circuit 0" can be operated as a heating circulation pump or alternatively as a boiler circulation pump/measurement point pump ( page 43). Key to illustration ( 42/) A Slot A with ZM422 central module for boiler/burner control and one heating circuit without mixing valve and one DHW system with cylinder charging pump (cylinder system), thermal disinfection and DHW circulation pump (with manual control mode) B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot for one function expansion module 2 Slot 2 for one function expansion module 3 Power switch 4 Burner emergency mode switch 5 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) 6 Fuse 7 Boiler water temperature control 8 Safety temperature limiter (adjustable) / Basic version of 42 digital controller /2 ZM422 central module of 42 controller Key to illustration ( 42/2) Module fault indicator (LED) 2 Summer mode LED for heating circuit 0 3 LED for heating circuit 0 circulation pump/boiler circulation pump 4 DHW circulation pump LED 5 Cylinder charging pump LED 6 Manual mode switch for heating circuit 0 and DHW 7 Manual burner control switch 8 Button and LED for variably increasing burner output 9 Button and LED for variably decreasing burner output 0 LED for burner stage II/burner modulation LED for burner stage I 2 Burner fault LED 3 Flue gas test button

45 4000 system digital controllers 4 Burner control The 42 controller can control singlestage, 2-stage or modulating-control burners via the standardised 7-pin burner connector. There is also a special function which enables control of two boilers with single-stage burners (2 single-stage burners). In conjunction with a 422 analogue controller on the succeeding boiler, outside-temperature based load limiting or boiler sequence switching is possible. Pump function The pump function offers three alternative options Heating circuit control (heating circuit 0) Boiler circulation pump Measuring point pump If the option "Boiler circulation pump" or "Measuring point pump" has been activated on the Service menu on the MEC2 control pad, the "Heating circuit 0" functions are no longer available. Heating circuit control pump function (heating circuit 0) The following options are available if the function "Heating circuit 0" is activated: Outside-temperature driven control of a heating circuit without mixing valve via the space heating circulation pump Option of connecting a separate remote control for room-temperature override Adjustable, automatic switching between summer/winter modes separately for each heating circuit Boiler circulation pump function The control logic and the behaviour of the boiler circulation pump are dependent on the boiler type setting (boiler safety function page 45). Measuring point pump function The measuring point pump is not subject to any required boiler operating conditions. It always runs alongside the boiler with a definable run-on time. A typical application scenario is integration in the boiler circuit with isolation from the circulating flow by means of a low-loss header ( page 47). DHW heating Individually timer-controlled DHW heating using a cylinder charging pump (cylinder system), thermal disinfection, daily monitoring and control of a DHW circulation pump External electrically isolated input (optional function terminal WF) either for an external heat demand override for a heating circuit function on the basic 42 controller or for activating the DHW function (once-only cylinder charging) or for thermal disinfection Option of hot water priority or simultaneous operation with the heating circuits Standard specifications 42 digital controller with MEC2 control pad ( 42/) Outside temperature sensor FA Boiler water temperature sensor FK 42: control of burner, DHW heating and heating circuit ( heating circuit w/o mixing valve) External switch (electrically isolated) connected to WF: Contact Heating circuit DHW 3 Manual daytime 2 Manual night-time or pump fault FA Thermal disinfection or once-only cylinder charging Pump fault FG ) Optional function terminal on basic controller can be allocated once by software settings for connecting an external override switch 23 WF PZ KR ) KR 23 WF ) oder or BF HK0 FK SV VK FB KR PS PH-HK0 BR BRII RK 42 MAG 43/ Possible connections to basic version of 42 controller (for wiring diagram page 49, for abbreviations page 84) 43

46 system digital controllers Expansion of 42 controller functions Additional modules ) for 42 Module FM442 function module 2 heating circuits with mixing valve (mixer) FM443 function module Solar thermal system with one or two heat consumers FM444 function module Alternative heat source and/or thermal store FM445 function module DHW (cylinder charging system) Module FM448 function module Heat demand or centralised fault signal and heat meter ZM426 option module 2nd safety temperature limiter LON-Gateway LON BUSinterface LON-Gateway LON BUSinterface 44/ Expansion of 42 controller functions by additional modules ) Two spare expansion slots on 42 controller 42 in ECOCAN-BUS network with other digital controllers Easycom/Easycom Pro Adresse Address ECO-BUS 3 2 Address Adresse ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS max Adresse Fixed ECO-BUS address fest 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS 44/2 Example of combination of 42 controller with other digital controllers in ECOCAN-BUS network Technical data for 42 controller Controller 42 Controller 42 Power supply 230 V AC ± 0 % Adjustable from Safety temperature limiter STB C Frequency 50 Hz ± 4 % (tested to DIN 3440, July 984 edition) Capillary tube sensor Power consumption 5 VA Boiler water temperature control TR Adjustable from C Measuring point / Max. switching current 5 A Capillary tube sensor (tested to DIN 3440, July 984 edition) heating circulation pump PH Cylinder charging pump PS Max. switching current 5 A Single and 2-stage burner control 230 V; 8 A; 2-point DHW circulation pump PZ Max. switching current 5 A Modulating burner control 230 V; 8 A; 3-point Boiler water temperature sensor FK NTC sensor, dia. 9 mm External optional function WF )2) Electrically isolated input Outside temperature sensor FA 2) NTC sensor MEC2 or BFU/F remote control 2) BUS communication 44/3 Specifications of 42 controller ) Switch load 5 V DC / 0 ma 2) Max. lead length 00 m (shielded upwards of 50m) controller function description This function description relates only to the basic version. The 42 controller also has two spare module slots for function/expansion modules. For details of the possible additional functions that can be incorporated in the 42 controller by means of expansion modules, please refer to the function description for the module concerned ( 44/). 44

47 4000 system digital controllers 4 Boiler control using the 42 controller Required boiler operating conditions Every time the boiler is started up, the hot flue gas comes into contact with the cooler boiler surfaces. The boiler heat exchanger may have cooled down to ambient temperature, e.g. at the end of the night-time low-output phase. As the flue gas contains water vapour, condensation may form on the boiler surfaces if the temperatures are below a certain level. The temperature at which that occurs is called the condensation point and is different for every fuel. The controller configuration may require entry of the type of fuel so that the required operating conditions can be adjusted to suit the fuel. With condensing boilers, condensation of the water vapour in the flue gas is intentionally brought about in order to make use of the heat released by condensation. With low-temperature and Ecostream boilers, by contrast, condensation has to be avoided in order to protect the boilers against corrosion. The temperature range up to the condensation point is passed through most quickly if the boiler can heat up first before the full system volume flows through it. The 4000 control system offers optimum adaptation and adjustment options for maintaining the boiler-specific required operating conditions. Every digital boiler controller has defined functions specifically adapted to the Buderus floor-standing boiler models. In that way, the boiler safety functions can be implemented by the correct software settings for the boiler type on the Service menu of the MEC2 control pad in conjunction with the appropriate plumbing configuration. Boiler safety functions Low temperature boilers When the boiler-water temperature falls below a minimum level, the boiler circulation pump, heating circuit pumps and cylinder charging pump are switched off, and when the boiler-water temperature rises, are not switched on again until a certain switching differential is passed. This boilersafety related function is referred to as the "pump control logic". The switching threshold depends on the boiler type and is preset at the factory. Ecostream boilers For this boiler type, a factory-set "operating flow temperature" for the Ecostream boiler is ensured. If the temperature falls below that level (measured by the boiler-water temperature sensor FK), the volumetric flow rate is automatically reduced by means of mixing valves. That control function is assisted by switching off the boiler circulation pump, the heating circuit pumps and the cylinder charging pumps if the boiler flow temperature falls below a certain level. At the same time, the boiler is run with a minimum setting for the boiler flow temperature when there is a demand for heat from heat consumers. Only possible for control of the operating flow temperature Superimposed control of heating circuit mixing valves Regardless of the heat demand from the heating circuits, the heating circuit mixing valves are closed when the temperature falls below the operating flow temperature. For this setting, all heating circuits must be fitted with an mixing valve and controlled by the controller. Low-temperature boilers with base temperature The method of operation is the same as for Ecostream boilers. However, the operating flow temperature is higher and the factory-set minimum required boiler flow temperature is always active whenever there is a demand for heat (heating mode). The same options for controlling the operating flow temperature are available as with Ecostream boilers. Gas condensing boilers If this boiler type is selected, there are no required boiler operating conditions to be maintained. No boiler safety functions are required. Burner control The 42 digital controller can control single-stage, 2-stage or modulating-control burners. The burner is controlled dynamically within fixed switching thresholds (hysteresis settings) depending on the difference between the required boiler flow temperature and the actual boiler flow temperature (control deviation). The controller calculates the required setting for the boiler flow temperature from the required temperatures, e.g. for the heating circuits or the DHW. 45

48 system digital controllers Dynamic switching differential The dynamic switching differential is a burner control function which takes account of the actual current heat demand from the heating system. It dynamically combines two different requirements for the switching characteristics of the burner. Firstly, there is a fixed setting for the burner switching threshold. For a single-stage burner and the first stage of a 2-stage or modulating-control burner, it is a difference of ±7 K between the required boiler flow temperature and the actual boiler flow temperature. For the second stage of a 2-stage burner, the control deviation is ±8 K. The 42 controller switches the burner or burner stages on/off when the relevant fixed threshold is passed ( 46/). Secondly, the controller constantly checks the difference between the required boiler flow temperature and the actual boiler flow temperature. From that information, the controller calculates the total control deviation over a specific time period (integral). If the figure calculated exceeds a set specified limit, the burner is switched on/off even if the fixed threshold has not been reached ( 46/2). On the basis of those two different burner control requirements, which positively influence the starting characteristics of the burner, it is possible to achieve optimum adaptation to the current output demand (effective switching difference) ( 46/3). ϑ FL [ C] ϑ FL [ C] I I FL, Set FL, Act FL, Set FL, Act Large control deviation II Small control deviation 46/2 Principle of dynamic switching differential with different control deviations II t [s] t [s] Fixed cut-out hysteresis settings II (OFF) I (EVERYTHING OFF) 8 7 a Δϑ [K] 7 ➀ b ➁ ➂ +8 K 8 a ϑ FL [ C] FL, Set 7 K FL, Act 8 K FL, Act +7 K BR II BR t [s] ➀ Switching of stages and 2 using fixed hysteresis ➀ Switching of stages and 2 using dynamic switching differential ➀ Switching using fixed hysteresis (stage 2) and dynamic hysteresis (stage ) I (ON) II t [s] (EVERYTHING ON) Fixed cut-in hysteresis settings 46/ Fixed switching thresholds for burner stages according to control deviation 46/3 Progression of effective (optimised) switching differential Key to illustration ( 46/ and 46/2) I Burner stage I II Burner stage II t Time ϑ FL Boiler flow temperature ϑ FL, Act Actual temperature at boiler-water temperature sensor Required temperature at boiler-water temperature sensor ϑ FL, Set Key to illustration ( 46/3) a Effective switching differential b Required flow temperature t Time Δϑ Temperature difference 46

49 4000 system digital controllers 4 42: heating circulation pump as measuring point pump With the appropriate plumbing configuration, the circulation pump PH-HK0 ("Heating circuit 0") can be operated as a measuring point pump if the option "Pump function" is activated. A typical application for a measuring point pump is a single-boiler system without required operating conditions and with flow isolator (low-loss header). Isolation from the circulating flow is advisable for systems with large water volumes on the heat consumer side if the volumetric flow rate in the boiler circuit (primary circuit) is smaller than the total of the flow rates on the heat consumer side (secondary circuit). The measuring point pump is used to circulate the flow over the boiler-water temperature sensor, which in this case is not on the boiler but on the lowloss header. Therefore, the pump always switches on whenever the burner is operating. The pump does not switch off until a certain delay (run-on time) has elapsed after the burner cuts out. The run-on time can be set on the MEC2 control pad. Basically, the run-on time can be cancelled altogether or constantly active, but should preferably be set to between 30 and 60 minutes. FA 42 FM442 BF 2BF PZ HK HK2 KR FV 2FV VK SV PH-HK0 FK FB KR PS PH SH 2PH 2SH RK MAG 47/ Example system for 42 controller with heating circulation pump PH-HK0 as measuring point pump ("Heating circuit 0" 43/) and expansion module for heating circuit control (function module FM442 72/2, for abbreviations page 84) 47

50 system digital controllers Control of heating circuit using 42 controller The basic version of the 42 digital controller can control one heating circuit without an mixing valve ("Heating circuit 0") on the basis of outside temperature. The basic version of the controller performs the control function by operating the circulation pump by means of a separate 2-point signal (230 V AC). The appropriate characteristic heating curves for the various standard heating system configurations are stored on the controller. Adaptation to the individual system layout is straightforward using the MEC2 control pad. Heating system options for basic version Radiator or convector Automatic calculation of characteristic heating curve to suit heating system Base point Heating characteristic is a linear progression between two points, space heating flow temperature is dependent on outside temperature Constant Pre-control of ventilation systems or swimming pool heating; heating always based on a constant required space heating flow temperature regardless of outside temperature Room thermostat The required space heating flow temperature is dependent only on the measured room temperature Each heating circuit function can be adapted to the requirements of the system by means of the following additional functions: Adjustment of low-setting temperature to EN 283 Various low-setting modes for night-time operation Various low-setting modes for the holiday function Adaptation of characteristic heating curve Room temperature override or Optimisation of cut-in and cut-out The standard EN 283 is the European standard for calculating the heat requirement for buildings. According to EN 283, dimensioning of heat sources and heating surfaces must take an additional allowance into account for rooms with intermittent heating. A new function is the option of cancelling the low-setting phase for each heating circuit if the outside temperature falls below a definable, corrected level. That prevents excessive cooling of the living areas. As a result, the additional allowance for a greater initial heating output can be dispensed with when dimensioning the boiler. For the holiday function, a separate low-setting mode can be selected from the familiar options Room control, Reduced, Off, and Outside control. Therefore, the 4000 controller can be adjusted to different user requirements in the holiday period. The optional function terminal can be allocated either to the heating circuit function or the DHW function. An optional function terminal provides the facility either for an external heat demand override for a heating circuit function on the basic 42 controller or for externally activating the DHW function (once-only cylinder charging) or thermal disinfection. More information on the functions can be found in the section describing the functions of the FM442 function module ( page 73 ff.). If the option "Pump function" has been activated on the Service menu on the MEC2 control pad, the "Heating circuit 0" functions are no longer available. In combination with a low-temperature boiler without return temperature requirements, a low-temperature boiler with base temperature or an Ecostream boiler with required operating conditions, heating systems with lower design temperatures are not advisable for the directly connected heating circuit without mixing valve. When planning the heating circuit functions for a directly connected heating circuit without mixing valve, the following limitations must be taken into account: No underfloor heating system No underfloor heating programme for screed drying DHW heating controlled by 42 All DHW heating functions using the 42 are the same as those provided by the FM44 function module ( page 69). 48

51 4000 system digital controllers Wiring diagram for 42 controller B BUS (internal) A Controller module CM43 Power module NM482 5) ECO-BUS S Netz 2 3 N L L N N L2 Boiler module ZM422 AUT 0 max l+ll k 8) 8) k2 k3 8) 8) 8) 8) 0 AUT k4 k5 k6 ECOCAN-BUS 0,4 0,75 mm 2 6) N L ) 0) Operation 0 I a b 2 AUT b a ) ) High limit Boiler water safety cut-out 2 4 temperature 3 (STB) controller (TR) Netz N L N WF FG FB FK FA BF ,4 0,75 mm 2 N L Fuse 0 AT N L SI BR SG UE PH-HK0 PS PZ N BR II ) /PE N L Component Mains 230 V 50Hz max. permissible fuse rating Component 0A (sow) Connection example for safety components (on-site) Signal mode Signal fault N B4 S3 T T2 L Controller L via safety devices Gas/oil burner Burner connection stage 2) max.8 A (BR) Terminals for flue gas damper (SG) Terminals for flue gas monitor (UE) 3,5 2 3,5 2 3,5 2 max. 5 A max. 5 A max. 5 A 2) 2) 2) N L Heating circuit pump (PH-HK0) or as option boiler pump (PH-HK0) N L Cylinder primary pump (PS) N L DHW circulation pump (PZ) B5 T6 T7 T8 Signal mode Controller Burner connection stage 2 or connection for modulating burner (BRII) 2 3 Selection function (zero volt) (WF) 9) Flue gas temp. sensor (FG) DHW temp. sensor (FB) Boiler water temp. sensor (FK) 2 2 Outside temp. sensor (FA) + 2 Remote control MEC2 or BFU (BF) 3) Switching states Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. Ensure the mains power is correctly wired to the terminals. Do not use an earthed plug. Caution! The earth lead (yellow/green) must not be used as a control lead. ) Switch opens when the set temperature is exceeded. 2) The total current drawn by all electrical consumers must not exceed 0 A. 3) Please note! Only one MEC2 may be allocated to each controller. The MEC2 can either be plugged directly into the controller module or connected to one of the ZM.. or FM.. modules using the room fitting kit (optional accessory page 7): 4) Connection option with example of safety components (external) 5) If several ECOCAN-BUS devices are connected, the switches S (terminal resistors on the NM482) on the two outermost ECOCAN-BUS devices must be closed. 6) Shielded wires are not required for standard applications. Only connect the shielding at one end! 7) See also servicing instructions 8) Automatic control input 9) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): Heating circuit: -3 manual daytime mode = heat demand, -2 manual night-time mode or pump fault DHW: -3 thermal disinfection or once-only cylinder charging, -2 pump fault 0) Power supply for additional module in slot ) Power supply for additional module in slot 2 Stage Stage 2 / modulierend Switch position k k2 k3 AUT 0 max l+ll Control mode Pushbutton Pushbutton pressed Control mode hotter pressed Control mode colder Switch position 0 AUT = hotter = colder L (PH) (PS) (PZ) k4 k5 k6 Control Control mode mode Z Control mode Control voltage 230 V LV 49/ Wiring diagram for 42 controller (for abbreviations page 84) 49

52 system digital controllers controller for single floor-standing boiler or 432 and 4322 controllers for systems with multiple floor-standing boilers 4.4. Brief description Possible applications The 432 and 4322 digital controllers can each control one Buderus floor-standing oil/gas boiler with single-stage, 2-stage or modulating-control burner. They also support operation of dual-fuel burners. They can each be expanded by the addition of up to four function modules to suit the requirements of the heating system. Fitting the FM458 strategy module to the 432 controller enables control of multi-boiler systems A B 3 4 Key to illustration ( 50/) A Slot A with ZM434 central module for boiler/ burner control B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot for one function expansion module 2 Slot 2 for one function expansion module 3 Slot 3 for one function expansion module 4 Slot 4 for one function expansion module 5 Power switch 6 Burner emergency mode switch 7 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) 8 Fuse 9 Boiler water temperature control 0 Safety temperature limiter (adjustable) Key to illustration ( 50/2) Module fault indicator (LED) 2 Boiler circuit summer mode LED 3 Boiler circuit pump LED 4 LED for boiler circuit mixing valve directing flow to boiler 5 LED for boiler circuit mixing valve directing flow to system 6 Manual switch for boiler circuit (boiler circuit mixing valve or pump) 7 Manual burner control switch 8 Button for variably increasing burner output 9 Button for variably decreasing burner output 0 LED for burner stage II/burner modulation LED for burner stage I 2 Burner fault LED 3 Flue gas test button / Basic versions of digital controllers 432 and 4322 (slave controller in multi-boiler systems) /2 ZM434 central module for 432 and 4322 controllers 50

53 system digital controllers 4 Boiler safety functions The following boiler types and the corresponding boiler safety function options for ensuring required operating conditions can be set on the Service menu of the MEC2 control pad: Low-temperature boiler (required boiler operating conditions ensured by pump control logic) Ecostream boiler (required boiler operating conditions ensured by boiler circuit mixing valve or superimposition of heating circuit mixing valves) Low-temperature boiler with raised minimum boiler water temperature/base temperature (required boiler operating conditions ensured as for Ecostream boilers) Low-temperature boiler with raised minimum return temperature (required boiler operating conditions ensured as for Ecostream boilers) Gas-fired condensing boiler The correct settings in conjunction with the appropriate plumbing configuration guarantee that the required boiler operating conditions are maintained. Burner control The controller's central module controls single-stage, 2- stage or modulating-control burners on the basis of output demand. With dual-fuel burners, it can switch between oil and gas. Control is normally effected by means of separate leads for burner stages and 2. Alternatively, the burner can be controlled by a 0-0 V signal, in which case the burner lead for stage 2 is not required. Multi-boiler systems Fitting the FM458 strategy module to the 432 controller (maximum of two per system) enables control of up to eight boilers according to a strategy. A 4322 or EMS controller is required for each sequential boiler ( 5/). Special functions for single and multi-boiler systems Separate boiler characteristic specifiable if heat consumers externally controlled ( page 56) Control of a boiler circuit pump for systems with unpressurised headers or low-loss headers Output-based control of a boiler circuit pump by means of a 0-0 V signal in conjunction with modulating-control burners Application of an electrically isolated signal for an external fault or for switching between gas and oil operation in the case of dual-fuel burners Special functions for multi-boiler systems in conjunction with the FM458 strategy module Parallel or series operation specifiable Automatic sequence switching, either daily, based on hours of operation, based on outside temperature or by electrically isolated switch Definable load limit based on outside temperature or an electrically isolated input Definable boiler sequences Isolation of sequential boilers taking account of automatic sequence switching Definable run-on period for boiler circuit pumps for utilisation of residual heat from sequential boilers 0-0 V input for application of external temperature requirement or output requirement (heat demand) where heating circuit is externally controlled 0-0 V or 0-20 ma output for externally signalling temperature requirement (heat demand) to master controller (BEMS) Indication of status of individual boilers Electrically isolated output for centralised fault signalling Electrically isolated input for application of an external heat meter signal 432 FM458 EMS-BUS Easycom/Easycom Pro Adresse Address ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS 3 2 Adresse Fixed address fest ECO-BUS 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS BC0 Heizkessel Boiler Heizkessel Boiler 2 2 Heizkessel Boiler 3 3 Heizkessel Boiler 4 4 5/ Example combination of 432 and 4322 digital controllers and other digital controllers as expansion units for a 4-boiler system with floor-standing boilers showing assignment of boilers and addresses on ECOCAN-BUS network (for explanation 4/) 5

54 system digital controllers Standard specifications 432 digital controller with MEC2 control pad or 4322 digital controller with boiler display ( 50/) 432 or 4322: control of burner and boiler circuit (boiler safety) FA outside temperature sensor (only 432) Boiler water temperature sensor FK Additional temperature sensor FZ for low-loss header or as return temperature sensor Burner cable, stage 2 FA (MEC2) BF U PU 0 0 V 2 ES External switch connected to ES: external fault (/2 = make switch) PK FZ SR FG FK BR 432 (4322) or BRII U BR 0 0 V 52/ Possible connections to basic version of 432 or 4322 controller (for wiring diagram page 59, for abbreviations page 84) Expansion of 432 and 4322 controller functions Additional modules ) for 432 and 4322 Module FM44 function module DHW (cylinder system) heating circuit with mixing valve (mixer) FM442 function module 2 heating circuits with mixing valve (mixer) FM443 function module Solar thermal system with one or two heat consumers FM444 function module Alternative heat source and/or thermal store FM445 function module DHW (cylinder charging system) Module FM448 function module Heat demand or centralised fault signal and heat meter FM458 function module Strategy module for four boilers with 4000 and/or EMS ZM426 option module 2nd safety temperature limiter LON-Gateway LON BUS interface 52/2 Expansion of 432 and 4322 controller functions by additional modules ) Four spare expansion slots on 432/4322 controller 52

55 4000 system digital controllers in ECOCAN-BUS network with other digital controllers Easycom Adresse Address ECO-BUS 3 2 Address Adresse ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS max Adresse Fixed ECO-BUS address fest 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS 53/ Example of combination of 432 controller with other digital controllers in ECOCAN-BUS network; 4322 only required for multi-boiler systems (for bus addresses 5/) Technical data for 432 and 4322 controllers Controller 432 / 4322 Controller 432 / 4322 Power supply 230 V AC ± 0 % Adjustable from Safety temperature limiter STB C Frequency 50 Hz ± 4 % (tested to DIN 3440, July 984 edition) Capillary tube sensor Power consumption 5 VA Boiler water temperature control TR Adjustable from C Boiler circuit mixing valve SR Max. switching current 5 A (tested to DIN 3440, July 984 edition) Capillary tube sensor control 230 V; 3-point switching Single and 2-stage burner control 230 V; 8 A; 2-point controller (PI 230 V; 8 A; 3-point Modulating burner control characteristic) Recommended positioner motor 20 s (adj. betw s) Electrically isolated input External fault signal input ) ES or running time Boiler circuit pump PK Max. switching current 5 A Change-over for dual-fuel burners Boiler water temperature sensor FK NTC sensor, dia. 9 mm MEC2 or BFU/F remote control ) BUS communication Additional temperature sensor FV/FZ ) NTC sensor, dia. 9 mm Pump output requirement (U PU ) 0-0 V output Outside temperature sensor FA ) NTC sensor Burner output requirement (U BR ) 0-0 V output 53/2 Technical data of 432 and 4322 controllers ) Max. lead length 00m (shielded upwards of 50 m) and 4322 controller function description This function description relates only to the basic version. The 432 and 4322 controllers also have four spare module slots for function/expansion modules. For details of the possible additional functions that can be incorporated in the 432/4322 controller by means of expansion modules, please refer to the function description for the module concerned ( 52/2). Boiler control using the 432 and 4322 controllers Required boiler operating conditions Every time the boiler is started up, the hot flue gas comes into contact with the cooler boiler surfaces. The boiler heat exchanger may have cooled down to ambient temperature, e.g. at the end of the night-time low-output phase. As the flue gas contains water vapour, condensation may form on the boiler surfaces if the temperatures are below a certain level. The temperature at which that occurs is called the condensation point and is different for every fuel. The controller configuration may require entry of the type of fuel so that the required operating conditions can be adjusted to suit the fuel. With condensing boilers, condensation of the water vapour in the flue gas is intentionally brought about in order to make use of the heat released by condensation. With low-temperature and Ecostream boilers, by contrast, condensation has to be avoided in order to protect the boilers against corrosion. The temperature range up to the condensation point is passed through most quickly if the boiler can heat up first before the full system volume flows through it. The 4000 control system offers optimum adaptation and adjustment options for maintaining the boiler-specific required operating conditions. Every 53

56 system digital controllers digital boiler controller has defined functions specifically adapted to the Buderus floor-standing boiler models. In that way, the boiler safety functions can be implemented by the correct software settings for the boiler type on the Service menu of the MEC2 control pad in conjunction with the appropriate plumbing configuration. Boiler safety functions Low temperature boilers When the boiler-water temperature falls below a minimum level, the boiler circulation pump, heating circuit pumps and cylinder charging pump are switched off, and when the boiler-water temperature rises, are not switched on again until a certain switching differential is passed. This boilersafety related function is referred to as the "pump control logic". The switching threshold depends on the boiler type and is preset at the factory. Ecostream boilers For this boiler type, a factory-set "operating flow temperature" for the Ecostream boiler is ensured. If the temperature falls below that level (measured by the boiler-water temperature sensor FK), the volumetric flow rate is automatically reduced by means of mixing valves. That control function is assisted by switching off the boiler circulation pump, the heating circuit pumps and the cylinder charging pumps if the boiler flow temperature falls below a certain level. At the same time, the boiler is run with a minimum setting for the boiler flow temperature when there is a demand for heat from heat consumers. That function is only effective in "Burner ON" mode. The following boiler safety functions for controlling the operating flow temperature are possible: Superimposed control of heating circuit mixing valves for single-boiler systems Regardless of the heat demand from the heating circuits, the heating circuit mixing valves are closed when the temperature falls below the operating flow temperature. For this setting, all heating circuits must be fitted with an mixing valve and controlled by the controller. Control of a separate boiler circuit mixing valve If the temperature drops below the boiler's operating flow temperature, the boiler circuit mixing valve (motorised mixing valve) is closed (for possible plumbing configurations 45/3 or 45/4). This setting is advisable when supplying heat to externally controlled heating circuits or for heating circuits without mixing valve. Corresponding external control function Condition: during burner ON mode, an operating flow temperature of 50 C must be reached within 0 minutes and maintained as the minimum temperature, e.g. by volumetric flow rate restriction. Low-temperature boilers with base temperature The method of operation is the same as for Ecostream boilers. However, the operating flow temperature is higher and the factory-set minimum required boiler flow temperature is always active whenever there is a demand for heat (heating mode). The same options for controlling the operating flow temperature are available as with Ecostream boilers. Low-temperature boilers with minimum return temperature For this boiler type, a factory-set minimum return temperature for the low-temperature boiler is ensured. If the return temperature falls below that minimum setting (measured by the return temperature sensor FR or, in multi-boiler systems, by the strategy return temperature sensor FRS), the volumetric flow rate is automatically reduced by means of mixing valves. That control function is assisted by switching off the boiler circuit pump, the heating circuit pumps and the cylinder charging pumps if sudden high demand levels occur. The following options are possible for controlling the minimum return temperature: Superimposed control of heating circuit mixing valves Regardless of the heat demand from the heating circuits, the heating circuit mixing valves are closed when the return temperature falls below the minimum level. For this setting, all heating circuits must be fitted with an mixing valve and controlled by the controller. Control of a separate boiler circuit mixing valve If the boiler return temperature (sensor FR) drops below the minimum requirement, the boiler circuit mixing valve (motorised mixing valve) is closed (for possible plumbing configurations 45/ or 45/2). This setting is advisable when supplying heat to externally controlled heating circuits or for heating circuits without mixing valve. Gas condensing boilers If this boiler type is selected, there are no required boiler operating conditions to be maintained. No boiler safety functions are required. 54

57 4000 system digital controllers 4 Burner control The 432 digital controller can control single-stage, twin single-stage, 2-stage or modulatingcontrol burners and dual-fuel burners. The burner is controlled dynamically within fixed switching thresholds (hysteresis settings) depending on the difference between the required boiler flow temperature and the actual boiler flow temperature (control deviation). If the minimum and maximum boiler output levels are specified, the 432 can control burners on the basis of heat output. The modulating-control burner is operated by means of a PID controller which uses the difference between the required boiler flow temperature and the actual boiler flow temperature to calculate a required output to be produced by the burner. This is the case regardless of the output used (3- point output or 0-0 V output). If the modulatingcontrol burner is controlled via the 3-point output, the controller calculates the burner output by integrating (totalling) all signals issued via the 3-point output to determine the position of the burner mixing valve. If the 0-0 V output is used, the controller assumes that the burner executes the commands as required. As a rule, modulating-control burners are controlled via burner terminal BR for activating base-load output and burner terminal BR II for controlling modulation ( 55/). As an alternative option, modulation of a modulating-control burner can also be directed by way of a 0-0 V signal ( 55/2). If burner output control by the 432 using a 0-0 V signal is intended, the burner control unit must be capable of this method of control. Depending on manufacturer and model, burner control units may offer the function as standard or as an option requiring additional equipment. The 432 controller provides adjustment parameters for adapting the 0-0 V signal to suit the burner control unit. Control of multi-stage burners is effected by way of burner terminals BR and BR II for stages I and II respectively. The controller calculates the required boiler output from a comparison between the highest required heat-consumer temperature, e.g. for the heating circuits or DHW system (required boiler flow temperature), and the actual boiler flow temperature. The controller sets the burner to the output level previously calculated to meet the system requirement. 55/ Burner control via burner terminals BR and BRII U BR [V] 0 BR BRII BR BR U BR (0 0 V) 55/2 Control of modulating-control burners via burner terminal BR and terminal U BR Key to illustration ( 55/2) a Minimum output a Modulation: 0 V = 0 % b Modulation: 0 V = Low-load output a Burner output [%] 432 a BRII b 00 55

58 system digital controllers Dynamic switching differential The dynamic switching differential is a burner control function which takes account of the actual current heat demand from the heating system. It dynamically combines two different requirements for the switching characteristics of the burner. Firstly, there is a fixed setting for the burner switching threshold. For a single-stage burner and the first stage of a 2-stage or modulating-control burner, it is a difference of ± 7 K between the required boiler flow temperature and the actual boiler flow temperature. For the second stage of a 2-stage burner, the control deviation is ± 8 K. The 432 controller switches the burner or burner stages on/off when the relevant fixed threshold is passed ( 56/). Secondly, the controller constantly checks the difference between the required boiler flow temperature and the actual boiler flow temperature. From that information, the controller calculates the total control deviation over a specific time period (integral). If the figure calculated exceeds a set specified limit, the burner is switched on/off even if the fixed threshold has not been reached ( 56/2). On the basis of those two different burner control requirements, which positively influence the starting characteristics of the burner, it is possible to achieve optimum adaptation to the current output demand (effective switching difference) ( 56/3). ϑ FL [ C] ϑ FL [ C] I I FL, Set FL, Act FL, Set FL, Act Large control deviation II Small control deviation 56/2 Principle of dynamic switching differential with different control deviations II t [s] t [s] Fixed cut-out hysteresis settings II (OFF) I (EVERYTHING OFF) 8 7 a Δϑ [K] 7 ➀ b ➁ ➂ +8 K 8 a ϑ FL [ C] FL, Set 7 K FL, Act 8 K FL, Act +7 K BR II BR t [s] Scenario : Switching of stages and 2 using fixed hysteresis Scenario 2: Switching of stages and 2 using dynamic switching differential Scenario 3: Switching using fixed hysteresis (stage 2) and dynamic hysteresis (stage ) I (ON) II t [s] (EVERYTHING ON) Fixed cut-in hysteresis settings 56/ Fixed switching thresholds for burner stages according to control deviation 56/3 Progression of effective (optimised) switching differential Key to illustration ( 56/ and 56/2) I Burner stage I II Burner stage II t Time ϑ FL Boiler flow temperature ϑ FL, Act Actual temperature at boiler-water temperature sensor Required temperature at boiler-water temperature sensor ϑ FL, Set Key to illustration ( 56/3) a Effective switching differential b Required flow temperature t Time Δϑ Temperature difference 56

59 4000 system digital controllers 4 Boiler characteristic The "boiler characteristic" function can be used to ensure a minimum heat supply (minimum flow temperature dependent on outside temperature) for an external controller. Primarily, it applies to externally controlled heating circuits which are unable to provide the 4000 controller with a demand-based heat requirement. The boiler characteristic is defined by a linear progression between the base point as the minimum setting and the design temperature at minimum outside temperature as the maximum setting ( 57/). The controller processes the required settings from the boiler characteristic as a heat demand from a heat consumer. As with a heating circuit, it is possible to define a daytime and night-time programme (reduced output requirement) for the boiler characteristic between which it is possible to switch automatically or manually. In automatic mode, the controller can also switch between summer and winter settings. It switches to summer mode when the corrected outside temperature exceeds a definable threshold. Key to illustration A Design maximum (e.g. factory setting) A Base point (e.g. factory setting) ϑ A Corrected outside temperature Required boiler flow temperature ϑ FL ϑ FL [ C] F ϑ A [ C] 57/ Example of a boiler characteristic dependent on the corrected outside temperature A 57

60 system digital controllers Pump function Boiler circulation pump The boiler circuit pump starts and runs simultaneously with burner operation. In addition to using a straightforward switching signal, there is also the option of modulating the boiler circuit pump volumetric flow rate in the case of boilers with modulating-control burners. In that case, a 0-0 V signal is used to control the boiler circuit pump's volumetric flow rate according to burner output. This function allows the boiler circuit pump's volumetric flow rate to be adjusted to the variations in burner output ( 58/). The minimum pump modulation level (0 V control signal) should not be less than 50 %, i.e. with a burner output signal of 0 V, the volumetric flow rate through the boiler should not fall below 50 %. Adjustment of the volumetric flow rate is effected by settings on the control unit supplied by the pump manufacturer. The boiler circuit pump must be provided with the appropriate optional equipment for the speed control function. Depending on the set boiler type, the boiler circuit pump may be briefly switched off by the controller during the operating phase. That is done for boiler safety purposes, e.g. if temperatures fall below certain set levels. The control logic and the behaviour of the boiler circulation pump are thus dependent on the boiler type setting. The boiler circuit pump is always switched on whenever the burner is operating or, in the case of multi-boiler systems, whenever the FM458 strategy module switches the boiler on. In addition, the boiler circuit pump is switched off if the boiler safety cut-out is active. This does not apply in the case of lowtemperature boilers with boosted return temperature as the required boiler operating conditions can only be met if the boiler circuit pump is running. The pump does not switch off until a certain delay (run-on time) has elapsed after the burner cuts out. The purpose of this is to utilise the boiler's residual heat as effectively as possible. The run-on time can be set on the MEC2 control pad. Basically, the run-on time can be cancelled altogether or constantly active, i.e. the pump is then only switched off if the boiler safety cut-out is active. Measuring point pump In contrast with the boiler circuit pump, the measuring point pump is not subject to any required boiler operating conditions. It always runs alongside the boiler with a definable run-on time. U PU [V] M Burner output [%] 0 0 V 58/ 0-0 V signal for output-based control of a boiler circuit pump in conjunction with modulating-control burners Switching between fuels on dual-fuel burners 00 Switching fuels from oil to gas and vice versa on modern dual-fuel burners is often carried out directly and automatically by means of a centralised telecontrol signal from the energy provider. The purpose of this is to switch over to the more economical fuel as quickly as possible according to demand. In order that the controller settings are also adjusted to the different fuel type, the control signal from the energy company can also be applied to the 432 and 4322 controller's central module as an electrically isolated signal (terminal ES) and processed. If that function is used, the application of an external electrically isolated fault signal is no longer possible. The reverse also applies, i.e. if the input is already in use for a fault signal, the fuel switching function on the controller is not available. If the controller switches the fuel to gas, the control method for a modulating-control burner is automatically and exclusively applied. Changing the fuel to oil is automatically associated with adoption of the control method for a 2-stage burner. Service messages An automatic service reminder can be activated on the Service menu on the MEC2 control pad. The service reminder can be based on hours of duty or date. The service reminder can be transmitted via the telecontrol system. PK 58

61 4000 system digital controllers 4 M Wiring diagram for 432 and 4322 controllers B BUS (internal) A Controller module CM43 Power module NM482 Boiler module ZM422 ECO BUS 2 3 S 5) Netz N L N L L N N L2 AUT 0 max l+ll k 7) k2 7) 7) 0 AUT k3 k4 k5 k6 7) 7) 7) ECOCAN-BUS 0,4 0,75 mm 2 9) 8) AUT Operation 0 I Fuse each 0 AT 2) 6) a b L 2a 2 L2 2b 2 ) High limit safety cut-out 3 (STB) b a 2 4 ) Boiler water temperature controller (TWK) Netz 5 N N L ES FG FZ FK FA BF UBR UPU N 2 x 0,4 0,75 mm 2 L SI N L /PE N L Mains 230 V 50Hz max. permissible fuse rating 20 AT on-site Component Component ) 3 Connection example for safety components (on-site) BR SG N 8 9 B4 S3 0 2 T T2 L 7 UE N SR PK x,5 2 5x,5 2 max 8 A Signal hours run Signal fault Boiler water temp. controller (TR) Burner enable L via safety equipment 2) Gas/oil burner Burner connection stage max.8a 2) (BR) Terminals for flue gas damper (SG) Terminals for flue gas monitor (UE) N hotter colder 4x,5 2 max 5 A Servomotor return temperature (SR) 2) N M 3x,5 2 max 5 A L Boiler pump (PK) 2) 36 BR II T B5 T7 max 8 A T8 Signal hours output voltage L burner close/off burner open/on Burner connection stage 2 or connection for modulating burner (BRII) 2) External fault input (zero volt) (ES) or input fuel changeover two-fuel burner 5VDC 0 ma Flue gas temp. sensor (FG) DHW temp. sensor (FB) Boiler water temp. sensor (FK 2 2 Outside temp. sensor (FA) Switching states Remote control MEC2 or BFU (BF) 3) Voltage output 0-0 V Burner (UBR) M M Voltage output 0-0 V Pump (UPU) Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. Ensure the mains power is correctly wired to the terminals. Do not use an earthed plug. Caution! The earth lead (yellow/green) must not be used as a control lead. ) Switch opens when the set temperature is exceeded. 2) The total current per circuit (inc. the modules in slots and 2) must not exceed 0 A. It is imperative that the above figure is adhered to and checked after commissioning in order to prevent damage to equipment! 3) Please note! Only one MEC2 may be allocated to each controller. The MEC2 can either be plugged directly into the controller module or the room fitting kit (optional accessory page 7) can be used to connect it to one of the ZM.. or FM.. modules. 4) Wiring example for safety components. 5) If several ECOCAN-BUS devices are connected, the switches S (terminal resistors on the NM482) on the two outermost ECOCAN-BUS devices must be closed. 6) L2: fuse for modules in slots A, and 2 L: fuse for modules in slots 3 and 4 7) Automatic control input 8) Power supply for function/expansion module in slot or 2 9) Power supply for function/expansion module in slot 3 or 4 Switch position AUT 0 max l+ll Stage k k2 k3 Control mode Stage 2 / modulating Pushbutton pressed Control mode hotter Pushbutton pressed Control mode colder Switch position 0 AUT = hotter = colder (PK) (SR) (SR) k4 k5 k6 Control mode Control mode M Control mode Control voltage 230 V LV 59/ Wiring diagram for 432 and 4322 controllers (for abbreviations page 84) 59

62 system digital controllers controller as autonomous heating circuit controller or slave unit incorporating control of a feed pump 4.5. Brief description Possible applications The basic version of the 4323 digital controller can be used as an autonomous heating circuit controller incorporating monitoring of the heat supply from a thermal store or as a slave unit incorporating control of a feed pump on the basis of demand. As standard, the unit includes the heating circuit control function (one heating circuit with mixing valve). It can be expanded by the addition of four function modules to suit the requirements of the heating system. In combination with the FM456, FM457 or FM458 function modules, the 4323 controller can also be used to control multi-boiler systems. With the FM443 function module, a solar thermal system can be integrated in the 4000 control system, while the FM444 function module allows incorporation of an alternative heat source. To expand the available functions, it can also be combined with other digital controllers (e.g. 422) in an ECOCAN-BUS network. In such situations, the 4323 (as autonomous heating circuit controller) is a master controller which monitors the manually/externally controlled heating of a thermal store and makes the stored heat available to the connected heat consumers ( 6/). As a slave unit in an ECOCAN-BUS network, the 4323 controller is able to communicate with a master boiler controller within a 4000 control system ( 6/2). 60/ Basic version of 4323 digital controller A B Autonomous heating system controller or slave unit Autonomous heating circuit controller incorporating monitoring of the heat supply (heating characteristic of a thermal store) by minimum heating temperature and maximum heating time or slave unit incorporating demand-based control of a feed pump Automatic shutdown of heating circuits if heat supply insufficient 0-0 V input for external required setting (heat demand) where heating circuit is externally controlled 0-0 V output for signalling required setting to externally controlled heat source or master controller (BEMS) 60/2 ZM433 central module of 4323 controller Key to illustration ( 60/) A Slot A with ZM433 central module for controlling a heating circuit with mixing valve (as autonomous heating circuit controller) a feed pump (as slave unit) B Slot B with CM43 controller module including slot for MEC2 control pad or boiler display Slot for one function expansion module 2 Slot 2 for one function expansion module 3 Slot 3 for one function expansion module 4 Slot 4 for one function expansion module 5 Power switch 6 Connection for external service devices or MEC2 (5-pin SUB-D socket for Service Key or Online cable) 7 Fuses Key to illustration ( 60/2) Module fault indicator (LED) 2 Summer mode LED for heating circuit 3 Circulation pump LED for heating circuit 4 Actuator opening LED for heating circuit 5 Actuator closing LED for heating circuit 6 Manual mode switch for heating circuit 7 Manual mode switch for feed pump 8 Feed pump LED 60

63 4000 system digital controllers 4 Boiler control The 4323 digital controller supplemented by the function modules FM456, FM457 or FM458 is suitable for controlling boilers featuring EMS. With the function modules, it is capable of controlling multi-boiler cascade systems with up to eight EMS boilers. The following boiler types can be set on the Service menu of the MEC2 control pad: Low temperature boiler Condensing boiler An FM456 cascade module should also be specified for controlling a single-boiler system with EMS. In conjunction with the appropriate plumbing configuration and the correct settings, the EMS guarantees that the required boiler operating conditions are maintained. Heating circuit control Outside-temperature driven control of one heating circuit with mixing valve and circulation pump Option of connecting a separate remote control Adjustable, automatic switching between summer/winter modes separately for each heating circuit Electrically isolated input for external mode switch or external heat demand override and external pump fault signal Standard specifications 4323 digital controller with CM43 controller module, ZM433 central module, MEC2 control pad or boiler display and safety components ( 60/) Outside temperature sensor FA Feed temperature sensor FZB 4323: Autonomous heating circuit controller ( heating circuit with mixing valve; thermal store as heat source) 4323: Slave unit with feed pump and heating circuit control ( heating circuit with mixing valve) FA FA BF HK BF HK VK FZB FV PH FV PH SH VK PZB FZB SH RK RK KR Logalux PU... 6/ Possible connections to basic version of 4323 controller used as autonomous heating circuit controller (for wiring diagram page 64, for abbreviations page 84) 6/2 Possible connections to basic version of 4323 controller used as slave unit (for wiring diagram page 64, for abbreviations page 84) 6

64 system digital controllers Expansion of 4323 controller functions Additional modules ) for 4323 Module FM44 function module DHW (cylinder system) heating circuit with mixing valve (mixer) FM442 function module 2 heating circuits with mixing valve (mixer) FM443 function module Solar thermal system with one or two heat consumers FM444 function module Alternative heat source and/or thermal store FM445 function module DHW (cylinder charging system) Module FM448 function module Heat demand or centralised fault signal and heat meter FM456 function module Cascade system for two modulating control boilers with EMS/UBA.5 FM457 function module Cascade system for four modulating control boilers with EMS/UBA.5 FM458 function module Strategy module for four boilers with 4000 and/or EMS LON-Gateway LON BUS interface 62/ Expansion of 4323 controller functions by additional modules ) Four spare expansion slots on 4323 controller 4323 (as autonomous heating circuit controller) 4323 Easycom Address Adresse 0 ECO-BUS 3 2 Adresse Fixed ECO-BUS address fest 3 2 TAE ECOCAN-BUS 62/2 Example combination of 4323 controller (as autonomous heating circuit controller); 4323 has no BUS link to heat source controller and only controls heat distribution (for thermal store as heat source 63/2) 4323 (as slave unit) in ECOCAN-BUS network with other digital controllers Easycom Adresse Address ECO-BUS 3 2 Address Adresse ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS max Adresse Fixed ECO-BUS address fest 3 2 TAE ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS 62/3 Example of combination of 4323 controller (as slave unit) with other digital controllers in ECOCAN-BUS network; each controller has BUS link to 432 master boiler controller (for incorporation of feed pumps for two slave units 64/2) 62

65 4000 system digital controllers Technical data for 4323 controller Controller 4323 Controller 4323 Power supply 230 V AC ± 0 % Max. switching current Feed pump PZB 5 A Frequency 50 Hz ± 4 % Feed temperature sensor FZB NTC sensor, dia. 9 mm Power consumption 5 VA Flow temperature sensor FV/FZ NTC sensor, dia. 9 mm Heating circuit mixing valve SH Max. switching current 5 A Outside temperature sensor FA ) NTC sensor control 230 V; 3-point switching External optional function WF )2) Electrically isolated input controller (PI characteristic) MEC2 or BFU/F remote control BUS communication Recommended positioner motor 20 s (adj. betw s) 0 0 V Input for external required level signal running time Space heating circulation pump PH Max. switching current 5 A Output for required level signal 0 0 V / 0 20 ma 63/ Specifications of 4323 controller ) Max. lead length 00 m (shielded upwards of 50 m) 2) Switch load 5 V DC / 0 ma controller function description This function description relates only to the basic version. The 4323 controller also has four spare module slots for function/expansion modules. For details of the possible additional functions that can be incorporated in the 4323 controller by means of expansion modules, please refer to the function description for the module concerned ( 62/) controller as autonomous heating circuit controller A controller is termed an autonomous heating circuit controller if it controls only heat consumers and as a master controller has its own outside temperature sensor. Such controllers are suitable for demand-based supply of energy from a thermal store that is heated by manually or externally controlled heat sources. As standard, the 4323 controller includes a feed temperature sensor FZB which can be located on the thermal store ( 63/2). The controller can then monitor not only the thermal store temperature but also its heating characteristic on the basis of a definable "minimum heating temperature" and "maximum heating time". If the thermal store temperature drops below the minimum heating temperature when the system is in operation, the controller switches the heat consumers off. The external heat source then given the opportunity to charge the thermal store to its minimum heating temperature. If it fails to do so within the set maximum heating time, all heating circuit pumps are switched on again. If a heat shortage exists, the system operator receives a warning message on the MEC2 control pad. The 4323 controller also has a standard interface (0-0 V) normally found on autonomous heating circuit controllers for signalling the heat demand from the controlled heat consumers to an externally controlled heat source (e.g. a CHP module). If DHW heating is controlled by an FM44 or FM445 function module, the controller does not switch the cylinder charging pump back on until the temperature measured by the feed temperature sensor FZB exceeds not only the minimum heating temperature but also the actual DHW temperature so that the DHW is not cooled down. FA VK RK FZB Logalux PU /2 Example of system using basic version of 4323 as autonomous heating circuit controller (for abbreviations page 84) FV PH SH BF HK 63

66 system digital controllers 4323 controller as slave unit with feed pump A controller is designated a slave unit if connected to a master controller in an ECOCAN-BUS network of 4000 system digital controllers. The heat demand from the heat consumers connected to the 4323 controller (acting as slave unit) is signalled via the ECOCAN-BUS to the master controller which controls the external heat source (boiler) directly or several boilers via a cascade/strategy module. The 4323 controller (acting as slave unit) only controls the feed pump PZB which supplies the externally produced heat to the slave unit's heating circuit header. When doing so, it is subject to the boiler safety function settings on the boiler controller in order that the required operating conditions of the heat source are guaranteed. As the outside temperature is also broadcast on the ECOCAN-BUS by the master controller, it is not necessary to connect a separate outside-temperature sensor to the 4323 controller (when acting as a slave unit). If a separate outside-temperature sensor is nevertheless desired, it can easily be connected. Such an option is advisable in cases where parts of the building face in different directions (north/south). Where there are long supply pipes between the heat source and the slave system, heat losses will occur. In order to compensate for those losses, there is the option of specifying a "boiler compensation differential". The controller adds the set figure for the boiler compensation differential to the temperature requirement for the heat consumers (heating circuit required temperature). FK FA FA VK RK ECOCAN-BUS SV MAG PZB FB 64/ Example of system using basic version of 4323 as slave unit with feed pump and separate outside-temperature sensor (for abbreviations page 84) PZ KR FZB KR PS FV PH SH KR PH- HK0 BF HK BF HK0 KR FA 4323 ECOCAN-BUS 4323 BF BF HK HK FV 42 ECOCAN-BUS PH FV PH PZ BF HK0 PZB FZB SH PZB FZB SH KR KR KR KR SV FB KR PS PH- HK0 FK VK RK MAG 64/2 Example of system using two standard 4323 controllers as slave units, each with separate feed pump but without separate outside-temperature sensor (for abbreviations page 84) 64

67 4000 system digital controllers 4 Control of heating circuit using 4323 controller The control functions control the circulation pumps via separate 2-point signals (230 V AC) and the heating circuit mixing valves via separate 3-point signals (230 V AC). The appropriate characteristic heating curves for the various standard heating system configurations are stored on the controller. Adaptation to the individual system layout is straightforward using the MEC2 control pad. Heating system options Radiator/convector or underfloor Automatic calculation of characteristic heating curve to suit heating system Base point Heating characteristic is a linear progression between two points, space heating flow temperature is dependent on outside temperature Constant Pre-control of ventilation systems or swimming pool heating; heating always based on a constant required space heating flow temperature regardless of outside temperature Room thermostat The required space heating flow temperature is dependent only on the measured room temperature Each heating circuit function can be separately adapted to the requirements of the system by means of the following functions: Adjustment of low-setting temperature to EN 283 Various low-setting modes for night-time operation Various low-setting modes for the holiday function Adaptation of characteristic heating curve Room temperature override or Optimisation of cut-in and cut-out More information on the functions can be found in the section describing the functions of the FM442 function module ( page 73 ff.). Input and output of heat demand signals The 4323 can input and output required settings in the form of a 0-0 V signal. This function should be specified if the 4323 controller is to be used to control the heating circuits and other functions in systems with externally controlled boilers. The 4323 controller generates a 0-0 V signal from the heating system's maximum required flow temperature to signal demand to the externally controlled boiler system. ϑ VSet [ C] U E [V] 65/ External required setting input U A [V] ϑ VSet [ C] 65/2 Required setting output Key to illustration ( 65/ and 65/2) ϑ FL Required boiler flow temperature U A Output signal to external system Input signal from external system U E 65

68 system digital controllers M Wiring diagram for 4323 controller A BUS (internal) B 8) ZM433 central module Power module NM 482 Controller module CM43 PZB 0 AUT 7) 7) 7) 7) Netz S ECO BUS L2 N N L L N AUT k6 k3 k2 k 3) L N 4) ECOCAN-BUS 9) 2 x 0,4 0,75 mm 2 L N 4 U FA FZB WF FV BF PZB 63 6 PH SH L Netz N 2b 2a b a Operation 0 I mm² max 5 A ) L M N max 5 A ) L M N max 5 A ) 44 colder 43 4 hotter N 2 Fuse 0 AT (slow) L2 ) 5) L Fuse 0 AT (slow) ) 5) Feed pump (PZB) Heating circuit pump (PH) Heating circuit servomotor (SH) L L N N /PE Output 0-0 V 0-20 ma (U) 6) Input 0-0 V (U) 2 Outside temp. sensor (FA) Feed temp. sensor (FZB) Selection function (zero volt) 6) 0) Flow temp. sensor (FV) Remote control MEC2 or BFU (BF) 2) Mains 230 V 50 Hz max. permiss. fuse rating 20 A (slow) on-site Cross-section of the power cable min. 2.5 mm². Switching conditions ZM433 Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. Ensure the mains power is correctly wired to the terminals. Do not use an earthed plug. Caution! The earth lead (yellow/green) must not be used as a control lead. ) The total current per circuit (inc. the modules in slots and 2) must not exceed 0 A. It is imperative that the above figure is adhered to and checked after commissioning in order to prevent damage to equipment! 2) Please note! Only one MEC2 may be allocated to each controller. The MEC2 can either be plugged directly into the controller module or the room fitting kit (optional accessory page 7) can be used to connect it to one of the ZM.. or FM.. modules. 3) If several ECOCAN-BUS devices are connected, the switches S (terminal resistors on the NM482) on the two outermost ECOCAN-BUS devices must be closed. 4) Shielded wires are not required for standard applications. Only connect the shielding at one end! 5) L2: fuse for modules in slots A, and 2 L: fuse for modules in slots 3 and 4 6) See also servicing instructions 7) Automatic control input 8) Power supply for function/expansion module in slot or 2 9) Power supply for function/expansion module in slot 3 or 4 0) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): Heating circuit: -3 manual daytime mode = heat demand, -2 manual night-time mode or pump fault Feed circuit PZB Switch position 0 AUT (PZB) k6 Control mode Switch position 0 AUT = hotter = colder Heating circuit (PH) (SH) (SH) k3 k2 k Control mode M Control mode Control mode Control voltage 230 V LV M 66/ Wiring diagram for 4323 controller (for abbreviations page 84) 66

69 Function modules for expansion of digital controllers 5 5 Function modules for expansion of digital controllers 5. Function module FM44 for DHW heating with a cylinder system (e.g. Logalux indirect DHW cylinder*) and heating circuit control ( heating circuit with mixing valve) 5.. Brief description Possible applications The FM44 function module is suitable for controlling a DHW system (cylinder system) and a heating circuit with mixing valve. One can be fitted to each controller assuming the DHW function for a cylinder system is not already provided as a basic function of the controller (e.g. 42 or 42). The controller detects the function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad. DHW heating Individually timer-controlled DHW heating using a cylinder charging pump (cylinder system), daily monitoring, thermal disinfection and control of a DHW circulation pump Electrically isolated external input for once-only charging of cylinder outside of set times or for activating thermal disinfection Electrically isolated external input for fault signal from cylinder charging pump or for an inert anode for display on the MEC2 control pad Option of hot water priority or simultaneous operation with the heating circuits Heating circuit control Outside-temperature driven control of one heating circuit with mixing valve and circulation pump Connection for a separate remote control for roomtemperature override for the heating circuit Adjustable, automatic switching between summer/winter modes Input for external electrically isolated mode switch signal or external heat demand and electrically isolated input for a pump fault signal Standard specifications Function module FM44 ( 67/) DHW temperature sensor FB 67/ FM44 function module Key to illustration Terminal connectors 2 Module fault indicator (LED) 3 DHW LED (cylinder temperature below required temperature in night-time mode) 4 Cylinder charging pump LED 5 DHW circulation pump LED 6 Thermal disinfection LED 7 Manual mode switch, DHW system 8 Circuit board 9 Manual mode switch, heating circuit function 0 Actuator closing LED for heating circuit Actuator opening LED for heating circuit 2 Circulation pump LED for heating circuit 3 Summer mode LED * In the UK & Ireland this product was unavailable at the time of printing. 67

70 5 Function modules for expansion of digital controllers Function module FM44: control of DHW heating and heating circuit ( heating circuit with mixing valve) External switch (electrically isolated) connected to 2 WF: /2 (break switch) = Pump fault or inert anode /3 (make switch) = External activation of thermal disinfection or once-only cylinder charging 2 3 2WF 2PZ KR FV PH External switch (electrically isolated) connected to WF /2 (break switch) = Pump fault /3 (make switch) = Ext. heat demand 2 3 WF BF HK Alternative connection to WF: (only if no BFU (BFU/F) remote control connected and no MEC2 control pad assigned): /2/3 (make switch) = External mode switching (daytime/night-time/automatic) FM44 2FW KR 2PS SH VK RK 68/ Possible connections to function module FM44 (for wiring diagram page 78, for abbreviations page 84) 5..2 Possible applications for FM44 function module Controllers with slot ) for FM44 Controller 422 Boiler controller (cascade system with up to 4 boilers) or controller for function expansion 432 Boiler controller Controller 4322 Controller for sequential boiler (multi-boiler system) 4323 Autonomous heating circuit controller or slave unit 68/ system controllers with slot for FM44 function module ) Only one FM44 function module can be used on each controller; DHW heating using cylinder system only possible as alternative to cylinder charging system (function module FM445) 5..3 Specification for FM44 function module Function module FM44 Function module FM44 Power supply 230 V AC ± 0 % Space heating circulation pump PH Max. switching current 5 A Frequency 50 Hz ± 4 % Cylinder charging pump PS Max. switching current 5 A Power consumption 2 VA DHW circulation pump PZ Max. switching current 5 A Heating circuit mixing valve SH Max. switching current 5 A DHW temperature sensor FB ) 68/3 Technical specifications of function module FM44 ) Max. lead length 00 m (shielded upwards of 50 m) 2) Switch load 5 V DC / 0 ma NTC sensor, dia. 9 mm Control 230 V; 3-point switching Flow temperature sensor FV/FZ ) NTC sensor, dia. 9 mm Recommended positioner motor running time controller (PI characteristic) DHW external optional function WF )2) 20 s (adj. betw s) Heating circuit external optional function WF )2) Electrically isolated input Electrically isolated input 68

71 Function modules for expansion of digital controllers Function description for FM44 function module DHW heating Timer control The DHW heating function can either follow the same timer programme as for the heating circuits or its own separate timer programme. There is the option of setting hot water priority or simultaneous operation with the heating circuits. Charging process If the cylinder temperature drops below the required temperature by the amount specified for the hysteresis setting, DHW heating starts in daytime mode (automatic re-charging). The controller sets a higher required boiler water temperature to achieve faster DHW heating. The required boiler water temperature is raised to a figure that exceeds the required DHW temperature by a definable "boiler compensation differential". The amount by which the boiler water temperature should exceed the required DHW temperature can be set on the Service menu on the MEC2 control pad. Depending on boiler type, the cylinder charging pump may not start until the required boiler operating conditions are met. The charging process finishes as soon as the required DHW temperature is reached. The controller switches the boiler off and the cylinder charging pump cuts out after completing a set pump run-on time. Cut-in optimisation If this function is activated, heating of the DHW starts in advance of the actual cut-in point. The controller calculates the starting point, taking account of the residual heat in the cylinder, so that the required DHW temperature has already been reached by the set cut-in point. The calculation is based on a maximum cylinder heating time of 30 minutes. This is a convenience parameter for dimensioning the boiler in relation to the size of the cylinder. Residual heat utilisation If this function is activated, the controller calculates the available energy that can be given off by the boiler after the burner is switched off. As a result, the burner is switched off before the required DHW temperature is reached. The first time that the controller activates DHW heating, it switches the burner off when the cylinder temperature is 2 K below the required temperature. The cylinder charging pump continues to run until the required temperature is reached. From the dynamic characteristics of the cylinder temperature, the controller calculates the new temperature difference at which the burner can switch off. That determines the optimum burner cut-out point for the next charging sequence. In order that the residual heat utilisation can be constantly adapted to the variable system conditions, the function must remain permanently active. This can only be achieved if the DHW priority option is active as effective analysis is not possible if heat is being drawn by the heating circuits at the same time. DHW circulation From the point of view of a high level of hot water convenience, DHW circulation should always be considered when planning a heating system that includes DHW heating. It involves the fitting of a return pipe to the cylinder which branches off from the hot water pipe as close to the hot water points as possible and incorporates a pump and non-return valve. The DHW then circulates around that loop. When a hot water tap is turned on, hot water is then immediately available. In large buildings (apartment blocks, hotels, etc.), installation of a DHW circulation loop is also worth considering from the point of view of water loss. Where taps are a long distance from the cylinder, it not only takes a long time for the water to run hot if there is no circulation loop, a large amount of water also goes to waste. According to the German Energy Saving Regulations (EnEV), DHW circulation loops must be fitted with automatic devices for shutting off the DHW circulation pump. In a 4000 control system, the DHW circulation pump has a separate timer programme. It can either be individually programmed or based on the timings for the heating system and/or the DHW heating. In daytime mode, the controller operates the DHW circulation pump either intermittently or continuously. DHW circulation pipes must be insulated against heat loss according to the recognised technical regulations. The temperature difference between the hot water outlet and the point of entry into the circulation loop must not be more than 5 K. The DHW circulation pipes must be dimensioned in accordance with DIN or DVGW Worksheet W553 (DVGW = German Gas and Water Association). According to DVGW Worksheet W55, DHW circulation loops should be fitted in small systems with pipe capacities of > 3 l between the exit point from the water heater and the hot water point as well as in large systems. DHW circulation systems can be switched off for up to 8 hrs a day for energy saving purposes if the hygienic conditions meet requirements. In large systems, the cylinder temperature must not fall below 60 C. For small systems, the recommended minimum cylinder temperature is 50 C. 69

72 5 Function modules for expansion of digital controllers Once-only cylinder charging In night-time mode, the LED indicator (water tap symbol) on the function module and the MEC2 control pad light up when the cylinder temperature drops below the required level by the amount specified for the hysteresis setting. Once-only cylinder charging can then be activated by means of the function button on the MEC2 control pad or an electrically isolated external input (external switch). The DHW circulation pump runs in constant mode. If applicable, the boiler used for DHW heating starts up and heats up the DHW cylinder until the required cylinder temperature is reached or "once-only cylinder charging" is cancelled on the MEC2 control pad. While the "once-only cylinder charging" function is active, the relevant LED indicator on the function module or MEC2 control pad flashes. If the cylinder is still at the required DHW temperature, the DHW circulation pump is run for 3 minutes outside the set programme times. Daily monitoring The "daily heating" function monitors whether the DHW temperature in the DHW cylinder (including solar cylinder if present) has reached a set temperature of 60 C at the temperature sensor FB once a day. If it has, the boiler remains off. Otherwise, the water in the DHW cylinder is heated up once by the boiler. The starting time for this function is user definable. This function meets a requirement of DVGW Worksheet W55. Thermal disinfection The thermal disinfection function heats up the domestic hot water to a temperature, measured by temperature sensor FB, sufficient to kill pathogens (e.g. legionella bacteria). Both the cylinder charging pump and the DHW circulation pump run constantly during the thermal disinfection process. The DHW circulation pump ensures that a large proportion of the DHW system is heated up to high temperatures so that pathogens are killed and the system thus "thermally disinfected". The "thermal disinfection" function is monitored by temperature sensor FB and can be activated either automatically (daily or once a week at a programmable time) or manually by means of an external electrically isolated switch (as alternative to once-only cylinder charging). A separate required DHW temperature is specifiable for this function. The DHW circulation pump and the connected plastic hoses must be suitable for temperatures over 60 C if the thermal disinfection function is used. To protect against scalding, it is advisable to activate thermal disinfection only during night-time hours and to specify thermostatically controlled taps or a thermostatically controlled mixer unit downstream of the cylinder's hot water outlet. More information can be obtained from DVGW Worksheet W55. It provides guidelines for DHW heating and piping systems and suggests measured for limiting growth of legionella in large and small systems. Frost protection Outside of the programmed DHW heating times, this function ensures that the DHW cylinder does not cool down to temperatures low enough for there to be a risk of freezing. If the cylinder temperature falls below the frost protection temperature of 5 C, the DHW cylinder is heated to the set required DHW temperature in heating mode. Holiday function A holiday programme for DHW heating can be activated which either mirrors the timings of the heating circuit timer programmes or has its own individual timings. Both DHW heating and DHW circulation are turned off when the programme is active. Heating circuit control All heating circuit control functions provided by the FM44 function module are the same as those provided by the function module FM442 ( page 73 ff.). 70

73 Function modules for expansion of digital controllers Wiring diagram for function module FM44 internal BUS in the control unit HK / WW-module FM44 3) 3) M 3) 3) 3) 6) 0 AUT k5 k4 0 AUT k3 k2 k L N 2PZ 2PS SH PH 2FB 2WF 2BF FV WF x,5 ² max 5 A 3 x,5 ² max 5 A 4 x,5 ² max 5 A 3 x,5 ² max 5 A 0,4-0,75 mm² = hotter = colder - + M N L M N L N M N L DHW circulation pump (2PZ) Cylinder primary pump (2PS) Servomotor heating circuit (SH) Heating circuit pump (PH) DHW temp. sensor (2FB) Selection function (zero volt) (2WF) Remote control MEC2 or BFU (2BF) Flow temp. sensor (FV) Selection function (zero volt) (WF) ) 4) 2) 5) ) Function only possible if no BFU is connected or no MEC2 is assigned. 2) Please note! Only one MEC2 may be allocated to each controller. The MEC2 can either be plugged directly into the controller module or the room fitting kit (optional accessory page 69) can be used to connect it to one of the ZM.. or FM.. modules. 3) Automatic control input 4) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): -3 = Thermal disinfection or once-only cylinder charging, -2 = Pump fault 5) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): Heating circuit: -3 manual daytime mode = heat demand, -2 manual night-time mode or pump fault 6) Power supply connector Switch position 0 AUT Heating circuit k k2 k3 Control mode pump Control mode colder Switching states M Control mode hotter Switch position 0 AUT DHW circuit Control voltage 230 V LV k4 Control mode Pump k6 Control mode 7/ Wiring diagram for function module FM44 (for abbreviations page 84) 7

74 5 Function modules for expansion of digital controllers 5.2 Function module FM442 for heating circuit control (2 heating circuits with mixing valve) 5.2. Brief description Possible applications The FM442 function module is capable of controlling two heating circuits with mixing valve. It can be used in any digital controller in the 4000 system. The controller detects the function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad. Heating circuit control Outside-temperature driven control of two heating circuits with mixing valve and circulation pump Connection for a separate remote control for roomtemperature override for each heating circuit Adjustable, automatic switching between summer/ winter modes separately for each heating circuit Input for external electrically isolated mode switch signal or external heat demand and electrically isolated input for external pump fault signal for each heating circuit Key to illustration ( 72/) Terminal connectors 2 Module fault indicator (LED) 3 Summer mode LED for heating circuit 4 Circulation pump LED for heating circuit 5 Actuator opening LED for heating circuit 6 Actuator closing LED for heating circuit 7 Manual mode switch, heating circuit 8 Circuit board 9 Manual mode switch, heating circuit 2 0 Actuator closing LED for heating circuit 2 Actuator opening LED for heating circuit 2 2 Circulation pump LED for heating circuit 2 3 Summer mode LED for heating circuit 2 Standard specifications Function module FM442 ( 72/) Flow temperature sensor FV/FZ / Function module FM Function module FM442: heating circuit control (2 heating circuits with mixing valve) External switches (electrically isolated) connected to WF and 2 WF: /2 (break switch) = Pump fault /3 (make switch) = Ext. heat demand 2 3 WF oder BF HK 2 3 2WF oder 2BF HK2 Alternative connection to WF and 2 WF: (only if no BFU (BFU/F) remote control connected and no MEC2 control pad assigned): /2/3 (make switch) = External mode switching (daytime/night-time/automatic) FM442 FV PH SH 2FV 2PH 2SH VK RK 72/2 Possible connections to function module FM442 (for wiring diagram page 78, for abbreviations page 84) 72

75 Function modules for expansion of digital controllers Possible applications for FM442 function module Controllers with slot ) for FM442 Controller 42 Boiler controller ( boiler) or Autonomous heating circuit controller or slave unit 422 Boiler controller (cascade system with up to 4 boilers) or controller for function expansion 42 Boiler controller Controller 432 Boiler controller 4322 Controller for sequential boiler (multi-boiler system) 4323 Autonomous heating circuit controller or slave unit 73/ 4000 system controllers with slot for FM442 function module ) More than one FM442 function module can be used on each controller if sufficient slots are available Specification for FM442 function module Function module FM442 Function module FM442 Power supply 230 V AC ± 0 % Heating circuit mixing valve SH Max. switching current 5 A Frequency 50 Hz ± 4 % control 230 V; 3-point switching Power consumption 5 VA controller (PI characteristic) Space heating circulation pump PH Flow temperature sensor FV/FZ ) Max. switching current 5 A NTC sensor, dia. 9 mm 73/2 Technical specifications of function module FM442 ) Max. lead length 00 m (shielded upwards of 50 m) 2) Switch load 5 V DC / 0 ma Recommended positioner motor running time Heating circuit external optional function WF )2) 20 s, adj. betw. 0 and 600 s Electrically isolated input Function description for FM442 function module Corrected outside temperature An outside-temperature driven controller adjusts the heat output to the demand. The lower the outside temperature, the higher the heating system's flow temperature must be. The outside temperature sensor must be fitted so that it measures the outside temperature without extraneous influences ( 7/). A building's heat storage capacity and its characteristic resistance to heat transfer will delay the effect of outside temperature variation on the rooms inside. For that reason, the decisive factor for heating requirement inside the rooms is not the current outside temperature, but rather the "corrected" outside temperature. The 4000 control system allows the degree of compensation applied to fluctuations of the outside temperature to be defined. That means that the controller can be adapted to suit the characteristics of the building. Automatic switching between summer and winter modes Taking account of the outside temperature and the heat storage capacity of the building, i.e. the corrected outside temperature, a threshold for switching from summer to winter mode is defined. That threshold can be set separately for each heating circuit. In summer mode, heating mode is deactivated, i.e. the controller switches off the circulation pump for the heating circuit concerned and closes the heating circuit mixing valve. The summer/winter change-over function is always active whenever the selected heating circuit is in automatic mode. If daytime or night-time mode is activated manually or if an external heat demand is signalled via an electrically isolated input, the heating circuit is heated to its set required temperature. 73

76 5 Function modules for expansion of digital controllers Heating systems The following heating systems can be selected: None Radiators Convector Underfloor Base point Constant Room controller Heating system: None The heating circuit function is not required for the selected heating circuit. None of the heating control functions listed below are subsequently displayed for the heating circuit concerned. Heating system: Radiator/Convector/Underfloor The heating characteristics for the various systems are automatically calculated to suit the required curve progression and their system temperatures are already preset. The characteristics can easily be individually adapted to the specifics of the heating system by adjusting the parameters "Minimum outside temperature" and "Design temperature" on the MEC2 control pad. A fixed limit can be set for the characteristics by means of the parameter "Maximum flow temperature" ( 74/). Heating system: Base point The flow temperature is dependent on the outside temperature and has a linear relationship to it. The heating characteristic is a straight line connecting the base point with a second point that is determined by the design temperature. The base point is definable by specifying a heating circuit flow temperature at a preset outside temperature of +20 C ( 74/2). Heating system: Constant This system is intended for controlling a swimming pool heating system or ventilation systems if the required flow temperature must always be the same regardless of outside temperature ( 74/2). If the heat demand (switching between daytime and night-time modes) is to be indicated externally by a swimming pool control or a ventilation system via an electrically isolated switch, then the FM442 function module must be specified. In low-output heating mode, the heating characteristics is shifted downwards by a definable temperature difference. Manual switching between daytime and night-time modes takes priority over switching between summer and winter modes. 74/ Heating characteristic for heating systems "Radiator" and "Underfloor" 74/2 Heating characteristic for heating systems "Base point" and "Constant" Key to illustration ( 74/ and 74/2) A Design point at minimum outside temperature and design temperature B Limit point (definable max. flow temperature) F Base point fb Heating characteristic(s) for heating system "Underfloor" ( 74/) fp Heating characteristic for heating system "Base point" ( 74/2) hk Heating characteristic(s) for heating systems "Radiator" or "Convector" ( 74/) ko Heating characteristic for heating system "Constant" ( 74/2) ϑ A Outside temperature Flow temperature ϑ V ϑ V [ C] ϑ V [ C] B B hk" fb" hk' ϑ A [ C] B F ko fp hk fb' ϑ A [ C] fb A A A 74

77 Function modules for expansion of digital controllers 5 Heating system: Room thermostat The required space heating flow temperature is dependent only on the measured room temperature. This requires a BFU remote control or the MEC2 control pad with integral room temperature sensor to be installed in the room. The heating characteristic is defined by a minimum flow temperature (required room temperature +5 K) ➊ and a maximum flow temperature (definable maximum heating circuit temperature) ➋ ( 75/). The modulation range is between - K (for the maximum temperature) ➌ and + K (for the minimum temperature) ➍ relative to the required room temperature. Within that range, the required flow temperature is proportionally adjusted to the control deviation. The heating circuit pump switches off when the actual room temperature rises above the upper limit for the required room temperature by the hysteresis allowance of 0.2 K ➎. The pump does not switch on again until the actual room temperature has dropped below the upper limit for the required room temperature by the hysteresis allowance of 0.2 K ❻. Cut-in optimisation is not advisable in combination with a slow-response heating system (e.g. an underfloor heating system). Optimisation possibilities for heating systems with outside-temperature dependent characteristic The 4000 control system provides a number of convenient optimisation options: Automatic adaptation (calculation) of heating characteristic Room temperature override Cut-in and cut-out optimisation (optimisation of daytime-night-time switchover and vice versa) Automatic adaptation (calculation) of heating characteristic Using the room temperature sensor of the BFU remote control or the MEC2 control pad, the controller detects the current temperature in a reference room ( page 72). The controller starts from a "quasi static" situation (virtually constant temperature for hour) and memorises how it has achieved that situation. If a correction to the heating characteristic was necessary (by room intervention), it results in an adjustment to the design temperature ( 75/2). That involves calculating an average of the most recent correction figures so that the system initially optimises abruptly and then more gradually as system operating time increases. This function is always active so that on a day with several "quasi static" situations, multiple correction figures may be produced. 75/ Heating characteristic for heating system "Room thermostat" Key to illustration ➊ Heating system running with set maximum temperature ➋ Heating system running with set maximum temperature ➌ Control deviation of K ➌ to ➍ Flow temperature proportional to control deviation ➍ Control deviation of + K ➎ Heating circuit pump switches off ❻ Heating circuit pump switches on ϑ Act room temp Actual room temperature ϑ Set room temp Required room temperature ϑ V,Set,Max. Maximum flow temperature ϑ V,Set,Min. Minimum flow temperature 75/2 Automatic adaptation of heating characteristic Key to illustration h Heating characteristic h Automatically corrected heating characteristic ϑ A Outside temperature Flow temperature ϑ V ϑ V,Set [ C] ϑ V [ C] Set, Max. Set, Min. Set room temp + 5 K ,5 0,5 0 +0,5 + +,5 ϑ Act room temp ϑ Set room temp [K] h' h ϑ A [ C] 75

78 5 Function modules for expansion of digital controllers Room-temperature override with outside-temperature based control When a system is controlled on the basis of outside temperature with room-temperature override, the heating characteristic is rapidly adapted to the building and the heat demand by constantly monitoring the room and flow temperatures. An outside-temperature dependent heating characteristic (radiator, underfloor or convector heating system) remains selected and a maximum room effect is specified in addition. That effect defines the limits of the control deviation between the required room temperature and the actual room temperature. The resulting room-temperature control deviation is counterbalanced by an adjustment to the flow temperature brought about by shifting the heating characteristic within the limits of the override range. A difference of C between actual and required room temperature changes the heating circuit flow temperature by approx. 3 C. Room-temperature override always requires a BFU remote control or an MEC2 control pad in a reference room ( page 72). Cut-in optimisation If this function is activated, heating of the heating circuit starts before the cut-in point is actually reached so that the desired room temperature is reached by the set and desired time ( 76/). Therefore, an estimation is required of when the heating system must switch on in order that the room temperature reaches a certain level at a particular time. That requires installation of a BFU remote control or MEC2 control pad in a reference room ( page 72). The starting point for calculating the cut-in optimisation is a period of 60 minutes. The cut-in optimisation period is limited to a maximum of 240 minutes. In order that rapid heating up can be achieved, the maximum heating circuit temperature is assumed. At the start of the heating-up phase, the current room temperature and the corrected outside temperature are stored and included in the calculation. As soon as the desired room temperature is reached, the heating-up phase comes to an end. The controller generates a correction factor which is taken from the time span of the heating-up sequence from the starting point (actual room temperature) to the ending point (required room temperature) and which is updated after every heating-up sequence. Taking account of the current room temperature and the corrected outside temperature, it calculates from that the optimum cut-in time for the heating circuit in order to obtain the specified room temperature in the living areas by the set time. Cut-in optimisation is not advisable in combination with a slow-response heating system (e.g. an underfloor heating system). Switch-off optimisation Cut-out optimisation is performed in analogous fashion to cut-in optimisation except that in this case low-output heating mode is started prematurely. Immediately before the low-output phase, the controller prevents the burner starting up if the room temperature has not fallen below the set temperature. ϑ [ C] t [h] 76/ Heating circuit cut-in optimisation by 4000 control system in combination with cut-in optimisation for DHW heating if DHW priority is set Key to illustration a DHW temperature b Room temperature t Time ϑ temperature ➊ Cut-in point for DHW heating ➋ Cut-in point for heating circuit ➌ Ending point (desired DHW and room temperature) a b 76

79 Function modules for expansion of digital controllers 5 Heating circuit control low-output phases (nighttime mode) The connected heating circuits always switch to lowoutput heating mode (night-time mode) whenever the set switching time is reached in automatic mode or the operating mode is manually changed on the MEC2 control pad or the remote control. The facility for manually switching to this mode can also be implemented by means of an external switch (button) connected to the FM442 function module (or FM44 or 42). For heating circuits within a 4000 control system, four different modes can be set for the low-output mode (night-time mode). Outside control This mode is a combination of the Off and Reduced heating modes. Below a definable outside temperature, the boiler operates in Reduced mode and above that temperature, in Off mode. Off The heating circuit is always switched off in lowoutput mode. In this mode, the heating circulation pump is completely switched off but the frost protection function remains in effect. Reduced The controller is set to a lower room temperature requirement (night-time temperature) and constantly controls the heating circulation pump. The controller operates on the basis of an outsidetemperature dependent heating characteristic shifted downwards by an equal amount across its full range. Room control The heating system remains in Off mode as long as the room temperature does not exceed a set minimum temperature (night-time temperature). Otherwise it switches to Reduced heating mode. This function can only be activated if a remote control in a reference room ( page 72) has been connected. Holiday function Depending on the nature of use of the building, it may be occupied or unoccupied during the holiday period. Depending on the occupation pattern, the living areas may need to be heated or only kept above freezing. For the holiday function, a separate low-output mode can be selected from the options Room control, Reduced, Off, and Outside control. That means that one of the modes familiar from the low-output heating phases can be set for the holiday period. Thus the 4000 controller can be adapted more effectively to different user requirements in the holiday period. With the setting "Holiday low-output mode: Off", the heating circulation pump is completely switched off but the frost protection function remains in effect. Cancelling low-output phases at low outside temperatures (EN 283) The standard EN 283 is the European standard for calculating the heat requirement for buildings. According to EN 283, dimensioning of heat sources and heating surfaces must take additional allowances into account for rooms with intermittent heating. If, however, the low-output phase is cancelled at the right time when the outside temperature drops below a certain level, heating surfaces and heat sources can be dimensioned without the additional allowance. This function makes it possible to cancel the lowoutput phase for each heating circuit if the outside temperature falls below a definable, corrected outside temperature. That prevents excessive cooling of the living areas. As a result, the additional allowance for a greater initial heating output can be dispensed with when dimensioning the boiler. Key to illustration Outside temperature ϑ A Standby Standby Reduced Reduced +5 5 ϑ A [ C] 77/ Adjustment of low-output temperature Day ) Function "Outside temperature below which low-output is cancelled" not activated 2) Function "Outside temperature below which low-output is cancelled" activated Special "Screed drying" function for an underfloor heating system with mixing valve With the FM442 (or FM44) function module, there is the facility for a separate heating programme for screed floor drying if an underfloor heating circuit is connected. Control is effected by operating a motorised 3-way valve. The programme sequence for the "Screed drying" function is explained in detail in the description of the 42 controller ( 32/). With the 42 controller in conjunction with a wall-mounted boiler with UBA universal burner control unit, the special function "Screed drying" can also be selected for a directly connected heating circuit without mixing valve ( page 32). ) 2) 77

80 5 Function modules for expansion of digital controllers Wiring diagram for function module FM442 internal BUS in the control unit HK / HK-module FM442 M M 3) 3) 3) 3) 3) AUT AUT 0 0 5) k6 k5 k4 k3 k2 k 3) L N 2SH 2PH SH PH BF 2FV 2WF BF FV WF x,5 ² max 5 A 3 x,5 ² max 5 A 4 x,5 ² max 5 A 3 x,5 ² max 5 A 0,4-0,75 mm² = hotter = colder = hotter = colder N M N L N N M L Servomotor Heating circuit 2 (2SH) Heating circuit pump (2PH) Servomotor Heating circuit (SH) Heating circuit pump (PH) 2) Flow temp. sensor (2FV) Selection function (zero volt) (2WF) ) 4) Flow temp. sensor MEC2 o r BFU (BF) Flow temp. sensor (FV) ) 2) Remote control MEC2 or BFU (2BF) Selection function (zero volt) (WF) Switching states ) Function only possible if no BFU is connected or no MEC2 is assigned. 2) Please note! Only one MEC2 may be allocated to each controller. The MEC2 can either be plugged directly into the controller module or the room fitting kit (optional accessory page 69) can be used to connect it to one of the ZM.. or FM.. modules. 3) Automatic control input 4) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): Heating circuit: -3 manual daytime mode = heat demand, -2 manual night-time mode or pump fault 5) Power supply from power supply module Switch position 0 AUT Heating circuit 2 k4 k5 k6 Control mode Pump Control mode colder Control mode hotter Switch position 0 AUT Control voltage 230 V Heating circuit k4 k5 k6 Control mode pump Control mode colder M Control mode hotter LV 78/ Wiring diagram for function module FM442 (for abbreviations page 84) 78

81 Function modules for expansion of digital controllers Function module FM443 for controlling a solar thermal system for DHW heating or for DHW heating and space heat boosting 5.3. Brief description Possible applications The function module FM443 enables control of a solar thermal system with up to two heat consumers. The following combinations are supported: Solar DHW heating as st heat consumer Solar DHW heating and space heating boost with a combination cylinder as st heat consumer ( 88/) Solar DHW heating and space heating boost with separate thermal store as 2nd heat consumer ( 80/) Solar DHW heating and space heating boost with a combination cylinder and solar swimming pool heating as 2nd heat consumer ( 8/) Solar DHW heating and solar swimming pool heating as 2nd heat consumer One module of this type may be fitted in each controller. The function module FM443 and the function "DHW heating with cylinder system" (basic version of 42 or 42 controller or FM44 function module) should be specified for a controller. By using the FM443 function module, control of the solar thermal system is integrated in heating circuit control. The linking of the two controllers enables intelligent control functions such as optimisation of recharging for the DHW system. Optimisation of recharging prevents reheating of the DHW cylinder by the boiler when the solar yield and the stored heat are sufficient for supplying hot water. The FM443 function module has an optimised solar circuit control function. Variable-speed control of the solar circuit pumps opens the way for adjusting the volumetric flow rate to different temperature differences. In the first instance, that allows high usable temperatures for DHW heating convenience, and secondly high solar yields. Another advantage of linking the controllers for the solar thermal system and the heating system is the implementation of requirements arising from DVGW Worksheet W55. The controller detects the function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad. 79/ FM443 function module Key to illustration Terminal connectors 2 Module fault indicator (LED) 3 Maximum collector temperature LED 4 Solar circuit pump 2 LED (secondary pump) 5 LED for solar circuit pump 2 or motorised diverter valve set to position for solar circuit 2 6 LED for motorised diverter valve set to position for solar circuit 7 Manual selector for solar circuit 8 Circuit board 9 Manual mode switch for solar circuit function 0 LED for motorised diverter valve set to "Heating boost using thermal store on" (thermal store mode) LED for motorised diverter valve set to "Heating boost using thermal store off" (bypass mode) 2 Solar circuit pump LED 3 LED for maximum temperature in cylinder 8 79

82 5 Function modules for expansion of digital controllers V Control of solar thermal system Variable-speed control of a solar circuit pump (AC pumps only) and control of a motorised diverter valve for switching between heat consumers or variable-speed control of separate solar circuit pumps (AC pumps only) for the first and second heat consumers High-flow/low-flow mode for the first heat consumer (solar DHW heating) by variable control of solar circuit pump volumetric flow rate Optimised DHW recharging by integration in the overall system incorporating Buderus combination DHW cylinders Logalux P and PL/twin-coil cylinders Logalux SM or SL Temperature-differential based charge transfer between the DHW heated by the solar preheating stage and the DHW cylinder (standby cylinder) Charge recirculation/transfer for daily heating and/or thermal disinfection of the solar preheating stage Thermal store bypass circuit for heating system integration of the solar thermal system in conjunction with a combination cylinder or thermal store (solar heating boost) or balancing cylinder circuit for the boiler in conjunction with a combination cylinder or thermal store Integrated heat quantity function for one or two solar heat consumers in combination with the Buderus accessory set WMZ.2 Standard specifications Function module FM443 ( 79/) Collector temperature sensor FSK Cylinder temperature sensor FSS (reference sensor) Function module FM443: solar thermal system control for DHW heating and space heating boost with separate thermal store as 2nd heat consumer FM443 FSK ÜS Logasol AW Connection of a water-heating stove boiler or solid fuel boilers R WMZ-ZV V R Logasol KS0.. WWM PSS MAG AW VS FB PS KR FPB- FP RS VS VH RH WMZ-FV SU WMZ-FR FE V FSS R Logalux SM... RS EK FE FSS2 V R Logalux PL... A SPB AB B FPB- FR MAG VK RK Logano (NTK) 42 80/ Possible connections to function module FM443 (for wiring diagram page 90) Key to illustration Logasol KS0 Complete pump station w/o solar controller Detailed information can be found in the planning document for Logasol solar technology for DHW heating and space heating boost system. Logalux SM Twin-coil solar cylinder Logalux PL Thermosiphon thermal store Logano (NTK) Low-temperature boiler (For other abbreviations page 84) 80

83 Function modules for expansion of digital controllers 5 Function module FM443: solar thermal system control for DHW heating and space heating boost with combination cylinder and solar swimming pool heating as 2nd heat consumer ÜS 42 + FM443 FSK Logasol FA EMS-BUS Logamax plus GB V 50 Hz RSB WWM PZ PK FK M FV TW PH SH M WT FV2 PH SH PSB SMF SWT FSS2 FSB PS2 PSS Logasol KS0.. AW FB EZ VS3 TW VS4 M SU FPB-FP RS4 FSS VS RS EK Logalux PL.../2S SPB A M B AB FPB-FR 8/ Example of system with combination cylinder and swimming pool control using function module FM443 (for wiring diagram page 90) Key to illustration Logasol KS0 Complete pump station w/o solar controller Detailed information can be found in the planning document for Logasol solar technology for DHW heating and space heating boost system. Logalux PL /2S Thermosiphon combination cylinder Logamax plus GB62 Gas condensing boiler (For other abbreviations page 84) 8

84 5 Function modules for expansion of digital controllers Possible applications for FM443 function module Controllers with slot ) for FM443 Controller 42 Boiler controller ( boiler) or Autonomous heating circuit controller or slave unit 422 Boiler controller (cascade system with up to 4 boilers) or controller for function expansion 42 Boiler controller Controller 432 Boiler controller 4322 Controller for sequential boiler (multi-boiler system) 4323 Autonomous heating circuit controller or slave unit 82/ 4000 system controllers with slot for FM443 function module ) Together with the function module FM443 a function for DHW heating with cylinder system (basic version of 42 or 42 controller or FM44 function module) should be specified; in combination with a cylinder charging system (function module FM445), the recharging optimisation function is limited Specification for FM443 function module Function module FM443 Function module FM443 Power supply 230 V AC ± 0 % Cylinder temperature sensors FSS and FSS2 NTC sensor, dia. 9 mm Frequency 50 Hz ± 4 % Collector temperature sensor FSK ) Power consumption 82/2 Technical specifications of function module FM443 ) Max. lead length 00 m (shielded upwards of 50 m) 5 VA Thermal store bypass temperature sensor for NTC sensor, dia. 6 mm NTC sensor solar circuit pump PSS Max. switching current 2 A Return/thermal store FPB-FR/-FP dia. 9 mm Solar circuit pump PSS2 Max. switching current 5 A Heat meter temperature sensor NTC sensor Motorised diverter valves SPB and SU Max. switching current 5 A for return/flow WMZ-FR/-FV dia. 9 mm Control 230 V; 2-point characteristic Volumetric flow meter WMZ-ZV Electrically isolated Secondary pump PS2 Max. switching current 5 A signal input 82

85 Function modules for expansion of digital controllers Function description for FM443 function module Solar thermal system control for two heat consumers The FM443 function module is capable of controlling two solar heat consumers. The first solar heat consumer is usually the solar DHW system and the second normally the solar space heating boost system The first heat consumer is the one that takes priority ( 83/). FSK HK ÜS Logasol FV HSM-E PH SH Logasol KS0..E PSS2 PSS Logasol KS FM443 EMS- BUS WWM PZ PS VS 2 FPB-FP M FSS AW PS2 Logano MC0 Buderus VS FSS2 VS RS M4 RS3 Logalux PL... A B AB FPB-FR TW M RS EK Logalux SU.../ST... AW EZ FB EK Logalux LT... 83/ Example of system with swimming pool control using function module FM443 (for wiring diagram page 90) Key to illustration Logasol KS0 Complete pump station w/o solar controller Logalux SU.../ST... DHW cylinder Detailed information can be found in the planning Logalux PL Thermosiphon thermal store document for Logasol solar technology for DHW Logano EMS boiler heating and space heating boost system. (For other abbreviations page 84) Logalux LT... DHW cylinder Switching on the first heat consumer In the morning or when the first sunlight appears, the system is still cold and all pumps are off. As the collector temperature rises (sensor FSK) the rate of temperature rise is monitored. As soon as the cut-in condition for heat consumer (solar DHW heating) is met, the controller switches the solar circuit on by means of the solar circuit pump PSS. Depending on the temperature measured by the threshold sensor FB (DHW temperature sensor for DHW heating with cylinder charging system), the controller switches the solar circuit pump PSS to lowflow or high-flow mode. Low-flow/High-flow control Low-flow/high-flow control is the variable-speed control of the solar circuit pump. In low-flow mode, low volumetric flow rates produce high temperatures in order to bring the DHW up to the required temperature as quickly as possible, i.e. greater DHW convenience. In high-flow mode, a high solar yield is achieved. When the solar thermal system is switched on, the controller constantly monitors the cylinder charge status for the DHW system using a threshold sensor FB positioned centrally in the cylinder (DHW temperature sensor for DHW heating with cylinder system). On the 83

86 5 Function modules for expansion of digital controllers basis of the fixed threshold temperature (45 C), the controller switches the volumetric flow rate between low and high. Low-flow mode If the temperature measured by the threshold sensor FB is below 45 C, the controller switches over to lowflow mode. At low cylinder temperatures, the system operates with a low volumetric flow rate and, therefore, a higher flow temperature to heat up the DHW as quickly as possible. The controller varies the volumetric flow rate so as to maintain a required temperature difference of 30 K between the collector (sensor FSK) and the cylinder (reference sensor FSS) ( 84/). The solar circuit pump PSS is switched off if the temperature difference at a minimum flow rate of 30 % drops below the set minimum of 5 K due to lack of sunlight ( 84/3). High-flow mode When the temperature measured by the threshold sensor FB exceeds the set level of 45 C, the convenience requirement is satisfied and the controller switches over to high-flow mode. Due to the lower flow temperature at the high flow rate, heat loss is less and greater efficiency is achieved. The controller varies the volumetric flow rate so as to maintain a temperature difference of 5 K between the collector (sensor FSK) and the cylinder (reference sensor FSS). A Buderus thermosiphon cylinder prevents intermixing by only heating the temperature layer that matches the flow temperature ( 84/2). The solar circuit pump PSS is switched off if the temperature difference at a minimum flow rate of 30 % drops below the set minimum of 5 K due to lack of sunlight ( 84/3). Volumetric flow control (variable speed control) Volumetric flow control (variable speed control) of the solar circuit pump PSS is performed by way of a semiconductor relay. It is effected without electrical losses by half-wave suppression at phase zero. It is, therefore, not possible to use an electronically controlled pump (with frequency converter). The maximum switching current for the solar circuit pump PSS is limited to 2 amperes by the semiconductor relay. Nor is it possible to increase the power output by connecting a load-side contactor. AW FSS V R 84/ Heating a twin-coil solar cylinder in low-flow mode with Δϑ = 30 K using low variable pump speed until the temperature at the threshold sensor FB reaches 45 C AW FSS V R 84/2 Heating a thermosiphon cylinder according to its temperature stratification in high-flow mode with Δϑ = 5 K using high variable pump speed (> 45 C at sensor FB!) AW FB EK FB EK FB VS RS VS RS VS RS FSS V EK R 84/3 Heating a thermosiphon cylinder according to its temperature stratification in high-flow mode with Δϑ < 5 K but > 5 K under low sunlight conditions (min. pump speed 30 %) Key to illustration ( 84/ to 84/3) ϑ Actual DHW temperature at threshold sensor FB Δϑ Temperature difference between collector and solar cylinder (bottom) For other abbreviations page 84 84

87 Function modules for expansion of digital controllers 5 Recharging optimisation One of the main tasks of a solar thermal system is DHW heating. A significant advantage of the FM443 function module is the integration of solar thermal system control in the control of the heating system and, therefore, optimisation of DHW system recharging by integration in the overall system. This function optimises reheating of the DHW by the boiler by lowering the required DHW temperature according to the solar yield and the capacity of the twin-coil solar cylinder. In order to ensure that the desired level of DHW convenience is provided, a minimum cylinder temperature for activation of this function has to be set on the MEC2 control pad ( 85/). To use the recharging optimisation function as well as all other functions that make use of DHW heating (thermal disinfection and daily monitoring of DHW heating including solar preheating stage), the function module FM443 must always be specified on the controller with the DHW heating. Solar yield In the morning, i.e. at first sunlight, lowering the required DHW temperature based on solar yield has greater significance as the temperature at the sensor FSS may be at cold water level due to hot water being drawn from the taps. To calculate the solar yield, the controller monitors the rate of temperature rise measured by the DHW temperature sensor FB and the solar reference sensor FSS. From that, a proportional amount for lowering the required DHW temperature is calculated which is subtracted from the set required temperature. The reduced required DHW temperature prevents the boiler unnecessarily recharging the cylinder. Capacity of solar cylinder Calculation of the available heat (capacity) of the solar cylinder is a second method of reducing the required DHW temperature which runs alongside the solar yield calculation. However, it tends to affect the required DHW temperature later in the day, i.e. when the amount of sunlight is starting to decrease. If the temperature measured by the solar reference sensor FSS is within the range of the set minimum cylinder temperature, a figure for lowering the required DHW temperature is calculated. That second reduction is subtracted from the set required DHW temperature along with the reduction for "solar yield", which may result in an adjustment of the already lowered DHW temperature requirement. ϑ Sp [ C] / "Recharging optimisation" function VS RS 5:30 8:00 0:0 7:00 22:00 t [h] Key to illustration a Sunlight b Top DHW temperature sensor (FB) c Solar cylinder bottom temperature sensor (FSS) d Required DHW temperature ➀ Charging ➁ Recharging ➂ Solar yield ➃ Solar yield t Time ϑ Sp DHW cylinder temperature VS PS ➀ ➁ ➂ ➃ FB FSS RS a b c d 85

88 5 Function modules for expansion of digital controllers Thermal disinfection and daily monitoring of solar DHW cylinder including solar preheating stage Together with the function for DHW heating with cylinder system (basic version of 42 or 42 controller or FM44 function module) the FM443 function module monitors the DHW cylinder including solar preheating cylinder and ensures daily heating to 60 C. Consequently, the requirements of DVGW Worksheet W55 can be guaranteed as well as thermal disinfection of the DHW system including solar preheating stage. Daily monitoring and/or thermal disinfection should preferably take place at a time when hot water is not being drawn from the taps, e.g. during the night. Daily monitoring In order to ensure system operation in accordance with the technical regulations as per DVGW Worksheet W55, the entire water contents of the preheating stage must be heated to 60 C once a day. The temperature in the standby cylinder must always be 60 C. Daily heating of the preheating stage can be carried out either during normal operation by means of solar charging or by way of conventional recharging. The FM443 function module monitors the temperatures in the DHW system using the sensors in the preheating cylinder (temperature sensor FSS) and the standby cylinder (DHW temperature sensor FB). If the temperatures recorded by both temperature sensors have not reached the required 60 C by solar charging, the circulation pump PS2 is switched on and the boiler provides the additional heat. By using pump P2, the entire water contents of the DHW system between the hot water outlet on the standby cylinder and the cold water inlet on the preheating stage are heated up. Pump PS2 remains switched on until the required temperature is reached at both temperature sensors. Thermal disinfection The thermal disinfection function heats up the domestic hot water to a temperature, measured by temperature sensor FB, sufficient to kill pathogens (e.g. legionella). Both the cylinder charging pump and the DHW circulation pump run constantly during the thermal disinfection process. The DHW circulation pump ensures that a large proportion of the DHW system is heated up to high temperatures so that pathogens are killed and the system thus "thermally disinfected". The "thermal disinfection" function is monitored by temperature sensor FB and can be activated either automatically daily or once a week at a programmable time or manually by means of an external electrically isolated switch (as alternative to once-only cylinder charging). A separate required DHW temperature is specifiable for this function. DHW heating using twin-coil cylinder, combination cylinder or series of cylinders Solar energy can be used for DHW heating using either a single-cylinder solution (twin-coil cylinder or combination cylinder) or separate cylinders for solar preheating stage and standby cylinder (DHW cylinder) connected in series. Charge recirculation pump function with twincoil DHW cylinder or combination cylinder Twin-coil solar cylinders and combination cylinders are standby cylinders and solar preheating stages in one. The standby section is heated by the boiler and the solar thermal system feeds the solar yield into the solar preheating stage. Pump PS2 is used to ensure daily monitoring and/or thermal disinfection of the entire cylinder. With twin-coil solar cylinders, if "Charge recirculation" is set for the pump function, the pump connected to terminal PS2 is used for thermally disinfecting/heating the standby section and the solar preheating stage to 60 C once a day if required to prevent legionella formation ( 86/). V R AW 86/ Charge recirculation (for abbreviations page 84) FB FSS VS PS KR RS EK WWM PS2 KR KR 86

89 Function modules for expansion of digital controllers 5 Charge transfer pump function with separate solar preheating stage (cylinders connected in series) With separate cylinders connected in series, a separate preheating cylinder is heated by the solar thermal system. The DHW cylinder (standby cylinder) heated by the boiler is also a separate cylinder. In order to be able to use the entire cylinder capacity for solar charging, a pipe must be run from the standby cylinder's hot water outlet to the preheating cylinder's cold water inlet. A pump on PS2 is used to circulate the water ( 87/). AW KR KR PS2 WWM VS PS KR RS With separate cylinders connected in series, if "Charge transfer" is set for the pump function, the pump connected to that terminal transfers the charge between the solar cylinder and the standby cylinder heated by the boiler based on the temperature difference between them. As soon as the solar cylinder is warmer than the cylinder heated by the boiler, pump PS2 is switched on and the contents of the two cylinders are interchanged. In addition, that pump is used for thermally disinfecting/heating the solar cylinder (solar preheating stage) and the DHW cylinder (standby cylinder) to 60 C once a day if required to prevent legionella formation. Second solar heat consumer Integration of the second solar heat consumer is a task performed by the function module FM443. Change-over from the first to the second solar heat consumer requires the first solar heat consumer to be switched off. The solar controller switches over to the second heat consumer either by means of a motorised diverter valve SU ( 80/) or an additional solar circuit pump PSS2 ( 83/). Change-over to the second solar heat consumer takes place if The first heat consumer has reached the maximum cylinder temperature, or The temperature spread between the collector temperature sensor FSK and the reference sensor FSS is no longer sufficient, despite the pump running at minimum speed, to charge the first heat consumer Change-over check When charging the second solar heat consumer, the controller constantly checks whether the cylinder temperature of the first solar heat consumer has dropped below the maximum. If so, it checks every 30 minutes whether the available solar energy from the collector is sufficient to charge the first heat consumer as the priority consumer to its maximum. To that end, the solar circuit pump is switched off for two minutes. This function is called "Change-over check". EK V R KR FSS 87/ Charge transfer (for abbreviations page 84) FB 87

90 5 Function modules for expansion of digital controllers Second solar heat consumer thermal store or combination cylinder for space heating boost Thermal store bypass The function module FM443 has a bypass function for solar heating boost using a thermal store. That enables the solar energy "harvested" from the sun and stored in the thermal store to be used to boost the space heating system. A thermal store bypass circuit connects into the space heating return. That circuit can be implemented either using a thermal store ( 80/) or a combination cylinder ( 88/). Based on the temperature difference between the system return (sensor FPB-FR) and the thermal store (sensor FBP-FP), the thermal store bypass function controls switching of the motorised diverter valve SPB between the thermal store, i.e. directing the flow though the thermal store, and the bypass, i.e. directing the flow past the thermal store and directly into the boiler return or low-loss header return. The Buderus HZG accessory set includes the necessary motorised diverter valve and two temperature sensors. For the SBH heating boost accessory kit, two sensors (AS and FV/FZ) have to be ordered separately. Alternatively, a conventional motorised mixing valve can be used. The following parameters can be set for this function: The cut-in temperature differential at which change-over from directing the flow through the bypass to through the thermal store takes place The cut-out temperature differential at which the flow is switched back to the bypass Balancing cylinder As an alternative to the thermal store bypass circuit, the FM443 function module also offers the option of using the thermal store as a balancing cylinder for the boiler ( 88/2). In addition to the solar thermal system, the boiler uses the volume of the thermal store as a heat equaliser. The boiler is switched on when the temperature in the thermal store (sensor FPB-FP) drops below the temperature required by the heating system and is switched off when the temperature in the thermal store (sensor FBP-FR) reaches the required system temperature. The boiler's burner on and off times are dependent on the charge level of the thermal store. The boiler always charges the thermal store at maximum output. The required temperature for the thermal store is dependent on the required temperatures for the heat consumers such as heating circuits and DHW system, i.e. is based on the heating system. The required system temperature is the maximum requirement from the heat consumers in the heating system. The heating system is supplied with heat from the thermal store. Great care is required when planning plumbing configurations for systems with balancing cylinders. Since the thermal store and the system's heat consumers are connected in parallel, balancing of the volumetric flow rates is absolutely imperative for a properly functioning system. The design maximum volumetric flow rate of the heating system must not exceed the boiler's volumetric flow rate. Depending on the plumbing configuration, the thermal store for heat consumer or the thermal store for heat consumer 2 can be the balancing cylinder. The setting "Balancing cylinder SP" or "Balancing cylinder SP2" on the controller specifies whether thermal store or 2 acts as the balancing cylinder. EK V R AW WWM FB AW MAG VK FM443 88/ Solar space heating boost using thermal store bypass circuit with a combination cylinder as st heat consumer Key to illustration Logasol KS0 Complete pump station w/o solar controller Detailed information can be found in the planning document for Logasol solar technology for DHW heating and space heating boost. Logalux PL /2S Thermosiphon combination cylinder Logano (NTK) Low-temperature boiler For other abbreviations page 84 FSK WMZ-FV SU M V Logalux PL.../2S R Logasol KS0... PSS WMZ-FR WMZ-ZV FSS VS KR PS RS (RK) FPB-FP A SPB AB B FPB- FR 42 + FM443 FB FSS 88/2 Solar space heating boost using balancing cylinder circuit (for abbreviations page 84) RK VH RH Logano (NTK) FPB-FP FPB-FR FSS2 42 EMS-BUS Buderus 88

91 Function modules for expansion of digital controllers 5 Second solar heat consumer integration by system separation The function module FM443 provides the facility for incorporating a second solar heat consumer in the heating control system by way of system separation ( 89/). In that way, it is possible to transfer heat between two separate fluid systems via a heat exchanger. If the circulation system is switched over to the second heat consumer, output PS2 can be used to control a secondary pump which circulates the transferred heat around the separate system. In that way, a swimming pool, for instance, can be heated using solar energy. The swimming pool is then the second solar heat consumer instead of the thermal store for the space heating boost function. The output PS2 can be used for the charge transfer/charge recirculation functions or for the secondary pump with a separated system FM443 M 89/ Integration of a second solar heat consumer by system separation e.g. swimming pool heating (for abbreviations page 84) WT FV3 PH SH PSB SMF SWT Logasol 230 V 50 Hz FSS2 FSB PS2 RSB Heat meter The function module FM443 has an integrated "heat meter" function which enables separate recording of heat usage according to heat consumer. As standard, the function can be used for collector arrays of up to 5 flat plate collectors. The Buderus heat meter accessory set WMZ.2 consists of a return temperature sensor WMZ-FR, a flow temperature sensor WMZ-FV and the volumetric flow meter WMZ-ZV ( 89/2). From the measured temperatures and the volumetric flow rate, the controller calculates the heat usage taking account of the glycol content of the heat transfer fluid in the solar circulation system. The glycol content is important when calculating heat usage. If too low a figure is set for the glycol content on the MEC2 control pad, the "heat meter" function calculates a solar yield figure that is too high, and vice versa. A statistics function enables comparisons of the heat quantities "harvested". The solar yield can be shown in the following ways: By day: Today/Yesterday/Two days ago V R WMZ-ZV FM443 WMZ-FV WMZ-FR By week: This week/last week/two weeks ago R V For the entire year The heat meter input can handle a maximum of 800 signal pulses a minute. The signal pulse value of l per signal pulse is a fixed setting. 89/2 Components of the heat meter (detail from 80/, for abbreviations page 84) 89

92 5 Function modules for expansion of digital controllers Wiring diagram for function module FM443 internal BUS in the control unit Solar module FM443 P ) ) ) ) ) ) AUT AUT ) k6a k5 k4 k3 k2 k L N PSS SPB PS SU PSS 2 FPB WMZ FR FP FR FV ZV FSS2 2 FSS FSK x,5 ² max 5 A 4 x,5 ² max 5 A 3 x,5 ² max 5 A 4 x,5 ² max 5 A 0,4-0,75 mm² 3 x,5 ² max 5 A M N L N N By Pu M L N M L N 2 Solar circuit pump (PSS) 3-way diverter valve for buffer bypass circuit (SPB) Secondary pump solar circuit 2 (PS 2) Solar circuit pump 2 (PSS2) 3-way diverter valve cylinder / cylinder 2 (SU) Return temp. sensor (FR) Buffer temp. sensor (FP) for buffer bypass circuit (FPB) Return temp. sensor Heat meter (FR) Flow temp. sensor Heat meter (FV) Temp. sensor solar cylinder 2 bottom (FSS 2) Temp. sensor solar cylinder bottom (FSS) Collector temp. sensor (FSK) 000 m 3 Flow meter (ZV) ) Automatic control input 2) Power supply connector Switch position 0 AUT P Solar circuit buffer bypass (PB) (PSS ) (SPB) k6a k5 k4 Control mode M PB: Bypass Switching states PB: Buffer Solar circuit 2 solar circuit selection Switch (PS 2) (PSS 2) position k3 k k k2 0 AUT 2 Control mode Heating Control mode solar cylinder 2 (diverter valve) M Heating solar cylinder (diverter valve) Control voltage 230 V LV 90/ Wiring diagram for function module FM443 (for abbreviations page 84) 90

93 Function modules for expansion of digital controllers Function module FM444 for incorporating an alternative heat source 5.4. Brief description Possible applications The function module FM444 enables incorporation of an alternative heat source and/or a thermal store in the heat source management system. Alternative heat sources are distinguished by the fact that they utilise energy from the environment for heating buildings and run on fuels such as wood, woodchips or pellets or are not exclusively used for producing heat. The alternative heat source is always the lead boiler, i.e. is give the first opportunity to provide the heat required by the heating system. Boilers are used like sequential boilers, i.e. only switched on or off as required. Alternative heat sources are fundamentally different in design and function from familiar boilers. The setting options on the FM444 function module are thus accordingly variable. One module of this type may be fitted in each controller. Incorporation of the alternative heat source is generally implemented by way of a thermal store. Alternative heat source and boiler are switched on and off as required according to the temperature in the thermal store. The temperatures measured at the various measuring points in the thermal store determine the boiler management. The function module FM444 offers a number of different setting options for incorporating the thermal store and, therefore, the alternative heat source. Furthermore, the function module FM444 can also be used in heating systems where there is no alternative heat source but where a thermal store provides heat for the heating system or in autonomous heating systems which do not have a Buderus boiler. By expanding the controller by the addition of an FM456, FM457 or FM458 function module, an alternative heat source can be integrated in the heat source management system for a multi-boiler system. The controller detects the function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad / Function module FM444 Key to illustration Terminal connectors 2 Module fault indicator (LED) 3 LED (WE) for feedback for alternative heat source in operation 4 LED (PWE) for heat source pump switched on 5 LED (SWR) for mixing valve for return temperature control (hotter for the heat source, i.e. more heat added) 6 LED (SWR) for mixing valve for return temperature control (cooler for the heat source, i.e. less heat added or more into the heating system) 7 Manual mode switch for heat source pump 8 Circuit board 9 Manual mode switch for automatic heat source/emergency cooling 0 LED (SWE) for mixing valve for integration of heat source or thermal store (heat source/thermal store not integrated) LED (SWE) for mixing valve for integration of heat source or thermal store (heat source/thermal store integrated) 2 (LED (WE-ON) for automatic heat source switched on or emergency cooling active in case of manual heat source 3 Button for disable/enable standard heat source 4 LED for standard heat source disabled

94 5 Function modules for expansion of digital controllers Functions and connection options Integration of an alternative heat source into the heating system Automatic continued operation for fuel-alternation systems Integration of "manually" started heat sources e.g. solid-fuel boilers, stove boilers Integration of "automatic" heat sources e.g. pellet boilers, pellet stoves, CHP modules, woodchip boilers, heat pumps or fuel cell boilers Integration of thermal stores for boosting the heating system Thermal store bypass circuit (series connection) or Alternative to boiler or Balancing cylinder Button for time-limited boiler lock-out when using alternative heat sources, e.g. solid fuel boilers Electrically isolated switch WE-ON For selection/deselection of "automatic" alternative heat source by 4000, e.g. CHP module or heat pump or For implementing an emergency cooling function for "manually" or "externally" started alternative heat sources Separate required setting and timer programme for individually starting the alternative heat source started by the 4000 Facility for return temperature control for the alternative heat source including control of an mixing valve and a pump Standard specifications FM444 function module Two 6 mm temperature sensors Two 9 mm temperature sensors FM444 function module: small boiler system with manual alternative heat source, e.g. Pellet boiler and wall-mounted boiler with EMS 42 Logamax plus EMS-BUS PK FK FA FM444 BC0 HK HK2 FV FV PH PH ) FWG FWV SH SH FB FWR FPO FAR PWE SWR FPU SWE Solid Logano fuel boiler S... Logalux PL.../2S ) Flue gas temperature sensor FWG not absolutely necessary 92/ Possible connections to function module FM444 (for wiring diagram page 03 f, for abbreviations page 84) 92

95 Function modules for expansion of digital controllers 5 FM444 function module: large boiler system with automatic alternative heat source, e.g. CHP module HK HK2 FV PH FV PH FVS SH SH SWE FAR SK PK PK EMS-BUS Logmatic FM442 + FM444 + FM458 FWV FPO MC0 BC0 FK FK FM444 FPM FPU Logano plus GB32 WE-ON Loganova CHP BHKW 93/ Possible connections to function module FM444 (for wiring diagram page 03 f, for abbreviations page 84) Possible applications for FM444 function module Controllers with slot ) for FM444 Controller 42 Boiler controller ( boiler) or Autonomous heating circuit controller or slave unit 422 Boiler controller (cascade system with up to 4 boilers) or controller for function expansion 42 Boiler controller Controller 432 Boiler controller 4322 Controller for sequential boiler (multi-boiler system) 4323 Autonomous heating circuit controller or slave unit 93/ system controllers with slot for FM444 function module ) The FM444 function module should always be fitted to the master control unit 93

96 5 Function modules for expansion of digital controllers Specification for FM444 function module Function module FM444 Function module FM444 Power supply 230 V AC ± 0 % PT000 sensor sensing range Frequency 50 Hz ± 4 % Flue gas temperature sensor FWG up to 350 C, resolution K Power consumption 2 VA Tolerance ±0 % Output Alternative heat source pump Max. switching current 5 A Alternative heat source flow temperature sensor FWV Alternative heat source return temperature sensor FWR Thermal store top temperature sensor FPO NTC sensor Switch WE-ON min. 5 V DC, 0 ma max. 230 V AC / 5 A NTC sensor Control Actuator for integrating heat source Control Return temperature control mixing valve 230 V NTC sensor 230 V Thermal store centre temperature sensor FPM NTC sensor Running time of mixing valve motors 0 s (adj. from s) 3-point switching controller (PI characteristic) Thermal store bottom temperature sensor FPU NTC sensor Type of controller System return temperature sensor FAR NTC sensor 94/ Technical specifications of function module FM Function description for FM444 function module The function module FM444 distinguishes between the following types of alternative heat source: Heat sources started automatically "by 4000" Externally controlled heat sources started "by external controller" Heat sources started "manually" The distinction is made because the behaviour of those types of heat source is fundamentally different and the FM444 function module thus has different possibilities for communicating with them. As with control of the boiler, the FM444 function module should always be specified on the master control unit. Only when fitted to the master controller does the FM444 module have an influence over boiler control and take control of heat source management. Furthermore, only the master controller processes all requirements from the heating system as a whole, i.e. including from the slave units. Automatic heat sources "started by 4000" Automatic heat sources that are started "by 4000" are selected/deselected by the electrically isolated switch WE-ON on the FM444 function module. The fuel supply to those heat sources is automatic. Characteristics Automatic fuel supply; continuous operation presents no problems, 4000 has unrestricted control over the automatic alternative heat source and can select/deselect it as required to cover heat demand from the heating system. Boiler start-up is prevented according to the possibilities. This setting supports alternative heat sources such as Pellet-burning boiler Woodchip boilers CHP modules, heat-demand driven Fuel cell boilers, heat-demand driven Technicalities of control integration On receipt of heat demand from the heating system, the alternative heat source is selected/deselected by means of the electrically isolated switch WE-ON on the FM444 function module. A controller integrated in the automatic heat source monitors the internal processes. The FM444 module monitors operation of the alternative heat source by means of its flow temperature (sensor FWV). Heat source management is effected by comparing the highest required system temperature with the actual system temperature. Depending on the plumbing configuration, the actual system temperature may be measured at various different points (sensors) or the measurement point may change while the system is in operation (e.g. alternative circuit). In order to prevent insufficient supply of heat to the heating system, the boiler starts up and provides additional heat if the alternative heat source is not supplying adequate temperatures. 94

97 Function modules for expansion of digital controllers 5 In heating systems in which the automatic heat source delivers its heat to a thermal store or a low-loss header, there is a special arrangement. In such systems, a boiler lock-out prevents the boiler starting up after an abrupt change in the required temperature. An abrupt change in the required temperature refers to a sudden alteration in the required system temperature within a very short time, e.g. when DHW heating is required. The lock-out time is factory set to 30 minutes but is adjustable. In order to prevent insufficient supply of heat to the heating system, the boiler is re-enabled so as to be able to cover demand when that period has elapsed. The automatic alternative heat source is selected if the temperature at the measurement point for the actual system temperature falls below the required system temperature by a set hysteresis differential. The alternative heat source is deselected if the temperature at the measurement point for the actual system temperature exceeds the required system temperature by a set hysteresis differential. If the temperature required in the heating system is provided by the alternative heat source, the boiler remains off as long as the actual system temperature is higher than the required system temperature. Plumbing configuration with thermal store ( 95/) In heating systems with thermal stores, the boiler and alternative heat source are operated according to the temperatures in the thermal store. The automatic alternative heat source is selected if the temperature in the thermal store (sensor FPM) falls below the required temperature demanded by the system. The alternative heat source is deselected when the lower part of the thermal store (sensor FPU) has been heated up to the required system temperature. The boiler is not called upon until the temperature in the thermal store (sensor FPO) drops below the required system temperature. FWV FM444 WE ON 4 PWE FWR SWR FPO Plumbing configuration without thermal store In heating systems without thermal store, heat source management is effected by comparing the required system temperature with the actual system temperature at the reference sensor. The FM444 module always calls on the alternative heat source first. FPM FPU SWE 95/ Automatic heat sources "started by 4000" (for abbreviations page 84) FAR Automatic heat sources "started by external controller" Alternative heat sources started "by external controller" can not be controlled by the FM444 function module. The fuel supply is automatic. Characteristics Heat is provided, 4000 has no influence over the heat source This setting supports alternative heat sources such as Heat pumps CHP module, electricity-demand driven Fuel cell boilers, electricity-demand driven Technicalities of control integration The FM444 function module uses either the temperature of the alternative heat source (sensor FWV) or the flue gas temperature (sensor FWG, optional) to detect operation of the externally controlled alternative heat source. Detection of operation is based on specification of a definable temperature threshold. If detection of operation by the temperature of the alternative heat source (sensor FWV) is selected, that temperature threshold for the alternative heat source must be higher than any temperature that has to be maintained for boiler protection. Heat source management is effected by comparing the highest required system temperature with the actual system temperature. As the FM444 function module has no means of influencing the alternative heat source, the boiler is enabled without a delay period in plumbing configurations with a thermal store when the temperature drops below the thermal store temperature (sensor FPO). In plumbing configurations without a thermal store, the actual system temperature is detected at various points (sensors) and when the temperature drops below the required system temperature, the boiler is enabled immediately. 95

98 5 Function modules for expansion of digital controllers Manual heat sources "started manually" In the case of heat sources that are started "manually", fuel supply and firing up are not automatic. Operation requires a sequence of actions (manually filling logburning boiler, lighting logs and emptying ash pan) that does not take place automatically. Characteristics Manual fuel supply; continuous operation only possible within limitations This setting supports alternative heat sources such as Log-burning boilers Manually fed coil-burning boilers Stove boilers driven by hot-water demand Technicalities of control integration ( 96/) The FM444 function module detects whether the alternative heat source is in operation by its flow temperature (sensor FWV) or flue gas temperature (sensor FWG). If operation is detected by the flow temperature (sensor FWV), the thermal store is charged on the basis of temperature difference by the thermal store charging pump PWE. Control of the pump PWE is based on the temperature difference between the alternative heat source flow (sensor FWV) and the thermal store (bottom sensor FPU). If operation is detected by means of temperature sensor FWG, the thermal store charging pump PWE is controlled on the basis of the definable temperature threshold (sensor FWG). As the FM444 function module has no means of influencing the alternative heat source, the boiler is enabled without a delay period in plumbing configurations with a thermal store when the temperature drops below the thermal store temperature (sensor FPO). In autonomous heating systems with FM444 function module in which the manually started heat source alone is used for the heating and domestic hot water, the cylinder charging pump PS is controlled on the basis of temperature difference when DHW heating is required. The pump PS is switched on as long as the temperatures in the DHW cylinder (sensor FB) are lower than the temperature in the thermal store (sensor FPO). When the temperature in the DHW cylinder reaches the temperature of the thermal store, pump PS switches off. Cooling of the DHW cylinder is effectively prevented. FWG FWV PWE FWR FPO FPU SWE FAR 96/ Manual heat sources "started manually" (for abbreviations page 84) Possibilities for accessing the alternative heat source via the MEC2 control pad The most important operating data from the alternative heat source and the thermal store are easily accessible to the user and can be displayed centrally on the MEC2 control pad. Thus the system operator can obtain a clear summary of the most important heating system information. The following details are displayed: Temperatures in the thermal store Temperature of the "alternative heat source" Hours of duty of the "alternative heat source" Status of the "alternative heat source" In addition to displaying the operating data, the following settings and queries can be made on the MEC2 control pad for alternative heat sources that are started "by 4000". Operating data Separate timer programme and required temperature Change of operating mode for an automatic alternative heat source Temperature threshold for summer mode Separate required setting and timer programme for the alternative heat source started "by 4000" By direct comparison with an oil/gas boiler, most alternative heat sources require substantially longer to be fired up and ready to supply heat. Heating up times of as much as two hours are entirely possible. In order to nevertheless enable seamless integration in the heating system, an alternative heat source that is started "by 4000" can be started according to its own timer programme and its own heat demand that is independent of the heating system. With its own separate timer programme, the alternative heat source has sufficient time to heat itself/the thermal store up to 96

99 Function modules for expansion of digital controllers 5 the set required temperature. When the heat consumers in the system switch to daytime mode, there is sufficient available output ( 97/). This function enables the alternative heat source to be operated according to its own required temperature that is independent of the heating system (e.g. CHP module). If the alternative heat source is to be operated according to the required system temperature, its own timer programme should be cancelled when the heat consumer timer programmes switch over to daytime mode. Changing operating mode for the alternative heat source started "by 4000" Timer programme Timer programme Timer programme Timer programme Required DHW temperature HK HK2 WW WE 80 C Night Night Night Night Day t [h] Timer programme for alternative HS Day Day Day Night The operating mode for the alternative heat source can be set by means of the Daytime/Night-time/Automatic buttons on the MEC2 control pad. The following operating mode options are provided: Manual ON ( 97/2, Item 3) the alternative heat source operates in "Constant daytime" mode Automatic mode ( 97/2, Item 2) the alternative heat source is started as required by the FM444 function module Manual OFF ( 97/2, Item ) the alternative heat remains switched off regardless of any heat demand (manually disabled) Summer mode for the automatic heat source started "by 4000" Setpoint Alternative HS Daytime required temperature Heating circuits Night-time required temperature Heating circuits 70 C 60 C 55 C t [h] Setpoint System 97/ Required temperature when operating the alternative heat source with a separate timer programme If a timer programme has been defined and activated for the alternative heat source, a separate temperature threshold for switching between summer and winter mode for the alternative heat source can be specified on the MEC2 control pad /2 Changing operating mode on the MEC2 control pad Key to illustration ( 97/2) Button with LED for constant night-time mode (constant low heating mode) 2 Button with LED for Automatic mode (daytime and night-time modes as programmed) 3 Button with LED for constant daytime mode (constant heating mode) 97

100 5 Function modules for expansion of digital controllers Manual boiler delay (preheating function) On the FM444 function module there is a button for manually disabling start-up of a boiler. The preheating function allows the user to disable the boiler. That allows time for the alternative heat source to heat up and deliver heat to the system. The boiler is re-enabled by pressing the button again or when the lock-out period has elapsed, thus preventing insufficient supply of heat to the system. The lock-out time for the boiler after the button is pressed is factory set to 60 minutes. However, the preheating function can also be set so that the boiler remains permanently off until the button is pressed again. Disabling of the boiler is indicated by the LED "Standard heat source disabled" on the front of the module ( 98/). The function is mainly intended for heating systems with "manually" started heat sources. If the operator needs to fire up a solid-fuel boiler, this button can be used to disable the standard boiler. If the manual alternative heat source does not then fire up during the preheating phase, the heating system is supplied by the standard boiler once the lock-out period has elapsed and automatic continued operation is ensured. 98/ Button for manually disabling the boiler on the FM444 function module Emergency cooling function for alternative heat sources started "manually" and "by external controller" When used in combination with manual heat sources (started "manually") and automatic heat sources over which the 4000 has no control (started "by external controller"), the FM444 function module offers an emergency cooling function. If the temperature exceeds the definable maximum temperature of the alternative heat source by 4 K, emergency cooling is activated. An externally installed arrangement can be activated via the electrically isolated switch "WE-ON". It can be used to switch on a pump, for instance, or send a signal to a monitoring device. This function enables energy that would otherwise be lost by opening the temperature relief valve to be used for the heating system. WE ON FM444 4 L on site N 98/2 Emergency cooling function using function module FM444 Notes on the flue system In a system in which an alternative heat source started "by 4000" or "by external controller" is operated in combination with a standard boiler, separate flue systems are always required. In a system in which an alternative heat source started "manually" is operated in combination with a standard boiler, a single flue or separate flue systems are possible. If the standard boiler and alternative heat source are connected to the same flue system, a flue gas temperature monitor (ATW) is always required. The flue gas temperature monitor operates as a safety device acting on the sequential safety system and shuts down the boiler. In the case of floor-standing boilers with EMS, a UM0 switch-over module or a BRM0 external burner module is imperative for single-flue systems (for wiring diagram page 03 f.). 98

101 Function modules for expansion of digital controllers Integrating the alternative heat source Ensuring required operating conditions Every time the heat source is started up, the hot flue gas comes into contact with the cooler boiler surfaces. As the flue gas contains water vapour, condensation forms on the boiler surfaces if the temperatures are below a certain level. The temperature at which that occurs is called the condensation point and is different for every fuel. The temperature range up to the condensation point or minimum heat source temperature is passed through most quickly if the boiler can heat up first before the full system volume flows through it. The condensation point is specified as an operating requirement by the manufacturer concerned. In that way, the boiler safety functions can be implemented by the correct settings on the Service menu of the MEC2 control pad in conjunction with the appropriate plumbing configuration. Minimum return temperature When this function is activated, a definable minimum return temperature for the alternative heat source is guaranteed by means of the heat source return mixing valve SWR. The volumetric flow rate from and to the heat source is regulated by the mixing valve. If the temperature falls below the minimum return temperature (sensor FWR), the flow rate to the system is reduced by means of the mixing valve SWR. In heating systems without thermal store, the pumps connected to the controller are also switched off to provide additional assistance. The pumps are switched on again when the heat source reaches the set minimum temperature. Pump control logic With this setting, the required operating conditions are ensured by switching the pump output. If the temperature falls below the definable minimum temperature for the alternative heat source (sensor FWV), the pump PWE connected to the controller is switched off; when the temperature rises again (sensor FWV) it is switched on again according to a switching differential. This safety function is referred to as the "pump control logic". In heating systems without thermal store, the pumps connected to the controller are also switched off to provide additional assistance. The pumps are switched on again when the heat source reaches the set minimum temperature. Externally controlled safety function External control of the required operating conditions is also possible. The safety function is then performed by the external heat source's controller or another external controller. The pump PWE and mixing valve SWR connections on the FM444 function module than have no function. Delivery of heat to the heating system by the alternative heat source The FM444 offers a number of possibilities for delivery of heat to the heating system by the alternative heat source. Pump The pump PWE (heat source pump PWE) is operated to deliver the heat produced by the alternative heat source. The general parameters for operating the pump PWE are, depending on programming, guaranteeing the required operating conditions, reaching the temperature thresholds or reaching a temperature differential between heat source flow (sensor FWV) and thermal store (sensor FPU). The runon time for pump PWE can be defined or it can be set to continuous operation. Flow control The flow control function is an additional option for heat delivery for automatic alternative heat sources that are started by 4000 and are incorporated in the heating system by way of a thermal store or a low-loss header. The mixing valve SWR, which is required for controlling a minimum return temperature, is operated as an override to control the flow temperature. The volumetric flow rate to the thermal store or low-loss header is controlled according to the temperature of the alternative heat source in such a way that the temperature of the alternative heat source is at least equal to the required flow temperature demanded by the heating system. The run-on time for pump PWE can be defined or it can be set to continuous operation. External control The external heat source's controller or another external controller performs the heat delivery function and, if necessary, the safety function for the alternative heat source. The pump PWE and, if applicable, the mixing valve SWR connections on the FM444 function module than have no function. 99

102 5 Function modules for expansion of digital controllers Integrating the thermal store The function module FM444 can incorporate an enormous variety of heat sources in the control strategy. For optimum operation of those heat sources, Buderus recommends physical integration into the system by way of an adequately dimensioned thermal store. That recommendation is based on different requirements on the part of the alternative heat sources in terms of heating-up time and duty periods compared with oil/gas boilers. The method by which the alternative heat source is integrated in the system is greatly dependent on a number of parameters including Type of heat source Demands made by the heat source in respect of correct operation Dimensioning of the overall system, especially the amount of heat required throughout the year as minimum consumption (ordered annual demand pattern) Clean burn-down phase for log-burning boilers Favourable start-stop ratio with CHP modules/pellet boilers Building heating system/system temperatures The thermal store isolates the timing of energy generation from the demand for it. A thermal store allows the alternative heat source to be operated continuously and under optimum conditions. For guidance on the dimensioning of the thermal store, please refer to the planning documents for the product concerned. Alternative buffer circuit The function module FM444 offers the function "Alternative" for heating system boosting using a thermal store ( 00/). The alternative control method compares the required system temperature with the temperature in the thermal store (sensor FPO) and switches the motorised diverter valve SWE between thermal store, i.e. directing the flow through the thermal store, and the boiler. If the thermal store temperature is sufficient for the required system temperature, the boiler remains off and the flow is not directed through it. If the thermal store temperature drops below the required system temperature demanded by the heating system, the motorised diverter valve SWE is switched over to the boiler and the boiler covers the demand from the heating system. Meanwhile, the alternative heat source continues to charge the thermal store. As soon as the temperature in the thermal store (sensor FPO) is sufficient to supply the heating system from the thermal store, and therefore from the alternative heat source, the standard boiler is switched off. In order to utilise the energy remaining in the boiler, the motorised diverter valve delays for a short time before switching over to the thermal store, after which the flow is no longer directed through the boiler. Alternative operating mode means that the thermal store charged by the alternative heat source and the boiler are in use in alternation with one another. Due to the way the system is plumbed, simultaneous operation of the two heat sources is not possible. When dimensioning the heat sources, it is important to ensure that each heat source must be capable on its own of covering the heat demand from the system. The configuration can be implemented using a thermal store. The required temperature for the thermal store is a dynamic figure dependent on the required temperatures for the heat consumers such as heating circuits and DHW system, i.e. is based on the heating system. The required system temperature is the maximum requirement from the heat consumers in the heating system. Another advantage of the alternative configuration is that the flow only circulates through the boiler as and when demand requires. The alternative configuration is advisable when the alternative heat source is to be the main heat provider. FPO SWE EMS-BUS Buderus 00/ Schematic diagram of thermal store alternative configuration (for abbreviations page 84) 00

103 Function modules for expansion of digital controllers 5 Buffer bypass circuit with diverter valve The function module FM444 has a "thermal store bypass" function for integrating the thermal store ( 0/). The thermal store bypass control mode compares the temperature of the heating-system return (sensor FAR) with the temperature of the thermal store (sensor FPO). Based on the temperature difference between the system return and the thermal store, the motorised diverter valve SWE is switched between the thermal store, i.e. directing the flow through the thermal store, and the bypass, i.e. bypassing the thermal store. After that the flow passes through the boiler or the low-loss header. The motorised diverter valve directs the entire flow of the heating system either through the thermal store or through the bypass. The thermal store and the boiler are connected in series with the system. The alternative heat source charges the thermal store. The two heat sources, i.e. alternative heat source (via the thermal store) and boiler, can jointly cover the heat demand from the system. The configuration can be implemented either using a thermal store or a combination cylinder. This method of integration is advisable for alternative heat sources with a lower output than is required to cover the heat demand (base load demand); the thermal store (and therefore the alternative heat source) covers the base load demand of the heating system and the boiler is used to cover demand peaks; if the alternative heat source is used occasionally to provide heat but essentially the boiler covers the heat demand from the system. The advantage of this configuration is that the temperature in the thermal store can be allowed to drop as far as the temperature of the system return. The alternative heat source/thermal store can feed energy into the system continuously. As with the thermal store bypass configuration using diverter valve, the thermal store and the boiler are connected in series with the system. The alternative heat source charges the thermal store. The two heat sources, i.e. alternative heat source (via the thermal store) and boiler, can jointly cover the heat demand from the system. The thermal store bypass pump configuration provides the control system requirement for the thermal store to be dimensioned for a proportion of the system flow volume. The thermal store is dimensioned on the basis of the size of the alternative heat source; the pump defines the flow volume required for incorporation of the alternative heat source. The configuration can be implemented either using a thermal store or a combination cylinder. Correct positioning for the sensors FPO and FAR is decisive for correct control of the pump SWE. FPO SWE FAR Buderus EMS-BUS 0/ Schematic diagram of thermal store bypass configuration using diverter valve (for abbreviations page 84) EMS-BUS Buffer bypass circuit with pump The function module FM444 has a "pump" function for integrating a thermal store ( 0/2). Based on the temperature difference between the system return (sensor FAR) and the thermal store (sensor FPO), the thermal store bypass pump function controls operation of the pump connected to output SWE. The flow is circulated through the thermal store if the temperature in the thermal store (sensor FPO) is higher than the system return temperature (sensor FAR), otherwise pump SWE is switched off. In addition, pump SWE is controlled according to the demand from the system. If the system is not calling for a required temperature, pump SWE remains switched off. When the pump is switched on, this function circulates a proportion of the total heating system flow volume through the thermal store. SWE FPO FAR Buderus 0/2 Schematic diagram of thermal store bypass configuration using pump (for abbreviations page 84) 0

104 5 Function modules for expansion of digital controllers Heating boost using balancing cylinder The FM444 function module offers a function for using the thermal store as a balancing cylinder for the boiler ( 02/). The boiler uses the volume of the thermal store as a heat equaliser in addition to the alternative heat source. The boiler is switched on when the temperature in the thermal store (sensor FPO) drops below the temperature required by the heating system and is switched off when the temperature in the thermal store (sensor FPU) reaches the required system temperature. The boiler's burner on/off times are dependent on the charge level of the thermal store. The boiler always charges the thermal store at maximum output. The required temperature for the thermal store is dependent on the required temperatures for the heat consumers such as heating circuits and DHW system, i.e. is based on the heating system. The required system temperature is the maximum requirement from the heat consumers in the heating system. The heating system is supplied with heat from the thermal store. Great care is required when planning plumbing configurations for systems with balancing cylinders. Since the thermal store and the system's heat consumers are connected in parallel, balancing of the volumetric flow rates is absolutely imperative for a properly functioning system. The design maximum volumetric flow rate of the heating system must not exceed the boiler's volumetric flow rate. FPO FPU 02/ Schematic diagram of space heating boost using balancing cylinder (for abbreviations page 84) ) EMS-BUS Buderus ) To prevent incorrect circulation through the boiler, fitting of a solenoid valve is recommended. Integrating the alternative heat source by means of a low-loss header The function module FM444 supports incorporation of an alternative heat source connected to a low-loss header. The temperature in the low-loss header is the determining factor for boiler management. Alternative heat source and boiler are switched on and off as required according to the temperature in the low-loss header. This method of integration requires an automatic alternative heat source that is started "by 4000". The alternative heat source is selected/deselected by means of the shared flow sensor. This configuration can be used in systems with multiple floor-standing boilers with function module FM458 (temperature sensor FVS) or wall-mounted boiler systems with function module FM456/FM457 (temperature sensor FK). The alternative heat source is the lead boiler, i.e. is selected first and deselected last. The method of integration requires that the alternative heat source can deliver at least the same ΔT and the same flow temperature as the standard boiler(s). By comparing the required system temperature with the combined actual flow temperature (sensor FK/FVS), the heat source management function decides whether heat output is required or the heat demand is being met. With this method of integration, if an alternative heat source is unable to deliver the required system temperature demanded, it is not enabled or is deselected for safety reasons. If the flow temperature at the common temperature sensor FK/FVS is below the required level for the heating system by a hysteresis differential, the boiler management system first selects the alternative heat source. The alternative heat source is selected by means of the FM444 function module. After the alternative heat source has been started up, all other boilers remain off for a specified lock-out period. The lock-out time is adjustable and has a factory setting of 30 minutes. During that period, the alternative heat source supplies the heat to meet the demand from the system. If the output from alternative heat source is insufficient, the other boilers are enabled after the lockout period has elapsed. If the demand from the system diminishes, the heat source management reduces output/switches off boilers. The alternative heat source remains in operation longest. The alternative heat source is not switched off until the common flow temperature measured by temperature sensor FK/FVS exceeds the required system temperature by a hysteresis differential FK FM444 + FM458 Loganova BHKW 02/2 Integrating the alternative heat source by means of a low-loss header (for abbreviations page 84) FK FWV SWR FWR PWE FVS 02

105 M Function modules for expansion of digital controllers 5 AUT 0 0 M AUT N L N L Netz Module Netz Module 2 3 EV M AUT 0 0 M AUT Integrating the alternative heat source in systems without thermal store Incorporating an alternative heat source without a thermal store is not advisable and should only be done in exceptional cases. This method of integrating the alternative heat source in the system is dependent on a number of parameters including Type of heat source Demands made by the heat source in respect of correct operation Dimensioning of the overall system, especially the amount of heat required throughout the year as minimum consumption (ordered annual demand pattern) If there is a need to dispense with a thermal store, it is important to ensure that the automatic alternative heat source has similar characteristics to an oil/gas boiler with respect to heating-up time and duty periods. Without a thermal store, the FM444 function module only supports alternative heat sources which have similar operating characteristics to oil/gas boilers. Alternative heat sources that have substantially different characteristics but are nevertheless incorporated in the heating system without a thermal store are not properly supported by the control technology. The function of the heating system may then be substantially impaired. Whether the FM444 function module can be used in systems without thermal store must be determined on the basis of individual planning and consultation with a Buderus agent ( back page) Wiring diagram for function module FM444 Function module FM444: 2 boilers connected to a common flue system Control unit System 4000 Alternative Control unit EMS Control unit System /22 FM444 FM 444 I WE ON SWE WE PWE SWR MC x 4323 FM444 FM 444 I WE ON SWE WE PWE SWR UM0 2) SI PH 6 63 FWG 2 EV FWG 2 In case of connection, remove jumper Flue gas temperature limter to DIN3440 or EN2597 Charge door safety switch (on-site) S0 ATW ) NC 3) C NO connect only, if fault message is required FWG ATW S0 In case of connection, remove jumper Flue gas temperature limter to DIN3440 or EN2597 Charge door safety switch (on-site) S0 ATW NC C ) NO S0 ATW FWG Solid fuel boiler Oil/gas fired fan-assisted boiler Always observe the applicable electrical safety standards as well as the local regulations. The safety instructions in the servicing manual for the FM444 must also be followed. ) Max. switch contact load for ATW: 230 V / 6 (4) A 2) For further information regarding terminal SI, refer to the wiring diagram for the controller used. 3) Safety switch on fuel filler door opens when door is opened. 03/ Wiring diagram for function module FM444 (for abbreviations page 84) 03

106 5 Function modules for expansion of digital controllers Function module FM444 internal BUS in the control unit Module FM444 - heat source 2 2) 2) 2) 2) 2) 2) 3) 0 AUT k6 k5 k4 k3 k2 k L N WE ON SWE SWR PWE FPU 2 FPM 2 FPO 2 FAR FWG FWR FWV RS232 ) 4) 4x,5 ² max 5 A 4x,5 ² max 5 A 3x,5 ² max 5 A 0,4-0,75 mm² N N N M L 3-way diverter valve heat source (SWE) Servomotor return (SWR) Pump alternative heat source (PWE) Temp. sensor buffer bottom (FPU) Temp. sensor buffer centre (FPM) Temp. sensor buffer top (FPO) Temp. sensor system return (FAR) Temp. sensor PT000 heat source flue gas (FWG) Temp. sensor heat source return (FWR) Temp. sensor heat source flow (FWV) Switching states Always observe the applicable electrical safety standards as well as the local regulations. ) If output WE ON is used for a low voltage circuit, a 230 V circuit must not be switched by that output beforehand. 2) Automatic control input 3) Power supply from power supply module 4) Output for electrically isolated ON signal. Automatic heat source, alternative emergency cooling for manual heat source. Max. switch load 230 V AC / 5 A, min. switch load 5 V DC/0 ma Switch position 0 AUT I (WE ON) (SWE) k3 k5 k4 Control mode Control mode M Control mode Switch position 0 AUT (PWE) (SWR) k6 k k2 Control mode Control voltage 230 V M Control Control mode mode LV 04/ Wiring diagram for function module FM444 (for abbreviations page 84) 04

107 Function modules for expansion of digital controllers Function module FM445 for DHW heating using a cylinder charging system (e.g. Logalux LAP* or LSP* heat exchanger set) 5.5. Brief description Possible applications The FM445 function module enables control of DHW heating using upright and horizontal stratified cylinders with a Buderus cylinder charging system with either the Logalux LAP heat exchanger set (charging system with top-mounted heat exchanger) or Logalux LSP heat exchanger set (charging system with sidemounted heat exchanger). One FM445 function module may be fitted in each controller. It is automatically detected by the controller and shows all definable parameters on the Service menu of the MEC2 control pad. When planning cylinder charging systems using the FM445 function module, it is important to take into account that the heat exchanger temperature sensors are optimised in terms of their function and dimensions exclusively for the heat exchangers in the Buderus Logalux LAP or LSP cylinder charging systems. Only AC pumps are suitable as cylinder charging pumps DHW heating Individually timed temperature control by varying volumetric flow rate of the primary and secondary circuit pumps or by controlling the primary circuit mixing valve with maximum volumetric flow rate from primary circuit pump and variable volumetric flow rate from secondary circuit pump Separate timer programmes for daily monitoring, thermal disinfection and DHW circulation pump operation Electrically isolated output for heat demand signal to external controller Electrically isolated external input for once-only charging of cylinder outside of set times or for activating thermal disinfection Electrically isolated external input for fault signal from cylinder charging pump or for an inert anode for display on the MEC2 control pad Anti-scaling function Option of hot water priority or simultaneous operation with the heating circuits Facility for setting cut-in and cut-out hysteresis 05/ FM445 function module Key to illustration Module fault indicator (LED) 2 DHW LED (cylinder temperature below required temperature in night-time mode) 3 LED for secondary circuit pump (PS2) 4 DHW circulation pump LED 5 Thermal disinfection LED 6 Manual mode switch for secondary circuit pump (PS2) 7 Circuit board 8 Manual mode switch for primary circuit pump (PS) 9 Actuator closing LED for heating circuit 0 Actuator opening LED for heating circuit LED for primary circuit pump (PS) 2 LED for anti-scaling function, secondary circuit pump (PS2) 7 Standard specifications Function module FM445 ( 05/) DHW temperature sensor FSM (cylinder centre sensor) DHW temperature sensor FSU (cylinder bottom sensor) DHW temperature sensor FWS (in heat exchanger) * In the UK & Ireland this product was unavailable at the time of printing. 05

108 5 Function modules for expansion of digital controllers Function module FM445: cylinder charging system with primary circuit temperature control by motorised mixing valve Function module FM445: cylinder charging system with primary circuit temperature control by varying pump volumetric flow rate FM445 External switch (electrically isolated) connected to WF: /2 (break switch) = pump fault /3 (make switch) = once-only cyl. charge FM445 External switch (electrically isolated) connected to WF: /2 (break switch) = pump fault /3 (make switch) = once-only cyl. charge WA 2 3 WF WA 2 3 WF VH RH SK PS WT FWS PS2 AW KR FSM FSU EK EZ PZ KR VH RH PS KR WT FWS PS2 AW KR FSM FSU EK EZ PZ KR 06/ Possible connections to function module FM445 with temperature control by motorised mixing valve in primary circuit (for wiring diagram page 0, for abbreviations page 84) 06/2 Possible connections to function module FM445 with temperature control by varying pump flow rate in primary circuit (for wiring diagram page 0, for abbreviations page 84) Possible applications for FM445 function module Controllers with slot ) for FM445 Controller 42 Boiler controller ( boiler) or Autonomous heating circuit controller or slave unit 422 Boiler controller (cascade system with up to 4 boilers) or controller for function expansion 42 Boiler controller Controller 432 Boiler controller 4322 Controller for sequential boiler (multi-boiler system) 4323 Autonomous heating circuit controller or slave unit 06/ system controllers with slot for FM445 function module ) Only one FM445 function module can be used on each controller; DHW heating using cylinder charging system only as alternative to cylinder system (basic version of 42 or 42 controller or function module FM44) 06

109 Function modules for expansion of digital controllers Specification for FM445 function module Function module FM445 Function module FM445 Power supply 230 V AC ± 0 % Max. switching current DHW circulation pump PZ 5 A Frequency 50 Hz ± 4 % DHW temperature sensor FWS NTC sensor, dia. 8 mm Power consumption ) 2 VA (in heat exchanger) Length 300 mm Primary circuit mixing valve LH Max. switching current 5 A DHW temperature sensor FSU NTC sensor, dia. 9 mm Control 230 V; 3-point switching (bottom of cylinder) controller (PI characteristic) DHW temperature sensor FSM NTC sensor, dia. 9 mm Recommended running times 20 s, adj. betw. 0 and 600 s (centre of cylinder) Primary circuit pump PS Max. switching current 2 A External optional function WF 2)3) Electrically isolated input Secondary circuit pump PS2 Max. switching current 2 A MEC2 or BFU/F remote control 2) BUS communication 07/ Technical specifications of function module FM445 ) The total current drawn by all electrical consumers must not exceed 0 A 2) Max. lead length 00 m (shielded upwards of 50 m) 3) Switch load 5 V DC / 0 ma Function description for FM445 function module Control functions in primary circuit The supply of heat, i.e. the volumetric flow rate in the primary circuit can be controlled by varying the speed of the primary circuit pump PS, by means of a primary circuit mixing valve SK (motorised mixing valve or flow restrictor) or, with wall-mounted boilers, by controlling the modulating-control burner via the UBA burner control unit or EMS. The corresponding functions can be set on the "LAP primary circuit" menu on the MEC2 control pad Service menu. Control of primary circuit pump speed Volumetric flow control (variable speed control) of the primary circuit pump PS is performed by way of a semiconductor relay. It is effected without electrical losses by half-wave suppression at phase zero. It is, therefore, not possible to use an electronically controlled pump (with frequency converter). The maximum switching current for the primary circuit pump PS is limited to 2 amperes by the semiconductor relay. Nor is it possible to increase the power output by connecting a load-side contactor. The speed of the secondary circuit pump PS2 is controlled in the same way. With the semiconductor NC relays used (for wiring diagram 0/), emergency mode operation of the primary and secondary pumps is guaranteed even if the lowvoltage power supply fails. Primary circuit mixing valve The primary circuit pump runs at maximum speed and the motorised mixing valve SK is used to control the heat supply. Control of the modulating control burner via the UBA burner control unit The function "LAP primary circuit via UBA/EMS" only appears in conjunction with Buderus modulating EMS boilers or wall-mounted boilers with UBA.5. The internal boiler pump functions as the primary circuit pump with the UBA.5 which is connected to the heat exchanger via a motorised diverter valve (cylinder flow). It runs at maximum speed. The flow temperature for heating the DHW is controlled by burner modulation. Hydraulic systems with modulating EMS boilers (e.g. Logano plus GB32 or Logamax plus GB62) must be mounted with a low loss header module. Then implement LAP control of primary circuit via pump control system or actuating element. Heat demand signal to an external controller Heat demand is signalled to an external controller via an electrically isolated switch (terminal WA). That electrically isolated output has a maximum load rating of 230 V/5 A. 07

110 5 Function modules for expansion of digital controllers Cut-in conditions DHW heating is activated by means of the DHW temperature sensor FSM (cylinder centre sensor) according to a separate timer programme. When that timer programme is in daytime mode, the charging sequence starts when the DHW temperature measured by temperature sensor FSM drops below the set required DHW temperature by the cut-out hysteresis differential (definable) and the cut-in hysteresis differential (also definable). Charging sequence If the cut-in conditions are met, the primary circuit pump PS or the motorised mixing valve operates at maximum setting (00 % volumetric flow rate 08/, ➊). The secondary circuit pump PS2 remains off at this point ➋. The DHW temperature sensor FWS must therefore always be positioned so that it detects the temperature in the heat exchanger even when there is zero flow rate in the secondary circuit. Only when the actual temperature detected by the DHW temperature sensor FWS has reached the required level does the secondary circuit pump PS2 start to operate at the minimum flow rate of 30 % ➌. The controller adjusts the pump delivery, and therefore the volumetric flow rate, so that the required temperature is maintained at the DHW temperature sensor FWS ➍. The primary circuit pump PS or the motorised mixing valve continues to operate at maximum until the required level is exceeded at the DHW temperature sensor FWS at 00 % volumetric flow rate in the secondary circuit (maximum delivery rate of secondary circuit pump PS2 ➎). The primary circuit control functions then ensure by reducing the volumetric flow rate that the required temperature at the DHW temperature sensor FWS is not exceeded ➏. The charging sequence ends if one of the cut-out conditions is met ( page 08). The controller switches the primary circuit pump PS off ➐, the secondary circuit pump PS2 continues to run ➑ if a run-on time has been set ( anti-scaling function). It is important to ensure that the set heat source flow temperature in the primary circuit exceeds the desired DHW temperature by at least 0 K depending on heat exchanger design. Cut-out conditions The cut-out conditions are met if the temperature measured by the DHW temperature sensor FSU (cylinder bottom sensor) exceeds the set required temperature by the cut-out hysteresis differential or the timer programme switches DHW heating to night-time mode. Anti-scaling function The anti-scaling function is intended to prevent the build-up of limescale in the heat exchanger when the water flow is static combined with high temperatures. In order to effectively achieve that, the controller switches the secondary circuit pump PS2 on if the heat exchanger temperature exceeds the anti-scaling function temperature by a definable amount. The secondary circuit pump continues running until the temperature detected by the DHW temperature sensor FWS drops below the set temperature after the charging sequence. Daily monitoring The same setting options for controlling daily monitoring for the cylinder system are available with the function module FM445 as with the function module FM44 ( page 70). Thermal disinfection The same setting options for controlling thermal disinfection for the cylinder system are available with the function module FM445 as with the function module FM44 ( page 70). DHW circulation The same setting options for controlling a DHW circulation pump for the cylinder system are available with the function module FM445 as with the function module FM44 ( page 69). n P [%] PS PS2 t [s] 08/ Charging sequence for DHW heating using function module FM445 with temperature control by varying volumetric flow rate of primary and secondary circuit pumps Key to illustration n P Speed of cylinder charging pump PS Primary circuit pump PS2 Secondary circuit pump t Time For switching points Charging sequence 08

111 Function modules for expansion of digital controllers 5 DHW temperature sensor The FM445 function module is supplied as standard with three temperature sensors for controlling the temperature of the cylinder charging system DHW temperature sensor FSM (cylinder centre sensor) DHW temperature sensor FSU (cylinder bottom sensor) DHW temperature sensor FWS (heat exchanger secondary circuit sensor) DHW temperature sensors FSM and FSU These are Buderus standard sensors with a diameter of 9 mm. The DHW temperature sensors FSM (cylinder centre sensor) and FSU (cylinder bottom sensor) monitor the temperature in the cylinder and switch the DHW heating on/off via the cylinder charging system. DHW temperature sensor FWS The DHW temperature sensor FWS (heat exchanger secondary circuit sensor) is a special sensor with a length of approx. 300 mm that is immersed directly in the fluid without the use of an immersion sleeve. Due to its geometry and relatively low mass it responds very quickly. In conjunction with external systems, the sensor FWS must be positioned so that it detects the temperature in the heat exchanger even when there is zero flow rate in the secondary circuit. That can be ensured by using a Buderus Logalux LAP or LSP heat exchanger set ( 09/). VH RH FM445 SK PS KR 2 3 PS2 FWS 09/ Positioning of measuring point for DHW temperature sensor FWS supplied with function module FM445 in cylinder charging system with a Buderus Logalux LSP heat exchanger set Key to illustration Items comprising Logalux LSP heat exchanger set For details refer to the planning document for dimensioning and selection of DHW cylinders. 2 Plate type heat exchanger 3 Sensor sleeve for DHW temperature sensor FWS 4 Buderus Logalux SF DHW cylinder or alternatively Logalux LF 5 Four-way branch fitting from cylinder connection set for Logalux SF with integral non-return valve and drain valve For abbreviations page 84 EK AW PZ KR FSM FSU AW EW EZ AK

112 5 Function modules for expansion of digital controllers Wiring diagram for function module FM445 internal BUS in the control unit LAP-module FM445 AUT 0 2) P ) ) ) ) ) ) AUT 0 k6a k5 k4 S k3a k2 k L N PS SK PS 2 PZ WA FWS FSU FSM FVF FBS U WF ) 0-0 V Output 0,4-0,75 mm² 3 x,5 ² max. 5 A 4 x,5 ² max. 5 A 3 x,5 ² max. 5 A 3 x,5 ² max. 5 A 6) 6) 6) 6) = hotter = colder M N L N M N L M N L 2 FB 2 3 Cylinder charging pump PS primary circuit Servomotor primary circuit runtime 2 min. (SK) Cylinder primary pump secondary circuit (PS 2) DHW circulation pump (PZ) DHW temp. sensor Heat exchanger (FWS) DHW temp. sensor cylinder bottom (FSU) DHW temp. sensor cylinder centre (FSM) 5) Selection function (zero volt) (WF) 4) Switching states ) Automatic control input 2) Power supply connector 3) Output for heat demand signal to external controller (electrically isolated): 4 = Make switch, 2 = Break switch 4) Optional function input for electrically isolated external circuit (switch load 5 V DC/0 ma): 3 = Thermal disinfection or once-only cylinder charging, 2 = Pump fault 5) Connection to DHW temperature sensor terminal (FB) on Series 2000 and 4000 controllers (e.g. Ecomatic HW420 or HS420) 6) The total current drawn by all electrical consumers must not exceed 0 A. Switch position 0 AUT Primary circuit M (PS ) (SK) Switch (PS 2) (PZ) k6a k5 k4 position k3a k2 k Control mode Control mode colder Control mode hotter 0 AUT Secondary circuit Control voltage 230 V LV Control mode Control mode WA Control mode 0/ Wiring diagram for function module FM445 (for abbreviations page 84) 0

113 Function modules for expansion of digital controllers Function module FM448 for output of an electrically isolated centralised fault signal and external imposition and output of heat demand 5.6. Brief description Possible applications The main function of the FM448 function module is output of a centralised fault signal. If a fault occurs on the system, a relay switches over an electrically isolated switch. In addition, this module is also suitable for external imposition and output of a temperature heat demand via a 0-0 V signal in heating systems with externally controlled heating circuits. The function module FM448 can be used in any digital controller in the 4000 system. The controller detects the FM448 function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad. Functions and connection options Electrically isolated switch for output of centralised fault signals via a relay Facility for connection of a heat meter with digital display of heat consumption Facility for connection of a fill-level limit sensor for monitoring an oil tank system Configurable 0-0 V input for external imposition of a required setting as required temperature Configurable 0-0 V output for external required temperature demand 6 5 / Function module FM Standard specifications Function module FM448 ( /) Key to illustration Terminal connectors 2 Module fault indicator (LED) 3 Centralised fault LED 4 Circuit board 5 Service/Signal reset button (for suppressing signal forwarding) 6 Service function LED

114 5 Function modules for expansion of digital controllers Possible applications for FM448 function module Controllers with slot ) for FM448 Controller 42 Boiler controller ( boiler) or Autonomous heating circuit controller or slave unit 422 Boiler controller (cascade system with up to 4 boilers) or controller for function expansion 42 Boiler controller Controller 432 Boiler controller 2) 4322 Controller for sequential boiler (multi-boiler system) 4323 Autonomous heating circuit controller or slave unit 2/ 4000 system controllers with slot for FM448 function module ) Only one FM448 function module may be fitted in each controller 2) The function module FM448 can not be used together with the function module FM458 in the 432 controller Specification for FM448 function module Function module FM448 Function module FM448 Power supply 230 V AC ± 0 % Heat meter ZW Electrically isolated input Frequency 50 Hz ± 4 % Heat demand from system 0 0 V, 0 20 ma Power consumption 2 VA to external device U Output Electrically isolated output AS Max. switching current 5 A Heat demand to system 0 0 V Centralised fault signal from external device U Input Fill-level limit sensor GFS Electrically isolated input 2/2 Technical specifications of function module FM448 2

115 Function modules for expansion of digital controllers Function description for FM448 function module Centralised fault signal and Service button If, for instance, a burner fault, sensor failure or a fault in the external sequential safety system occurs, the 4000 digital control system generates a fault signal. The fault signal can also be output universally for all controllers by the FM448 function module via the ECOCAN-BUS as an electrically isolated signal. Consequently, it is possible to forward the fault signal to a control centre or connect it to an indicator/alarm (warning lamp, audible signal or the like) in a caretaker's accommodation. While servicing is in progress or until the fault has been rectified, the external fault signal can be suppressed by pressing the Service button. Limit level sensor A limit level sensor can be connected to the FM448 function module (terminal GFS), e.g. for monitoring the oil level in an oil tank system. When that switch is tripped, the fault report on the MEC2 control pad shows "Fill level limit". As it is a control system fault signal, it is also output via the FM448 function module's electrically isolated switch for centralised fault signals. Heat consumption recording The FM448 function module provides a facility for connecting a heat meter (terminal ZW). The essential requirement is electrically isolated output of the heat consumption by the heat meter. On the MEC2 control pad, meter input "by signal pulse" is activated. The pulse value equivalence can be calibrated to kw, 0 kw, 00 kw or 000 kw per pulse on the MEC2 control pad. The actual heat consumption is recorded on the basis of the total number of pulses from the heat meter and displayed on the MEC2 control pad. The heat consumption can be viewed by day, week and year. ϑ VSet [ C] / External required setting input U A [V] 3/2 Required setting output U E [V] ϑ VSet [ C] Imposition and output of an external heat demand The FM448 function module can be used to input or output external required settings using a 0-0 V signal ( 3/ and 3/2). This function should be specified for single-boiler systems with externally controlled heating circuits if the boiler circuit is to be implemented with the 4000 control system. The FM448 function module converts the 0-0 V signal to a required flow temperature for the boiler system. The controller compares that required flow temperature with the actual flow temperature measured by the shared flow temperature sensor. It then enables the boiler output levels according to a control deviation. Key to illustration ( 3/ and 3/2) ϑ FL Required boiler flow temperature U A Output signal to external system Input signal from external system U E 3

116 5 Function modules for expansion of digital controllers Wiring diagram for function module FM448 BUS in the control unit (internal) Function module FM448 Netz N L AS ZW GFS U U ) N L Mains N Netz L Control voltage 230 V AC ) LV 3,5 2 max. 8 A 0,4 0,75 mm m 3 3) 4) Input 0 0 V Output 0 0 V 0 20 ma AS ZW GFS U U ) Power supply connector 2) Power supply connector for other modules 3) Heat meter input: electrically isolated switch connectable 4) Fill-level limit sensor input: electrically isolated switch connectable 4/ Wiring diagram for function module FM448 (for abbreviations page 84) 4

117 Function modules for expansion of digital controllers Function modules FM456 and FM457 for controlling multi-boiler cascade systems 5.7. Brief description Possible applications The function modules FM456 and FM457 can be used in combination with the 42, 422 or 4323 digital controller. The enable control of multi-boiler cascade systems using Buderus boilers (modulatingcontrol gas condensing boilers) with EMS. The method by which a Buderus boiler with UBA universal burner control unit or SAFe safety burner control unit is controlled is described in the section on the 42 controller ( page 22 ff.). The 42, 422 or 4323 controller detects the FM456 and/or FM457 function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad, where the boiler type can also be specified. Boiler control If multiple controllers are to be specified for a heating system and if they communicate via the ECOCAN-BUS, it is important to ensure that control of the boiler is always undertaken by the master controller. Therefore, for controlling a wall-mounted boiler cascade system comprising more than four boilers, the function modules must be fitted on one controller Series control of a 2-boiler cascade system using one FM456 function module in 42 (plus boiler using FM455), 422 or 4323 controller Series control of a 4-boiler cascade system using one FM457 function module in 42 (plus boiler using FM455), 422 or 4323 controller Series control of a 6-boiler cascade system using one FM457 and one FM456 function module only possible in 422 or 4323 controller Series control of an 8-boiler cascade system using two FM457 function modules only possible in 422 or 4323 controller Additional control functions Electrically isolated output of a centralised fault signal Configurable 0-0 V input for external imposition of a required setting as required temperature or required heat output Choice of fixed or automatic boiler sequence switching Heating circuit control and DHW heating Outside-temperature driven control of a heating circuit without mixing valve via the space heating circulation pump without facility for connection of a separate remote control Adjustable, automatic switching between summer/winter modes Individually timer-dependent control of DHW heating by the UBA/EMS of the first boiler in the cascade system via a motorised diverter valve (cylinder system) with daily monitoring, thermal disinfection and control of a DHW circulation pump / FM457 function module Key to illustration Terminal connectors 2 Module fault indicator (LED) 3 Summer mode LED for heating circuit 2 4 Circulation pump LED for heating circuit 5 LED for motorised diverter valve (switched over to DHW heating by UBA of boiler ) 6 Flue gas test LED 7 Manual mode switch, heating circuit function 8 Circuit board 9 LED for burner 4 on (boiler 4 operation, not with FM456) 0 LED for burner 3 on (boiler 3 operation, not with FM456) LED for burner 2 on (boiler 2 operation) 2 LED for burner on (boiler operation)

118 5 Function modules for expansion of digital controllers Standard specifications Function module FM456/FM457 ( 5/) Boiler water temperature sensor FK for low-loss header If used in the 422 controller, an outsidetemperature sensor FA is required in addition! Function module FM456/457: control of two to four wall-mounted boilers as cascade system and control of heating circuit ( heating circuit without mixing valve); DHW heating by EMS of st boiler FA FM Logamax plus Logamax plus Logamax plus Logamax plus UBA/ EMS UBA/ EMS2 UBA/ EMS3 UBA/ EMS4 BC0 BC0 BC0 BC0 HK MAG ) SA SMF MAG ) SA SMF MAG ) SA SMF MAG ) SA SMF KR PH KR KR KR KR PZ 2) SU VK FK KR RK VS RS FB 2) Logalux SU... ) Notes on calibrating can be found in the planning document for the boiler 2) External control of DHW circulation pump 6/ Possible connections to function modules FM456 and FM457 (for wiring diagram page 2, for abbreviations page 84) Possible applications for FM456 and FM457 function modules Controllers with slot ) for FM456 and FM457 Controller 42 Boiler controller (master for wall-mounted boiler cascade system) 422 Boiler controller (master for wall-mounted boiler cascade system) Controller 4323 Boiler controller (master for wall-mounted boiler cascade system) 6/ system controllers with slot for FM456 and FM457 function modules ) Function modules FM456 and FM457 can only be used in the master controller 6

119 Function modules for expansion of digital controllers 5 Selection table for function modules FM456, FM457 and FM458 Permissible controllers / Selection table for function modules FM456, FM457 and FM458E Explanation of symbols: possible, not possible ) For more information on function module FM458 page 22 ff. 2) Control of a single-boiler system with EMS 3) Function module FM458 does not support boilers with UBA.x FM456 FM457 FM458 ) Max. number of modules Possible module combinations FM456 / FM457 FM456 / FM457 FM458 / FM458 Combination of boiler with 4000/ EMS Max. number of boilers per module 4000 EMS, multi-stage EMS, modulating control Boiler sequence series parallel Sequence switching Daily Outside temperature Operating time Switch Load limit Outside temperature Switch 2) 2 Centralised fault signal output 0-0 V input 0-0 V output Heat meter input 2) ) 4 3) Technical specifications for function modules FM456 and FM457 Function module FM456/FM457 Function module FM456/FM457 Power supply 230 V AC ± 0 % External imposition of required setting U 0 0 V Frequency 50 Hz ± 4 % Boiler water temperature sensor FK ) NTC sensor, dia. 9 mm Power consumption 2 VA Outside temperature sensor FA ) NTC sensor Space heating circulation pump PH Max. switching current 5 A MEC2 or BFU/F remote control ) BUS communication Centralised fault signal output AS Max. switching current 5 A Function module FM456/FM457 UBA 2) BUS communication 7/2 Technical specifications of function modules FM456 and FM457 ) Max. lead length 00 m (shielded upwards of 50 m) 2) Max. lead length 0 m Function description for FM456 and FM457 function modules Cascade system control Special features of boiler control using low-loss header with multi-boiler cascade systems When planning multi-boiler cascade systems it is important to be aware that the maximum volumetric flow rate through each wall-mounted boiler must not be exceeded. The water volume is automatically determined by the integral pump. A branch regulating valve, e.g. the Tacosetter, is used to balance the maximum water volume. The branch regulating valve is fitted in the boiler flow. Flow equalisation is performed by means of a low-loss header. With a cascade system, not all of the wall-mounted boilers will be constantly in operation at the same time. Nevertheless, it is important that the flow and return pipes and the low-loss header are dimensioned for the maximum cascade system output. 7

120 5 Function modules for expansion of digital controllers Cascade system control using FM456 and FM457 with large changes in required temperature (> 0 K) Figures 8/ and 8/2 show schematic representations of the dynamic temperature pattern in the low-loss header. No account is taken of the fact that during the heating-up phase, an e-function occurs! Cut-in response ( 8/) ➊ When the required temperature changes, boiler is enabled for 00 % output by the controller at the starting point t Start. Modulation is controlled by the boiler's EMS. ➋ After a certain time, the controller checks the rate of temperature rise in the low-loss header (target figure). ➌ If the present boiler output is unable to achieve the required temperature (target temperature < required temperature) within a target time t Target (30 minutes), the next boiler is enabled for 00 % output. ➍ The above sequence is repeated until the maximum system output is reached, or the output is sufficient to reach the required temperature within the target time The lower example in Figure 8/ showing DHW heating in the summer illustrates how the required temperature is reached with fewer boilers when the system load is lower. In that way, unnecessary starting of the 3rd and 4th boilers is avoided. ϑ VH [ C] ϑ VH [ C] Heating mode in winter Target Set K+K2+K3+K4 70 K+K2+K3 60 K+K K K t [min] t Start t Target 90 DHW heating in summer Set Target K+K2 K 0 K t [min] t Start t Target Cut-out response ( 8/2) ➀ When the required temperature changes, boiler 4 is switched off and modulation of boiler 3 enabled at the starting point t Start. ➁ In similar fashion to the cut-in response, the controller checks the rate of temperature fall in the low-loss header (target figure) after a specified time. ➂ If the present boiler output is too great to reach the required temperature (target temperature > required temperature) within the target time t Target, the next boiler (3) is switched off and modulation enabled for another boiler (2). ➃ The above sequence is repeated until the system output reaches 0 %, or the output is sufficiently low to reach the required temperature within the target time The UBA universal burner control unit's flow detection system is unaffected by the process. 8/ Cut-in response of cascade system control by FM457 function module with large changes in required temperature and different system loads; function module FM456 controls in same way ϑ VH [ C] K+K2+K3+K Set t Start Target K+K2+K3 K+K2 K K t [min] t Target 8/2 Cut-out response of cascade system control by FM457 function module with large changes in required temperature; function module FM456 controls in same way Key to illustration ( 8/ and 8/2) K Boiler (number ) in operation t Time Heating circuit flow temperature ϑ VH 8

121 Function modules for expansion of digital controllers 5 Cascade system control using FM457 (or FM456) with small changes in required temperature and maximum system load When the system is in heating mode, there are often small changes in the required temperature as the heating circuit temperatures are finely adjusted. The Buderus cascade control system using the FM456 or FM457 function module in combination with full modulating-control boilers is ideally suited to such requirements. Figure 9/ shows the response of a cascade system with four identical boilers dependent on system load as a static graph. That response applies to load changes with small variations in the required temperature. It also prevents cycling of the boilers. Key to illustration Q A System load (cascade system heat output) Q K Boiler load (heat output of boiler number ) t Time Q K4 [%] 0 00 Q A [%] 50 Q K3 [%] Q K2 [%] 0 00 Q K [%] 0 0 t [s] 9/ Cut-in and cut-out response of FM457 function module during heating mode; function module FM456 controls in same way Cut-in response ( 9/ left half) ➊ Boiler starts up at base-load output. ➋ Boiler then modulates up to 00 % output. ➌ Boiler 2 starts up at base-load output. ➍ Boiler initially modulates back (matches base-load output of boiler 2) and then up to 00 % again if heat demand increases. ➎ Boiler 2 modulates up to 00 % output. Subsequently, boilers 3 (➏) and 4 (➐) respond in similar fashion to boilers and 2 when modulating up. Cut-out response ( 9/ right half) ➀ Boiler 4 modulates down to base-load output. ➁ Boiler 3 modulates down to base-load output. ➂ Boiler 4 switches off. ➃ Boiler 3 initially modulates up (matches base-load output of boiler 4) and then down to base-load output again if heat demand decreases. ➄ Boiler 2 modulates down to base-load output. ➅ Boiler 3 switches off. Subsequently, boilers 2 (➆) and (➇) respond in similar fashion to boilers 4 and 3 when modulating own. 9

122 5 Function modules for expansion of digital controllers DHW heating The function modules FM456 and FM457 also offer the option of controlling a DHW system as standard. The DHW heating function on the function modules FM456 and FM457 is designed so that the EMS or the UBA universal burner control unit on boiler of the cascade system always implements DHW heating by way of a motorised diverter valve. There are two alternatives for implementing DHW heating by a Buderus wall-mounted boiler. UBA integral water heater/ems integral water heater DHW heating via the wall-mounted boiler's internal motorised diverter valve with integral indirect water heater smaller than 50 litres. UBA cylinder/ems cylinder DHW heating via the wall-mounted boiler's internal motorised diverter valve or a separate motorised diverter valve for indirect water heaters larger than 50 litres. The method of operation of the above two DHW heating alternatives is described in more detail in the section on the 42 ( page 26). If DHW heating is to be implemented using all connected wall-mounted boilers in the cascade system, an FM44 function module must be specified. Heating circuit control The basic version of the function modules FM456 and FM457 can each control one heating circuit without mixing valve by controlling a heating circuit pump on the basis of outside temperature. The appropriate characteristic heating curves for the various standard heating system configurations are stored on the controller. Adaptation to the individual system layout is straightforward to perform using the MEC2 control pad. The heating circuit functions of all definable heating systems (e.g. "Radiator", "Underfloor" or "Constant") can be implemented with the same level of functionality as with the function module FM442 ( page 73 ff.). However, when planning the heating circuit functions, the following limitations must be taken into account: No possibility for connecting an MEC2 control pad/bfu remote control No cut-in/cut-out optimisation or residual heat utilisation No room temperature override No imposition of an external fault signal for a circulation pump No external mode switching If any of those functions is required, the function module FM442 must be specified as additional heating circuit control equipment if necessary in a supplementary controller if all module slots are already used. Additional control functions Imposition of an external heat demand The function module FM456 or FM457 can be used to input an external required setting by means of a 0-0 V signal. This function should be specified if the heating circuits are externally controlled and the boiler circuit is to be implemented with the 4000 control system. The 0-0 V signal is converted into a required flow temperature for the boiler system. The controller compares that required flow temperature with the actual flow temperature measured by the shared flow temperature sensor. It then enables the boiler output levels according to a control deviation. The 0-0 V signal can, however, also be used for specifying a required heat output for single-boiler systems or multi-boiler cascade systems comprising boilers that are identical in terms of type and output. The boilers are enabled by the FM456/FM457 function module according to required heat output and a boilerspecific current heat output demanded. Output control by an external system precludes consideration of other control functions by the 4000 control system, e.g. heating circuits or DHW heating. Centralised fault signal If, for instance, a burner fault, sensor failure or a fault in the external sequential safety system occurs, the 4000 digital control system generates a fault signal. As standard, the fault signal can also be output universally for all controllers via the ECOCAN- BUS as an electrically isolated signal. Consequently, it is possible to forward the fault signal to a control centre or connect it to an indicator/alarm (warning lamp, audible signal or the like) in a caretaker's accommodation. 20

123 Function modules for expansion of digital controllers Wiring diagram for function modules FM456 and FM457 internal BUS in the control unit Module - Front view Module FM457 7) 0 AUT k k2 Control voltage 230 V 2 LV 3 4 O AUT AS 4 2 PK 63 6 Mains L N UBA UBA UBA UBA EMS EMS EMS EMS 2 2 U FK FA L N only with FM457 L N 3 x,5 ² max 5 A ) 4) L N ) 5) 4 2 Output central fault message (AS) 8) L M N Heating circuit pump (PK) (UBA) 4 3 (UBA) 4 3 (UBA) 4 3 (UBA) 4 (EMS) 2 (EMS) 2 (EMS) 2 (EMS) 2 Boiler 4 EMS/UBA 4 Boiler 3 EMS/UBA 3 Boiler 2 EMS/UBA 2 Boiler EMS/UBA Input 0-0 Volt (U) Check for correct polarity! Boiler water temp. sensor (FK) 2 Outside temp. sensorr (FA) 3) 2) 3) only with FM457 6) ) Only connect one power supply according to choice of module slot. 2) Only connect outside-temperature sensor (FA) to FM456/FM457 if no other FA is connected. 3) If two FM456/457 modules are present, connect all sensors to the left-hand FM456/457 module. 4) Power supply from power supply module 5) Power supply from 3-pin wiring-loom connector 6) Please note! The factory-fitted jumper across terminals 3/4 on the UBA.x must first be removed from all UBAs. Incorrect connection inside the gas wall-mounted boiler can lead to equipment damage. Therefore, always check the connections on the UBA universal boiler control units. 7) Automatic control input 8) Max. switch load 230 V AC / 8 A, min. switch load 5 V DC / 0 ma 2/ Wiring diagram for function modules FM456 and FM457 (for abbreviations page 84) 2

124 5 Function modules for expansion of digital controllers 5.8 Function module FM458 as strategy module 5.8. Brief description Possible applications The function module FM458 is the strategy module for the medium to high output range. It can only be used in the 432 and 4323 digital controllers. The FM458 module is equally suitable for controlling up to four boilers with 4000 and/or EMS. Is should be specified on the 432 or 4323 master controller with the ECOCAN-BUS address 0 or. Up to two FM458 modules are possible and enable control of up to eight Buderus boilers. The strategy module enables the individual boiler output levels according to control deviation and time (integral). To that end it records the flow temperature in the shared system flow (strategy flow temperature sensor FVS) and the required temperature demand from all heat consumers in the heating system. The FM458 strategy module allows boilers with 4000 and boilers with EMS to be mixed. Modulating-control and multi-stage boilers can be combined with one another regardless of whether the boiler with EMS is a floor-standing or wall-mounted boiler. The controller detects the function module automatically and shows all definable parameters on the Service menu of the MEC2 control pad Key to illustration Module fault indicator (LED) 2 LED for DHW via EMS boiler 3 LED for flow too cold (output raised) 4 LED for flow too hot (output lowered) 5 Flue gas test LED 6 Circuit board 7 LED for boiler 4 in operation 8 LED for boiler 3 in operation 9 LED for boiler 2 in operation 0 LED for boiler in operation 22/ Function module FM458 Strategy functions Combination of up to four boilers fitted with 432/4322 boiler controllers and EMS, 4323 controller for wallmounting in systems with EMS boilers Maximum of eight boilers by combining two FM458 function modules Combination of boilers with single-stage, 2-stage and modulating-control burners Parallel or series boiler sequence to accommodate system-specific usage levels Automatic load limiting based on choice of outside temperature or external switch Automatic boiler sequence switching, either daily, based on outside temperature, based on hours of operation or by external switch Automatic boiler sequences or user-defined specification of different boiler sequences for sequence switching Isolation of sequential boilers taking account of load limit and automatic sequence switching Configurable 0-0 V input for external imposition of a required setting as required temperature or required heat output 22

125 Function modules for expansion of digital controllers 5 Configurable 0-0 V output for external required temperature demand Status indication of individual output levels DHW heating controlled by EMS on boiler Electrically isolated input for application of an external heat meter signal Centralised fault signal via relay with electrically isolated switch Standard specifications Function module FM458 ( 22/) Strategy flow temperature sensor FVS Function module FM458: control of boilers with 4000 and EMS. FVS FA BEMS DDC / GLT / Fremdregelung External control 0 0 V 0 0 V (0 20 ma) max. 230 V / 8 A FRS 2) FM458 ) SR FM EMS... EMS4 2 EL 2 U 3 4 U 2 4 AS 2 ZW Kessel Boiler 2: 2 Kessel Boiler : Logano plus GB32 Logano GE... FK BEMS Higher level controller (Direct Digital Control) GLT Higher level controller (building control system) ) Control of boiler circuit pump by 432/4322 2) Control of Logano plus GB32 boiler circuit pump by MC0 23/ Possible connections to function module FM458 (for wiring diagram page 34, for abbreviations page 84) Function module FM458: control of up to four boilers with modulating-control, single-stage or 2-stage burners FA FVS ) SR SR SR FM ) ) ) FK FK FK FK Kessel Boiler : Kessel Boiler 22: Boiler Kessel 33: Kessel Boiler 4: 4 Logano SB... Logano GE... Logano GE... Logano GE... ) Control of boiler circuit pump by 432/ /2 Possible connections to function module FM458 (for wiring diagram page 34, for abbreviations page 84) 23

126 5 Function modules for expansion of digital controllers Possible applications for FM458 function module Controllers with slot ) for FM458 Controller 432 Boiler controller (master in multi-boiler system) Controller 4323 Autonomous heating circuit controller or slave unit 24/ 4000 system controllers with slot for FM458 function module ) Up to 2 FM458 function modules can be fitted on the master control unit Selection table for function modules FM456, FM457 and FM458 FM456 ) Permissible controllers /2 Selection table for function modules FM456, FM457 and FM458E Explanation of symbols: possible, not possible ) For more information on function modules FM456 and FM457 page 5 ff. 2) Control of a single-boiler system with EMS 3) Function module FM458 does not support boilers with UBA.x FM457 ) FM Max. number of modules Possible module combinations FM456 / FM457 FM456 / FM457 FM458 / FM458 Combination of boiler with 4000/ EMS Max. number of boilers per module 4000 EMS, multi-stage EMS, modulating control Boiler sequence Series Parallel Sequence switching Daily Outside temperature Operating time Switch Load limit Outside temperature Switch 2) 2 Centralised fault signal output 0-0 V input 0-0 V output Heat meter input 2) ) 4 3) Specification for FM458 function module Function module FM458 Function module FM458 Power supply 230 V AC ± 0 % External load limit EL Electrically isolated input Frequency 50 Hz ± 4 % Heat meter ZW Electrically isolated input Power consumption 2 VA Heat demand from system 0 0 V, 0 20 ma Electrically isolated output AS Max. switching current to external device U Output 5 A Centralised fault signal Heat demand to system 0 0 V Strategy sensor set FVS/FRS NTC sensor, dia. 9 mm from external device U Input 24/3 Technical specifications of function module FM458 24

127 Function modules for expansion of digital controllers Planning notes for function module FM458 Boiler safety in multi-boiler systems When planning multi-boiler systems, ensuring boiler safety for every boiler is of prime importance. In combination with the appropriate plumbing configuration (e.g. pressurised or low-pressure header, low-loss header) that is guaranteed with the correct controller settings ( 26/). When upgrading old systems, the heating circuits are frequently externally controlled, e.g. by a higher-level BEMS system. In such cases, system isolation, e.g. by means of a low-loss header, and the use of boiler circuit mixing valves and boiler circuit pumps is advisable in order to ensure the safety of the boiler concerned. Priority of boiler control compared with strategy When controlled by the function module FM458, the strategy function basically switches the burner on and off. However, the burner's required operating conditions have the highest priority and are always met under any circumstances. In order to prevent critical boiler operating situations, the boiler with 432/4322 or EMS controls its burner independently in the following situations: Frost protection If the boiler flow temperature drops to the frost protection limit, the burner switches on. For boilers with required operating conditions, the burner is switched off after the boiler safety sequence has been completed; for condensing boilers, the burner is switched off according to a hysteresis differential. Excess temperature As soon as the boiler flow temperature has reached its maximum level, the burner switches off. Required operating conditions As long as the boiler's operating flow temperature is below the required level, the boiler remains in operation. An exception to that rule is the lowtemperature boiler with minimum return temperature because it would run continuously in certain operating situations. Position of strategy flow temperature sensor In multi-boiler systems with strategy flow temperature sensor FVS, the sensor should be placed as close to the boiler system as possible. Additional time lags due to large distances between the boiler system and the strategy flow temperature sensor have a negative effect on the control characteristics, especially in the case of boilers with modulating-control burners. It is particularly important to take account of that aspect of the positioning of the strategy flow temperature sensor FVS in plumbing configurations with pressurised header (without flow isolation). Connecting boilers with EMS and 4000 Correct functioning requires unambiguous assignment of the boiler address ( 25/). The boilers are numbered consecutively in ascending order starting from address. The address for boilers with 432 or 4322 is assigned by setting the CAN-BUS address (address code switch); for boilers with EMS it is done by connection to terminal EMS, EMS2, EMS3 or EMS4 on the FM458 function module. Each boiler address may only be assigned once. Duplication of an address assignment by the 4000 and EMS results in an error message. The order of the boiler sequence can be altered by parameter settings regardless of address. FM Address Adresse EMS 4 EMS 3 EMS 2 EMS ECO-BUS 3 2 ECOCAN-BUS ECOCAN-BUS 4322 ECOCAN-BUS ECO-BUS 3 2 Address Adresse 3 Heizkessel Boiler Heizkessel Boiler 2 2 Heizkessel Boiler / Connecting boilers with 432 and

128 5 Function modules for expansion of digital controllers Overview: boiler safety in multi-boiler systems Application Unpressurised header (flow isolation) Pressurised header 4322 Logano 432 Logano Exclusively boilers of same type with 4000 Boiler safety function possible by means of Heating circuit mixing valves ) or Boiler circuit mixing valve (motorised diverter valve) or Pump control logic 2) Boiler safety function possible by means of: Heating circuit mixing valves ) or Boiler circuit mixing valve (motorised restrictor valve) Combination of boilers of different types with 4000 Boiler safety function possible by means of Boiler circuit mixing valve (motorised diverter valve) or Pump control logic 2) Boiler safety function possible by means of: Boiler circuit mixing valve (motorised restrictor valve) Logano Logano plus EMS-BUS EMS-BUS 4323 Exclusively boilers of same type with EMS Boiler safety function possible by means of Pump control logic 3) Not supported Logano plus EMS-BUS Logano plus EMS-BUS 4323 Combination of boilers of different types with EMS Boiler safety function possible by means of Not supported Pump control logic 3) BC0 Buderus Logano plus Logano 432 EMS-BUS Combination of boilers with 4000 and EMS (mixed cascade system) Boilers with 4000 Boiler safety function possible by means of Boiler circuit mixing valve (motorised diverter valve) or Pump control logic 2) Not supported Logano Logano plus Boilers with EMS Boiler safety function possible by means of Pump control logic 3) 26/ Boiler safety in multi-boiler systems ) Requirement: all heating circuits must be equipped with mixing valves controlled by In the case of uncontrolled heating circuits or externally controlled heating circuits, boiler safety must be ensured by other means. 2) Only with LT boilers in low output range 3) Ensured by EMS of boiler concerned 26

129 Function modules for expansion of digital controllers Function description for FM458 function module Control mode ( 27/) The function module FM458 can be used to run multiboiler systems in series or parallel. Basically, series operation means that the lead boiler is switched on first. If its output is insufficient, the FM458 function module enables the next boiler in the sequence ( 28/). With parallel operation, by contrast, all boilers are run at base-load output before all are switched simultaneously to maximum output ( 28/2). The controlled variable is the actual system temperature measured in the shared flow (sensor FVS). The required temperature demand arises from the combined temperature demands of all heat consumers in the system or, if external controllers are used, from an externally imposed requirement, e.g. via the voltage input U in the form of a 0 0 V signal. The maximum required system temperature from all heat consumers is always the temperature requirement that is served by the strategy. The control deviation between required system temperature and actual system temperature is integrated over time. If the integral exceeds definable limits, base-load output by the lead boiler is enabled. The strategy function of the FM458 module enables all burners on the basis of integrals. In the case of boilers with modulating-control burners, the strategy function calculates the heat output and enables modulation to the calculated output. In contrast with modulating-control burners, the second output level of boilers with multi-stage burners is also enabled using an integral. Series operation ( 28/) The strategy function first switches on base-load output from boiler. Next, the strategy function calculates the degree of modulation for the burner of boiler and constantly adjusts it to the demand from the heating system. If the modulation level of boiler reaches 00 %, the strategy function starts the integral for switching in boiler 2. When the integral exceeds a specific limit, base-load output from boiler 2 is enabled. If, subsequently, the actual system temperature measured in the shared flow exceeds the required system temperature due to the additional output from boiler 2, the strategy function reduces the modulation level of boiler. Boiler 2 remains on until boiler can take over the base-load output of boiler 2. At that point boiler 2 is switched off again. That prevents the two boilers operating simultaneously for too long. If, on the other hand, the actual system temperature is still below the required level despite the additional output from boiler 2, boiler is run up to 00 % output and the strategy calculates the modulation level for boiler 2 and controls supply of the required output by adjusting the output of boiler 2. In contrast with modulating-control burners, the second output level of boilers with multi-stage burners is also enabled using an integral. Key to illustration I Burner stage I II Burner stage II t Time ϑ FL, Act Actual temperature at boiler-water temperature sensor ϑ FL, Set Required temperature at boiler-water temperature sensor Boiler flow temperature ϑ FL ϑ FL [ C] ϑ FL [ C] I I FL, Set FL, Act FL, Set FL, Act Large control deviation II Small control deviation 27/ Principle of dynamic switching differential with different control deviations II t [s] t [s] 27

130 5 Function modules for expansion of digital controllers Parallel operation ( 28/2) Fundamentally, the description of series operation also applies to parallel operation. Only the order in which the output levels are switched in is controlled differently. With parallel operation, the strategy function first enables base-load output from boiler and then base-load output from boiler 2. Modulation of all boilers is controlled simultaneously. If boilers with multi-stage burners and modulating-control burners are combined, and if all boilers are operating at base-load output, the modulating-control burners are first simultaneously adjusted to higher output. If those boilers are operating at 00 % output and if a control deviation still exists, the second stages of the multi-stage burners are switched on one after the other. Parallel operation is primarily suitable for condensing boilers. The efficiency of such boilers increases the more condensation heat from the flue gas is utilised. The low flue temperatures (up to 30 C) required are achievable at medium output levels. Factors counting against parallel operation include increased radiant heat losses and duplicated use of electrical energy. Powerful fans, pumps or mixing valve motors can mean that the increase in boiler efficiency referred to is offset by the higher consumption of electricity. In comparison with parallel operation, series operation has a better electrical energy balance. max. c min. off max. b min. off max. a min. off On/Off mode Total output [%] 28/ Series operation with FM458 Key to illustration a Boiler : modulating-control burner b Boiler 2: modulating-control burner c Boiler 3: 2-stage burner max. c min. off b a max. min. off max. min. off On/Off mode Total output [%] Heat demand [%] Heat demand [%] 28/2 Parallel operation with FM458 Key to illustration a Boiler b Boiler 2 c Boiler 3 28

131 Function modules for expansion of digital controllers 5 Heating-up and cooling-down modes In addition to normal control mode, the strategy function also recognises a heating-up and a coolingdown mode. If the required temperature demand from the heating system alters abruptly, the strategy function switches to one of those modes. The graphs below show schematic representations of the dynamic temperature pattern in a low-loss header. No account is taken of the fact that during the heating-up phase, an e-function occurs. Heating-up mode with function module FM458 in response to sudden large changes in required temperature (> 5 K) Heating-up mode is always started if the required system flow temperature rises abruptly by at least 5 K ( 29/). Series operation ➊ If no boiler is is enabled at the starting point t Start, the FM458 function module immediately enables 00 % output from the lead boiler. If there is already a boiler in operation, 00 % output from that boiler is enabled. Burner operation is controlled by the 432/4322 boiler controller or the relevant boiler's EMS. ➋ Starting point t Start and actual system temperature are recorded. After a certain delay, the controller checks the rate of temperature rise in the low-loss header (target figure) and calculates the expected heating-up time. The length of the delay is such to be certain that the burner can be started and the heat generated by the boiler can have an effect on the strategy flow temperature sensor FVS. ➌ If the expected heating-up time exceeds a target time t target, the current boiler output is insufficient 00 % output is enabled from the next boiler. ➍ The above sequence repeats itself until the maximum system output is reached, or the output is sufficiently low to reach the required temperature within the target time Parallel operation In parallel operation, if no boiler is enabled at the starting point, base-load output is immediately enabled from the lead boiler. If the expected heating-up time exceeds a definable limit, base-load output is enabled from another boiler. Once all boilers are in operation, modulated output is increased. 29/ Cut-in response of cascade system control by function module FM458 with large changes in required temperature and different system loads Key to illustration K Boiler (number ) in operation t Time System flow temperature ϑ VH ϑ VH [ C] Target Set K+K2+K3+K4 70 K+K2+K3 60 K+K K K t [min] t Start t Target 29

132 5 Function modules for expansion of digital controllers Cooling-down mode with function module FM458 in response to sudden large changes in required temperature (> 5 K) Cooling-down mode is always started if the required system flow temperature falls abruptly by at least 5 K ( 30/). Series operation ➀ At the starting point t Start the FM458 function module reduces the last boiler in the sequence to minimum output. Burner operation is controlled by the 432/4322 boiler controller or the relevant boiler's EMS. ➁ Starting point t Start and actual system temperature are recorded. After a certain delay, in similar fashion to heating-up mode, the controller checks the rate of temperature fall in the low-loss header (target figure) and calculates the expected coolingdown time. The length of the delay is such to be certain that the burner output can be modulated down or the second stage can be switched off and the lower boiler temperature can have an effect on the strategy flow temperature sensor FVS. ➂ If the expected cooling-down time exceeds a target time t target, the current boiler output is too high in relation to the consumption by the heating system and the last boiler in the sequence is switched off. At the same time, the last boiler remaining in operation is reduced to minimum output. ➃ The above sequence repeats itself until the system output reaches 0 % or the output is sufficiently low to reach the required temperature within the target time Parallel operation In parallel operation, if modulation is active at the starting point, the modulated output is immediately reduced to the minimum. If the second burner stages are in operation and if the expected cooling-down time exceeds a definable limit, one second stage is switched off. If the second burner stages are no longer in operation and if the expected cooling-down time exceeds a definable limit, the boilers are switched off one after the other. 30/ Cut-out response of cascade system control by FM458 function module with large changes in required temperature Key to illustration K Boiler (number ) in operation t Time System flow temperature ϑ VH ϑ VH [ C] K+K2+K3+K Set t Start Target K+K2+K3 K+K2 K K t [min] t Target 30

133 Function modules for expansion of digital controllers 5 Load limit The "Load limit" function can be used to adjust the number of boilers to the lower system load at times when demand is low. Boilers that are not required are disabled. However, the load limit is cancelled if insufficient heat supply is guaranteed due to failure of individual burner stages or boilers. The following criteria may be applied to disabling of sequential boilers by the "Load limit" function. Outside-temperature dependent load limit This function disables the sequential boilers automatically according to a definable outside temperature (setting range 0 C to +30 C). Up to two temperature limits can be defined depending on the number of boilers. The outside temperature range is thus divided into three zones. Zone is the high outside-temperature range. The number of boilers allowed for that zone is definable. As the outside temperature falls, additional boilers are allowed. Depending on the number of boilers, all boilers may be allowed in Zone 2 or Zone 3. In heating systems with more than three boilers, more boilers are gradually allowed in Zone 2 as the outside temperature falls ( 3/). Load limit imposed by external electrically isolated switch A definable number of boilers can be disabled by means of the external electrically isolated switch (external connection to terminal EL on function module FM458). All boilers can be disabled if required. If, for example, external heat sources are available, the function can be used to switch off the boilers. Outside-temperature dependent sequence switching The strategy function changes the order of the individual boilers according to predefined temperature thresholds. Figure 3/2 shows an example of the possible different boiler sequences (if automatically controlled by FM458). Outside-temperature dependent sequence switching is of interest as a load management feature in systems comprising boilers with different heat outputs. Daily sequence switching The strategy function switches to a different boiler sequence cyclically at 00:00 hours every day. Daily sequence switching is of interest if the load is to be spread as evenly as possible between boilers of the same type and output. No. of boilers a b c Temperature thresholds [ C] 3/ Outside-temperature dependent load limit Key to illustration a 3rd zone: all boilers allowed b 2nd zone: 2 or 3 boilers allowed c st zone: boiler allowed Boiler sequence and sequence switching The function module FM458 manages not only the individual burner stages and enabling of them but also the order of the boiler sequence. It thus determines which boiler operates when as lead boiler and whether or in what circumstances the sequence is switched. Boilers with faults are taken into account in boiler sequence control. If output is demanded from a boiler with a fault, the sequence control immediately enables the next boiler in the sequence. The order of the various boiler sequences can be defined automatically or manually. With an automatic boiler sequence, the various sequences are defined by the FM458 function module. However, it is also possible to select all boiler sequences manually. The five setting options described below are available for sequence switching. Manual boiler sequence The system operator specifies a set boiler sequence that is always observed. The option "No sequence switching" must be set for the strategy on the Service menu on the MEC2 control pad. No. of boilers 2 3 4th zone 3rd zone 2nd Zone st zone Sequence D Sequence C Sequence B Sequence A Temperature thresholds [ C] 3/2 Outside-temperature dependent sequence switching and the corresponding boiler sequences with automatic control by FM458 3

134 5 Function modules for expansion of digital controllers Sequence switching based on hours of operation The strategy function switches to a different boiler sequence cyclically at 00:00 hours if the relevant lead boiler has exceeded a set number of operating hours ( 32/). Operating-hours based sequence switching is of interest if the load is to be spread as evenly as possible between boilers of the same type and output. Sequence switching based on external switch An external electrically isolated switch (external connection to terminal ZW on function module FM458) can be used to switch between two defined boiler sequences. With this option the FM458 function module offers even greater flexibility with regard to sequence switching. Other, unknown criteria can be applied to switching between two manually selected boiler sequences. Input and output of heat demand signals Temperature-based control The FM458 function module can be used to input or output external required settings using a 0-0 V signal ( 32/2 and 32/3). This strategy function should be specified if the heating circuit or the strategy in the case of multi-boiler systems is to be implemented with the 4000 control system and the heat consumers of the heating systems are externally controlled. The FM458 function module generates a required system temperature from the 0-0 V signal. It compares that required system temperature with the actual system temperature measured by the shared flow sensor (strategy flow temperature sensor FVS). The FM458 function module then enables the boiler output levels according to the control deviation. Control based on a 0-0 V required temperature signal from an external control system can be combined with other control functions of the 4000 control system, e.g. heating circuits or DHW heating. The highest temperature demand becomes the required system temperature and is provided by the boilers. Output-based control The 0-0 V signal can be used to specify a required output by an external controller. Based on the output demand from the external controller, the FM458 module calculates output levels and calls for boiler-specific outputs from individual boilers. Control based on a 0-0 V required output signal from an external system precludes consideration of other control functions. It is not possible to simultaneously control heating circuits or DHW heating using the 4000 control system. 32/ Sequence switching of multiple boilers based on hours of operation 32/2 External required setting input 32/3 Required setting output Key to illustration ( 32/2 and 32/3) ϑ FL Required boiler flow temperature U A Output signal to external system Input signal from external system U E ϑ VSet [ C] U A [V] Boiler Boiler 2 Boiler Lead boiler change-over U E [V] Operating hours ϑ VSet [ C] 32

135 Function modules for expansion of digital controllers 5 Boiler characteristic and system characteristic with multi-boiler systems With a multi-boiler system, a separate boiler characteristic can be set for each boiler. For a multiboiler system strategy, that means that the required flow temperature is based on the boiler characteristic with the greatest heat demand. That required flow temperature must be reached at the strategy flow temperature sensor FVS (e.g. in the low-loss header). If a boiler with its own boiler characteristic is disabled, the heat demand from the set boiler characteristic remains in effect for the system and the strategy function. The boiler characteristic is defined by a linear progression between the base point as the minimum setting and the design temperature as the maximum setting ( 57/). Temperature-based control using the boiler characteristic can be combined with other control functions performed by the 4000 control system, e.g. heating circuits or DHW heating. The highest temperature demand becomes the required system temperature and is provided by the boilers. Centralised fault signal If a burner fault, sensor failure or a fault in the external sequential safety system occurs, the 4000 digital control system generates a fault signal. As standard, the fault signal can also be output universally for all controllers via the ECOCAN- BUS as an electrically isolated signal. Consequently, it is possible to forward the fault signal to a control centre or connect it to an indicator/alarm (warning lamp, audible signal or the like) in a caretaker's accommodation. DHW heating In combination with boilers with the basic version of EMS, the FM458 function module offers the facility for controlling DHW heating. The DHW heating function on the function module FM458 is designed so that DHW heating is always implemented by the EMS on the first boiler by way of a motorised diverter valve. There are two alternatives for implementing DHW heating using EMS on a Buderus wall-mounted boiler. EMS motorised diverter valve DHW heating via the wall-mounted boiler's internal motorised diverter valve or a separate motorised diverter valve for indirect water heaters larger than 50 litres. EMS integral water heater DHW heating via the wall-mounted boiler's internal motorised diverter valve with integral indirect water heater smaller than 50 litres. The method of operation of the above two DHW heating alternatives is described in more detail in the section on the 42 controller ( 8 ff.). If DHW heating is to be implemented using all boilers, an FM44 function module must be specified ( page 67 ff.). 33

136 5 Function modules for expansion of digital controllers Wiring diagram for function module FM458 Control voltage 230 V LV internal BUS in the control unit Strategy module FM458 AS 2 EMS EMS2 EMS3 EMS4 FVS FRS ZW EL U U ,5 2 0,4 0,75 mm2 0,4 0,75 mm (EMS) 2 (EMS) 2 (EMS) 2 (EMS) ) Heat source (EMS) MC0 or UBA3.x Heat source (EMS) MC0 or UBA3.x Heat source (EMS) MC0 or UBA3.x Heat source (EMS) MC0 or UBA3.x System flow temp. Sensor (FVS) System return temp. Sensor (FRS) Input heat meter (ZW) or external input reversal Input ext. load limit (EL) Input 0 0 V (U) Output 0 0 V 0 20 ma (U) Boiler Boiler 2 Boiler 3 Boiler 4 ) Centralised fault signal output: Max. switch load 230 V / 8 A, min. switch load 5 V DC / 0 ma 34/ Wiring diagram for function module FM458 (for abbreviations page 84) 34

137 2 3 4 Interfaces and communication 6 6 Interfaces and communication 6. RS232 gateway as bus interface for Description of function Interface for static installation (wall-mounted) for use with heating systems RS232 gateway, application 4000 communication interface with higher-level BEMS/building control systems, e.g. for switching operating modes, changing required settings, displaying actual readings, forwarding status and fault messages ( 4000 communication protocol can be disclosed on request) or RS232 gateway, application communication interface with PC/laptop and ECO-SOFT program (for system operation, querying and long-term data recording) Connection to 4000 control system inc. multi-boiler systems/slave units (4xx, 42, 432, 4322, 4323, 44 via ECOCAN-BUS) RS232 connection: USB connection to PC/laptop possible using converter (optional accessory) BUS interface with 4000, requirement: RS232 gateway The system requirements for the ECO-SOFT PCbased service software must be observed. Key to illustration ( 35/) On/Off button 2 Power On LED 3 LED for data transmission via ECO-BUS 4 LED for data transmission via EMS-BUS 5 LED and Reset button for resetting faults 6 Terminal cover 35/ RS232 gateway bus interface Interface converter Dimensions W/H/D Weight Power supply (at 50 Hz ± 4 %) Power consumption Gateway RS232 30/40/40 mm 0.5 kg 230 V AC ± 0 % 5 VA Degree of protection IP communication ECOCAN-BUS, max. 000 m Interface RS232 gateway, max. 0 m ) Ambient temperatures In operation In transit C C 6 35/2 Specifications of RS232 gateway ) Connecting lead available as optional accessory 42 FM Gateway RS232 Adresse Address ECO-BUS Adresse Address ECO-BUS Address Adresse ECO-BUS Address Adresse ECO-BUS max Adresse Fixed ECO-BUS address fest 3 2 ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS ECOCAN-BUS 35/3 Example of combination of RS232 gateway with digital controllers in ECOCAN-BUS network 35

138 6 Interfaces and communication LON gateway for communication with a higher-level control system for Description of function LONWorks interface to LONMARK specifications for integrating the heating system as a LON node in a LON network Remote control and monitoring of the heating system via LON For use with 42 and 43xx digital controllers Access to heating system boilers and heat consumers with the possibility for performing the following operations via LON BUS Switching operating modes (continuous daytime/continuous nighttime/automatic) Specifying heat requirement Displaying temperature readings Changing required temperatures Displaying fault messages from the entire heating system Providing data as SNVT (Standard Network Variable Type) for 2 boilers 5 heating circuits DHW heating Solar thermal system Connection to the LON network by 2-core, twistedpair cable FTT0-A transceiver for user-configurable topology or line bus topology LED indicators included Operating status LON BUS communication ECOCAN-/EMS BUS communication 2 buttons LON service button On/Off button Includes CD with product database System-related configuration of the external system is required. 36/ LON gateway Key to illustration On/Off button 2 Power On LED 3 LED for data transmission via ECO-BUS 4 LON LED and service button for commissioning 5 Terminal cover FM LON-Gateway Adresse Address ECO-BUS 3 2 Address Adresse 2 ECO-BUS 3 2 Adresse Fixed ECO-BUS address fest 3 2 FTT0-A LON ECOCAN-BUS ECOCAN-BUS 36/2 Example of combination of LON gateway with digital controllers in ECOCAN-BUS network 36

139 4000 system analogue controllers system analogue controllers controller for operating a floor-standing boiler with constant boiler water temperature without required operating conditions or in combination with a higher-level control system (e.g. BEMS) 7.. Brief description Possible applications The 422 analogue controller is suitable for operating a floor-standing oil/gas boiler with constant boiler water temperature without required operating conditions or in combination with a higher-level control system (e.g. BEMS). The 422 analogue controller can control single-stage, 2-stage or modulating-control burners. Burner control by 422 (without higher-level control system) Enabling of all burner stages Limiting of boiler water temperature to the level set on the boiler water temperature control (constantmode operation) Required boiler operating conditions not taken into consideration (if function is required it is only possible with expansion module ZM427) According to the 2 of the German Energy Saving Regulations, the 422 controller must be operated in conjunction with an automatic device for outside-temperature or room-temperature controlled operation with a timer programme. Burner control by higher-level control system Enabling of burner stages Limiting of boiler water temperature to the level set on the boiler water temperature control Compliance with required boiler operating conditions 2 A / Basic version of 422 analogue controller Key to illustration A Slot A for ZM425 central module ( 50/2) Slot for ZM TAAN expansion module 2 Slot 2 for ZM426 expansion module 3 Slot 3 for ZM427 expansion module 4 Test button for testing safety temperature limiter (when button is pressed, temperature control is bypassed) 5 Power switch 6 Fuse 7 Boiler water temperature control 8 Safety temperature limiter Standard specifications 422 analogue controller with ZM425 central module and safety devices ( 37/) ZB ZB2 2 37/2 ZM425 central module of 422 controller Key to illustration Boiler water temperature indicator 2 Burner fault indicator (lamp) ZB Operating time recorder, burner stage I (optional accessory) ZB2 Operating time recorder, burner stage II (optional accessory) 37

140 system analogue controllers 422: safety systems for a floor-standing boiler; higher-level control system for enabling burner stages (required) and for compliance with required boiler operating conditions (optional) BEMS DDC / GLT Enable signal (electrically isolated) Burner stage I Burner stage II or modulating control VK PK RK SR BR BRII FZ 422 BR BRII BEMS Higher-level control system (Direct Digital Control) GLT Higher-level control system (building control system) For wiring diagram page 38 For other abbreviations page 84 38/ Possible connections to basic version of 422 controller; higher-level control system for enabling burner stages required according to 2 of German Energy Saving Regulations; compliance with required burner operating conditions by means of higherlevel BEMS/building control system optional (e.g. 44 control cabinet system (with module BS434) or by means of expansion module ZM427 (in 422 controller 44/) 7..2 Expansion of 422 controller functions Additional modules ) for 422 Module ZM426 option module 2nd safety temperature limiter Module ZM427 option module Boiler safety (required operating conditions) 38/2 Expansion of 422 controller functions by additional modules ) Two spare expansion slots on 422 controller 7..3 Technical data for 422 controller Controller 422 Controller 422 Power supply 230 V AC ± 0 % Adjustable from 00 Safety temperature limiter STB 20 C Frequency 50 Hz ± 4 % (tested to DIN 3440, July 984 edition) Capillary tube sensor Power consumption 5 VA Adjustable from 50 Boiler water temperature control TR 05 C Burner fault output 230 V; max. 3 A (tested to DIN 3440, July 984 edition) Capillary tube sensor Burner operation, stage 230 V; 0 A 38/3 Specifications of 422 controller 38

141 4000 system analogue controllers controller function description This function description relates only to the basic version. However, the 422 controller also has three spare module slots for expansion modules. For details of the possible additional functions that can be incorporated in the 422 controller by means of expansion modules, please refer to the function description for the module concerned ( 38/2). The 422 analogue controller should be specified when constant-mode operation of a floorstanding boiler or a higher-level control system (e.g. BEMS) is envisaged. This controller together with the safety temperature limiter and the boiler water temperature control provides the basic minimum for meeting the safety requirements of a boiler with constant boiler-water temperature. Burner control by 422 (without higherlevel control system) The basic version of the 422 controller has jumpers fitted to the terminals for the burner enabling signals for the first and second stages ( 40/). The effect is that all burner stages are enabled when the controller is switched on. The boiler is heated up to the temperature set on the boiler-water temperature control and kept at that temperature (constant-mode operation). If the boiler has required operating conditions, they are not taken into account. The 422 controller can only ensure compliance with the required operating conditions of, for example, Ecostream or low-temperature boilers by operating a boiler circuit mixing valve (motorised mixing valve) by being combined with the expansion module ZM427 and a boiler circuit pump. According to the 2 of the German Energy Saving Regulations, the 422 controller must be operated in conjunction with an automatic device for outside-temperature or room-temperature controlled operation with a timer programme. Burner control by higher-level control system In combination with a higher-level control system (e.g. BEMS) the burner is operated via the control system's electrically isolated switch in stage, 2 stages or by modulating control. In that case, the 422 controller meets the safety requirements by means of the safety temperature limiter (STB) and the boilerwater temperature control (TR). It limits the boiler water temperature to the set level by means of the boiler-water temperature control by interrupting burner operation. The required boiler operating conditions can be directly achieved for the various boilers by the higherlevel control system. Alternatively, the expansion module ZM427 controlling an obligatory boiler circuit mixing valve (motorised mixing valve) and a boiler circuit pump is also suitable for the purpose. 39

142 system analogue controllers 7..5 Wiring diagram for 422 controller Operation Fuse 0 A T a STB 6) ZB 9) Stage Stage h h Test 0) 2b 2a b a STB 2 3 STB2 Stage Stage ABR 6) TR 8) 8) 8) ) 2) N L Netz N L SI BR SG UE UE N ABR 2 BR II Control voltage 230 V AC 7) 8) 8) /PE N L Mains ) N B4 S3 T T2 L SG UE ABR 4) 36 B T6 T7 39 T8 Signal mode Signal fault Controller max. 0 A 2) 3) BR L via safety devices Signal stage Controller stage 2 5) BRII Installation, fuses, mains isolator, emergency stop switches and safety measures must comply with local regulations. The earth lead (yellow/green) must not be used as a control lead. Connections to the controller differ according to system configuration. ) Power supply 230 V AC / 50 Hz, max. fuse rating 0 A T 2) The total current drawn by all electrical consumers must not exceed 0 A. 3) Connection for gas/oil burner, stage I 4 Burner fault indicator, external 5) Connection for gas/oil burner, stage II, or for modulating-control burner 6) Switch trips when temperature rises. 7) Connection option showing example of safety components (external) 8) If connection used, jumpers must be removed! 9) Operating time recorder for burner stages I and II as optional accessory in slot for ZM425 central module 0 When button is pressed, temperature control is bypassed) ) Expansion module ZM426 (for wiring diagram page 42) as controller expansion module with (2nd) safety temperature limited 2) Expansion module ZM427 (for wiring diagram page 46) as boiler operating module for ensuring required boiler operating conditions with conventional boilers 40/ Wiring diagram for 422 controller (for abbreviations page 84) 40

143 Expansion modules for 4000 system controllers 8 8 Expansion modules for 4000 system controllers 8. ZM426 expansion module as controller expansion module with (2nd) safety temperature limiter 8.. Brief description Possible applications The expansion module ZM426 is suitable for the use of a second safety temperature limiter (2nd STB) in a 4000 control system for heating systems over 300 kw without flash tank but in combination with a maximum pressure limiter. Only one can be fitted in each controller. According to EN 2828, a flash tank is not required in heating systems over 300 kw provided there is an additional safety temperature limiter in combination with a maximum pressure limiter for each boiler. This additional safety temperature limiter can be set to 20 C, 0 C or 95 C and is designed for a maximum switching current of 0 A (2.3 kva). 2 Standard specifications ZM426 expansion module ( 4/) 4/ ZM426 option module Key to illustration Test button for testing safety temperature limiter (STB) (when button is pressed, temperature control is bypassed) 2 Safety temperature limiter (STB) 8..2 Possible applications for ZM426 function module Controllers with slot ) for ZM426 Controller 42 Boiler controller 422 Boiler controller Controller 432 Boiler controller 4322 Controller for sequential boiler (multi-boiler system) 4/ system controllers with slot for ZM426 expansion module ) Only one ZM426 expansion module may be fitted in each controller 4

144 8 Expansion modules for 4000 system controllers 8..3 Technical data for ZM426 expansion module Expansion module ZM426 Expansion module ZM426 Power supply 230 V AC ± 0 % Adjustable from 00 Safety temperature limiter STB 20 C Frequency 50 Hz ± 4 % (tested to DIN 3440, July 984 edition) Capillary tube sensor Max. switching current 0 A (2,3 kva) 42/ Specifications of ZM426 expansion module 8..4 Wiring diagram for ZM426 expansion module SI STB STB ) STB ) Zusatzmodul Additional module ZM426 ZM426 Additional Zusatzmodul module ZM426 ZM426 ) Switch trips when temperature rises. 42/2 Wiring diagram for ZM426 expansion module (for abbreviations page 84) 42

145 Expansion modules for 4000 system controllers Expansion module ZM427 for maintaining required boiler operating conditions with 422 controller 8.2. Brief description Possible applications The ZM427 expansion module is intended exclusively for use in the 422 analogue controller and is suitable for ensuring the required boiler operating conditions for conventionally operated boilers. Only one can be fitted in each controller. Boiler safety functions By controlling a boiler circuit pump and a boiler circuit mixing valve (motorised mixing valve), the expansion module ZM427 ensures the required boiler operating conditions for the following types of boiler: Ecostream boiler Low temperature boiler with minimum return temperature In conjunction with the appropriate plumbing configuration, compliance with the required boiler operating conditions is guaranteed. If the boiler circuit is operated in automatic mode, the appropriate settings must be made on the PCB (service interface) of the ZM427 expansion module for that purpose. The ZM427 is also suitable for isolating sequential boilers in multi-boiler systems by operating the boiler circuit mixing valve. Burner control The ZM427 expansion module controls single-stage, 2- stage, modulating-control or 2 single stage burners. There are two possible methods of burner control which can be set by means of the manual controls ( 43/, Item 7) Direct, electrically isolated burner-stage enabling by a higher-level control system (AUT), e.g. BEMS or Enabling of all burner stages by the controller (hand or max. output symbol), in which case burner modulation is also infinitely adjustable manually if applicable According to the 2 of the German Energy Saving Regulations, the 422 controller must be operated in conjunction with an automatic device for outside-temperature or room-temperature controlled operation with a timer programme. Standard specifications ZM427 expansion module ( 43/) Flow temperature sensor FV/FZ / ZM427 option module Key to illustration Sensor FZ fault indicator (LED) 2 Boiler circuit pump LED 3 LED for boiler circuit mixing valve opening 4 LED for boiler circuit mixing valve closing 5 Manual switch for boiler circuit (boiler circuit mixing valve or pump) 6 Circuit board 7 Manual burner control switch (inc. flue gas test) 8 Button for variably increasing burner output 9 Button for variably decreasing burner output 0 LED for burner stage II/burner modulation LED for burner stage I

146 8 Expansion modules for 4000 system controllers Expansion module ZM427 (in 422 controller): compliance with boiler operating conditions for a floor-standing boiler; enabling of burner stages by higher-level control system required DDC / GLT Enable signal (electrically isolated) Burner stage I Burner stage II or modulating control VK BR RK BRII PK ZM427 SR BR BRII FZ 422 BR BRII BEMS Higher-level control system (Direct Digital Control) GLT Higher-level control system (building control system) For wiring diagram page 46 For other abbreviations page 84 44/ Possible connections to expansion module ZM427 in combination with 422 controller; higher-level control system for enabling burner stages required according to 2 of German Energy Saving Regulations Possible applications for ZM427 function module Controllers with slot ) for ZM427 Controller 422 Boiler controller Controller 44/ system controllers with slot for ZM427 expansion module ) Only one ZM427 expansion module may be fitted in each controller Technical data for ZM427 expansion module Expansion module ZM427 Expansion module ZM427 Power supply 230 V AC ± 0 % Max. switching current Boiler circuit mixing valve SR 5 A Frequency 50 Hz ± 4 % control 230 V; 3-point switching Power consumption 2 VA controller (PI characteristic) Boiler circuit pump PK Max. switching current 5 A Positioner motor running time 20 s Flow temperature sensor FV/FZ ) NTC sensor, dia. 9 mm Burner operation, stage 230 V; 0 A 44/3 Specifications of ZM427 expansion module ) Max. lead length 00m (shielded upwards of 50m) 44

147 Expansion modules for 4000 system controllers Function description for ZM427 function module Expansion module ZM427: return temperature control With return temperature control mode, the boiler is operated with a fixed figure for the return temperature. The return temperature can be set to between 30 C and 60 C on the PCB (service interface) of the module by means of the potentiometer P. Return temperature control is constantly active by means of a separate boiler circuit mixing valve (motorised mixing valve) and bypass pump (without flow isolation 45/) or by means of a separate boiler circuit mixing valve (motorised mixing valve) and boiler circuit pump (with flow isolation by means of low-loss header 45/2) When the boiler switches on, the boiler circuit pump PK is switched on. After burner switches off, the boiler circuit pump PK is allowed to run on for a certain time before being switched off. That pump run-on period can be set by means of potentiometer P2 to between 30 and 60 minutes for the lead boiler or to 5 minutes (potentiometer at stop) for the sequential boiler in a multi-boiler system. The boiler circuit mixing valve SR for the sequential boiler closes. Expansion module ZM427: Ecostream control (operating flow temperature control) With Ecostream control mode, the boiler is operated with a fixed figure for the operating flow temperature. That flow temperature can be set to between 30 C and 60 C on the PCB (service interface) of the module by means of the potentiometer P. In "Burner ON mode", the flow from the boiler is disabled by means of the boiler circuit mixing valve SR (motorised mixing valve) as long as the operating flow temperature is not reached. When the boiler switches on, the boiler circuit pump PK (if present) is switched on and operating flow temperature control by means of the boiler circuit mixing valve SR is activated ( 45/3 or 45/4). When the burner is switched off, the boiler circuit mixing valve SR immediately opens completely. The boiler circuit pump PK is allowed to run on for a certain time, which can be set by means of potentiometer P2, before being switched off. That pump run-on period can be set to between 30 and 60 minutes for the lead boiler or to 5 minutes (potentiometer at stop) for the sequential boiler in a multi-boiler system. The boiler circuit mixing valve SR for the sequential boiler closes. ZM / Plumbing configuration for return temperature control with separate mixing valve and bypass pump (for abbreviations page 84) ZM /2 Plumbing configuration for return temperature control with separate mixing valve, boiler circuit pump and flow isolation ZM SR PK KR 45/3 Plumbing configuration for Ecostream control with separate mixing valve and pressurised header (without low-loss header) ZM427 FZ FZ SR PK SR FZ SR PK FZ WH WH VH RH VH RH VH RH VH RH /4 Plumbing configuration for Ecostream control with separate mixing valve, boiler circuit pump and flow isolation 45

148 8 Expansion modules for 4000 system controllers Wiring diagram for ZM427 expansion module 6) Additional module ZM Stage 2 3 Stage 2 3) 3) 3) 3) 3) 3) 4) 5) AUT AUT 0 max 0 l+ll k4 k5 k6 k k2 k3 Netz N L PK 6 63 SR Stage 2 Stage FZ ) 3,5 2 max. 5 A 4,5 2 max. 5 A Control voltage 230 V AC LV 0,4 0,75 2 N M L N = hotter = colder PK SR 2) Stage 2 Stage FZ ) Power supply from 422 controller ( page 40) 2) External input (electrically isolated) for modulating control 3) Automatic control input 4) Button for increasing modulating-control burner output 5) Button for decreasing modulating-control burner output 6) Connection on 422 controller 46/ Wiring diagram for ZM427 expansion module (for abbreviations page 84) 46

149 Overview of example systems 9 9 Overview of example systems 9. Wall-mounted single-boiler systems with 42 or 4323 controller System diagram ) 42 (FM455) Logamax plus HK BC0 HK2 Application/Equipment Notes 2) Single-boiler system Logamax plus gas condensing boiler Controlled system components 2 Heating circuits with mixing valve DHW system (cylinder system) using motorised diverter valve with hot water priority only ("EMS motorised diverter valve" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment 42 controller inc. FM455 function module in combination with EMS, one spare module slot for function/expansion module, function expansion via ECOCAN-BUS possible page 2 page 8 Logalux SU Single-boiler system Logamax plus gas condensing boiler page 2 page 8 (FM455) Logamax plus BC0 HK HK2 Controlled system components 2 Heating circuits with mixing valve DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment 42 controller inc. FM455 function module in combination with EMS, one spare module slot for function/expansion module, function expansion via ECOCAN-BUS possible Logalux SU FM442 (FM455) Logamax plus HK BC0 HK2 HK3 HK4 Single-boiler system Logamax plus gas condensing boiler Controlled system components 3 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 8 page 72 Control system equipment 42 controller inc. FM455 function module in combination with EMS/UBA.5, function module FM442, function expansion via ECOCAN-BUS possible Logalux SU... 47/ Overview of example systems for wall-mounted single-boiler systems with 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 47

150 9 Overview of example systems System diagram ) Application/Equipment Notes 2) 42 FM443 (FM455) Logamax plus HK BC0 HK2 Single-boiler system Logamax plus gas condensing boiler Controlled system components 2 Heating circuits with mixing valve Solar DHW system with twin-coil solar cylinder (cylinder system), DHW reheating using cylinder charging pump ("EMS charging pump" alternative) with DHW circulation pump, thermal disinfection, daily monitoring including solar preheating stage; non-return valve required if thermostatic DHW mixer fitted page 2 page 8 page 79 Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM443, function expansion via ECOCAN-BUS possible Logalux PL FM443 (FM455) Logamax plus HK BC0 HK2 Single-boiler system Logamax plus gas condensing boiler Controlled system components 2 Heating circuits with mixing valve Solar DHW system (cylinder system) and space heating boost using combination cylinder, DHW reheating using motorised diverter valve ("EMS motorised diverter valve" alternative with hot water priority only) with DHW circulation pump, thermal disinfection, daily monitoring including solar preheating stage; non-return valve required if thermostatic DHW mixer fitted page 2 page 8 page 79 Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM443, function expansion via ECOCAN-BUS possible Logalux PL.../2S Logamax plus BC FM442 FM442 FM456 FM445 HK... HK5 Single-boiler system Logamax plus gas condensing boiler Controlled system components 2 Heating circuits with mixing valve DHW system (cylinder charging system alternative to DHW "cylinder system" as per basic version of 42 controller), primary circuit pump controlled by FM445 ("LAP primary circuit via pump" alternative) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 60 page 72 page 05 page 5 Control system equipment 4323 controller in combination with EMS/UBA.5, function modules 2 x FM442, FM445 and FM456, function expansion via ECOCAN-BUS possible Logalux LSP 48/ Overview of example systems for wall-mounted single-boiler systems with 42 or 4323 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 48

151 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) 4323 FM442 FM442 FM444 FM456 Logamax plus BC0 HK... HK5 Single-boiler system Manual alternative heat source, e.g. Solid fuel boiler Logamax plus gas condensing boiler Controlled system components 5 Heating circuits with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and bypass integration DHW system (cylinder system) and space heating boost using Logalux PL.../2S combination cylinder, DHW reheating using motorised diverter valve ("EMS motorised diverter valve" alternative with hot water priority only) with DHW circulation pump, thermal disinfection and daily monitoring inc. solar preheating stage; non-return valve required if thermostatic DHW mixer fitted page 2 page 60 page 72 page 9 page 5 Solid Logano fuel S... boiler Logalux PL.../2S Control system equipment 4323 controller in combination with EMS, function modules 2 x FM442, FM444 and FM456, function expansion via ECOCAN-BUS possible 42 FM444 (FM455) Logamax plus BC0 HK HK2 Single-boiler system Manual alternative heat source, e.g. Solid fuel boiler Logamax plus gas condensing boiler Controlled system components 2 Heating circuits with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and balancing cylinder integration for Logamax plus gas condensing boiler DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 8 page 9 Solid Logano fuel S... boiler Logalux SU... Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM444, function expansion via ECOCAN-BUS possible 42 FM444 (FM455) Logalux SU... HK HK2 Single-boiler system Automatic alternative heat source, e.g. Heat pump Logamax plus gas condensing boiler page 2 page 8 page 9 Logamax plus BC0 Controlled system components 2 Heating circuits with mixing valve Logatherm heat pump inc. thermal store charging and bypass integration DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Logatherm Heat WPS... pump Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM444, function expansion via ECOCAN-BUS possible 49/ Overview of example systems for wall-mounted single-boiler systems with 42 or 4323 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 49

152 9 Overview of example systems 9.2 Wall-mounted multi-boiler cascade systems with 42 or 422 controller System diagram ) Application/Equipment Notes 2) BC0 Logamax plus () (2) BC0 FM FM442 HK HK2 HK3 2-boiler cascade system (all boilers same type, different boiler outputs possible) Logamax plus gas condensing boiler Controlled system components: 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using motorised diverter valve with hot water priority only ("Motorised diverter valve" alternative by EMS of st boiler) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 34 page 72 page 5 Control system equipment: 422 controller with FM456 function module in combination with 2 x EMS, and function module FM442, function expansion via ECOCAN-BUS possible Logalux SU FM456 (FM455) 3-boiler cascade system (all boilers same type, different boiler outputs possible) Logamax plus gas condensing boiler page 2 page 8 page 5 BC0 Logamax plus () (2) BC0 (3) BC0 HK HK2 Controlled system components: Heating circuit with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment: 42 controller inc. FM455 function module in combination with x EMS, and function module FM456 in combination with 2 x EMS, function expansion via ECOCAN- BUS possible Logalux SU FM457 FM44 Logamax plus () (2) (3) (4) BC0 BC0 BC0 BC0 HK HK2 4-boiler cascade system (all boilers same type, different boiler outputs possible) Logamax plus gas condensing boiler Controlled system components: Heating circuit with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump (by FM44 function module, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 34 page 67 page 5 Control system equipment: 422 controller with FM457 function module in combination with 4 x EMS, and function module FM44, function expansion via ECOCAN-BUS possible Logalux SU... 50/ Overview of example systems for wall-mounted multi-boiler cascade systems with 42 or 422 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 50

153 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) 42 FM457 (FM455) Logamax plus () (2) (3) (4) BC0 BC0 BC0 BC0 HK (5) BC0 HK2 HK3 5-boiler cascade system (all boilers same type, different boiler outputs possible) Logamax plus gas condensing boiler Controlled system components: 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using motorised diverter valve with hot water priority only ("EMS motorised diverter valve" alternative by EMS of st boiler. e.g. using Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 8 page 5 Control system equipment: 42 controller inc. FM455 function module in combination with x EMS, and function module FM457 in combination with 4 x EMS, function expansion via ECOCAN- BUS possible Logalux SU... FM FM456 HK 6-boiler cascade system (all boilers same type, different boiler outputs possible) Logamax plus gas condensing boiler page 2 page 34 page 5 BC0 () (2) BC0 Logamax plus (3) (4) BC0 BC0 (5) BC0 (6) BC0 Controlled system components: Heating circuit without mixing valve DHW system (cylinder system) using motorised diverter valve with hot water priority only ("EMS motorised diverter valve" alternative by EMS of st boiler. e.g. using Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment: 422 controller inc. FM457 function module in combination with 4 x EMS, and function module FM456 in combination with 2 x EMS, function expansion via ECOCAN- BUS possible Logalux SU FM457 FM457 Logamax plus () (2) (3) (4) (5) BC0 BC0 BC0 BC0 BC0 HK2 HK (6) (7) (8) BC0 BC0 BC0 8-boiler cascade system (all boilers same type, different boiler outputs possible) Logamax plus gas condensing boiler Controlled system components: 2 Heating circuits without mixing valve DHW system (cylinder system) using motorised diverter valve with hot water priority only ("EMS motorised diverter valve" alternative by EMS of st boiler. e.g. using Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 34 page 5 Control system equipment: 422 controller with FM457 function module in combination with 4 x EMS, and function module FM457 in combination with 4 x EMS, function expansion via ECOCAN- BUS possible Logalux SU... 5/ Overview of example systems for wall-mounted multi-boiler cascade systems with 42 or 422 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 5

154 9 Overview of example systems 9.3 Wall-mounted and floor-standing boilers with EMS and 42/4323 controller System diagram ) Application/Equipment Notes 2) 42 (FM455) Single-boiler system Wall-mounted boiler with EMS & integral DHW store page 2 page 8 VK V Heizkreis VS Boiler Logano with integral Logano DHW plus HK HK2 Controlled system components 2 Heating circuits with mixing valve DHW system (cylinder system) using motorised diverter valve with hot water priority only ("EMS motorised diverter valve" alternative, e.g. with DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment 42 controller inc. FM455 function module in combination with EMS, one spare module slot for function/expansion module, function expansion via ECOCAN-BUS possible 42 FM443 (FM455) HK BC0 Buderus Logano HK2 Single-boiler system Floor-standing boiler with EMS Controlled system components 2 Heating circuits with mixing valve Solar DHW system with twin-coil solar cylinder (cylinder system), DHW reheating using cylinder charging pump ("EMS charging pump" alternative) with DHW circulation pump, thermal disinfection and daily monitoring including solar preheating stage; non-return valve required if thermostatic DHW mixer fitted Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM443, function expansion via ECOCAN-BUS possible page 2 page 8 page 79 Logalux PL... Logano Logano plus (FM455) 42 FM442 HK HK2 HK3 HK4 Single-boiler system Floor-standing boiler with EMS Controlled system components 4 Heating circuits with mixing valve DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM442, function expansion via ECOCAN-BUS possible page 2 page 8 page 72 Logalux SU... 52/ Overview of example systems for wall-mounted and floor-standing boilers with EMS and 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 52

155 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) (FM455) 42 FM443 HK HK2 Single-boiler system Floor-standing boiler with EMS Controlled system components 2 Heating circuits with mixing valve Solar DHW system (cylinder system) and space heating boost using Logalux PL.../2S combination cylinder, DHW reheating using cylinder charging pump ("EMS charging pump" alternative) with DHW circulation pump, thermal disinfection and daily monitoring including solar preheating stage; non-return valve required if thermostatic DHW mixer fitted page 2 page 8 page 79 Logalux PL.../2S BC0 Buderus Logano Control system equipment 42 controller inc. FM455 function module in combination with EMS/UBA.5, function module FM443, function expansion via ECOCAN-BUS possible 4323 FM442 FM442 FM456 FM443 HK... HK5 Single-boiler system Floor-standing boiler with EMS Controlled system components 5 Heating circuits with mixing valve Solar DHW system (cylinder system) and space heating boost with two heat consumers (e.g. using Logalux SM... twin-coil cylinder and Logalux PL... twin-coil thermosiphon thermal store), DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring including solar preheating stage; non-return valve required if thermostatic DHW mixer fitted page 2 page 60 page 72 page 79 page 5 BC0 Buderus Control system equipment 4323 controller in combination with EMS, 2 x FM442, FM443 and FM456 function modules, function expansion via ECOCAN-BUS possible Logalux PL... Logalux PU... Logano (FM455) 42 FM444 Single-boiler system Manual alternative heat source, e.g. Solid fuel boiler Floor-standing boiler with EMS page 2 page 8 page 9 BC0 Buderus Logano HK HK2 Controlled system components 2 Heating circuits with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and bypass integration DHW system (cylinder system) and space heating boost using Logalux PL.../2S combination cylinder, DHW reheating using cylinder charging pump ("EMS charging pump" alternative) with DHW circulation pump, thermal disinfection and daily monitoring; non-return valve required if thermostatic DHW mixer fitted Solid Logano fuel boiler S... Logalux PL.../2S Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM444, function expansion via ECOCAN-BUS possible 53/ Overview of example systems for floor-standing boilers with EMS and 42/4323 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 53

156 9 Overview of example systems System diagram ) Application/Equipment Notes 2) Logano BC0 Buderus 42 FM444 (FM455) HK HK2 Single-boiler system Automatic alternative heat source Floor-standing boiler with EMS Controlled system components 2 Heating circuits with mixing valve Automatic alternative heat source inc. thermal store charging and bypass integration DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 8 page 9 Logalux SU... Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM444, function expansion via ECOCAN-BUS possible (FM455) 42 FM444 BC0 Buderus HK HK2 Single-boiler system Manual alternative heat source, e.g. Solid fuel boiler Floor-standing boiler with EMS Controlled system components 2 Heating circuits with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and balancing cylinder integration for Logamax plus gas condensing boiler DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring page 2 page 8 page 9 Solid Logano fuel boiler S... (FM455) 42 BC0 Buderus Logano FM444 Logano Logalux SU... HK Logalux SU... HK2 Logatherm Heat WPS... pump Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM444, function expansion via ECOCAN-BUS possible Single-boiler system Automatic alternative heat source, e.g. Heat pump Floor-standing boiler with EMS Controlled system components 2 Heating circuits with mixing valve Logatherm heat pump inc. thermal store charging and bypass integration for space heating boost DHW system (cylinder system) using cylinder charging pump ("EMS charging pump" alternative, e.g. with Logalux SU...W DHW cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM444, function expansion via ECOCAN-BUS possible page 2 page 8 page 9 54/ Overview of example systems for floor-standing boilers with EMS and 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 54

157 Overview of example systems Multi-boiler systems with 42/4323 controller System diagram ) 42 FM456 (FM455) 0 0 V Application/Equipment Notes 2) 2-boiler system (all boilers same type, different boiler outputs possible) Logano plus GB32 with EMS page 2 page 8 page 5 HK HK2 Controlled system components Heating circuit with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative) with DHW circulation pump, thermal disinfection and daily monitoring Imposition of required setting (0 0 V) by function module FM456 Logano plus GB32 (2) Logano plus GB32 () Logalux SU... Control system equipment 42 controller inc. FM455 function module in combination with EMS, function module FM456, function expansion via ECOCAN-BUS possible Logano Logano plus (4) 4323 FM44 FM442 FM458 MC0 MC0 MC0 MC0 Logano Logano plus (3) MC0 Logano Logano plus Logano Logano plus (2) 4323 FM44 FM442 FM458 Logamax plus BC0 Logano Logano plus () HK HK HK2 HK2 HK3 Logalux SU... HK3 Logalux SU... 4-boiler system (any combination of boilers) Logano with EMS Logano plus with EMS Controlled system components 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative) with DHW circulation pump, thermal disinfection and daily monitoring Imposition of required setting (0 0 V) by function module FM458 possible Control system equipment 4323 controller in combination with EMS, function modules FM44, FM442 and FM458, function expansion via ECOCAN-BUS possible 2-boiler system (any combination of boilers) Logano with EMS Logano plus with EMS Logamax plus gas condensing boiler Controlled system components 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative) with DHW circulation pump, thermal disinfection and daily monitoring Imposition of required setting (0 0 V) by function module FM458 possible Control system equipment 4323 controller in combination with EMS, function modules FM44, FM442 and FM458, function expansion via ECOCAN-BUS possible page 2 page 60 page 67 page 72 page 22 page 2 page 60 page 67 page 72 page 22 55/ Overview of example systems for multi-boiler systems with 42 or 4323 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 55

158 9 Overview of example systems 9.5 Floor-standing single-boiler systems with 42 controller System diagram ) Application/Equipment Note 2) 42 FM442 FM HK HK2 HK3 HK4 HK5 Single-boiler system Logano plus gas condensing boiler (BWK) with internal condensing heat exchanger (BWT) Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (ESK) (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (NTK) (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) page 2 page 42 page 72 Logano Logano plus Logalux SU... Controlled system components: 4 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 42 controller with 2 x FM442 function modules, function expansion via ECOCAN-BUS possible Single-boiler system Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) 42 FM442 FM HK HK2 HK3 page 2 page 42 page 72 page 79 Logalux SL... Logano Logano plus Controlled system components: 2 Heating circuits with mixing valve Heating circuit without mixing valve Solar DHW system (cylinder system) with Logalux SL... stratified charge cylinder, DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring inc. solar preheating stage; nonreturn valve required if thermostatic DHW mixer fitted Control system equipment: 42 controller with FM442 and FM443 function modules, function expansion via ECOCAN- BUS possible 56/ Overview of example systems for floor-standing single-boiler systems with 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 56

159 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) Logalux PL.../2S 42 FM442 FM Logano Logano plus HK HK2 HK3 Single-boiler system Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) Controlled system components: 2 Heating circuits with mixing valve Heating circuit without mixing valve Solar DHW system (cylinder system) and space heating boost with Logalux PL.../2S combination cylinder, DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring inc. solar preheating stage; non-return valve required if thermostatic DHW mixer fitted Controllers: 42 controller with FM442 and FM443, function expansion via ECOCAN-BUS possible page 2 page 42 page 72 page FM442 FM Logano Logano plus HK Logalux LSP HK2 HK3 Single-boiler system Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) Controlled system components: 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder charging system alternative to DHW "cylinder system" as per basic version of 42 controller), with DHW circulation pump and thermal disinfection Control system equipment: 42 controller with FM442 and FM445 function modules (recommended for condensing boilers), function expansion via ECOCAN-BUS possible page 2 page 42 page 72 page FM442 FM Logano Logano plus HK Logalux SU... HK2 HK3 Single-boiler system Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) Controlled system components: 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 42 controller with FM442 function module, function expansion via ECOCAN-BUS possible page 2 page 42 page 72 57/ Overview of example systems for floor-standing single-boiler systems with 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 57

160 9 Overview of example systems System diagram ) Application/Equipment Notes 2) 42 Logano Logano plus 42 (FM442) (FM444) HK HK2 Single-boiler system Manual alternative heat source, e.g. Solid fuel boiler Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) page 2 page 42 page 72 page 9 Solid Logano fuel boiler S... Logalux SU... Controlled system components: 2 Heating circuits with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and bypass integration DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 42 controller with FM442 and FM444 function modules, function expansion via ECOCAN-BUS possible Single-boiler system Manual alternative heat source, e.g. Solid fuel boiler Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) 42 Logano Logano plus 42 (FM442) (FM444) HK HK2 page 2 page 42 page 72 page 9 Solid Logano fuel boiler S... Logalux PL.../2S Controlled system components: 2 Heating circuits with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and bypass integration DHW system (cylinder system) and space heating boost using Logalux PL.../2S combination cylinder, DHW reheating using cylinder charging pump ("EMS charging pump" alternative) with DHW circulation pump, thermal disinfection and daily monitoring; non-return valve required if thermostatic DHW mixer fitted Control system equipment: 42 controller with FM442 and FM444 function modules, function expansion via ECOCAN-BUS possible 58/ Overview of example systems for floor-standing single-boiler systems with 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 58

161 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) 42 Logano Logano plus 42 (FM442) (FM444) HK HK2 Single-boiler system Automatic alternative heat source Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) page 2 page 42 page 72 page 9 Logalux SU... Controlled system components: 2 Heating circuits with mixing valve Automatic alternative heat source inc. thermal store charging and thermal store alternative integration DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 42 controller with FM442 and FM444 function modules, function expansion via ECOCAN-BUS possible Single-boiler system Automatic alternative heat source Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) 42 Logano Logano plus 42 (FM442) (FM444) HK HK2 page 2 page 42 page 72 page 9 Logalux SU... Controlled system components: 2 Heating circuits with mixing valve Automatic alternative heat source inc. thermal store charging and bypass integration using pump DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 42 controller with FM442 and FM444 function modules, function expansion via ECOCAN-BUS possible 59/ Overview of example systems for floor-standing single-boiler systems with 42 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 59

162 9 Overview of example systems 9.6 Floor-standing single-boiler systems with 432 controller System diagram ) Application/Equipment Notes 2) 432 FM442 FM442 FM442 FM44 HK HK2... HK7 Single-boiler system Logano low-temperature boiler with base temperature (required operating conditions ensured by boiler circuit mixing valve) Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valve) page 2 page 50 page 67 page Controlled system components: 7 Heating circuits with mixing valve DHW system (cylinder system) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment: 432 controller with FM44 and 3 x FM442 function modules, function expansion via ECOCAN-BUS possible Logano Logalux SU FM442 FM442 FM44 FM443 HK HK2... HK5 Single-boiler system Logano low-temperature boiler with minimum return temperature (required operating conditions ensured by boiler circuit mixing valve and bypass pump) page 2 page 50 page 67 page 72 page Controlled system components: 5 Heating circuits with mixing valve Solar DHW system (cylinder system) and space heating boost with two heat consumers (e.g. using Logalux SM... twin-coil cylinder and Logalux PL... twin-coil thermosiphon thermal store), DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring including solar preheating stage; non-return valve required if thermostatic DHW mixer fitted Logalux PL... Logalux PU... Logano Control system equipment: 432 controller with FM44, 2 x FM442 and FM443 function modules, function expansion via ECOCAN-BUS possible 432 FM442 FM44 FM442 HK HK2... HK5 Single-boiler system Logano low-temperature boiler with minimum return temperature (required operating conditions ensured by heating circuit mixing valves and bypass pump) page 2 page 50 page 67 page 72 ECOCAN-BUS 432 Controlled system components: 5 Heating circuits with mixing valve DHW system (cylinder system) with DHW circulation pump, thermal disinfection and daily monitoring Communication with LON networks via LON gateway Control system equipment: 432 controller with FM44 and 2 x FM442 function modules, function expansion via ECOCAN-BUS possible Logano Logalux SU... 60/ Overview of example systems for floor-standing single-boiler systems with 432 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 60

163 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) 432 FM V HK HK2... HK... Single-boiler system Logano low-temperature boiler (NTK) with base temperature (required operating conditions ensured by boiler circuit mixing valve) Logano Ecostream boiler (ESK) (required operating conditions ensured by boiler circuit mixing valve) Logano low-temperature boiler with minimum return temperature (required operating conditions ensured by boiler circuit mixing valve with additional bypass pump, additional temperature sensor FZ not in flow but in return) page 50 page 432 Controlled system components: Heating circuits externally controlled Imposition of required setting (0 0 V) by function module FM448 Centralised fault signal output (indicator lamp, electrically isolated) via function module FM448 Logano Logalux SU... Control system equipment: 432 controller with function module FM FM442 FM442 FM448 FM445 HK HK2... HK4 Single-boiler system Logano plus gas condensing boiler with internal condensing heat exchanger Controlled system components: 4 Heating circuits with mixing valve DHW system (cylinder charging system e.g. with Logalux LSP heat exchanger set and Logalux SF... water cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Centralised fault signal output (indicator lamp, electrically isolated) via function module FM448 page 2 page 50 page 72 page 05 page 432 Control system equipment: 432 controller with 2 x FM442, FM445 and FM448 function modules, function expansion via ECOCAN-BUS possible Logano plus Logalux LSP 6/ Overview of example systems for floor-standing single-boiler systems with 432 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 6

164 9 Overview of example systems System diagram ) Application/Equipment Notes 2) 432 FM442 FM442 FM44 FM446 HK HK2... HK5 Single-boiler system Logano plus gas condensing boiler with external condensing heat exchanger (= Logano Ecostream boiler with connected condensing heat exchanger, required operating conditions ensured by boiler circuit mixing valve) page 2 page 50 page 67 page 72 Controlled system components: 5 Heating circuits with mixing valve DHW system (cylinder system) with DHW circulation pump, thermal disinfection and daily monitoring 432 Control system equipment: 432 controller with FM44 and 2 x FM442 function modules, function expansion via ECOCAN-BUS possible Logano plus Logalux SU Logano plus 432 FM442 FM442 FM44 FM444 Logalux SU... HK... HK5 Single-boiler system Automatic alternative heat source, e.g. Heat pump Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valves) Logano Ecostream boiler (ESK) (required operating conditions ensured by boiler circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) page 2 page 50 page 67 page 72 page 9 Logatherm Heat WPS... pump Controlled system components: 5 Heating circuits with mixing valve Logatherm heat pump inc. thermal store charging and bypass integration by means of pump for space heating boost DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 432 controller with FM44, 2 x FM442 and FM444 function modules, function expansion via ECOCAN-BUS possible 62/ Overview of example systems for floor-standing single-boiler systems with 432 controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 62

165 Overview of example systems Floor-standing multi-boiler systems with 432 or 4322 controllers System diagram ) Application/Equipment Notes 2) 4322 FM44 2 ECOCAN-BUS 432 FM442 FM442 FM44 FM458 HK HK2... HK6 2-boiler system (all boilers same type) Logano low-temperature boiler (NTK) (required operating conditions ensured by control mode of heating circuit pumps) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) Logano Ecostream boiler (ESK) (required operating conditions ensured by heating circuit mixing valves) Flow restrictor valves required for isolating the sequential boiler page 2 page 50 page 67 page 72 page Controlled system components: 6 Heating circuits with mixing valve 2 DHW systems (cylinder systems) with DHW circulation pump, thermal disinfection and daily monitoring Logano Logano 2 Logano ECOCAN-BUS 432 Logano 432 FM442 FM442 Logalux SU... FM44 FM458 HK Logalux SU... HK2 Logalux SU HK5 Control system equipment: 432 controller for boiler with FM44, 2 x FM442 and FM458; 4322 controller for boiler 2 with FM44, communication via ECOCAN-BUS 2-boiler system (all boilers same type) Logano low-temperature boiler (required operating conditions ensured by control mode or boiler circuit pump) Logano low-temperature boiler with base temperature (required operating conditions ensured by heating circuit mixing valves) Logano low-temperature boiler with minimum return temperature (strategy return temperature sensor FRS also required in shared return) Logano Ecostream boiler (required operating conditions ensured by heating circuit mixing valves) Non-return valves required for isolating the sequential boiler! Controlled system components: 5 Heating circuits with mixing valve DHW system (cylinder system) with DHW circulation pump, thermal disinfection and daily monitoring Communication with LON networks via LON gateway Control system equipment: 432 controller for boiler with FM44, 2 x FM442 and FM458; 4322 for boiler 2, communication via ECOCAN-BUS page 2 page 50 page 67 page 72 page 22 63/ Overview of example systems for floor-standing multi-boiler systems with 432/4322 controllers ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 63

166 9 Overview of example systems System diagram ) Application/Equipment Notes 2) Logano 2 FM FM442 FM442 FM458 ECOCAN-BUS 432 Logano plus 4322 HK HK HK2 Logalux LSP 432 Logalux PL... Logano 2 Logano plus HK HK4 HK5 432 FM442 FM442 FM FM443 FM44 2-boiler system Boiler : Logano plus gas condensing boiler (BWK) with internal condensing heat exchanger (BWT) Boiler 2: Logano low-temperature boiler with base temperature (required operating conditions ensured by boiler circuit mixing valve) Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valve) Controlled system components: 4 Heating circuits with mixing valve DHW system (cylinder charging system e.g. with Logalux LSP heat exchanger set and Logalux SF... water cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment: 432 controller for boiler with 2 x FM442 and FM458; 4322 for boiler 2 with FM445, communication via ECOCAN-BUS 2-boiler system Boiler : Logano plus gas condensing boiler with internal condensing heat exchanger Boiler 2: Logano low-temperature boiler with base temperature (required operating conditions ensured by boiler circuit mixing valve) Logano low-temperature boiler with minimum return temperature (additional temperature sensor in return required) Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valve) Controlled system components 5 Heating circuits with mixing valve Solar DHW system (cylinder system) with twincoil cylinder, DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring inc. solar preheating stage; non-return valve required if thermostatic DHW mixer fitted Control system equipment 432 controller for boiler with 2 x FM442 and FM458; 4322 for boiler 2 with FM44 and FM443, communication via ECOCAN-BUS page 2 page 50 page 72 page 05 page 22 page 2 page 50 page 67 page 72 page 79 page 22 64/ Overview of example systems for floor-standing multi-boiler systems with 432/4322 controllers 64

167 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) 4322 FM44 FM446 FM Logano ECOCAN-BUS 432 FM44 FM442 Logano plus FM458 FM446 HK HK2 Logalux SU HK6 Logalux SU... 2-boiler system Boiler : Logano plus gas condensing boiler with external condensing heat exchanger (= Logano Ecostream boiler with connected condensing heat exchanger, required operating conditions ensured by flow restrictor valve) Boiler 2: Logano Ecostream boiler (required operating conditions ensured by flow restrictor valve) Logano low-temperature boiler with minimum return temperature (required operating conditions ensured by flow restrictor valve) Controlled system components 6 Heating circuits with mixing valve 2 DHW systems (cylinder systems) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment 432 controller for boiler with FM44, FM442 and FM458; 4322 for boiler 2 with FM44 and FM442, communication via ECOCAN-BUS page 2 page 50 page 67 page 72 page 22 64/ Overview of example systems for floor-standing multi-boiler systems with 432/4322 controllers ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 65

168 9 Overview of example systems System diagram ) Application/Equipment Notes 2) FM442 FM444 FM442 FM442 FM ECOCAN-BUS 432 HK... HK6 2-boiler system (any combination of boilers) Automatic alternative heat source, e.g. CHP module Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with external condensing heat exchanger or Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valves) Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valves) Logano low-temperature boiler (required operating conditions ensured by pump control logic) page 2 page 50 page 72 page 9 page 22 Logano Logano plus Logano Logano plus BHKW CHP Loganova Controlled system components 6 Heating circuits with mixing valve Loganova CHP module inc. thermal store charging and bypass integration Control system equipment 432 and 4322 controllers with 3 x FM442, FM444 and FM458 function modules, function expansion via ECOCAN-BUS possible 432 FM44 FM442 FM HK HK2 HK3 2-boiler system (any combination of boilers) Logano with EMS (reqd. operating conditions ensured by pump control logic) Logano plus with EMS Logamax plus gas condensing boiler Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with internal condensing heat exchanger or Logano Ecostream boiler (op. cond. ensured by boiler circuit mixing valves) Logano Ecostream boiler (required operating conditions ensured by boiler circuit mixing valves) Logano low-temperature boiler (required op. cond. ensured by pump control logic) page 2 page 50 page 67 page 72 page 22 MC0 Logano Logano plus Logano Logano plus Logalux SU... Controlled system components 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative) with DHW circulation pump, thermal disinfection and daily monitoring Imposition of required setting (0 0 V) by function module FM458 possible Control system equipment 432 controller with FM44, FM442 and FM458 function modules, function expansion via ECOCAN-BUS possible 66/ Overview of example systems for floor-standing multi-boiler systems with 432 and 4322 controllers ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 66

169 Overview of example systems 9 System diagram ) Logano Logano Logano plus ECOCAN-BUS 4322 Logano Logano FM458 HK 3 x FM44 FM442 FM Logano Logano plus ECOCAN-BUS 4322 Logano Logano plus 4322 Logano Logano plus 0 0 V Logalux SU... HK2 HK... HK2 Logalux SU... HK... HK3 Application/Equipment Notes 2) 3-boiler system (any combination of boilers) Logano low-temperature boiler (NTK) (required operating conditions ensured by boiler circuit pump control logic) Logano low-temperature boiler with base temperature (required operating conditions ensured by boiler circuit mixing valve) Logano low-temperature boiler with minimum return temperature (reqd. op. cond. ensured by boiler circuit mixing valve, additional temperature sensor FZ required in return) Logano Ecostream boiler (ESK) (required operating conditions ensured by boiler circuit mixing valve) Controlled system components: Heating circuits externally controlled Imposition of required setting (0 0 V) by FM458 Centralised fault signal output (indicator lamp, electrically isolated) via function module FM458 Control system equipment 432 controller for boiler with function module FM458; one 4322 controller each for boilers 2 and 3, communication via ECOCAN-BUS 4-boiler system (any combination of boilers) Logano plus gas condensing boiler with internal condensing heat exchanger Logano plus gas condensing boiler with internal condensing heat exchanger or Logano Ecostream boiler (op. cond. ensured by boiler circuit mixing valves) Logano Ecostream boiler (ESK) (required operating conditions ensured by boiler circuit mixing valves) Logano low-temperature boiler (required op. cond. ensured by pump control logic) Controlled system components 2 Heating circuits with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative) with DHW circulation pump, thermal disinfection and daily monitoring Imposition of required setting (0 0 V) by function module FM458 possible Control system equipment 432 and 3 x 4322 controllers with FM44, FM442 and FM458 function modules, function expansion via ECOCAN-BUS possible page 2 page 50 page 22 page 2 page 50 page 67 page 72 page 22 67/ Overview of example systems for floor-standing multi-boiler systems with 432/4322 controllers ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 67

170 9 Overview of example systems /4323 controller as autonomous heating circuit controller or slave unit System diagram ) Application/Equipment Notes 2) 42 HK HK2 42 as autonomous heating circuit controller Thermal store with externally controlled heat source for outside-temperature driven heating circuit control and DHW heating Controlled system components: Heating circuit with mixing valve Heating circuit without mixing valve DHW system (cylinder system) using cylinder charging pump ("4000 cylinder" alternative) with DHW circulation pump, thermal disinfection and daily monitoring No feed pump and no monitoring of heat supply in thermal store Control system equipment: 42 controller, one spare slot for a function or expansion module 42 as autonomous heating circuit controller Control of solar thermal system for two heat consumers (solar DHW cylinder and thermal store) Thermal store as heat source for outsidetemperature driven heating circuit control and DHW reheating Controlled system components: Heating circuit with mixing valve Heating circuit without mixing valve Solar DHW system (cylinder system) and solar thermal store as second heat consumer, DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring inc. solar preheating stage; non-return valve required if thermostatic DHW mixer fitted No conventional heat source if thermal store heat supply inadequate page 8 page 26 VH RH Logalux SU FM443 HK HK2 page 8 page 26 page 79 Logalux PL... Logalux PU... Control system equipment: 42 controller with function module FM as autonomous heating circuit controller Heating circuit header with externally controlled heat source for outside-temperature driven heating circuit control and DHW heating No feed pump and no monitoring of heat supply in thermal store Controlled system components 2 Heating circuits with mixing valve DHW system (cylinder charging system alternative to DHW "cylinder system" as per basic version of 42 controller), primary circuit pump controlled by FM445 (e.g. using Logalux LSP heat exchanger set and Logalux SF... water cylinder) with DHW circulation pump, thermal disinfection and daily monitoring Control system equipment: 42 controller with function module FM FM445 HK HK2 page 8 page 26 page 05 VH RH Logalux LSP 68/ Overview of example systems with 42 controller as autonomous heating circuit controller ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 68

171 Overview of example systems 9 System diagram ) Application/Equipment Notes 2) VH RH 4323 FM44 HK0 HK 4323 as autonomous heating circuit controller Thermal store with externally controlled heat source for outside-temperature driven heating circuit control and DHW heating Controlled system components: 2 Heating circuits with mixing valve DHW system (cylinder system) with DHW circulation pump, thermal disinfection and daily monitoring Monitoring of heat supply with heat demand to heat source controller by required setting output (0 0 V), feed pump can be controlled Control system equipment: 4323 controller with function module FM44, three spare slots for function/expansion modules page 60 page 63 page 67 Logalux SU V 4323 FM442 FM442 FM44 FM446 HK0 HK... HK as autonomous heating circuit controller Heat supply using feed pump for outsidetemperature driven heating circuit control and DHW heating from heating circuit header with externally controlled heat source Controlled system components 6 Heating circuits with mixing valve DHW system (cylinder system) with DHW circulation pump, thermal disinfection and daily monitoring Monitoring of heat supply with heat demand to heat source controller by required setting output (0 0 V) page 60 page 63 page 67 page 72 VH RH Logalux SU... Control system equipment: 4323 controller with FM44 and 2 x FM442 function modules FM442 FM442 FM44 FM controller as slave unit Heat supply using feed pump for outsidetemperature driven heating circuit control and DHW reheating from heating circuit header with externally controlled heat source page 60 page 63 page 67 page 72 page 79 max. 5 ECOCAN-BUS HK0 HK... HK5 Controlled system components 6 Heating circuits with mixing valve Solar DHW system with twin-coil cylinder (cylinder system), DHW reheating, DHW circulation pump, thermal disinfection and daily monitoring inc. solar preheating stage; nonreturn valve required if thermostatic DHW mixer fitted Communication via ECOCAN-BUS with 4000 system master controller (e.g. 432) Logalux PL... VH RH Control system equipment: 4323 controller with FM44, 2 x FM442 and FM443 function modules 69/ Overview of example systems with 4323 controller as autonomous heating circuit controller or slave unit ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 69

172 9 Overview of example systems System diagram ) 42 FM444 (FM455) HK Application/Equipment Notes 2) 42 as autonomous heating circuit controller Manual alternative heat source, e.g. Solid fuel boiler Controlled system components: Heating circuit with mixing valve Logano solid fuel boiler inc. ΔT thermal store charging and direct integration DHW system (cylinder system) with DHW circulation pump and thermal disinfection page 2 page 8 page 26 page 9 Control system equipment: 42 controller inc. FM455 function module in combination with function module FM444, function expansion via ECOCAN-BUS possible Solid Logano fuel boiler S... Logalux SU... HK 42 FM444 (FM455) 42 as autonomous heating circuit controller Automatic alternative heat source Controlled system components Heating circuit with mixing valve Automatic alternative heat source inc. thermal store charging and direct integration DHW system (cylinder system) with DHW circulation pump and thermal disinfection Control system equipment: 42 controller inc. FM455 function module in combination with function module FM444, function expansion via ECOCAN-BUS possible page 2 page 8 page 26 page 9 Logalux SU FM443 FM44 FM as autonomous heating circuit controller Automatic alternative heat source, e.g. Pellet-burning primary stove Solar thermal system Controlled system components Heating circuit with mixing valve Automatic alternative heat source inc. thermal store charging and direct integration Solar DHW system (cylinder system) and space heating boost using Logalux PL.../2S combination cylinder; non-return valve required if thermostatic DHW mixer fitted Control system equipment: 4323 controller with FM44, FM443 and FM444 function modules page 8 page 26 page 60 page 67 page 79 page 9 Logalux PL.../2S 70/ Overview of example systems with 42/4323 controller as autonomous heating circuit controller or slave unit ) The system diagram provides a general guide to the possible configuration without obligation or claims as to its completeness. Actual execution in practice is subject to the applicable technical regulations. Safety equipment must be installed in accordance with local regulations. 2) More information about the required boiler operating conditions, the plumbing connections and the system components available from Buderus can be found in the relevant planning documents or the latest heating systems catalogue. 70

173 Installation notes 0 0 Installation notes 0. Electrical installation 0.. Remote controls Remote control MEC2 or BFU With a room-temperature driven control method, the flow temperature of a heating circuit is adjusted according to the temperature measured in a reference room. A room temperature sensor is integrated in the MEC2 control pad for this method of control. If the room temperature displayed on the MEC2 differs from the actual room temperature measured by a thermometer, the MEC2 has a calibration function for calibrating the room temperature sensor. Only one MEC2 control pad may be connected to each 4000 system digital controller, i.e. each CM43 controller module. For separate control of the other heating circuits, a BFU remote control ( 7/2) with integral room temperature sensor should be specified. However, multiple heating circuits can be assigned to one MEC2 remote control. The required room temperatures, summer/winter limits, holiday mode settings and mode switching conditions then apply to all heating circuits that are assigned to one MEC2 control pad. Room fitting kit for MEC2 used as remote control The room fitting kit ( 7/3) includes a wall-mounted holder for the MEC2 control pad and a boiler display unit. The wall-mounted holder can be fitted in any room up to 00 m distant from the controller. Connection requires only a 2-core cable with a core cross-sectional area of between 0.4 and 0.75 mm 2 which should be shielded if over 50m long. Electromagnetic shielding is also required if lowvoltage cables are routed alongside power cables (230 V AC) in a shared cable conduit (for EMC page 73). The boiler display unit should be plugged into the controller and shows the current operating status of the system instead of the MEC2. Key to illustration ( 7/3) Holes for fitting to a concealed mounting box 2 Holes for fixing to wall 3 Electrical connections on wall-mounted holder (2 x mm 2 ) 95 7/ MEC2 control pad equipped with room temperature sensor for use as remote control /2 BFU remote control with integral room temperature sensor /3 Wall-mounted holder for MEC2 control pad used as remote control 7