Technical information Commissioning instructions. TopTronic E basic module heat generator. TopTronic E basic module heat generator

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1 Technical information Commissioning instructions TopTronic E basic module heat generator TopTronic E basic module heat generator TopTronic E control module Hoval products may only be installed and commissioned by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician. Subject to modifi cations - 02/15 EN

2 TABLE OF CONTENTS 1. Bus terminating resistors Setting the addresses for the basic/controller modules (DIP switches) Commissioning assistant Configuration of the bus system Setting the address of control modules Devices on the bus General parameter settings Explanation of the screen Procedure for setting parameters Overview of hydraulic applications H-Gen Overview of function applications Setting the parameters of the individual devices on the bus system General settings Configuration of the control module Information Malfunctions Notes on electrical connection Notes for installation

3 BUS TERMINATING RESISTORS / ADDRESSING The installation instructions described how to install and wire up the individual basic/controller modules and their expansions. Room control module easy Room control module comfort The commissioning instructions now explain what steps are necessary for successful commissioning. The commissioning instructions refer to the commissioning assistant that runs automatically on the TopTronic E when it is started up for the first time and guides you through the complete commissioning. Before switching on and starting the commissioning assistant, check the following points and make any necessary settings: Control module Base module Longest distance (cable length) Heating circuit module Hoval CAN bus Buffer module Set the bus terminating resistors Set the addresses for all modules with DIP switches (Setting the addresses of the control modules is only possible after switching on) The commissioning assistant sets the addresses of the control modules and configures the entire plant. 1. Bus terminating resistors The bus terminating resistors must be activated on the devices that are furthest apart from one another. It is best to activate the terminating resistor on the heat generator and on each bus station (usually room control module) that is installed furthest away from it. Activate terminating resistors Fig. 03 If the components of the bus system are exclusively fitted in the heat generator, there is no need to activate the bus terminating resistors! 2. Setting the addresses for the basic/ controller modules (DIP switches) The addresses of the individual modules are set using the DIP switches on the circuit boards. Each module must have a different address. The addresses do not necessarily have to be set in consecutive sequence. Address switch DIP switch ON == bus terminating resistor activated Fig. 01 Fig. 02 Terminating resistor both DIP switches ON == bus terminating resistor activated Fig. 04 The factory settings for the modules were selected so that there is no need to change the address settings, as long as no module occurs twice in the bus system! (Exception: and FW (com)) 3

4 ADDRESSING All basic modules (, FW, etc.) are delivered with address 1! Fig. 05 Addressing table: DIP switch Addr. Factory setting DIP switch Addr. Factory setting Off 1 / FW Off 9 HK/WW ( No. 1) Off 2 Off 10 ( No. 2) Off 3 Off 11 ( No. 3) Off 4 Off 12 GLT (0-10V) ( No. 4) Off 5 Off 13 MWA (M-Bus) ( No. 5) Off 6 Off 14 ( No. 6) Off 7 Off 15 PS ( No. 7) Off 8 Off 16 SOL ( No. 8) Fig. 06 If there are several controller modules of the same type in the bus system, the modules must have different addresses set for them. Use the available vacant addresses for this! Setting the addresses of the control modules is only possible after switching on and it determines the allocation to the heat generators, heating and DHW circuits, etc. in the system. 4

5 3. Commissioning assistant The commissioning assistant guides you through the individual steps for configuring a simple heating system correctly in the shortest possible time. The following points must be carried out one after the other: 1. Configuration of the bus system 2. Setting the parameters of the individual devices on the bus system 3. General settings (time, etc.) 4. Configuration of the (room) control module If a more complex plant is involved, it will be necessary to make additional settings in the Service menu. Refer to the instructions for customer service technicians for this purpose! Commissioning must always be started on the control module fitted in the heat generator! Fig. 09 After that, enter the code of the particular user level (in case of questions, please contact Hoval customer service). 3.1 Configuration of the bus system The commissioning assistant appears automatically after the first startup, or can be started manually from the main menu. Fig Setting the address of control modules The addresses of the control modules has been set so that their function is defined right away when the address is entered on the control module. Fig. 07 Fig. 11 For example: control module is allocated to the basic module heat generator with address 1 Fig. 08 It is essential for the Plant configuration to be carried out as a first step. ly after that is the Room control module configuration started on each (room) control module. The control module can also optionally be allocated to the controller modules PS and SOL. Refer to the addressing table (Fig. 06) and the allocation table (Fig. 12) for this. 5

6 Allocation table: Fig. 12 BM control module After the address of the control module has been set on the heat generator, all devices are displayed on the bus system. Other (room) control modules on the bus system are only detected after they have been configured. 6

7 3.1.2 Devices on the bus Procedure for setting parameters 1. Use Edit to edit the first function (Fig. 15) Fig. 13 If installed basic/controller modules are not displayed, please check the following things: -- Address setting of all connected basic/controller modules (DIP switches) -- Wiring of the components (wiring diagram and connection diagram) -- Setting the terminating resistors (instructions for customer service technicians) -- CAUTION: Module expansions are not connected to the Hoval CAN bus, and are thus not displayed here If all basic/controller modules are available on the bus system, they will be configured in the next step. The hydraulic and function application is set on each module for this purpose. 1. Fig. 15 Amongst other things, the hydraulic and function application is set (see chapter 3.1.4) General parameter settings Explanation of the screen 2. Back to the starting screen (Fig. 16) Fig Fig. 14 Pos. 1 General function group - category via the entire controller system 2 General settings per basic/controller module 3 Bus address/name of the selected basic/controller module 4 Edit and configure the most important parameters of the selected basic/controller module 5 Scroll to next function group 6 Scroll to next function Fig Scroll to next function until all functions have been edited (Fig. 15) 4. Scroll to next function group (Fig. 15); see chapter 3.2 for more information All functions of a function group must be edited before it is permitted to scroll to the next function group! 7

8 The most important hydraulic applications in the controller modules PS and SOL can be found in the corresponding commissioning instructions. Explanation of the function application: normally, there is no need to make settings for the function applications because in most cases the correct function application will be preselected when the hydraulic application is selected. In various cases, adjusting the function application allows fine-tuning or deactivation of a function (see chapter 3.1.5). For detailed information about all other parameters, refer to the corresponding instructions for customer service technicians. 8

9 3.1.4 Overview of hydraulic applications H-Gen Functions that can be implemented TopTronic E basic module heat generator VF1 DKP Y 7 MK1 YK1 M DKP Number of the hydraulic application HK2 RLHH RLHH VF1 DKP MK1 DKP YK1 M valhoval hovalho va valhoval hovalhova valhoval hovalho va valhoval hovalhova RLF HP RLF HP YKR YKR AVR AVR YAV AVP AVF YAV AVP AVF DKP

10 VF1 VF1 MK1 MK1 YK1 M YK1 M 1 löschen 1Sie dieses valhoval hovalho va valhoval hovalhova 2 löschen 2Sie dieses ST1 valhoval hovalho va valhoval hovalhova 1 löschen 1Sie dieses valhoval hovalho va valhoval hovalhova 2 löschen 2Sie dieses valhoval hovalho va valhoval hovalhova HP2 HP Functions that can be implemented TopTronic E basic module heat generator and 1 module expansion HK2 HK2 HK3 RLHH 1 FE VF1 VF2 FE VF1 VF2 FE VF1 MK1 MK2 DKP MK1 MK2 MK1 1 YK1 M YK2 M YK1 M YK2 M YK1 M valhoval hovalho va valhoval hovalhova RLF HP YKR RLHH HK2 AVR 1 FE VF1 FE VF1 YAV AVP AVF DKP MK1 1 MK1 YK1 M YK1 M valhoval hovalho va valhoval hovalhova RLF HP YKR

11 17 AVR HK2 FE VF1 YAV AVP AVF DKP MK1 YK1 M * Module expansions (FE) are required for each of these hydraulic applications! See the instructions for customer service technicians for information about additional hydraulic functions. Please note that a suitable module expansion is required in many hydraulic applications. If no suitable hydraulic application is available, a similar hydraulic function must be selected and adapted by means of the function application. 11

12 3.1.5 Overview of function applications Function Gen. Standard Standard + Standard + Standard AVR AVR - only without 1 Additional not active not active 1-stage without HP (ST1=VA1, =VE2) via FA bus pump 1-stage with HP (ST1=VA1, =VE2, HP=VA2) via FA bus with HP (HP=VA2) FSK without HP (=VE2, RLF=VE1) via FA bus with HP, RLHH (RLF=VF1, YKR=YK1, HP=MK1) HK not active Mixed HK (-FE1) HC2 HK not active Mixed HK (HK2-- MK) HK3 HK not active Mixed HK (HK3-FE1) WW not active WM Pressure distributor KM No temperature control WW with charging pump Additional temperature control KAS 1 int, 2 int. power control, no power compensation, without sequence change, KM1 200kW FSK with HP (=VE2, RLF=VE1, HP=VA2) 0-10V temp. *) (=VE1, HP=VA2, nom VA10V)! Config. 0-10V separate! Mixed HK (-- MK) Mixed HK (HK2-FE1) KAS 2 int, 1 int. power control, no power compensation, without sequence change WW with switching valve Y7, and req. DKP KAS 2 int, 4 via CAN power control, no power compensation, without sequence change Direct HK (-- DKP) Direct HK (HK2-- MK1) Direct HK (HK3-FE1) *) In function appl. 4 ( type 0-10V temp.), additionally the output must be configured as 0-10V in General V/PWM! AVR Plant flow control Fresh air sensor Heat generator HP Main pump ST Stage VA Variable output Heat generator sensor VE Variable input FSK Solid-fuel boiler RLF Return sensor FA Automatic firing device RLHH Return temperature control VF Flow sensor YKR Actuator low temperature protection YK1 Actuator mixer 1 MK Mixing circuit FE Expanded functionality DKP Direct circuit pump WW Domestic hot water Y7 Water deflector valve for calorifier (single wire system) WM Heat manager KM Cascade manager KAS Cascade 12

13 3.2 Setting the parameters of the individual devices on the bus system After the basic settings of all functions under General, the most important parameters are listed in the other function groups ( heat generator, heating circuits, hot water, etc.) (1, Fig. 18). The parameters are divided into the corresponding function group and function with the specification on which module (address) the function is located (see 2, Fig. 18). 2 1 Fig. 21 Information about the parameters of the controller modules SOL, PS, etc. can be found in the corresponding commissioning instructions General settings Fig. 18 As the next step, settings must be made in the system (sample screen Fig. 22). In most cases, it is sufficient to check the suggested setting values! Using Edit (3, Fig. 18) it is possible to carry out the most important specific parameter settings (see example Fig. 19). Fig. 22 Fig. 19 The parameter settings for the function groups of heating circuits (Fig. 20) and hot water (Fig. 21) can be made in the same way as for the heat generator. Depending on the individual requirement, one of five start screen types can be set during commissioning. More information about this can be found in the Optional start screen chapter in the TopTronic E comfort operating instructions. Fig. 23 Fig

14 ce configuration of the plant has been completed successfully, start Configuration room control module on each room control module. Fig

15 3.4 Configuration of the control module Addressing room control modules Setting example: Room control module for the 2nd heating circuit 1: Call up commissioning assistant 2: Enter address no. of control module 3: Select and acknowledge controller module type BM Control module RBM.. Room control module 15

16 INFORMATION 4. Information The info screen (1, Fig. 25) is used for a quick overview of the plant - and can also be accessed using the home screen top right. 1 Fig. 27 Fig. 25 A different number of information values are displayed here depending on the user level. Statuses are displayed in most of the functions. Status heating circuit control: 0 = Switched off 1 = Normal heating mode 2 = Comfort heating mode 3 = Economical heating mode 4 = Frost mode 5 = Force acceptance (with force > +50%) 6 = Force throttling (with force < -50%) 7 = Holiday mode 8 = Party mode 9 = Normal cooling mode Fig. 26 Status heat generator control: 0 = Switched off 1 = Heating mode 2 = Flow time heating mode 3 = External blocked 4 = Cooling mode 5 = Flow time cooling mode 15 = Alarm 16 = Fault 17 = Blocked 26 = Bivalence deactivation 27 = Hot water charging block 28 = Minimum off-time 29 = Minimum on-time 32 = Post-run 33 = Delay follow-on H-Gen 34 = Overation overtemperature Fig. 28 Status domestic hot water control: 0 = Switched off 1 = Normal charging mode 2 = Comfort charging mode 3 = Force throttling (with electric heating element force < -50%) 4 = Force charging (with electric heating element force > +50%) 5 = Fault 6 = DHW draw-off (DHW draw-off active) 7 = Warning 8 = Reduced charging mode 16

17 MALFUNCTIONS 5. Malfunctions Cod. Description Cod. Description 30 Bus interruption to automatic device 146 Calorifier sensor bottom 31 Bus fault heat generator Calorifier sensor top 32 Bus fault heat generator Collector sensor 2 33 Bus fault heat generator Collector flow sensor (TKV) 34 Bus fault heat generator Collector return sensor (TKR) 35 Bus fault heat generator Volumetric current 36 Bus fault heat generator Additional calorifier sensor top (cert. DHW tank) 37 Bus fault heat generator Plate heat exchanger sensor (decentral charging) 42 Bus fault remote control 162 Plate heat exchanger sensor (central charging) 50 Flow actual value deviation (VF1) 163 Bypass sensor 51 Flow actual value deviation (VF2) 164 Pressure 52 Hot water actual value deviation 172 TPR PWT primary return temperature 53 Pump speed does not match ctrler. spec. 179 TUZ tank addition down temperature 54 Legionella prot. temperature not reached 180 TOZ additional calorifier sensor top 55 Caution frost protection active 181 TPR pump heat exch. primary return temperature 56 Ref. temp. circulation not reached 182 TSRU tank return switchover 57 Max. circulation temperature exceeded 183 Flow sensor primary circuit 60 Flow temperature guard heating circuit 184 TSV pump heat exch. secondary flow temperature 61 External fault via digital input 185 TSR pump heat exch. secondary return temperature 68 Screed drying active 187 Plant flow temperature (AVF) 69 Cleaning necessary 193 Buffer discharge flow sensor (PEF) 70 Maintenance necessary 194 Sensor thermostat 1 71 Error when charging from collector 1 on 195 tank Sensor thermostat 2 73 Error when charging from collector 2 on 196 tank Sensor thermostat 3 90 Fault heat generator Sensor 1 differential control 1 91 Fault heat generator Sensor 1 differential control 2 92 Fault heat generator Sensor 1 differential control 3 93 Fault heat generator Sensor 2 differential control 1 94 Fault heat generator Sensor 2 differential control 2 95 Fault heat generator Sensor 2 differential control 3 96 Fault heat generator Fresh air sensor 2 (2) 97 Fault heat generator No error 110 DHW sensor 2 (2), CW sensor (flow sensor inp.) 300 Ref. value > max. temperature in tank 111 Solar sensor DHW (TBU) 301 Maximum temp. > prot. temperature in tank 112 Circulation temperature 302 Legionella prot. temp. > max. tank temp. 113 DHW charging flow sensor (x) 303 Tanks 1 & 2 have the same priority 114 Heat generator sensor 304 Tanks 1 & 3 have the same priority 115 DHW sensor () 305 Tanks 1 & 4 have the same priority 17

18 MALFUNCTIONS 116 Fresh air sensor () 306 Tanks 2 & 3 have the same priority 117 Heating circuit flow sensor (VFx) 307 Tanks 2 & 4 have the same priority 118 Plant flow or buffer sensor (AVF/PF) 119 Collector sensor (TKO) 308 Tanks 3 & 4 have the same priority 120 Buffer switch-off sensor (PF2) 309 Switch-off thd. recharging >= (switch-on thd. recharging HYS_TEMP_DFLT) 121 Solar sensor heating 310 Switch-off thd. discharge >= (switch-on thd. discharge HYS_TEMP_DFLT) 122 Room air sensor 311 Switch-off thd. return flow increase >= (switch-on thd. return flow increase HYS_TEMP_ DFLT) 123 Heating circuit return sensor 312 Collector max. temp. > collector prot. temp. 124 Heat generator return sensor 313 Switch-off thd. collector pump >= (switch-on thd. collector pump tank HYS_TEMP_ DFLT) Heat generator flow and return sensor simultaneously Heat gen. flow sensor pre-ctrld. (flow 4-wy mixer) 314 Switch-off thd. add. boiler disch. >= (switch-on thd. add. boiler discharge HYS_TEMP_ DFLT) 315 No tank active, all types tank to RT circ. (05-054) > tank max. temp. 1 (08-059) 319 RT circ. (05-054) > leg. prot. temp. (05-004) 1) Controller malfunctions, automatic device malfunctions see corresponding FA instructions 18

19 NOTES ON ELECTRICAL CONNECTION 6. Notes on electrical connection WARNING Make sure that no cables are live before starting wiring work. The mains voltage connections on the left side and the entire lower connector strip carries or might be carrying 230 volts. These terminals are not allowed to be touched when live: potentially fatal electric shock hazard. Bus connections and sensor lines must be installed separately from power current cables. A qualified technician must install the electrical supply to the equipment. 7. Notes for installation The electrical installation and protection must be in accordance with local regulations. The basic/controller modules and module expansions must be left continuously connected to voltage so as to ensure function is possible at any time. Mains switches on the supply side must thus be restricted to emergency or main switches that are normally left in operating position. Before commissioning, check whether all electrical components have been connected correctly. 19

20 Conservation of Energy - Protection of the Environment