Strategy module FM458/CMC 930 For contractors Read carefully prior to commissioning or service. 6 720 803 196 (2011/06) GB / IE / AU Service instructions
2 1 Safety........................................ 5 1.1 About these instructions......................... 5 1.2 Determined use............................... 5 1.3 Standards and directives......................... 5 1.4 Explanation of the symbols used.................... 6 1.5 Observe this information......................... 6 1.6 Disposal................................... 8 2 Product and function description.................... 9 2.1 Front panel..................................11 2.2 Switch on the module PCB........................12 2.2.1 Module recognition switch.......................12 2.2.2 Voltage/current output.........................14 2.3 Terminology key..............................15 2.3.1 EMS boiler...............................15 2.3.2 CAN boiler...............................15 2.3.3 Mixed cascade.............................15 2.3.4 Series operation.............................16 2.3.5 Parallel operation............................17 2.3.6 Boiler sequence.............................18 2.3.7 Load limit................................20 3 Installation....................................23 3.1 Scope of supply...............................23 3.2 Checking the software versions.....................24 3.3 Installation in the CFB 930 control unit.................24 3.4 Connecting inputs and outputs.....................25 3.5 Connecting sensors............................26 3.6 Connecting EMS boilers..........................27 3.7 Assigning the boiler number.......................28 3.8 Recommended hydraulic schemes...................32 3.8.1 CAN boiler via low loss header.....................34 3.8.2 EMS boiler via low loss header.....................36 3.8.3 EMS boiler with EMS DHW.......................38 3.8.4 CAN boilers in series..........................40 3.8.5 CAN boilers in parallel.........................42 3.8.6 CAN boilers in "Tichelmann System"..................44 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
3 3.8.7 Twin-block boiler according to the "Tichelmann principle"....... 46 3.8.8 Mixed cascade via low loss header.................. 48 3.8.9 System with different EMS boilers................... 50 4 Integrating EMS boilers........................... 52 4.1 Base controller BC15........................... 52 5 Functions of the FM458/CMC 930................... 55 5.1 Operation with Programmer....................... 55 5.2 Integrating function module FM458/CMC 930 in the control unit. 56 5.2.1 Integrate function module FM458/CMC 930 on Programmer level... 56 5.2.2 Integrate function module FM458/CMC 930 manually on Programmer level..................... 56 6 General specification data......................... 58 6.1 0 10 V input................................ 58 6.2 Temperature control 0 10 V input................... 60 6.3 Output control for 0 10 V input.................... 62 7 Strategy data.................................. 66 7.1 Number of boilers............................. 66 7.2 Maximum system temperature...................... 67 7.3 Hydraulic decoupling........................... 68 7.4 Boiler sequences.............................. 69 7.5 Sequence switching............................ 72 7.5.1 "Sequence revers. none"........................ 73 7.5.2 Sequence reversal subject to hours run................ 74 7.5.3 Sequence reversal subject to outside temperature........... 76 7.5.4 "Sequence revers daily"........................ 78 7.5.5 "Sequence reverse external contact".................. 79 7.6 Load limit.................................. 80 7.6.1 Load limit according to outside temperature.............. 81 7.6.2 Load limit via external contact..................... 84 7.6.3 Operating mode serial / parallel.................... 85 7.6.4 Lead boiler run-on time (pump/servomotor).............. 86 7.6.5 Lag boiler run-on time (pump/servomotor)............... 87 FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
4 8 DHW data.....................................88 8.1 Selecting the DHW cylinder........................88 8.2 Setting the temperature range......................91 8.3 Selecting switching optimisation....................92 8.4 Selecting residual heat use........................93 8.5 Setting hysteresis..............................95 8.6 Selecting and setting up thermal disinfection.............97 8.7 Setting the thermal disinfection temperature.............99 8.8 Setting the day of the week for thermal disinfection........ 100 8.9 Setting the time for thermal disinfection............... 101 8.10 Daily heat-up................................ 103 8.11 Selecting the DHW circulation pump................. 104 8.12 Setting the DHW circulation pump intervals............. 106 9 Recording heat consumption...................... 108 9.1 Setting the recording of heat demand "acc. to impulses".... 108 9.2 Matching the impulse value....................... 110 9.3 Scanning heat demand......................... 111 9.4 Restarting the heat consumption count............... 112 10 Relay test.................................... 113 11 Fault log..................................... 115 12 Fault messages................................ 116 13 Strategy monitor data........................... 119 14 EMS boiler.................................... 122 14.1 EMS boiler monitor data......................... 122 14.2 Supplementary fault messages with EMS.............. 125 14.3 Maintenance messages for boilers with EMS............ 128 15 Technical data................................. 132 15.1 Function module FM458/CMC 930................... 132 16 Sensor curves................................. 133 17 Keyword index................................ 135 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Safety 5 1 Safety 1.1 About these instructions This chapter contains general safety instructions which must be observed during service work on the FM458/CMC 930 function module. Also closely observe the further safety instructions, which you can find in other chapters of these service instructions. Carefully read the safety instructions before commencing the work described below. If safety instructions are ignored, severe or even fatal injuries may result, as well as material losses and environmental damage. 1.2 Determined use You can integrate the function module FM458/CMC 930 into the control units CFB 910 and CFB 930. For faultless operation, you will need at least software version 8.xx for the control unit and Programmer programming unit. 1.3 Standards and directives The design and operation of this product conforms to the European Directives and the supplementary national requirements. Its conformity is confirmed by the CE designation. You may request the declaration of conformity. For this see the contact address at the back cover of these instructions. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
6 Safety 1.4 Explanation of the symbols used Two levels of danger are identified and signalled by the following terms: RISK OF FATAL INJURY WARNING! Identifies possible risks associated with a product that might lead to serious injury or even death if appropriate care is not taken. RISK OF INJURY/ SYSTEM DAMAGE CAUTION! Identifies potentially dangerous situations, which might lead to medium or slight injuries or to material damage. USER INFORMATION User tips for the optimum utilisation and adjustment of the appliance plus other useful information. 1.5 Observe this information The FM458/CMC 930 function module was designed and built according to the state of the art and the recognised safety-related standards. However, material losses resulting from inappropriate service work cannot be completely prevented. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Safety 7 Before commencing service work on the FM458/CMC 930 function module, read these service instructions carefully. RISK OF FATAL INJURY WARNING! from electric shock! The installation, electrical wiring, commissioning, electrical connection, as well as maintenance and repairs must only be carried out by a competent contractor who adheres to all current technical regulations and requirements. Regional regulations should be observed in this regard! RISK OF FATAL INJURY WARNING! from electric shock! Ensure that all electrical work is only carried out by an authorised electrician. Before opening the control unit: Isolate all poles of the power supply and secure against unintentional reconnection. RISK OF FATAL INJURY from electric shock! WARNING! The risk of voltage flashes through unintentional loosening of the cores at the terminals between the 230 V and the LV must be prevented. Therefore fix the wires from each cable away from each other (e.g. with cable ties) or only strip the wire for a very short section. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
8 Safety RISK OF INJURY/ SYSTEM DAMAGE CAUTION! from operator error. Operator errors can result in injury and damage to property. Ensure that children never operate the appliance unsupervised or play with it. Ensure that only personnel able to operate the appliance correctly have access to it. DAMAGE TO THE APPLIANCE CAUTION! from electrostatic discharge (ESD). Before unpacking the module touch a radiator or an earthed metal water pipe to discharge any electrostatic charge in your body. USER INFORMATION Ensure that a regulation isolator is available to disconnect all poles from the mains power supply. Install an isolator if none is available. USER INFORMATION Only use original Bosch spare parts. Losses caused by the use of parts not supplied by Bosch are excluded from the Bosch warranty. 1.6 Disposal Electronic components must not be disposed of with general domestic waste. Dispose of old modules correctly through an authorised disposal site. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 9 2 Product and function description USER INFORMATION This module can only be installed in the master with address 0 or 1. The function module FM458/CMC 930 is designed exclusively for use in the modular control system CFB 930. You can integrate the function module FM458/CMC 930 once or twice into a control unit of the control system CFB 930. The main function of the function module FM458/CMC 930 consists in operating a multi-boiler system according to your requirements. You can use the following functions or connection options after installing the FM458/CMC 930 function module: Module for use with control unit CFB 910 or CFB 930 any combination of boilers with 1-stage, 2-stage and modulating burners, and control system CFB 930 and/or control system EMS maximum of 8 boilers as the module can be used 2 x. Operation in parallel or series to take system-specific standard efficiencies into account Load limit either according to outside temperature or external contact Sequence reversal for boilers either daily, according to outside temperature, hours run or an external contact Central fault message function via relay with zero volt contact programmable 0-10 V input for external set value hook-up as set temperature or default output programmable 0-10 V output for external set temperature demand DHW heating via EMS of boiler 1 FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
10 Product and function description Heat meter input Internal communication via data BUS Encoded and colour-coded connection plugs Continued operation in case of faults 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 11 2.1 Front panel Fig. 1 Front panel FM458/CMC 930 function module 1 LED boiler 4 enabled 2 LED boiler 3 enabled 3 LED boiler 2 enabled 4 LED boiler 1 enabled 5 LED "Module fault" (red) general module fault 6 LED DHW active via EMS boiler 1 7 LED flow too cold, therefore higher output 8 LED flow too hot, therefore lower output 9 LED flue gas test active FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
12 Product and function description 2.2 Switch on the module PCB 2.2.1 Module recognition switch With this switch, the function module FM458/CMC 930 can be configured as the function module FM447 in the case of replacement. This is required in older systems with software versions below 8.xx, which do not yet recognise the FM458/CMC 930. Position Function FM458/ CMC 930 The module logs on as FM458/CMC 930. FM458/ CMC 930 The module logs on as FM447. USER INFORMATION The functions described in this document will not be available if the switch is set to FM447. For information regarding parameterisation, please see the service instructions for the control unit CFB 910 or CFB 930. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 13 FM458/ CMC 930 FM458/ CMC 930 6 720 649 442-01.1ITL Fig. 2 Position module recognition switch FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
14 Product and function description 2.2.2 Voltage/current output With the slide switch (voltage/current output), you can configure the output of the temperature demand (terminal U 3,4). Slide switch set to U: The temperature demand is issued as a voltage from 0 to 10 V. Slide switch set to I: The temperature demand is issued as a current from 0 ma to 20 ma. You can freely assign voltage or current (see Chapter 6.1 "0 10 V input", page 58). Fig. 3 Slide switch voltage/current output FM458/CMC 930 1 Slide switch (factory setting 0 10 V) 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 15 2.3 Terminology key 2.3.1 EMS boiler EMS boilers are boilers which are equipped with an energy management system, i.e. wall mounted boilers with UBA 3.x or floor standing boilers with MX10/MX15 and burner control unit. 2.3.2 CAN boiler CAN boilers are boilers which are connected to the control unit CFB 910/930 via the standardised 7-pole burner plug for stage 1 or the 4-pole burner plug for stage 2 or modulation. 2.3.3 Mixed cascade A mixed cascade is a multi-boiler system with up to 8 boilers in which completely different boiler types can be combined with each other, e.g. a) floor standing CAN boilers with EMS wall mounted boilers b) floor standing EMS boilers with EMS wall mounted boilers c) floor standing CAN boilers with floor standing EMS boilers or d) floor standing CAN boilers with floor standing boilers EMS boilers with EMS wall mounted boilers FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
16 Product and function description 2.3.4 Series operation In operation in series, the next boiler in the sequence will only be enabled if the previous boiler has reached 100 % of its output. Fig. 4 Diagram "Operation in series" 1 Boiler 1 (modulating burner) 2 Boiler 2 (modulating burner) 3 Boiler 3 (2-stage burner) 4 On/Off mode x Total heating system output y Heating system heat input 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 17 2.3.5 Parallel operation In parallel mode, the boilers are jointly matched to the demand. With this operation, the strategy function first enables the base stage of boiler 1, then the base stage for boiler 2 etc. When all boilers operate at their base stage, all boilers are modulated in parallel. Fig. 5 Diagram "parallel operation" 1 Boiler 1 2 Boiler 2 3 Boiler 3 4 On/Off mode x Total heating system output FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
18 Product and function description 2.3.6 Boiler sequence Alongside the individual power stages and their enabling, the function module FM458/CMC 930 manages the sequence of boiler switching. This determines which boiler functions as lead boiler and whether or in what circumstances the sequence will be reversed. The sequences of the different boiler circuits can be defined automatically (by the FM458/CMC 930) or manually. Five setting options are available for sequence reversal: "No sequence reversal" (manual boiler sequence selection) The system operator specifies a set boiler sequence that is always observed. The option "No sequence switching" must be set for the strategy at the service level on the Programmer programming unit. Daily sequence switching The strategy function switches to a different boiler sequence cyclically at 00:00 hours every day. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 19 Boiler sequence reversal after hours run The boiler sequence is selected in accordance with the hours run. This means that the strategy function switches to a different boiler sequence cyclically at 00:00 if the relevant lead boiler has exceeded a set number of hours of operation. Fig. 6 Boiler sequence reversal after hours run 1 Boiler 1 2 Boiler 2 3 Boiler 3 4 Lead boiler change-over 5 Hours run by the heating system FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
20 Product and function description Sequence reversal subject to outside temperature The boiler sequences A, B, C and D are selected subject to the outside temperature. The temperature changeover thresholds are freely adjustable (settings see Chapter 7.5 "Sequence switching", page 72). The following table shows an example for the different boiler sequences (in automatic mode by the FM458/CMC 930). Number of boilers 4th Zone Sequence D 3rd Zone Sequence C 2nd Zone Sequence B 1st Zone Sequence A 2 1-2 2-1 3 1-2-3 3-2-1 3-1-2 4 1-2-3-4 2-3-4-1 3-4-1-2 4-1-2-3 Temperature changeover thresholds 5 C 10 C 15 C Tab. 1 Factory-set boiler sequences (automatic) 2.3.7 Load limit The load limit (for settings, see Chapter 7.6 "Load limit", page 80) prevents the starting of lag boilers that are not required if high heat demands are strictly peak loads. The load limit function enables the number of boilers to be matched to lower system loads, e.g. during spring and autumn. Boilers that are not required are disabled. However, the load limit will be lifted if inadequate heat is provided due to faults in an individual boiler. The following dependencies can be drawn into consideration for blocking the lag boiler using the load limit function. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Product and function description 21 Load limit according to outside temperature This function blocks the lag boiler automatically depending on a set outside temperature (setting range of 0 C to +30 C). Fig. 7 Diagram "Load limit at outside temperature" 1 Zone 3 2 Zone 2 3 Zone 1 x Temperature thresholds y Number of boilers Subject to the number of boilers, up to 2 temperature thresholds can be defined. The outside temperature raneg is thus subdivided into up to 3 zones. Zone 1 is the high outside-temperature range. For this zone, the number of enabled boilers can be adjusted. As the outside temperature falls, additional boilers are allowed. All boilers can be enabled in zone 3. In heating systems with more than 3 boilers, boilers are variably enabled in zone 2 as the outside temperature drops (setting see Chapter 7.6 "Load limit", page 80). FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
22 Product and function description Load limit via external isolated contact An adjustable number of boilers can be blocked via the external zero volt contact (on-site connection to terminal EL in the FM458 / CMC 930 function module). All boilers can be blocked. This enables all boilers to be shut down, for example if external heat sources are available. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 23 3 Installation 3.1 Scope of supply Check the delivery for completeness. Fig. 8 Scope of supply for function module FM458/CMC 930 1 Heat conductive paste 2 9 mm sensor as contact sensor 1) 3 Function module FM458/CMC 930 4 Fixing material for 9 mm sensor 1) Subject to the installation situation, the sensors can be used for the sensor connections listed in Tab. 3, page 26. The curves are identical. Not shown: Operating instructions, service instructions, wiring diagram FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
24 Installation 3.2 Checking the software versions The software versions of the controller module CM 431 and the Programmer programming unit must be at least version 8.xx. Before installing the function module FM458/CMC 930, check the software version of the controller module CM 431 and the Programmer programming unit at the service level (at least Version 8.xx). You can obtain more detailed information from any Bosch branch. 3.3 Installation in the CFB 930 control unit Generally, you can fit the FM458 / CMC 930 function module into any vacant slot in the CFB 9x0 of the series CFB 930 (e.g. slot 1 4 in the CFB 9x0). USER INFORMATION Advice: Arrange the function module FM458/CMC 930 as far right as possible. This achieves a logical assignment of the heating circuits. The heating circuit modules should be inserted in the control unit starting from the left-hand side (slot 1). Exception: certain function modules must be installed in designated slots. This module can only be installed in the master control unit with ECO-CAN bus address 0 or 1. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 25 Fig. 9 Slot assignment 1 4 (Example CFB 9xx) 1 Slot 1, e.g. FM442/CMM 920 (heating circuit 1, heating circuit 2) 2 Slot 2, e.g. FM442/CMM 920 (heating circuit 3, heating circuit 4) 3 Slot 3: e.g. FM441/CMM 910 (heating circuit 5, DHW/circulation pump) 4 Slot 4: e.g. FM458/CMC 930 (strategy, for multi-boiler systems) 3.4 Connecting inputs and outputs The LV terminals and the 230 V outputs are available at the rear top of the FM458/CMC 930 function module. Coloured labels with inscriptions matching the appropriate plugs are fitted to the strips. Plugs are colour-coded and inscribed. Connect inputs and outputs correctly. For further information, see see Chapter 3.8 "Recommended hydraulic schemes", page 32 to Page 50. Fig. 10 FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
26 Installation Designation AS Description Output central fault message, zero volt min. breaking capacity 12 V/20 ma max. breaking capacity 230 V/5 A Tab. 2 Inputs and outputs (terminal designation) 3.5 Connecting sensors The sensor connections are on the back side of the function module FM458/CMC 930. Coloured labels with inscriptions matching the appropriate plugs are fitted to the strips. Plugs are colour-coded and inscribed. Sensor designation key FVS FRS ZW EL U in 1/2 U out 3/4 Tab. 3 Designation Fühler Vorlauf Strategie [Strategy flow sensor] Fühler Rücklauf Strategie [Strategy return sensor] Zählereingang Wärmemengenzähler [Meter input - heat meter] Eingang Lastbegrenzung [Load limit input] Voltage input 0 10 volt Output 0 10 volt Sensor connections Function This sensor is used to regulate a multi-boiler system. It defines the heat transfer point from the boiler to the system (system flow). This sensor is used to regulate the operating conditions of a multi-boiler system. It defines the system return. An external heat meter can be connected via a zero volt contact to this terminal; this can be evaluated in the statistic function. Option: Input for external boiler sequence reversal. This input enables the system to be operated externally, dependent either on flow temperature or output; the system flow sensor acts as a reference point. This output informs the external control system about the current set system flow temperature. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 27 USER INFORMATION Ensure that you connect the sensors correctly and in the correct positions. For further information, see Chapter 3.8 "Recommended hydraulic schemes", page 32 and following. USER INFORMATION When using two FM458/CMC 930 modules, connect the temperature sensors, the heat meter sensor, and the external sequence changeover and the external load limit to the module that is connected to boiler 1. If the voltage inputs are connected to each module as the default set temperature, the highest temperature will be used as the set value for the strategy. The voltage and fault message outputs are identical for both modules. 3.6 Connecting EMS boilers The connections for connecting EMS boilers are at the rear top of the FM458/CMC 930 function module. Labels with inscriptions matching the appropriate plugs are fitted to the strips. EMS 1 EMS 2 EMS 3 EMS 4 2 1 2 1 2 1 2 1 EMS 1 interface to EMS boiler 1 EMS 4 interface to EMS boiler 4 If a second FM458/CMC 930 is installed, terminal on the r.h. (2nd) FM458/CMC 930 is assigned to boiler 5, terminal EMS 1 to boiler 6, terminal EMS 2 to boiler 7 EMS 3 and terminal EMS 4 to boiler 8. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
28 Installation 3.7 Assigning the boiler number The boilers are numbered consecutively starting from boiler 1. Boiler numbers are assigned as follows: for CAN boilers, by adjusting the CAN BUS address (address DIP switches) for EMS boilers, via connection to terminal EMS 1, EMS 2, EMS 3 or EMS 4 on the FM458/CMC 930 module. Important: the assignment of the boiler numbers must be unambiguous. Each boiler number may only be assigned once! USER INFORMATION The boiler sequence utilises the boiler number and is freely programmable via parameters. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 29 Application 1: If only CAN boilers are installed, then the first CAN boiler will be equipped with the CFB 930 control unit with installed FM458/ CMC 930 module; this control unit is set to CAN address 1. The lag boilers receive the control unit CFB 910; these are numbered upwards with CAN addr. 2, 3 etc. Fig. 11 Multi-boiler system with CFB 930 control unit 1 CAN boiler 1 (Control unit with ECO-CAN bus address 1) 2 CAN boiler 2 (Control unit with ECO-CAN bus address 2) 3 CAN boiler 3 (Control unit with ECO-CAN bus address 3) FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
30 Installation Application 2: If only EMS boilers are installed, use the CSM 920 control unit. This will be equipped with the FM458/CMC 930 module and set to CAN address 0/1. Boiler numbers are permanently assigned to the relevant boiler via terminals EMS 1, EMS 2, EMS or EMS 4 in the FM458/CMC 930 module. The boilers are consecutively numbered upwards. Fig. 12 Multi-boiler system with EMS control unit 1 EMS boiler 1 (at terminal EMS1) 2 EMS boiler 2 (at terminal EMS2) 3 Control unit CSM 920 (control unit with ECO-CAN BUS address 0/1) 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 31 Application 3: If one or several CAN boiler(s) AND one or several EMS boiler(s) are installed, then the first CAN boiler will be equipped with the CFB 930 control unit with fitted FM458/CMC 930 module; this control unit is set to CAN address 1. The lag boilers will then be numbered upwards from 2, 3 etc. Fig. 13 Multi-boiler system with CFB 930 controller and EMS controller 1 CAN boiler 1 (Control unit with ECO-CAN bus address 1) 2 EMS boiler 2 (at terminal EMS2) 3 CAN boiler 3 (Control unit with ECO-CAN bus address 3) FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
32 Installation 3.8 Recommended hydraulic schemes The recommended and displayed hydraulic schemes are tailored to the type of heat source, and show a selection of the schemes that are made possible by the FM458/CMC 930 function module. We differentiate between EMS and CAN boilers. EMS boilers are factory-fitted with the EMS control system. Floor standing EMS boilers are fitted with the MX10/MX15 control unit with BC15 programming unit; wall mounted boilers are equipped with the BC15 programming unit. CAN boilers must each be equipped with a CFB 910/930 control unit. Corresponding parameters are listed for each hydraulic scheme. DAMAGE TO THE SYSTEM CAUTION! The hydraulic schemes listed in this chapter are only illustrations of relative positions of the sensors, pumps and servomotors/ actuators that may be required. For the sake of clarity, some hydraulic components that may be required, such as overflow valves, expansion vessels etc., are not shown. Install the hydraulic components in accordance with current technology. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 33 Designation Designation DV Motorised ring butterfly valve PS Cylinder primary pump EMS Energy Management System PZ DHW circulation pump FA Sensor outside temperature RK Boiler return FB Drinking water sensor RV line regulating valve FK Sensor boiler water temperature RWT Heat exchanger return FV Heating circuit flow sensor SH Heating circuit actuator FVS Strategy flow sensor SR Return servomotor HK Heat.circuit TWH Temperature limiter - underfloor heating circuit HB High temperature heating circuit VK Boiler flow LT Low temperature heating circuit VWT Heat exchanger flow PH CH circulation pump PK Boiler circulation pump Tab. 4 Abbreviations used in the hydraulic schemes FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
34 Installation 3.8.1 CAN boiler via low loss header 4-boiler system; boilers integrated via low loss header (pressureless distributor), heating circuits and DHW heating via primary pump (CB = condensing boiler, LTB = low-temperature boiler) Fig. 14 Hydraulic scheme 1 1 CAN boiler 1: e.g. condensing boiler 2 CAN boiler 2: e.g. low-temperature boiler 3 CAN boiler 3: e.g. low-temperature boiler 4 CAN boiler 4: e.g. low-temperature boiler 5 CFB 930 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 6 CFB 910 7 CFB 910 8 CFB 910 9 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 35 No. Parameter Adjustments Description 1. Number of boilers 4 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling yes 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. Notes: The operating conditions are met and the lag boilers are hydraulically blocked via the boiler circuit (either via the boiler circuit pump and 3-way boiler circuit actuator or via the boiler circuit pump and check valve). DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
36 Installation 3.8.2 EMS boiler via low loss header 4-boiler system with floorstanding condensing boilers; boilers connected via low loss header (hydraulic separator), heating zones and DHW heating via tank primary pump (BW boiler = condensing boiler, LT boiler = low temperature boiler) Fig. 15 Hydraulic scheme 2 1 EMS boiler 1: e.g. condensing boiler 2 EMS boiler 2: e.g. condensing boiler 3 EMS boiler 3: e.g. condensing boiler 4 EMS boiler 4: e.g. condensing boiler 5 CSM 920 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 6 DHW cylinder 7 MX10/MX15 8 MX10/MX15 9 MX10/MX15 10 MX10/MX15 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 37 No. Parameter Adjustments Description 1. Number of boilers 4 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling yes 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. Notes: The operating conditions are met and the lag boilers are hydraulically blocked via the boiler circuit pump and check valve. DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
38 Installation 3.8.3 EMS boiler with EMS DHW 4-boiler system with floorstanding condensing boilers; boilers connected via low loss header (hydraulic separator), heating circuits and DHW heating via tank primary pump of the EMS boiler 1 (BW boiler = condensing boiler). Fig. 16 Hydraulic scheme 3 1 EMS boiler 1: e.g. condensing boiler 2 EMS boiler 2: e.g. condensing boiler 3 EMS boiler 3: e.g. condensing boiler 4 EMS boiler 4: e.g. condensing boiler 5 CSM 920 with FM442/CMM 920 and FM458/CMC 930 6 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 39 No. Parameter Adjustments Description 1. Number of boilers 4 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling yes 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default boiler-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. Notes: DHW heating via diverter valve of EMS boiler 1 (see Chapter 8 "DHW data", page 88). Hydraulic blocking of the lag boiler via boiler circuit pump and check valve. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
40 Installation 3.8.4 CAN boilers in series 2-boiler system; boilers integrated in series (pressure distributor), heating circuits and DHW heating via primary pump (CB = condensing boiler, LTB = low-temperature boiler) Fig. 17 Hydraulic scheme 4 1 CAN boiler 1: e.g. condensing boiler 2 CAN boiler 2: e.g. low-temperature boiler 3 CFB 930 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 4 CFB 910 5 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 41 No. Parameter Adjustments Description 1. Number of boilers 2 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling no 4. Sequence reversal (Chapter 7.5, page 72) None 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. Notes: High efficiency through fixed boiler sequence with condensing boiler as lead boiler. The operating conditions are met and the lag boilers are hydraulically blocked via the boiler circuit (either via the boiler circuit pump and 3-way boiler circuit actuator or via the boiler circuit pump and check valve). DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
42 Installation 3.8.5 CAN boilers in parallel 2-boiler system; boilers integrated in parallel (pressure distributor); heating circuits and DHW heating via primary pump. Fig. 18 Hydraulic scheme 5 1 external condensing flue gas heat exchanger (boiler 1) 2 CAN boiler 1: e.g. oil/gas boiler 3 CAN boiler 2: e.g. oil/gas boiler 4 CFB 930 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 5 CFB 910 6 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 43 No. Parameter Adjustments Description 1. Number of boilers 2 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling no 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. Notes: Match the respective pressure drop on the boiler side through suitable measures, such as through sizing the pipework or balancing valves. Separate boiler circuit servomotors (motorised ring butterfly valves) for maintaining the operating temperatures plus for hydraulic blocking of lag boilers. Recommended load split of boilers: 50/50. Externally controlled heating circuit not recommended. DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
44 Installation 3.8.6 CAN boilers in "Tichelmann System" 2-boiler system; boilers integrated according to "Tichelmann System" (pressure distributor), heating circuits and DHW heating via primary pump (LTB = low-temperature boiler) Fig. 19 Hydraulic scheme 6 1 CAN boiler 1: e.g. low-temperature boiler 2 CAN boiler 2: e.g. low-temperature boiler 3 CFB 930 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 4 CFB 910 5 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 45 No. Parameter Adjustments Description 1. Number of boilers 2 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling no 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode serial boiler-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. information Only install boilers of the same type (same hydraulic pressure drop). Separate boiler circuit servomotors (motorised ring butterfly valves) for maintaining the operating temperatures plus for hydraulic blocking of lag boilers. Load split of boilers: 50/50 %. Externally regulated heating circuits are not recommended. DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
46 Installation 3.8.7 Twin-block boiler according to the "Tichelmann principle" 2-boiler system; boilers connected according to the "Tichelmann principle" (hydraulic separator); operating conditions for the 2-block boilers are ensured by internal control panels HT 3101e, heating circuits and domestic hot water by the tank primary pump. Fig. 20 Hydraulic scheme 7 1 CAN boiler 1: e.g. oil/gas boiler 2 CAN boiler 2: e.g. oil/gas boiler 3 CFB 930 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 4 CFB 910 5 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 47 No. Parameter Adjustments Description 1. Number of boilers 2 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling no 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. information Only install boilers of the same type (same hydraulic pressure drop). Internal boiler servomotors maintain the operating conditions and the hydraulic blocking of the lag boiler. Load split of boilers: 50/50 %. Externally regulated heating circuits are not recommended. DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
48 Installation 3.8.8 Mixed cascade via low loss header 2-boiler system; boilers integrated via low loss header (pressureless distributor), heating circuits and DHW heating via primary pump (CB = condensing boiler, LTB = low-temperature boiler) Fig. 21 Hydraulic scheme 8 1 CAN boiler 1: e.g. low-temperature boiler 2 EMS boiler 2: e.g. condensing boiler 3 CFB 930 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 4 MX10/MX15 5 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 49 No. Parameter Adjustments Description 1. Number of boilers 2 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling yes 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. information The operating conditions are met and the lag boilers are hydraulically blocked via the boiler circuit (either via boiler circuit pump and 3-way boiler circuit actuator (only CAN boilers) or via boiler circuit pump and check valve (EMS and CAN boilers)). DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
50 Installation 3.8.9 System with different EMS boilers 2-boiler system with floor standing and wall mounted boilers; boilers integrated via low loss header (pressureless distributor), heating circuits and DHW heating via primary pump (CB = condensing boiler) Fig. 22 Hydraulic scheme 9 1 EMS boiler 1: e.g. condensing boiler 2 EMS boiler 2: e.g. condensing boiler 3 MX10/MX15 4 CSM 920 with FM441/CMM 910, FM442/CMM 920 and FM458/CMC 930 5 DHW cylinder 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Installation 51 No. Parameter Adjustments Description 1. Number of boilers 2 2. Maximum system temperature 75 C system-specific 3. Hydraulic decoupling yes 4. Sequence reversal (Chapter 7.5, page 72) No default system-specific 5. Load limit (Chapter 7.6, page 80) No default system-specific 6. Operating mode No default system-specific 7. Lead boiler run-on time (pump) 60 min. 8. Run-on time for follow-on boiler 5 min. information The operating conditions are met and the lag boilers are hydraulically blocked via the boiler circuit pump and check valve. DHW heating via FM441/CMM 910 function module. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
52 Integrating EMS boilers 4 Integrating EMS boilers 4.1 Base controller BC15 The BC15 base controller enables the standard operation of boilers with EMS/UBA 3x or EMS/burner control unit. For information regarding the operation of the BC15, see the service instructions for the EMS boiler. USER INFORMATION Further functions are set via the Programmer programming unit. Both rotary selectors of the BC15 base controller must be set to "Aut" (otherwise a fault message will be issued). 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Integrating EMS boilers 53 2 3 4 5 6 1 11 10 9 8 7 Fig 23 Controls on the BC15 1 On/Off switch 2 Rotary selector for set DHW temperature 3 "DHW heating" LED 4 Status display 5 Rotary selector for maximum boiler water temperature in heating mode 6 "DHW demand" LED 7 "Burner" (On/Off) LED 8 Diagnostic plug 9 "Status display" key 10 "Flue gas test" key 11 "Reset" key (fault release button) FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
54 Integrating EMS boilers Setting the output limit The boiler output can be restricted to 11 kw (or 50 kw with higher boiler output) using a jumper on the back of the base controller. Remove the base controller. Remove jumper ( Fig. 24[1]) if the boiler output is to be restricted. Jumper Status Explanation Not inserted Output restricted to 11 kw (50 kw) (only for boilers with UBA 3) Inserted Unrestricted output (delivered condition) 1 Fig 24 Back of the BC15 base controller 1 Jumper for restricting output 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Functions of the FM458/CMC 930 55 5 Functions of the FM458/CMC 930 In the following sections, it is explained how to use the different functions and make settings via the Programmer programming unit. 5.1 Operation with Programmer SERVICE LEVEL GENERAL PARAM. Calling up the service level The respective service instructions of your control unit explain exactly how to use the Programmer programming unit. Here you will get a short overview of operating the Programmer. The Programmer has two operating levels available (level 1 with closed flap and level 2 with open flap) plus one service level (accessible via password). Various main menus are offered at the service level, giving access to sub-menus, where you can change the settings of the control units. 1 1 Display 2 Rotary selector 3 Function buttons 2 3 To reach the service level, press the following key combination (password), until "SERVICE LEVEL Gen. parameters" appears on the display. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
56 Functions of the FM458/CMC 930 5.2 Integrating function module FM458/CMC 930 in the control unit 5.2.1 Integrate function module FM458/CMC 930 on Programmer level After you have installed the FM458/CMC 930 function module ( see installation instructions "Modules for FB 9x0 control units"), your control unit will detect it automatically when it is switched on. USER INFORMATION If the function module FM458/CMC 930 is not automatically recognised, you must install it once manually via the Programmer programming unit. 5.2.2 Integrate function module FM458/CMC 930 manually on Programmer level Call up the service level. Turn the rotary selector until "SERVICE LEVEL Module selection" appears on the display. SERVICE LEVEL The display shows the main menu. Module selection Press "Display" to select the main menu "MODULE SELECTION". MODULE SELECTION Slot A The display shows "MODULE SELECTION Slot A". Boiler module ZM 434 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
Functions of the FM458/CMC 930 57 Turn the rotary selector to the position (slot) where the FM458/ CMC 930 function module is to be installed. The FM458/CMC 930 function module should be installed in e.g. slot 2. Hold down "Display" (the text in the lower line starts to flash) and turn rotary selector until the function module FM458/CMC 930 appears on the display. Release the display key". Press "Back". MODULE SELECTION slot 2 The function module FM458/CMC 930 ("strategy module") is installed on slot 2. Strategy module FM458 Press "Back" three times or close the operating flap to reach operating level 1. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
58 General specification data 6 General specification data 6.1 0 10 V input As soon as a module with 0 10 V input has been fitted in the control unit, the following masks appear as listed in the table below: Module FM448/ CMB 900-0-10V FM456/ CMC 910 FM457/ CMC 920 FM458/ CMC 930 Name Fault message module KSE 2 (EMS) KSE 4 (EMS) Strategy module Temperaturebased control ZM433 Substation X X X X X Output-based control X (CM431 V6.xx or higher) X (CM431 V6.xx or higher) X (CM431 V8.xx or higher) Call up the service level. "GENERAL PARAM." appears as the first main menu. Press "Display" to call up a submenu (here: "Min. outdoor temperature"). The display shows the selected submenu. GENERAL PARAM. Min outside temp -10 C Turn the rotary selector until the submenu "0 10 V input" appears. 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
General specification data 59 + Hold down "Display" and turn the rotary selector until the required set value appears (here: "Temp control"). GENERAL PARAM. The display shows the set value. Release "Display" to save the entry. 0-10 V input Temp. control 0 10 V input Input range OFF Temp.control Output control Factory setting Temp. control FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
60 General specification data 6.2 Temperature control 0 10 V input If you have selected "Temp. control" for a 0 10 V input, you can select the start and stop point, if required, for the external 0 10 V input. You can set the following: the set value in C for 0 V ("Temp. control 0V equates to") the set value in C for 10 V ("Temp. control 10V equates to") The following linear curve is calculated from these values: Fig 25 Input 0 10 V x Input voltage in V (factory setting) y Set boiler temperature in C The start value (start point) of the curve is set to 0.6 V for a positive curve, Fig. 25 shows the factory setting. Call up the service level. "GENERAL PARAM." appears as the first main menu. Press "Display" to call up a submenu (here: "Min. outdoor temperature"). 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
General specification data 61 The display shows the selected submenu. GENERAL PARAM. Min outside temp -10 C Turn the rotary selector until submenu "Temp. control equates to 0 V" or "Temp. control equates to 10 V" appears. + Hold down "Display" and turn the rotary selector until the required set value appears (here: "5 C"). The display shows the set value. GENERAL PARAM. Temp control Release "Display" to save the entry. 0 V equates to 5 C Press "Back" to return to the next level up. Turn the rotary selector until submenu "Temp. control equates to 10 V" appears. + Hold down "Display" and turn the rotary selector until the required set value appears (here: "90 C"). The display shows the set value. GENERAL PARAM. Temp control Release "Display" to save the entry. 10 V equates to 90 C FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
62 General specification data Input range Factory setting Temperature control 0 V 5 C 99 C 5 C Temperature control 10 V 5 C 99 C 90 C USER INFORMATION If a curve with a negative incline is programmed, e.g. 0 volt = 90 C, ensure that all 0 10 volt inputs of a control unit are controlled. An open input corresponds to 0 V and thus to a heat demand of e.g. 90 C. The demand should be set parallel at all 0 10 V inputs of a control unit, if applicable. 6.3 Output control for 0 10 V input The 0 10 V input can also be used for output control. If you have selected output control for the 0 10 V input, you can, if required, match the curve for external output control. You can set the following: The set output value for 0 V ("Output control equates to 0V equates to") The set output value for 10 V ("Output control equates to 10V equates to") The following linear curve is calculated from these values: 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module
General specification data 63 Fig 26 0 10 V input x Input voltage in V (factory setting) y Output demand in % The start value (start point) of the curve is set to 0.6 V with a positive curve. USER INFORMATION In case of external power control, the control units can no longer take internal heat demands, e.g. from heating zones or DHW function, into consideration. USER INFORMATION If a curve with a negative incline is programmed, e.g. 0 volt = 100 % output, ensure that all 0 10 volt inputs of this control unit are used. An open input corresponds to 0 V and thus to an output demand of 100 %. The demand should be set parallel at all 0 10 V inputs of a control unit, if applicable. FM458/CMC 930 Strategy module 6 720 803 196 (2011/06)
64 General specification data Call up the service level. "GENERAL PARAM." appears as the first main menu. Turn the rotary selector until the main menu "BOILER PARAM." appears. Press "Display" to call up a submenu (here: "No. of boilers"). Turn the rotary selector until submenu "Output control" appears. BOILER PARAM. The display shows the selected submenu. 0-10 V input Output-based control + Hold down "Display" and turn the rotary selector until the required value appears (here: "0 V corresponds to 0%"). BOILER PARAM. Output-based control 0 V equates to 0% The selected value flashes on the display. Release "Display" to save the entry. Turn the rotary selector until the submenu "10 V equates to...%" appears. + Hold down "Display" and turn the rotary selector until the required value appears (here: "10 V corresponds to 100%"). 6 720 803 196 (2011/06) FM458/CMC 930 Strategy module