Installation and operating instructions Cascade module KM Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. 08751/74-0 · Fax 08751/741600 · Internet: www.wolf-heiztechnik.de Part no.
Index Safety instructions.......................................................................3 Standards / Regulations..............................................................4 Terminology ...........................................................................5 Abbreviations / Equipment description........................................6 Installation ...........................................................................7 Configuration overview...........................................
Index / Safety instructions Emissions test .........................................................................52 Loading the standard values (reset)..........................................51 Fault codes .........................................................................53 Changing a fuse........................................................................54 Sensor resistances....................................................................55 Specification .............................
Standards / Regulations Standards and regulations The appliance and control accessories comply with the following regulations: EC Directives - 2006/95/EC Low Voltage Directive - 2004/108/EC EMC Directive EN Standards - EN 60730-1 - EN 55014-2 - EN 60529 Installation / Commissioning - According to DIN EN 50110-1, only qualified electricians may carry out the installation and commissioning of the heating control unit and connected accessories.
Terminology Terminology Header temperature The header temperature is the flow temperature in the header downstream of the low loss header. The header temperature therefore corresponds to the heating water temperature of heating systems equipped with a gas fired boiler. Heating water temperature The heating water temperature is the radiator flow temperature. The higher the heating water temperature, the higher the heat transfer to radiators.
Abbreviations / Equipment description Abbreviations SAF BPF MKF PF PK RLF SPF VF BS StE 0-10 V MKP MM SPLP LP BPP 3WUV StA CIR. HKP - Appliance description The cascade module (KM) comprises a cascade control for switching and modulating boilers. Only boilers of the same type (single stage, two-stage or modulating) and of the same output may be linked in a single cascade.
Installation Installation, cascade module 10.5 cm Mixer circuit pump Mixer motor OPEN Mixer motor CLOSE Output A1 eBUS Fault 12.5 cm - Remove the cascade module from its packaging. - Fitting directly to the wall. - Connect one outside temperature sensor to boiler 1 (address 1; boiler addressing, see page 26); alternative connection options see under "Electrical connection / Outside temperature sensor". - Install the outside temperature sensor at a north or north eastern wall at a height of 2-2.
Electrical connection Maximum thermostat When connecting the maximum thermostat at the "Max TH" terminals of the KM, only the mixer circuit pump will be stopped in case of faults (mixer no longer closes). Without a maximum thermostat, extremely high temperatures may occur in the underfloor heating circuit, should the KM develop a fault. This can result in the floor developing cracks.
Configuration overview Configuration overview Subject to the application of the KM, 13 different system versions are available. The different versions can be set with the configuration parameter (KM01).
Electrical connection Configuration 1: Mixer circuit and cylinder circuit Cylinder primary pump SPLP Power 230 VAC Maximum thermostat max.
Electrical connection Configuration 2: Mixer circuit and convector heater circuit Primary pump LP Power 230 VAC Zero volt contact PK Flow sensor; mixer circuit VF Boiler Header sensor SAF Maximum thermostat max.
Electrical connection Configuration 3: Mixer circuit and heating circuit Heating circuit pump HKP Power 230 VAC Flow sensor; mixer circuit VF Boiler Header sensor SAF Maximum thermostat max.
Electrical connection Configuration 4: Cylinder circuit and third party boiler control Cylinder primary pump SPLP Power 230 VAC Maximum thermostat max. TH1) Fault DHW message circulation output StA pump ZKP Burner control BSt Cylinder sensor SPF e.g.
Electrical connection Configuration 5: Mixer circuit and return temperature raising for central heating backup Buffer sensor PF Power 230 VAC Diverter valve 3 WUV Flow sensor VF; mixer circuit Boiler Return sensor RLF Header sensor SAF Maximum thermostat max.
Electrical connection Configuration 6: Heating circuit and return temperature raising for soft starting Heating circuit pump HKP Power 230 VAC Return sensor RLF Boiler Header sensor SAF Maximum thermostat max.
Electrical connection Configuration 7: Mixer circuit with indirect return temperature raising for soft starting Return Flow sensor RLF sensor, mixer circuit VF Power 230 VAC Boiler Header sensor SAF Maximum thermostat MaxTH 1) Mixer motor MM Mixer circuit pump MKP Fault message input StE (N/C)2) Mixer circuit Heating flow Heating return 1) 2) see description "Maximum thermostat" page 8 see description "Fault message input" page 8 16 3062449_0309
Electrical connection Configuration 8: Mixer circuit (factory setting) Flow sensor, mixer circuit VF Power 230 VAC Boiler Header sensor SAF Maximum thermostat MaxTH 1) Mixer motor MM Mixer circuit pump MKP Fault message input StE (N/C)2) Mixer circuit Heating flow Heating return 1) 2) see description "Maximum thermostat" page 8 see description "Fault message input" page 8 3062449_0309 17
Electrical connection Configuration 9: Heating circuit Power 230 VAC Heating circuit pump HKP Boiler Header sensor SAF Fault message input StE (N/C)2) Heating circuit Heating flow Heating return 2) see description "Fault message input" page 8 18 3062449_0309
Electrical connection Configuration 10: Cylinder circuit Power 230 VAC Cylinder sensor SPF Boiler Cylinder primary pump SPLP Header sensor SAF Fault message input StE (N/C)2) DHW cylinder Heating flow Heating return 2) see description "Fault message input" page 8 3062449_0309 19
Electrical connection Configuration 11: Convector heater circuit Power 230 VAC Primary pump LP Zero volt contact PK Boiler Header sensor SAF Fault message input StE (N/C)2) Convector heater circuit Heating flow Heating return 2) see description "Fault message input" page 8 20 3062449_0309
Electrical connection Configuration 12: 0 – 10 V input for telecontrol system Boiler Power 230 VAC Fault message output SA Fault message input StE (N/C)2) Header sensor SAF 0-10 VDC input 0-10 V from DDC system Heating flow Heating return 2) see description "Fault message input" page 8 3062449_0309 21
Electrical connection Configuration 13: Return temperature raising, wood burning boiler Power 230 VAC Diverter valve 3 WUV Boiler sensor KF Return sensor RLF Boiler 3) Header sensor SAF Maximum thermostat MaxTH 1) Mixer motor MM Fault message input StE (N/C)2) Mixer circuit pump MKP Buffer see description "Maximum thermostat" page 8 see description "Fault message input" page 8 3) if a boiler with WOLF control system is installed 1) 2) 22 3062449_0309
Commissioning Commissioning guidelines Implement the following steps in the order in which they are listed to achieve a successful commissioning with regards to addressing and programming all control components and the system configuration.
Commissioning Step 6 Configuration Wolf boiler control unit COB Parameter HG06 (pump operating mode): Select pump operating mode 1 in conjunction with Wolf boiler control unit COB. ⇒ HG06 = First description see COB control unit manual. Note: Parameter HG06 must not be changed for Wolf control units for wall mounted boilers and MGK standard control units. Step 7 Programming the following components 1.
Setting the eBUS address of the extension and programming modules (KM, MM, BM) Setting the eBUS address of the extension and programming modules (KM, MM and BM) Setting the eBus Address 0 Address 1 (factory setting) Address 2 Address 3 Address 4 Address 5 Address 6 Address 7 The address of the cascade module KM remains set to 1 (factory setting). In addition to the KM, up to six mixer modules MM can be connected to a single system.
Setting the eBUS address for Wolf boilers Setting of the eBUS address When operating several boilers (number of boilers >1) in conjunction for Wolf boilers with a cascade module, set the eBUS address for each boiler in accordance with the table below.
Switching times Switching times Mixer circuit: The switching times for the mixer circuit in the cascade module are stored in the cascade module. This is found at control level 2 → Time program → Heating system → Mixer 1 Heating circuit and cylinder: The switching times for the heating circuit and cylinder are always stored in the BM programming module. Time Block Switching Mixer Time Block Switching Mixer mode time mode time ON OFF ON OFF Time prog. 1 Mo-Su 1 5:00 21:00 Time prog.
List of parameters, standard setting / System Parameter list Standard setting Parameters TEMP DAY RED TEMP GRADIENT ROOM INFL W/S SWITCh ECO-RED This is found at control level 2 → Standard settings → Mixer 1 Setting range Individual setting Factory setting 5 °C - 30 °C 5 °C - 30 °C 0-3 OFF - ON 0 °C - 40 °C -10 °C - 40 °C 20°C 16 °C 0.
List of parameters MM Parameter list This is found at control level 2 → Contractor → Mixer 1 Contractor, mixer circuit in the KM Parameters MI01 MI02 MI03 MI04 MI05 MI06 MI07 MI08 MI09 MI10 MI11 MI12 MI13 MI14 MI15 MI16 MI17 MI18 Setting range Factory setting Min. mixer circuit temp 0 °C - 80 °C 0 °C Max.
List of parameters KM Parameter list Contractor cascade This is found at control level 2 → Contractor → Cascade Setting range Factory setting 1 13 8 KM02 Configuration Mode (single stage = 1; two-stage=2; modulating = 3) 1 3 3 KM03 Maximum header temperature 50 °C 85 °C 85 °C 40 °C 85 °C 75 °C 20 °C 2K 0 min 70 °C 20 K 30 min 20 °C 5K 5 min 10 h 2000 h 200 h 20 K/% 500 K/% 100 K/% 20 K/% 500 K/% 100 K/% 5s 500 s 50 s [AbCd] [12345] [12345] 10% 70% 0 [54321] [54321] 60% 10
List of parameters KM Display KM60 KM61 KM62 KM70 KM71 KM72 KM73 KM74 3062449_0309 Control deviation Overall modulation level Modulation level, boilers E1 E2 VF SAF 0 - 10 V - - - - 31
Parameters / Function description With the r.h. rotary selector, choose the mixer parameter to be modified (MM..) from the contractor menu level (after entering the correct code). The mixer parameter to be modified (MM..) is changed by pressing (display indication flashes) and then turning the r.h. rotary selector. After setting the mixer parameter to be modified (MM..), pressing the r.h. rotary selector again confirms the setting. Pressing the Info pushbutton returns the standard display.
MI 04 Screed drying If an underfloor heating system is started for the first time in new buildings, the set flow temperature may, as an option, be controlled independent of the outside temperature either to a constant value or to control the set flow temperature in accordance with an automatic screed drying program. If this function has been enabled (setting 1 or 2), it can be terminated by resetting parameter MI 04 to 0.
Parameters / Function description MI 06 Mixer circuit pump run-on time The mixer circuit pump / heating circuit pump will run on according to the set value after the mixer circuit / heating circuit has been switched OFF. MI 07 Mixer circuit proportional range Subject to application, the mixer circuit controller can be configured for the mixer circuit in the heating flow or for the mixer circuit for return temperature raising.
Parameters / Function description Example of a set return temperature = 30 °C: Actual return temperature [K] Time Mixer "CLOSE" Mixer "CLOSE" and pump "OFF" Forced actuation MI 09 max. cylinder heating time Cylinder heating is deemed to have been completed when the actual cylinder temperature is ≥ set cylinder temperature. Fault code 52 is issued and the control unit switches over to heating mode for the "Max. cylinder heating time", if cylinder heating is not completed within the max.
Parameters / Function description MI 12 Primary pump block For starting the primary pump, cylinder primary pump (configuration 1, 4 and 10) Or for ext. heat demand (configuration 2 and 11), we differentiate between two cases: a) Par. MI 12 = 0: The primary pump is started immediately after the demand is issued. b1) Par.
Parameters / Function description MI 17 Boiler excess temperature during cylinder heating Cylinder heating starts when the actual cylinder temperature < set cylinder temperature - 5 K. The set flow temperature then results from the set cylinder temperature + excess boiler water temperature during cylinder heating.
Parameters / Function description Note: Only contractors should adjust the KM parameters. With the r.h. rotary selector, choose the cascade parameter to be modified (KM..) from the contractor menu level (after entering the correct code). The cascade parameter to be modified (KM..) is changed by pressing (display indicator flashes) and then turning the r.h. rotary selector. After setting the cascade parameter to be modified (KM..), pressing the r.h. rotary selector again confirms the setting.
Parameters / Function description KM 04 Maximum flow temperature The "Maximum flow temperature" parameter limits the set header temperature of the heating circuits (mixer circuits and direct heating circuits) upwards. Parameter km 03 takes priority. KM 05 Minimum flow temperature The "Minimum header temperature" parameter limits the set header temperature downwards.
Parameters / Function description KM 12 Selection boiler sequence KM 12 8 Factory setting: d Setting range: A, b, C, d Individual settings: _________ The boiler sequence (A, b, C, d) is selected with the “Selection boiler sequence” parameter. Setting A: The boiler sequence selected under "Boiler sequence A" applies. Setting b: The boiler sequence selected under "Boiler sequence b" applies. Setting C: Automatic change of boiler sequence A and b (see parameter km 08).
Parameters / Function description Description and example of KM13 Boiler sequence A BUS address, boiler Parameters KM 13 A1 1 Order (1) in which the boiler starts The setting of the boiler sequence is illustrated using two boilers as example. KM 13 A1 1 R.h. rotary selector press at the programming module KM 13 A1 Select parameter KM 13 Select boiler sequence A with boiler address 1 Order boiler address 1 Order boiler address 1 flashes 1 R.h.
Parameters / Function description KM 13 A2 2 Order boiler address 2 flashes Turn the r.h. rotary selector on the programming module KM 13 Order boiler address 1 change from 2 to 1 A2 1 R.h. rotary selector press at the programming module KM 13 A2 Saving the new boiler sequence 1 Note: The sequence of all boilers must be matched if the sequence of one boiler is changed.
Parameters / Function description Additional information regarding the cascade algorithm for modulating boilers in conjunction with configuration 12 and parameter KM 31 = 1 In this case, the following functions do not apply: a) Shutdown conditions for an additional boiler, if the "actual header temperature > set header temperature + 1 K". b) Shutdown condition of the lead boiler if the "actual header temperature > set header temperature + header temperature hysteresis".
Parameters / Function description c) For two-stage boilers (KM 02 = 2; KM 15 and KM 16 exert no influence) With two-stage boilers, the second stage is treated as if it were a boiler in its own right that is always started after stage 1 and is always shut down prior to stage 1 of that boiler.
Parameters / Function description KM 17 DHW circulation pump Connecting a DHW circulation pump to the KM only works in conjunction with configuration 04 at the KM. The DHW circulation pump will only be enabled if the cylinder primary pump has been enabled via the "Cylinder heating" time slot.
Parameters / Function description Start enabling/start blocking for the lead boiler: - Start enabling: Boiler temperature, lead boiler > actual header temperature + hysteresis, modulation stop - Start enabling: Boiler temperature, lead boiler < actual header temperature + 5 K Hysteresis modulation stop KM 20 adjustable from 10 K to 50 K.
Parameters / Function description Falling header temperature: Sa_ist ≤ Sa_Soll - hysteresis, parallel mode ⇒ all mixers towards "CLOSE".
Parameters / Function description KM 27 Set boiler value and KM 28 Set boiler value hysteresis and KM 29 Set buffer value and KM30 Set buffer value hysteresis Configuration KM 01=13 a) Return temperature raising, wood burning boiler: The mixer control unit (mixer, return temperature raising and mixer circuit pump) transfers the energy from the wood burning boiler into the buffer, and at the same time regulates the return temperature.
Parameters / Function description Information regarding configuration 13: a) Without Wolf boiler and valve position AB → B ⇒ BM display "Actual header temperature = 0.0". Without a Wolf boiler, the cylinder primary pump block (parameter MI 12) must not be enabled in any MM or KM. b) With Wolf boiler and valve position AB → B ⇒ BM display "Actual header temperature = actual boiler water temperature of the Wolf boiler".
Parameters / Function description KM 31 Operating mode 0 - 10 V input Configuration KM 01 = 12 When using system configuration 12, the external voltage signal at the 0 - 10 V input of the cascade module is used as command variable. In addition, parameter KM 31 determines whether the command variable is used either a) to default the modulation level (KM31=1, factory setting, or a) to default the set header temperature (KM31=2).
Parameters / Function description KM 50 Test function Parameter KM50 enables the individual control of the relays. KM50 = 1 ⇒ Control, mixer circuit pump relay MKP KM50 = 2 ⇒ Control, mixer motor relay "OPEN" MM KM50 = 3 ⇒ Control, mixer motor relay "CLOSE" MM KM50 = 4 ⇒ Control, relay output A1 KM 60 Control deviation Indicates the control deviation = set header temperature - actual header temperature. KM 61 Overall modulation level Indicates the overall modulation level.
Additional functions / Reset Header frost protection The header is protected against frost if the program selector is set to "Standby" or "Summer mode". The burner will be enabled if the header temperature falls below 5 °C. All heating circuits and primary pumps are started at the cascade module, and the set mixer circuit temperature (if a mixer circuit is installed at the KM) of the KM are regulated to a flow temperature of 40 °C.
Fault codes When KM recognises a fault, the red LED flashes and the cascade module fault code is displayed on the associated BM as well as on the central BM (address 0). The following KM faults are transmitted via the BUS and are displayed. Fault code Description Cause Remedy FC52 maximum DHW cylinder heating time max.
Changing a fuse If the KM shows no function at all and there is no LED display, although power is ON, check the appliance fuse and change it, if required Changing a fuse: Note: If the KM is operated as part of the Wolf control system, the display of one of the existing BM programming modules is retained, as this is supplied via the eBUS link to the other control components. Prior to opening the casing, isolate the cascade module from the power supply. How to change a fuse: 1. 2. 3. 4.
Sensor resistances NTC Sensor resistances Temp. °C -21 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 3062449_0309 Resist. Ω 51393 48487 45762 43207 40810 38560 36447 34463 32599 30846 29198 27648 26189 24816 23523 22305 21157 20075 19054 18091 17183 16325 15515 14750 14027 13344 12697 12086 11508 10961 10442 9952 9487 9046 8629 Boiler sensor, cylinder sensor, solar cylinder sensor, outside temperature sensor, flow sensor, header sensor Temp.
Specification Specification Supply voltage................................................................... 230 VAC (+10 / -15%) / 2A / 50 Hz Power consumption, electronics . ..................................... < 8 VA Max. power consumption, mixer motor ............................ 30 VA Max. power consumption per pump outlet ....................... 250 VA 0 - 10 V input: Insensitive to pole reversal and voltage resistant.............................................................
Keyword index A Anti-seizing pump protection........................................................................................... 52 B Boiler sequence (KM 12)................................................................................................. 40 BUS feed (MI 10)............................................................................................................. 35 C Changing a fuse.....................................................................................................
Keyword index M MI 01 Minimum mixer circuit temperature....................................................................... 32 MI 02 Maximum mixer circuit temperature...................................................................... 32 MI 03 Heating curve distance.......................................................................................... 32 Mi 04 Screed drying........................................................................................................
Keyword index 3062449_0309 59
Wolf GmbH · Postfach 1380 · 84048 Mainburg · Tel. 08751/74-0 · Fax 08751/741600 · Internet: www.wolf-heiztechnik.
