Ultramax KKM Cascade Manager Installation Operation and ......Ultramax KKM Cascade Manager...

Ultramax KKM Cascade Manager Installation Operation and Users

Guide (E4031)

MHS Boilers Limited. 35 Noble Square, Burnt Mills Industrial Estate, Basildon, Essex. SS13 1LT.

Telephone: 01268 591010. Fax: 01268 728202.

LUKKM

01/11/05

KKM02B 2

Safety information

General

Power connectionregulations

Warranty conditions

Descriptions of operatingprocedures

Notes

E This attention symbol is used in these Instructions to pointout risks and dangers to the life and limb of persons and/ordamage to property.

Please note the connection conditions specified by your localelectrical power supply utility and the VDE regulations.Your heating control system may be installed and serviced onlyby appropriately authorised specialists.

E If the system is not installed professionally, this will involvea risk to life and limb.

If the system is not installed, commissioned, serviced and re-paired professionally, this will render the manufacturer's war-ranty null and void.

Certain operating sequences are explained using examples.The statuses of the controller are illustrated or described asboxes. The following status can be accessed by operating theoperating controls as shown or by performing the operation de-scribed.

Key symbols:

Press Programming key

(Selection/Entry confirmation)

Operate rotary knob

! Important information is highlighted with an exclamationmark.

GENERAL

KKM02B 3

Contents GENERAL................................................................................. 2Safety information ................................................................ 2

General................................................................................ 2Power connection regulations ............................................. 2Warranty conditions............................................................. 2Descriptions of operating procedures.................................. 2Notes ................................................................................... 2

Contents................................................................................ 3

OPERATION ............................................................................. 5Variant ................................................................................... 5

The cascade manager......................................................... 5Operating modes.................................................................. 5

Mode-selector switch........................................................... 6i Frost-protection mode..................................................... 6q Automatic mode .............................................................. 6B Normal mode .................................................................. 6C Reduced mode................................................................. 6F Summer mode ................................................................. 6W Service mode .................................................................. 6x Manual mode.................................................................... 6

Programming ........................................................................ 7Settings ............................................................................... 7Basic functions .................................................................... 8Display............................................................................... 11Basic function Room temperature ..................................... 11Basic function Time/Day.................................................... 12Basic function Parameter list ............................................. 12

Heating program................................................................. 12Heating program level ....................................................... 12

Entry of the heating programs ........................................ 12Recommended procedure: ............................................. 13Selection of a heating program....................................... 13

Weekday / Period level...................................................... 15Switching times level ......................................................... 16

Switching times.................................................................. 17Parameter level................................................................... 20

Settings at Parameter level ............................................... 20

EXPLANATORY INFORMATION ........................................... 22Definitions........................................................................... 22

Flow resp. boiler temperature............................................ 22Frost-protection control...................................................... 22Weather-dependent control............................................... 22Room sensor influence...................................................... 22

Functions ............................................................................ 23Room temperature P1 and P2........................................... 23Reduced temperature P3 .................................................. 23Hot-water generation P4.................................................... 23

KKM02B 4

One-off hot water............................................................... 23Heat slope P5 and P6 ....................................................... 23

Note on setting ............................................................... 23Guideline values............................................................. 24

Holiday P7 ......................................................................... 24Heating program P9 .......................................................... 24Warm-up optimisation ....................................................... 25

Maximum time advance.................................................. 25Circulation pump control.................................................... 25

Conditions for switch-off ................................................. 25Outside temperature delay ................................................ 25Delayed pump switch-off ................................................... 25Pump blocking protection .................................................. 25EEPROM check ................................................................ 26DCF receiver ..................................................................... 26Telephone switch .............................................................. 26

Error messages .................................................................. 27RESET function................................................................. 27

FOR THE FITTER ................................................................... 28Parameters.......................................................................... 28

Technician level................................................................. 28Explanatory information..................................................... 32

System bus ......................................................................... 35The heating installation system CXE................................. 35Bus ID................................................................................ 35

Remote controls ................................................................. 36Operation-control module BM............................................ 36

Sensors ............................................................................... 36Outdoor sensor AFS.......................................................... 36Boiler sensor KFS ............................................................. 37Flow sensor VFAS v ......................................................... 37Storage tank sensor SPFS................................................ 37

System switch .................................................................... 38Maximum delimiter ............................................................ 38Telephone switch .............................................................. 38

Electrical connection ......................................................... 38System diagram ................................................................ 39System diagram for hot-water boiler.................................. 40Connection diagram .......................................................... 41

Terminal assignment ...................................................... 41Installation .......................................................................... 42Technical data .................................................................... 43

Sensor resistances............................................................ 43Technical data ................................................................... 43

KKM02B 5

Variant

The cascade manager

Operating modes

The cascade manager KKM has been designed for control ofheating systems with burner cascades up to 8 modulatingburners and an additional one stage burner (on,off).The integrated bus interface allows integration of the cascademanager in controlled heating systems with up to 15 heatingcircuits. The unit configures itself automatically on start-up/commissioning by detection of the connected sensors. Thecirculation pumps are controlled demand-dependently inheating operation. This achieves tremendous energy savings.The heating system is thus operated optimally andeconomically by the KKM controller used.

A Hinged control panel coverB Mode-selector switchC DisplayD TimeE WeekdayF Header temperatureG Current setting of the mode-selector switch (Automatic

mode)

OPERATION

A

D C

B

E

GF

KKM02B 6

Mode-selector switch

i Frost-protection mode

q Automatic mode

B Normal mode

C Reduced mode

F Summer mode

W Service mode

x Manual mode

If the hinged control panel cover is closed, the rotary knobserves as the mode-selector switch for the KKM. The currentoperating mode is shown as a symbol on the display.

! If the operating mode is changed, the new setting time takeseffect after 5 seconds.

The controller is switched off.If the actual temperature drops below the frost-protectiontemperature, the controller operates continuously in frost-protection mode.

Automatic change from Normal mode to Reduced mode at theprogrammed switching times.

The controller operates continuously in Normal mode and stabi-lises the system to the set normal temperature. The timer is in-operable.

The controller operates continuously in Reduced mode andstabilises the system to the set reduced temperature. The timeris inoperable.

(Hot-water operation)The controller switches the burner on only for hot-water gen-eration. The heating system is switched off continuously (Frost-protection mode).

All pumps and burners are switched on. The mixers are movedto position "open".

(only via Manual/Automatic switch)All pumps and burners are switched on. The mixers are notcontrolled. This means that the mixers must be adjusted manu-ally.

KKM02B 7

Programming

Settings When the hinged front cover is opened, the KKM controllerswitches automatically to Information and Programming mode.All entries can be made on the basis of the same principle:

1. Open the hinged cover on the front of the controller -> Con-troller switches to INFO mode. The (down) arrow points tothe first basic function (Room temperature 1).

2. The required basic function is selected with the rotary knob. The basic functions cover adjustable parameters or other

operating levels.3. Activate the selected basic function with the Programming

key .4. If you press key and have selected a lower operating

level -> continue at Point 2!5. If you press key and have selected a setting, the control-

ler changes to Programming mode (the redlamp/programming indicator lights).

6. The setting can be changed with the rotary knob .7. Press key again; this saves the new value.8. If you close the hinged cover before pressing key , this

quits Programming mode. The controller switches to thestandard display (header temperature and time). Thechanged value is not saved.

! You can branch up to the next operating level by pressingkey and selecting the "RETURN" function (=> "End").

KKM02B 8

Basic functions

A Rotary knob (Select settings / Adjust values) B Manual/Automatic switch (RESET)C Programming indicator (red lamp)D Programming key E Optical interface (optional)F Hinged control panel cover (open)

a Basic functions arrowb Unlocking holes

The basic functions can be selected with the rotary knob af-ter opening the hinged front cover.

• P1 Room temperature 1Display of the current room temperature (left) and the relateddesired value (right) for heating circuit 1 and the symbol for theheating circuit status.- Key (red lamp lights)- Change the desired temperature with - Save the value with • P2 Room temperature 2Display of the current room temperature (left) and the relateddesired value (right) for heating circuit 2 and the symbol for theheating circuit status.- Key (red lamp lights)- Change the desired temperature with - Save the value with

KKM02B 9

• P3 Reduced temperatureDisplay of the economy temperature for the entire heating sys-tem (right).- Key (red lamp lights)- Change the economy temperature with - Save the value with • P4 Hot-water temperatureDisplay of the current storage tank temperature (left) and therelated desired value for hot-water generation (right).- Key (red lamp lights)- Change the desired temperature with - Save the value with • P5 Heat slope 1Display of the heat slope gradient for heating circuit 1 (right).- Key (red lamp lights)- Change the heat slope with - Save the value with • P6 Heat slope 2Display of the heat slope gradient for heating circuit 2 (right).- Key (red lamp lights)- Change the heat slope with - Save the value with • P7 Holiday Display of the programmed holiday period in days for the entireheating system (right).- Key (red lamp lights) - Enter the holiday period with - Save the value with • P8 Time/Day Display of the current time (right) and the weekday. The week-day is displayed by a digit at the top of the display (Monday = 1, ..., Sunday = 7). - Key (red lamp lights) - Change the time with - Key (red lamp continues to light) - Change the weekday with - Save the weekday and the time with • P9 Heating programLevel for programming and selecting the current heating pro-grams (see corresponding chapter).

KKM02B 10

• P10 Parameter listLevel for entry of further settings for the heating system.- Press key - Select the setting with . Display of the system values (right)with the related parameter number (left)-> see Parameter list.- Key (red lamp lights)- Change the value with - Save the value with

! If a parameter is not present in the system, this is either indi-cated by dashes on the display (----) or the parameter ismasked or cannot be selected with the rotary knob .

! Technician level (as of parameter No. 20 of the parameterlist) contains the code No. of the stored parameters (seeChapter Technician level).

KKM02B 11

Z

Z

a b c d e

Display

Basic function Roomtemperature

A Function display(arrow points to symbol)

1 Mixer 1 open2 Mixer 1 closed3 Mixer 2 open4 Mixer 2 closed5 Bus connection established6 Heating circuit pump 1 running7 Heating circuit pump 2 running8 Circulation pump running9 Switching burner10 Storage tank pump / Switchover valve hot-water boiler

B Parameter number / Temperature displayC Reduced mode / Switch-off timeD Heating mode / Switch-on timeE Parameter values (temperatures, gradients, times,

On/Off [1/0], Error numbers, End)F Weekday display (1-7)G Warning/Fault displayH Arrow points to basic functionI Holiday modeJ Heating time (1-3)K Current operating mode

a Arrow points to basic functionb Room temperature, heating circuitc Heating moded Desired room temperature valuee Heating circuit pumps 1 + 2 runningf Weekdayg Timeh Parameter numberi Parameter setting

Z

Z

12345

678910

A B C D E F A

K G

J I H

KKM02B 12

Basic function Time/Day

Basic function Parameter list

Heating program

Heating program level

Entry of the heating pro-grams

Two heating programs between which the user can constantlyselect can be entered for each heating circuit. After opening thehinged control panel cover, you can select basic function Heat-ing program with the rotary knob . You can move to Entrylevel with the Programming key .

1) Heating program:Choose the heating program for entry of the switching times(for heating circuits I or II, hot water or the circulation pump)with the rotary knob P9.

2) Press key .3) Weekday/Period:

Choose the weekday or the period for which the switchingtimes are to be defined with the rotary knob (illustration).

4) Press key .5) Switching time: Choose the switching time to be changed

with the rotary knob (illustration).6) Press key (red lamp lights).7) Adjust the switching time with the rotary knob .8) Save with key .9) Back (higher level): Choose "End" with the rotary knob .

Press key .

! If switching time entry in blocks (Mo-Fr, Sa-Su, Mo-Su) is ac-tivated, the current switching times of the first day of the blockare displayed. The display does not show the switching timesof the entire block. If you activate a switching time with theProgramming key (red lamp lights) and then save thevalue by pressing the Programming key again, all switch-ing values in the block are overwritten by the switching valuesof the first day in the block!

f g a

Z

Z

Z

Z

h i a

KKM02B 13

Recommended procedure:

Selection of a heating pro-gram

1) Enter all heating times for the period Monday to Sunday(overwrite all switching times of the week!).

2) Enter different switching times for the corresponding days.

1) Select function 03 resp. 06 with the rotary knob at Heatingprogram level.

2) Press key .3) Choose heating program 1 or 2 with the rotary knob .4) Press key . The selected heating program is now opera-

tive in Automatic mode.

KKM02B 14

Heating program level

After opening the hinged control panel cover,choose basic function Heating program P9 with the

rotary knob . Press key .

Enter the heating times for heating program 1 ofheating circuit 1(see Weekday / Period)

Enter the heating times for heating program 2 ofheating circuit 1 (see Weekday / Period)

Select the current heating program for heating cir-cuit 1 (Program 01 or 02) with



Select the current heating program for heating cir-cuit 2 (Program 01 or 02) with

Enter the Enable times for hot-water generation(see Weekday / Period)

Enter the Enable times for the circulation pump(see Weekday / Period)

You can quit Heating program level by pressingthe Programming key. You can choose anotherbasic function with the rotary knob . Closing thehinged control panel cover completes the entry.

KKM02B 15

Weekday / Period level

1 The heating circuit is indicated bythe arrow pointing to the relatedpump symbol.

After selecting the heating program1 for entry of the

switching times with key , choose the weekday orthe period for which the switching times are to applywith the rotary knob .

Enter the heating times for Monday

Start this procedure with key

Enter the heating times for Tuesday


Enter the heating times for Wednesday


Enter the heating times for Thursday


Enter the heating times for Friday


Enter the heating times for Saturday


Enter the heating times for Sunday


Enter the heating times for Monday to Friday


Enter the heating times for Saturday to Sunday


Enter the heating times for Monday to Sunday


Pressing key returns you to the Heating programlevel. You can then use the rotary knob to choose afurther heating program. Closing the hinged controlpanel cover completes the entry.

KKM02B 16

Switching times levelA Parameter number (see Table; for heating program 1 in this case)B Display of the selected weekday / period (Tuesday in this case)C Enter the switching time for heating time 1, 2 or 3 (1 in this case)D Enter the switch-on or switch-off time (switch-on time in this case)E Entry of switching time (6.00 hours in this case)F Display of the current program (for heating circuit 1 in this case).

After choosing the weekday or the period forwhich a switching time is to be entered, choosethe switching time to be changed with the rotaryknob .

Entry: Start time of the first heating time

Entry: End of the first heating time

Entry: Start time of the second heating time

Entry: End of the second heating time

Entry: Start time of the third heating time

Entry: End of the third heating time

Pressing key returns you to the Week-day/Period level. You can then use the rotaryknob to choose a further period. Closing thehinged control panel cover completes the entry.

KKM02B 17

Switching times Heating circuit 1 -> Heating program 1

Heatingtime 1

Heatingtime 2

Heatingtime 3

No. 11 12 13 14 15 16

Mo 06:00 22:00 - - - -Pers

Tu 06:00 22:00 - - - -Pers

We 06:00 22:00 - - - -Pers

Th 06:00 22:00 - - - -Pers

Fr 06:00 22:00 - - - -Pers

Sa 07:00 23:00 - - - -Pers

Su 07:00 23:00 - - - -Pers

Condition as delivered and table forcurrent values (please enter)!

Heating circuit 1 -> Heating program 2

Heatingtime 1

Heatingtime 2

Heatingtime 3

No. 21 22 23 24 25 26

Mo 06:00 08:00 16:00 22:00 - -Pers

Tu 06:00 08:00 16:00 22:00 - -Pers

We 06:00 08:00 16:00 22:00 - -Pers

Th 06:00 08:00 16:00 22:00 - -Pers

Fr 06:00 08:00 16:00 22:00 - -Pers

Sa 07:00 23:00 - - - -Pers

Su 07:00 23:00 - - - -Pers

KKM02B 18

Hot-water program

Heatingtime 1

Heatingtime 2

No. 01 02 03 04

Mo 05:00 21:00 - -Pers

Tu 05:00 21:00 - -Pers

We 05:00 21:00 - -Pers

Th 05:00 21:00 - -Pers

Fr 05:00 21:00 - -Pers

Sa 06:00 22:00 - -Pers

Su 06:00 22:00 - -Pers

Circulation pump

Heatingtime 1

Heatingtime 2

No. 01 02 03 04

Mo 05:00 21:00 - -Pers

Tu 05:00 21:00 - -Pers

We 05:00 21:00 - -Pers

Th 05:00 21:00 - -Pers

Fr 05:00 21:00 - -Pers

Sa 06:00 22:00 - -Pers

Su 06:00 22:00 - -Pers

KKM02B 19


Heatingtime 1

Heatingtime 2

Heatingtime 3

No. 11 12 13 14 15 16

Mo 06:00 22:00 - - - -Pers

Tu 06:00 22:00 - - - -Pers

We 06:00 22:00 - - - -Pers

Th 06:00 22:00 - - - -Pers

Fr 06:00 22:00 - - - -Pers

Sa 07:00 23:00 - - - -Pers

Su 07:00 23:00 - - - -Pers


Heatingtime 1

Heatingtime 2

Heatingtime 3

No. 21 22 23 24 25 26

Mo 06:00 08:00 16:00 22:00 - -Pers

Tu 06:00 08:00 16:00 22:00 - -Pers

We 06:00 08:00 16:00 22:00 - -Pers

Th 06:00 08:00 16:00 22:00 - -Pers

Fr 06:00 08:00 16:00 22:00 - -Pers

Sa 07:00 23:00 - - - -Pers

Su 07:00 23:00 - - - -Pers

Condition as delivered and table forcurrent values (please enter)!

KKM02B 20

Parameter level

Settings at Parameter level Operating mode

1) Open hinged control panel cover => Info mode.

2) Choose basic function Parameter list P10 with rotary knob. (See down arrow indicator).

3) Enter level with key .Display: Parameter number and current setting.

4) Choose sought setting with rotary knob . Table: "Parame-ter level of the E6.4031".

5) Press key (red lamp lights).

6) Change setting with rotary knob .

7) Save new setting with key (red lamp goes out).Close hinged control panel cover.

Operating example: One-off hot water

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Z

Z

Z

Z

Z

Z

Z

Z

Z

Z

Z

Z

KKM02B 21

Parameter level of the E6.4031

Parameter Designation Setting range Default System val-ues

01 Outside temperature Display only

02 One-off hot-water generation 0/1 (Off/On) 0

03 Desired flow temperature, heating circuit 1 Display only

04 Actual flow temperature, heating circuit 1 Display only

05 Desired flow temperature, heating circuit 2 Display only

06 Actual flow temperature, heating circuit 2 Display only

07 Desired header temperature Display only

08 Actual header temperature Display only

13 Maximum time advance 0-3 hours 2 hours

14 Time-controlled relay with hot-water enable 0/1 (Off/On) 0

15 Outside temperature delay 0-3 hours 0 hours

KKM02B 22

Definitions

Flow resp. boilertemperature

Frost-protection control

Weather-dependent control

Room sensor influence

In the case of temperatures, a distinction is made between theactual measured temperatures in the heating system and thepre-set or computed, desired temperatures necessary forheating. The flow temperature is the temperature of the waterflowing to the radiators of a heating circuit. It is regulated by themixers of the heating circuits, if present. The header tempera-ture is measured directly in the header. The desired tempera-ture of the header corresponds to the maximum computed flowtemperature in the heating system plus the adjustable heatslope offset for mixer circuits (parameter 27).

Frost-protection control prevents the heating system freezingup by automatically activating Heating mode (switch-on tem-perature = parameter 24). In Frost-protection mode, the desiredroom temperature for all heating circuits is set to 5°C and thedesired temperature for hot-water generation is set to 10°C.

The header or flow temperature is determined by the outsidetemperature, the set heat slope and the set desired room tem-perature.Exact setting of the heat slope is extremely important forweather-dependent control.The circulation pump is controlled weather-dependently. Thecirculation pump is switched on if there is a heating demandand in Frost-protection mode.

The current room temperature can be included in computationof the required flow temperature via the integrated roomtemperature sensor of the BM if using an operation-controlmodule.

EXPLANATORY INFORMATION

KKM02B 23

Functions

Room temperature P1 andP2

Reduced temperature P3

Hot-water generation P4

One-off hot water

Heat slope P5 and P6

Note on setting

The required room temperature for Heating mode can be pro-grammed at this point. Room temperature 1 is assigned to thefirst heating circuit of the KKM and room temperature 2 is as-signed to the second heating circuit. The entered value is re-quired for computing the flow temperature of the heating cir-cuits. If a remote control system with room sensor (BM) isconnected, the current temperature of the assigned referenceroom is shown on the display (left). It can be used for control-ling the room temperature on the basis of the room sensor in-fluence. If there is no room sensor in the heating circuit, you willsee two dashes [--] in the corresponding display.

The reduced or economy temperature is the temperature towhich the heating circuit is controlled during times other thanthe heating times, e.g. during the nighttime or in ECO mode.

The programmed hot-water temperature is stabilised byswitching the hot-water cylinder charging pump and the burner.

Activating this function (parameter 02) means that the hot-watercylinder tank is heated precisely once (e.g. in order to showerduring the reduced time).

The heat slope indicates what flow temperatures occur at spe-cific outside temperatures.The heat slope is dependent on the design of the heating sys-tem. The gradient of the heat slope indicates by how many de-grees the flow temperature changes if the outside temperaturerises or drops by 1°C.

Heat slope diagram:ϑA = Outside temperatureϑV = Boiler or flow temperature

• If the room temperature drops withdropping outside temperature, thegradient is set too low.

• If the room temperature increaseswith dropping outside temperature,the gradient is set too high.

20

40

60

80

100

V[°

C]

[°C]

+20 +10 0 -10 -16

A

0.6

1.5

2

1.3

1

0.8

2.53

0.4

0.2

KKM02B 24

Guideline values

Holiday P7

Heating program P9

The heat slope can best be set at outside temperatures below5°C. The change in heat slope setting must be made in smallsteps and at long intervals (min. 5 to 6 hours) because thesystem must first adjust to the new values each time the heatslope is changed.

• Underfloor heating S = 0.4 to 0.6• Radiator heating S = 1.0 to 1.5

You can use the controller's Holiday program during the holidayperiod. The duration of the holiday is entered in days. The Holi-day program is always activated at 12.00 hours and alwaysends at 24.00 hours of the last day of the holiday.

! If the holiday period is entered before 12.00 hours, the Holi-day program stops on the day of entry. If it is entered after12.00 hours, the program starts on the next day at 12.00hours. It thus also ends one day later.

The controller switches to Standby mode during the holiday.The Holiday symbol is shown on the display.Holiday mode can be terminated by operating the Programswitch.

The operation-control module allows entry of 2 heating pro-grams for each heating circuit.

Each heating program comprises 3 heating times for eachweekday. The heating times are defined by pairs of switchingtimes, consisting of switch-on time and reduced operation time.This allows you to save two different heating profiles (Holi-day/Working time, Early/Late shift). The current heating pro-grams can be selected using parameters 03 and 06 at Heatingprogram level.Moreover, it is possible to program a time program for activat-ing hot-water generation (07) and the circulation pump (08).These programs each contain two Enable times for each day.The circulation pump can also be switched via parameter 14 atParameter level with the hot-water enable times.

KKM02B 25

Warm-up optimisation

Maximum time advance

Circulation pump control

Conditions for switch-off

Outside temperature delay

Delayed pump switch-off

Pump blocking protection

Warm-up optimisation determines the optimum time advance ofstart of heating. This is calculated as a function of the outsidetemperature at the instant of maximum time advance. Warm-upoptimisation occurs only if the reduced time of the heating cir-cuit is at least 6 hours. The Time advance function ensures thatthe heated rooms have reached their desired temperature atthe switch-on instants of the heating times.

! If an operation-control module is connected, this provides theoption of room temperature-dependent time advance.

The maximum possible time advance of start of heating by theOptimisation function can be defined system-specifically by theuser (parameter 13).0 = No warm-up optimisation!

Demand-dependent circulation pump control (automaticsummertime switchover) switches the circulation pumps off ifthere is no heating demand. The mixers are closed at the sametime.

Room temperature-dependent control (only with BM)The room temperature exceeds the set desired temperature.

Weather-dependent controlThe outside temperature exceeds the desired room tempera-ture. The desired flow temperature is less than 20°C.

The selected outside temperature delay must be matched tothe type of construction of the building. In the case of heavytypes of construction (thick walls), a long delay (3 hours) mustbe selected since a change in outside temperature affects theroom temperature later accordingly. In the case of lightweighttype of construction (prefabricated dwellings), no delay shouldbe set (0 hours).

In the case of switch-off of the circulation pumps, the circulationpumps are not switched off until 5 minutes later if one of theburners was on during the last 5 minutes before the switch-offinstant.

The controller effectively prevents blocking of the pumps if theyare not switched on for long periods. The integrated protectionfunction switches on all pumps which have not been in opera-tion during the past 24 hours for one minute at 12.00 hoursevery day.

KKM02B 26

EEPROM check

DCF receiver

Telephone switch

Every 10 minutes, a check is conducted automatically in orderto establish whether the settings of the controller lie within thespecified limits. If a value is found to be out-of-range, it is sub-stituted by the related default value. The range transgression isindicated by the blinking E and the error number 81.In this case, the user should check the important settings of thecontroller. The warning symbol is cleared after the unit is re-started (RESET).

The KKM features a connection facility for a DCF receiver. Oncommissioning, the DCF receiver must be aligned so that theincorporated LED blinks uniformly. Each time the controller isswitched on and each night at 3.00 hours, the current time ofthe KKM is checked and corrected on the basis of the trans-mitted DCF signal.

The heating system can be switched over to Heating mode witha remote telephone circuit. It can be connected to terminals 2and 3 of plugs I resp. III. (see Chapter Electrical connection).As soon as a short circuit is detected at these terminals, thesystem switches to Heating mode. Only when the short circuit iscancelled again, does the heating system once again heat onthe basis of the set heating program.

KKM02B 27

Error messages

RESET function If a fault or error occurs in the heating system, you will see ablinking warning triangle (E) and the related error number onthe KKM display. Please refer to the table below for the signifi-cance of the displayed error code. Frequently, an error can beremedied by performing a RESET on the unit. The RESETswitch is located behind the housing lead-through (see Pa-rameter entry). The RESET switch can be operated using asmall screwdriver.

RESET : Corresponds to brief switch-off of the unit.The controller then continues to operate withthe set values.

RESET + : This overwrites all values with default values.The additional key ( ) must be pressed when switching overfrom RESET (Manual) to Automatic mode.

Error number Error designation SignificanceMixer error

E 70 Flow sensor defective The flow sensor of a heating circuit is defective (discontinuity/short circuit).Boiler error

E 75 Outdoor sensor defective The outdoor sensor is defective (discontinuity/short circuit).E 76 Storage tank sensor de-

fectiveThe storage tank sensor is defective (discontinuity/short circuit).

E 78 Header sensor defective The header sensor is defective (discontinuity/short circuit).E 79 Relay sensor defective The temperature sensor for the additional relay is defective (discontinuity/short

circuit).Internal errors

E 80 Room sensor defective The room sensor of a heating circuit is defective (discontinuity/short circuit).E 81 EEPROM error An error has occurred in the EEPROM -> Check parameter values!!!

Communication errorE 90 ID 0 and 1 on bus Bus IDs 0 and 1 may not be used simultaneously.E 91 Bus ID used The set bus ID is already in use by another device.E 92 Communication error General communication error

* If other error numbers are displayed, please refer to the instructions for the connected devices of the system (e.g. boiler module).

KKM02B 28

Parameters

Technician level (Parameter list as of number 20)

! It is not possible to set these parameters until after enteringthe code No.Code No. entry = Parameter 20Code ex-works: 1234

E Settings at Technician level should always be made withthe appropriate care since this level stores safety-relatedparameters!

E When programming the parameters at Technician level,please follow the manuals for the connected devices. Thetechnical manuals contain information and explanatory in-formation on the parameters.

Changing the parameters1) Open the hinged control panel cover2) Choose basic function Parameter list P10 with the rotary

knob .3) Press key .4) Choose parameter No. 20 with the rotary knob . è

Enter the code No.5) Press key (red lamp lights).6) Set the first digit with the rotary knob ..7) Press key (red lamp lights).8) Set the second digit with the rotary knob .9) Press key (red lamp lights).10) Enter digits three and four accordingly (red lamp goes

out).11) Choose the required parameter with rotary knob . (see

list).12) Press key (red lamp lights).13) Set the value with the rotary knob .14) Save the value with key .

! Parameters which cannot be set on the KKM owing to thesystem are identified by dashes [----] on the display or the pa-rameters are masked. It may be possible to set these pa-rameters on an operation-control module.

FOR THE FITTER

KKM02B 29

! The specified default values in the list below correspond tothe condition of the unit as delivered. System-specific valuescan be entered in the last column of the table. This simplifiesthe task of recommissioning after a parameter RESET.

! If you press the Programming key and choose a protectedparameter before entering the code No., parameter 20 (codescan) is displayed automatically.

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Code No.-protected parameters at Technician level

No. Parameter Setting range Default System values20 Entry of code No. 0000-9999 ----21 Code No. 0000-9999 123422 Bus ID, heating circuit 1 (HK1) 0-15 0 resp. 1 (VFAS)23 Bus ID, heating circuit 2 (HK2) 0-15 224 Frost-protection temperature (-5)°C - (+5)°C (-3)°C25 Max. flow temperature, heating circuit 1 50°C - 110°C 90°C26 Max. flow temperature, heating circuit 2 50°C - 110°C 90°C27 Heat slope offset 5-50 K 5 K31 Charging pump relief 0/1 (Off/On) 132 Parallel pump operation 0/1 (Off/On) 033 Hot-water short-time heating 0/1 (Off/On) 0Boiler parameters51 Maximum header temperature 50°C - 110°C 90°C52 Minimum header temperature 10°C - 60°C 10°C53 Temperature increase for hot water 0°C - 50°C 20°C54 Modulation depth for hot-water boiler 40% - 100% 80%55 Total modulation depth / system deviation Display only

KKM02B 31

Code No.-protected parameters at Technician level

No. Parameter Setting range Default System valuesBoiler parameters56 Boiler hysteresis temperature for first boiler 5-20 K 5 K58 Delay for next burner 0-30 min 0 (= 30 s)59 Limit difference with respect to 51 for KMs 0-20 K 5 K60 Hours until boiler sequence change 100-400 hours 200 hours61 Boiler dynamic resonse -> P (1/Kp) 20-500 K 100 K62 Reset time -> I (Tn) 5-500 s 50 s63 Boiler capacity for boilers 1-9 0-9999 kW 0 kW64 Burner operating time for boilers 1-9 Display only65 Boiler sequence 1 - - - -66 Boiler sequence 2 - - - -67 Type of sequence change 1-4 168 Boiler for hot-water preparation -- or 1-8 --69 Boiler switch-off in the case of capacity 10-60% 40%70 Boiler connection in the case of capacity 70-100% 90%Mixer parameters71 Mixer running time 1 (rating plate, motor 1) 30-240 s 120 s72 Mixer running time 2 (rating plate, motor 2) 30-240 s 120 sService81 Relais test After configuration Start with burner relay82 Sensor test After configuration Start with outside temperature sensor85 Software version E6 Display only

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Explanatory information ! Figures in the text correspond to parameter numbers (e.g. 24represents the frost-protection temperature).

22+23 Bus IDNo. of the heating circuit (see Chapter Bus ID).

24 Frost-protection temperatureIf the outside temperature drops below the programmed value, the systemswitches to Frost-protection mode.

25+26 Max. flow temperatureLimitation of the flow temperature of the heating circuit serves to protect thedownstream components (e.g. in the case of underfloor heating systems).

27 Heat slope offsetThe desired header temperature is computed by adding the desired tem-perature of the maximum-demanding mixer circuit to the heat slope offset.

31 Charging pump reliefThe charging pump is switched on when the header temperature exceedsthe storage tank temperature by 5°C. Switch-off if header temperature <storage tank temperature or if storage tank temperature > desired tempera-ture (+ delayed switch-off).

32 Parallel pump operationThe heating circuit pumps operate during hot-water generation.

33 Hot-water short-time heatingHeating of the storage tank temperature up to 60°C with every 20th heat-upoperation or at least once per week on Saturday at 1.00 hours.

51 Maximum header temperatureProtects against overheating of the boilers / prevents triggering of the safetytemperature delimiter.

52 Minimum header temperatureThe control function ensures that the header temperature during the heatingtimes does not drop below the set value.

53 Temperature increase for hot water[Not in the case of hot-water boiler (68)] Header temperature for hot-waterpreparation = desired hot-water temperature + temperature increase in thecase of hot water (header temperature > 70°C).

54 Modulation depth for hot water[Only in the case of hot-water boiler (68)] The hot-water boiler is operatedwith the entered modulation depth when the storage tank is heated.

55 System deviation / total modulation depthDisplay of the header system deviation (desired temperature - actual

temperature) [right]. When key is pressed, the total modulation depth ofthe system (capacity utilisation of the system in percent 0-99%) is alsoindicated [left].

56 Hysteresis temperature for boiler 1Switch-on of the boiler if the actual temperature drops below the desiredtemperature of the header. Switch-off at the earliest on reaching [desiredtemperature + hysteresis].

KKM02B 33

58 Delay for burnerIn the case of multi-stage systems, a further burner stage is enabled at theearliest after the delay elapses. The delay starts again after each start of aburner stage. Entering 0 results in a minimum delay of 30 seconds.

59 Limit difference with respect to parameter 51Protects against switch-off of the boilers in the event of overload. The boilersare down-modulated if the limit temperature (51 - 59) is reached.

60 Hours until boiler sequence changeThe KKM controller allows entry of two boiler sequences. The boilersequence can be substituted after the set number of operating hours of thefirst boiler of the current boiler sequence (see 65-67).

61 Boiler dynamic response A [°C]If the cumulative system deviation in Kelvin reaches the set value A, thisresults in connection of the total system capacity. Low values result in fastcontrol and may thus lead to overshoot.

62 Reset time B [s]Entry in seconds. Low values result in fast control and may thus lead toovershoot.

63 Boiler capacity (boilers 1-9)Entry of the rated boiler capacity in kW for each boiler. Display of the boilernumber [left]. Entry of the boiler capacity [right]. The boilers must benumbered in ascending sequence with no gaps. Exception: No. 9 = switchingboiler

64 Burner operating time (boilers 1-9)Display of the burner operating times. Display of the boiler number [left]. Thedisplayed values [right] can be reset by pressing the Programming key twice.

65 Boiler sequence 1Entry of the sequence in which the boilers are placed into operation in thecase of heating demand. Display of the start number [left] (selection with key

- red lamp lights). Entry of the boiler number [right]. Save with key .

66 Boiler sequence 2(See 65!) Entry of the second sequence for a boiler sequence change.

67 Type of sequence change (1-4)1) Only boiler sequence 12) Only boiler sequence 23) Change between sequence 1 and 2 after operating hours (see 60).4) 1/3 2/3 switchover. In the case of connection of the second boiler, the

first boiler is placed out of operation until the second boiler has reachedthe limit capacity (see 70).

68 Hot-water boiler

Entry of the boiler for hot-water preparation. Press key ; set boiler numberwith the rotary knob. [--] => Hot-water preparation via header. Save with key

.

69 Boiler switch-off in the case of capacityIf the actual modulation depth drops below this modulation depth, the lastboiler of the current sequence is deactivated.

KKM02B 34

70 Boiler connection in the case of capacityIf the actual modulation depth exceeds this modulation depth after the delayelapses, the next boiler of the current sequence is connected.

71 + 72 Mixer running timeControl parameter (see rating plate on motor operator). Required time forcomplete opening of the mixer (in seconds).

81 Relay testActivation by pressing the Programming key. The existing relays can beswitched with the rotary knob (burner, pumps and mixers). On the display, anarrow points to the symbol of the switched relay (see Chapter Display)ð 01 Heating circuit 1: Mixer openð 02 Heating circuit 1: Mixer closedð 03 Heating circuit 2: Mixer openð 04 Heating circuit 2: Mixer closedð 05 Heating circuit pump 1ð 06 Heating circuit pump 2ð 07 Time-controlled relayð 08 Switching boiler onð 09 Hot-water cylinder charging pumpð 10 Header pumpð 11 Boiler pump, switching boiler

82 Sensor test Activation by pressing the Programming key. The existing sensors can beselected with the rotary knob. The parameter number of the current sensorand the measured temperature value are shown on the display. Non-configured sensors are identified by dashes on the display.ð 01 Outside temperatureð 02 Header temperatureð 03 Storage tank temperatureð 04 Flow temperature, heating circuit Ið 05 ----ð 06 Flow temperature, heating circuit IIð 07 ----

85 Software versionDisplay of the unit's software version (please quote in the event of complaintsor errors).

KKM02B 35

System bus

The heating installationsystem CXE

Bus ID

CXE is a modular system for control of heating installationswhich can be configured flexibly for an extremely wide variety ofrequirements with up to 9 boilers and 15 heating circuits. Thesystem's components, 1 cascade manager, 1 CoCo connectioncontroller, up to 8 boiler controllers, up to 13 mixer modules andup to 15 operation-control modules, communicate via a bussystem. This minimises the wiring effort. The bus used hasmade it possible to implement a Plug and Play system. Thevarious components are simply coupled to the system bus. Themodules log on to the system automatically and search for theircommunication partners on the basis of the set bus ID.

The bus ID (0-15; parameters of Technician level) represents anumbering of the system's heating circuits. Each operation-control module and each mixer module receives the number ofthe assigned heating circuit as its bus ID (see 22 and 23).The boiler modules KM6xx are assigned their unique number(1-8) as the bus ID. The boilers are addressed on the basis ofthis number (see Boiler sequence).

! Heating circuit numbers (0-15) may not be assigned twice.The heating circuit numbers 0 and 1 may not be used simul-taneously. A heating circuit with the number 0 has no mixer.

KKM02B 36

Remote controls

Operation-control moduleBM

Sensors

Outdoor sensor AFS

The KKM permits connection of an operation-control moduleBM for each heating circuit via a bus line. The operation-controlmodule allows various operation-control functions and monitor-ing functions for the system values to be relocated to the maincontrolled zone – i.e. the living room. This achieves maximumcomfort and convenience. Please refer to the technical descrip-tion of the BM for a precise descrip-tion of the overall scope offunctions.

� Display of the system parameters� Entry of the heating circuit parameters� 4 different desired room temperatures� Entry of the holiday start day� Automatic adaptation of the heat slope

Installation location:• Wherever possible, on a northerly or north-easterly wall be-

hind a heated room• Approx. 2.5 m above ground• Not above windows or ventilation shafts

Installation:1. Detach the cover.2. Attach the sensor with the supplied screw.

KKM02B 37

Boiler sensor KFS

Flow sensor VFAS v

Storage tank sensor SPFS

Installation location:• Immersed sleeve for thermometer, temperature regulator and

boiler sensor in heating boiler

Installation:• Slide the sensor fully into the existing immersed sleeve.

Installation location:• In the case of boiler control, in place of the boiler sensor KFS

as close as possible behind the boiler on the heating flowpipe

• In the case of mixer operation v approx. 0.5 m behind thecirculation pump

Installation:1. Thoroughly clean the flow pipe.2. Apply heat-conductive paste.3. Secure sensor with stretch band.

Installation location:• In the immersed pipe of the hot-water cylinder tank (generally

on the front face of the tank)

Installation:• Slide the sensor as far as possible into the immersed pipe.

E The immersed pipe must be dry.

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T

System switch

Maximum delimiter

Telephone switch

Electrical connection

Electrical connection

If a maximum delimiter is required, it must beconnected between the pump of the heatingcircuit and the related relay terminal 4 resp. 5.

A telephone switch can be used to switch the heating system toHeating mode. Terminals 2 and 3 of connectors I and III areused for connection. As soon as a short circuit is detected atthese terminals, the system switches to Heating mode. If theshort circuit is cleared, the controller once again heats on thebasis of the set heating program.

E The controller is designed for an operating voltage of 230V AC at 50 Hz. The burner contact is a floating contact andmust always be connected in series with the mechanicalboiler thermostat.

E Caution: Do not lay bus lines and sensor lines togetherwith power cables in one cable!

I

III

KKM02B 39

System diagram

KKM02B 40

System diagram for hot-water boiler

KKM02B 41

Connection diagram

Terminal assignment

230 V ACSwitching capacity of relays 2(2) A, 250 V AC

ST7 (1+2): DCF antennaST1 (2+3): Telephone switch, heating circuit 1ST1 (4+5): Flow sensor, heating circuit 2ST1 (6+7): Storage tank sensorST1 (7+8): Header sensorST1 (9+10): Outdoor sensorST5 (1+2): Flow sensor, heating circuit 1ST3 (2+3): Telephone switch, heating circuit 2ST9 (1+2): Data line CAN busST9 (3+4): Power supply CAN bus

ST2 (1): Neutral conductor, mainsST2 (2): Power supply, unitST2 (3): Power supply, relayST2 (4): Pump, heating circuit 1ST2 (5): Pump, heating circuit 2ST2 (6): Storage tank pump / Switch-over valve, hot-water boilerST2 (7): Mixer, heating circuit 2 openST2 (8): Mixer, heating circuit 2 closedST2 (9+10): Switching boiler (SK)ST6 (1): Header relayST6 (2): Additional relay (time)ST4 (1): Mixer, heating circuit 1 openST4 (2): Mixer, heating circuit 1 closedST4 (3+4): Boiler pump (SK)

1 2 4 1 21 2 3 4 53 5 6 7 8 9 10

MM

L1N L1'

Lr

K

T1 T2D 1 D 2 I

v

2

v

1

D 1B u s

HL+ -

IX

II VI IV

III V I VII

r

KKM02B 42

a

e

d

c

b

C

B

E

A D

Installation Sketch showing basic mode ofoperation:A Controller, side view,

cutaway viewB Control panel plateC Mounting clampD Unlocking hole (see

ChapterParameter entry)

E Sharp-pointed tool

Installing the controller:1. Set the mounting clamp tothe wall thickness of the controlpanel (at the left and right-handside of the unit):a. Pull the mounting clamp at the bottom away from the con-

troller wall (toothing).b. In this condition, slide the mounting clamp down or up until

the distance from the edge of the unit corresponds to thethickness of the control panel wall.Detent position 1 ≅ 0.5-1.0 mm wall thicknessDetent position 5 ≅ 5.0 mm wall thickness

c. Press the mounting clamp against the controller wall at thebottom.

2. Press the controller into the control panel recess and checkthat it is firmly secure. If the controller wobbles: Remove thecontroller and move the mounting clamps up. Removing the controller:d. Insert a sharp-pointed tool at an angle with respect to the

exterior wall into one of the unlocking holes (the tool mustbe slid between mounting clamp and control panel wall).

e. Lever the tool with respect to the unit exterior wall. Thiscauses the mounting clamp to release the control panelwall.

Then slightly raise the unit at the corresponding side and repeatthe procedure on the other side of the unit.The unit can now be removed.

E Disconnect the unit from the power supply before removingit.

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Technical data

Sensor resistances

Technical data

The sensor resistances must be measured with the controllerdisconnected.

Temp. AFS, VFAS,KFS, SPFS

−20°C 700 Ω−10°C 760 Ω0°C 830 Ω

+10°C 900 Ω+15°C 935 Ω+20°C 970 Ω+25°C 1010 Ω+30°C 1050 Ω+40°C 1130 Ω+50°C 1215 Ω+60°C 1300 Ω+70°C 1390 Ω+80°C 1485 Ω+90°C

°C1585 Ω

Supply voltage to IEC 38 230 V AC ± 10%

Power consumption Max. 8 VA

Switching capacity of the relays 250 V 2(2) A

Maximum current on terminal L1' 10 A

Enclosure to EN 60529 IP 40

Safety class II to EN 60730 Totally insulated

Control panel installation to DIN 43700 Recess 138x92

Power reserve of the timer > 10 hours

Permitted ambient temperature during op-eration

0 to 50°C

Permitted ambient temperature for stor-age

-30 to 60°C

Sensor resistances Test resistance 1010 Ω± 1% at 25°C

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For your notes:

KKM02B 45

KKM02B 46

KKM02B 47

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