Buderus FM443 Installation And Service Instructions Manual Download Page 1

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For heating
contractors

Read carefully prior to
commissioning and
service work

Installation and Service

Instructions

Function module

FM443

Solar Module

6 72

0 6

623

11/

2008

US/

Summary of Contents for FM443

Page 1: ...For heating contractors Read carefully prior to commissioning and service work Installation and Service Instructions Function module FM443 Solar Module 6 720 618 623 11 2008 US CA ...

Page 2: ... switches 12 3 The functions of the FM443 15 3 1 Integrating the FM443 function module in the control panel 15 3 2 Changing the operating mode 18 3 3 Solar consumer 1 solar circuit 1 20 3 4 Buffer integration 22 3 5 Solar circuit heat meter 26 3 6 Pump function secondary circuit pump 30 3 7 Heat up of the pre heat stage 36 3 8 Solar consumer 2 solar circuit 2 38 4 Relay test 41 5 Fault log 43 6 Fa...

Page 3: ...l safety instructions that must also be observed Read the safety instructions carefully before carrying out the activities described below If the safety instructions are not observed serious or even fatal personal injury and damage to property and the environment may be caused 1 2 Intended use The FM443 function module can be installed in the control panels of the Logamatic 4000 control system For...

Page 4: ...ctrical components must be approved for the USA and Canada This product has been tested and certified and meets applicable standards for the US and Canadian markets WARNING RISK OF LIFE Identifies possible dangers emanating from a product that might cause serious injury or death if appropriate care is not taken CAUTION RISK OF INJURY SYSTEM DAMAGE Indicates a potentially dangerous situation that c...

Page 5: ...as maintenance and repairs must only be carried out by a trained contractor who adheres to all current technical regulations and requirements z The local regulations must be observed WARNING RISK OF LIFE due to electric shock z Make sure that all electrical work is carried out by a trained contractor z Before opening the control panel isolate all poles of the power supply and secure against accide...

Page 6: ...sed or play with it z Ensure that only personnel trained to operate the appliance correctly have access to it CAUTION DEVICE DAMAGE through electrostatic discharge ESD z Before unpacking the module touch a radiator or a grounded metal water pipe to discharge any electrostatic charge in your body USER NOTE Ensure that a circuit breaker is available to disconnect all poles from the mains power suppl...

Page 7: ...g the FM443 function module makes the following functions or connection options available Change the operating mode Integrate a solar consumer 1 e g storage tank Buffer bypass circuit for central heating Tank series circuit Integrate a solar heat meter WMZ available as an accessory from Buderus Integrate a solar consumer 2 e g swimming pool Thermal disinfection of the pre heat stage USER NOTE Befo...

Page 8: ...s circuit no central heating via tank 4 Solar circuit pump 1 5 Maximum temperature storage tank 1 6 Module Fault LED red general module fault 7 Maximum temperature of collector 8 Secondary solar circuit pump 2 or transfer pump enabled 9 Solar circuit pump 2 or 3 way valve 2 in solar circuit 2 position 10 3 way switching valve in solar circuit 1 position 11 Manual switch solar circuit selection LED...

Page 9: ...e top rear of the FM443 function module Colored labels with inscriptions matching the appropriate plugs are attached to the strips Plugs are color coded Tab 1 Connections 120 V Designation Description Netz Power supply PSS2 Solar circuit pump 2 SU 3 way switching valve tank 1 tank 2 PS2 Solar circuit 2 secondary pump SPB Buffer bypass circuit 3 way switching valve PSS1 Solar circuit pump 1 ...

Page 10: ... storage tanks in series Name Description FPB FR Buffer bypass circuit return temperature sensor FP Buffer bypass circuit buffer storage tank temperature sensor WMZ Ground terminal FR Return temperature sensor from solar circuit for heat metering FV Supply temperature sensor from solar circuit for heat metering ZV Flow meter from solar circuit for heat metering Sensor FSS2 Temperature sensor for s...

Page 11: ...in the 4000 series control panels e g slot 1 4 in Logamatic 43xx Tab 3 Possible slot assignments USER NOTE Position the FM443 function module as far to the right as possible in the control panel This ensures that the heating zones are in a logical order The heating zone modules should be installed in the control panel starting from the left side Possible slot assignments in the various control pan...

Page 12: ... the manual switch have different effects on the solar circuits or the two solar consumers CAUTION SYSTEM DAMAGE if the manual switch is set to Manual for an extended period the solar system may be damaged or parts may be damaged z Use the Manual position for short periods only USER NOTE In normal operation the manual switches should be in the AUT position ...

Page 13: ... drops so that reheating may start for example the collector protection is disabled the tank protection is disabled the collector frost protection is disabled USER NOTE If the manual switch is not in automatic mode a message to that effect appears on the MEC2 remote control and the Module fault LED on the module lights up Position Effect Solar circuit 1 solar circuit pump 1 and the bypass 3 way va...

Page 14: ...Position Effect The selection of the solar circuit is switched off Use this setting only for commissioning or for maintenance or service work Automatic changeover to charging of the solar consumers on the FM443 function module solar module is active this is the standard setting If the corresponding solar yield is available only solar consumer 2 solar circuit 2 is loaded The automatic changeover is...

Page 15: ... 4xxx control panel explain in detail how you operate the MEC2 remote control The following provides a brief overview of the MEC2 operation The MEC2 remote control offers two operating levels level 1 with closed flap and level 2 with open flap plus one service level accessible via password The service level has various main menus and submenus for set up of the controls Fig 2 MEC2 remote control 1 ...

Page 16: ...tomatically when it is switched on Manual integration of FM443 function module at the MEC2 level Call up the service level Turn the dial until service level module selection appears on the display Press Display to select the main menu module selection module selection Slot A is shown on the display USER NOTE If the FM443 function module is not recognized automatically you will need to install it m...

Page 17: ...FM443 function module is to be installed in slot 2 Hold Display down the text on the bottom line begins to flash and turn the dial until the FM443 function module appears on the display Release the Display button Press Back The FM443 function module solar panel is installed in slot 2 Press Back three times or close the operating flap to reach operating level 1 module selection Slot 2 solar module ...

Page 18: ...he heating zone button Turn the dial until select heat zone solar appears on the display Release the heating zone button USER NOTE With the operating mode Manual ON day mode button the collector protection function is switched on USER NOTE When the flap on the MEC2 remote control is closed it generally indicates the heating zone to which the MEC2 remote control is assigned If the MEC2 remote contr...

Page 19: ...tion but it switches the solar system off if the collector field or the tank s have exceeded the maximum allowable temperature This way the collector is protected against overheating If this operating mode is activated the hot medium in the solar system e g glycol water can flow from the tank to the collector field The cold medium 32 F 0 C of the solar thermal system e g glycol water mixture can f...

Page 20: ...ervice level Turn the dial until service level solar appears on the display Press Display to open the main SOLAR DATA menu Turn the dial until SOLAR DATA max temperature tank 1 appears on the display Press and hold the Display button and turn the dial The maximum tank temperature can now be set USER NOTE Only integrate a storage tank water heater for DHW heating as solar consumer 1 SOLAR DATA max ...

Page 21: ...ial until SOLAR DATA solar tank 1 lower to appears on the display Press and hold the Display button and turn the dial The tank temperature reduction can now be set SOLAR DATA solar tank 1 lower to none USER NOTE The FM443 function module has an optimization function for increasing the solar yield Depending on the solar yield the recharging temperature can be reduced to the value set here This give...

Page 22: ...pose storage tank SP2 3 4 1 Setting buffer integration Call up the service level Turn the dial until service level solar appears on the display Press Display to select the main menu SOLAR Turn the dial until SOLAR DATA buffer integration none appears on the display USER NOTE If a buffer bypass switch is installed in the heating system you must activate the buffer bypass function using the MEC2 rem...

Page 23: ...also be used for heating and the buffer tank should be integrated to increase the return temperature of a standard heat source Buffer integration as dual purpose tank If you set pendulum DHW 1 DHW 2 for the integration the module assumes that not just the solar system provides its energy to the buffer tank but the standard heat source also supplies its energy into the buffer tank and the system is...

Page 24: ...temperature in the system return by the amount specified under buffer in use if ΔT greater then the flow rate is managed through the buffer tank The buffer tank is flowed through as long as the temperature difference buffer tank system return does not exceed the set value for bypass in use if ΔT greater If this temperature difference is underrun then there is a switch to the bypass as long as the ...

Page 25: ...ference for the buffer flow Turn the dial one click clockwise until SOLAR DATA bypass in use if ΔT greater appears on the display Press and hold the Display button and turn the dial Now you can set the changeover temperature difference for the bypass flow SOLAR DATA buffer in use if ΔT greater 18 F Input range Factory setting buffer in use if ΔT greater 13 F 36 F 7 C 20 C 18 F 10 C SOLAR DATA bypa...

Page 26: ...the heat amount of the first and second solar consumers The heat quantity of the second solar consumer is calculated from the pump run time Activate the BTU counter function If you have activated this function yes then you must set the corresponding glycol content of the solar circuit USER NOTE This function can only be used in connection with the heat meter This set is available from Buderus as a...

Page 27: ...e level Turn the dial until service level solar appears on the display Press Display to open the main SOLAR DATA menu Turn the dial until SOLAR DATA BTU counter appears on the display Press and hold the Display button and turn the dial The heat amount recording can now be activated SOLAR DATA BTU counter no Input range Factory setting BTU counter yes no no ...

Page 28: ...ne click clockwise until the display shows SOLAR DATA antifreeze cont Press and hold the Display button and turn the dial The glycol content can now be set SOLAR DATA antifreeze cont 50 USER NOTE If a solar circuit is operated with glycol water the glycol content must be measured The solar yield is calculated from the specific heat capacity of the medium in the solar circuit and the flow Input ran...

Page 29: ... the display Press Display to select the main menu general specs Turn the dial until general specs heat consumption no display appears Press and hold the Display button and turn the dial Now you can set the display of the solar data for the statistics function only for single stage floorstanding boilers without EMS general specs heat consumption no display Input range Factory setting heat consumpt...

Page 30: ... not present factory setting secondary tank 2 secondary storage tank 2 complete loading heating of the pre heat stage reloading circ tank sequence switching 3 6 1 Setting buffer integration Call up the service level Turn the dial until service level solar appears on the display Press Display to select the main menu SOLAR Turn the dial until SOLAR DATA circ function none appears on the display Pres...

Page 31: ...ump is connected and this output is not activated by the FM443 function module Secondary tank 2 If for the pump function secondary tank 2 is set the pump connected works as secondary pump for the loading of the second solar consumer that is the second consumer is operated via a heat exchanger Input range Factory setting circ function none secondary tank 2 compl loading reloading circ none ...

Page 32: ...ng If compl loading is selected the pump is used to heat the solar pre heat stage of a bivalent solar storage tank to 140 F 60 C once a day in order to avoid the formation of legionella bacteria and for thermal disinfection of the solar pre heat stage Fig 3 Compl loading with switching with a solar storage tank PS2 FB FSS ...

Page 33: ...orage tank This means that as soon as the solar storage tank is warmer than the storage tank heated by the boiler the pump PS2 is switched on and the tanks are reloaded In addition with the help of this pump the solar storage tank that is the solar pre heat stage is heated up to 140 F 60 C once a day in order to avoid the formation of legionella bacteria and for thermal disinfection of the solar p...

Page 34: ...or Call up the service level Turn the dial until service level solar appears on the display Press Display to select the main menu SOLAR Turn the dial until SOLAR DATA reloading circ start up 18 F 10 C appears on the display Press and hold the Display button and turn the dial You can now set the start up temperature difference for the reloading circulator SOLAR DATA reloading circ start up 18 F Inp...

Page 35: ... up the service level Turn the dial until service level solar appears on the display Press Display to select the main menu SOLAR Turn the dial until SOLAR DATA reloading circ shut down 9 F 5 C appears on the display Press and hold the Display button and turn the dial You can now set the start up temperature difference for the reloading circulator SOLAR DATA reloading circ shut down 9 F Input range...

Page 36: ...tion of legionella bacteria The following settings are possible Off no heating of the pre heat stage factory setting Disinfection the pre heat stage is only heated up during the thermal disinfection Heat up the pre heat stage is only heated up during the daily heating up to 140 F 60 C Disinfection heat up the pre heat stage is heated up during the thermal disinfection and during the daily heating ...

Page 37: ...lay Press and hold the Display button and turn the dial Now you can set the heating of the pre heat stage SOLAR DATA solar tank 1 heating off USER NOTE The settings for daily heating and thermal disinfection are made using the hot water function Æ Service instructions for the control panel Input range Factory setting solar tank 1 heating off disinfection heat up disinf heat up off ...

Page 38: ...function The second consumer can be loaded by a 3 way valve or a separate pump 3 8 1 Activating second solar consumer Call up the service level Turn the dial until service level solar appears on the display Press Display to open the main SOLAR DATA menu Turn the dial until SOLAR DATA 2nd consumer appears on the display Press and hold the Display button and turn the dial The second consumer can now...

Page 39: ...olar consumer has been activated the switching must be set in the SOLAR DATA menu level Turn the dial until SOLAR DATA switch appears on the display Press and hold the Display button and turn the dial The various switching options can now be set SOLAR DATA switch automatic Input range Factory setting switch automatic always tank 1 always tank 2 automatic ...

Page 40: ...has been activated the maximum tank temperature must be set in the SOLAR DATA menu level Turn the dial until SOLAR DATA max temperature tank 2 appears on the display Press and hold the Display button and turn the dial The maximum tank temperature can now be set SOLAR DATA max temperature tank 2 140 F Input range Factory setting max temperature tank 2 68 F 194 F 20 C 90 C 140 F 60 C ...

Page 41: ...f the solar thermal system e g glycol water mixture can flow from the storage tank to the collector array the cold medium 32 F 0 C of the solar thermal system e g glycol water mixture can flow from the collector to the storage tank the storage tank temperature drops so that reheating may start for example the collector protection is disabled the tank protection is disabled the collector frost prot...

Page 42: ...appears on the display Press Display to open the main RELAY TEST menu The display shows RELAY TEST boiler Turn the dial until RELAY TEST solar appears on the display Press Display to open the RELAY TEST solar submenu The function on off of the following relays can be tested 3 way changeover valve bypass prim circ SP1 prim circ SP2 sec circ SP2 RELAY TEST boiler ...

Page 43: ... dial until service level fault log appears on the display Press Display to select the main menu fault log The following faults can be displayed bypass buffer sensor bypass return sensor heat consumption supply sensor heat consumption return sensor collector sensor sensor bottom tank 1 sensor bottom tank 2 differential selection volume flow reading service level fault log fault 1 SB return sensor ...

Page 44: ...or The bypass is not being controlled Buffer sensor defective Buffer sensor not connected or not correctly connected FM443 or control defective Check the sensor connection to the FM443 function module FPB FP Check the sensor on the bypass for breaks or incorrect installation position Check the device fuse bypass return sensor The bypass is not being controlled Return sensor defective Return sensor...

Page 45: ...nsor not connected or not correctly connected FM443 or control defective Check the sensor connection to the FM443 function module WMZ FR Check the sensor on the return of the solar system for breaks or incorrect installation position Check the device fuse collector sensor Tank 1 and tank 2 are not solar heated Collector sensor defective Collector sensor not connected or not correctly connected FM4...

Page 46: ...tched off The values set by the user are not logical The activation threshold is less than the deactivation threshold for tank 1 tank 2 or bypass Check the settings of the FM443 function module using the MEC2 remote control volume flow reading Heat quantity not metered Flow meter defective or not correctly connected FM443 function module defective The hydraulic system is defective Is the flow mete...

Page 47: ...t system data menu Call up the service level Turn the dial until service level act system data appears on the display Press Display to select the main menu DISPLAY The display shows DISPLAY boiler Turn the dial until monitor SOLAR appears on the display Press Display to open the monitor SOLAR submenu The current values and system status can be read in the submenu DISPLAY boiler ...

Page 48: ...tor temperature is too high or the tank temperature is too high or tank 1 is deactivated or another tank is being heated or there is an error in the FM443 function module STAND STILL The solar yield of the collector is insufficient to load tank 1 LOW FLOW Tank 1 is heated at a greater temperature difference low flow HIGH FLOW Tank 1 is heated at a lower temperature difference high flow monitor SOL...

Page 49: ...otal and momentary solar yield of solar circuit 1 7 2 Buffer bypass circuit The display indicates the status of the 3 way valve buffer bypass switching as well as the temperatures of the buffer tank and the heating return off The buffer bypass switching is switched off or was not activated via the MEC2 remote control The relevant outputs are not actuated by the solar control monitor SOLAR SP1 cent...

Page 50: ...ge tank The heater return is sent directly to the boiler The 3 way valve is in the bypass position tank The return temperature of the heating system is lower than the temperature in the buffer or in the lower part of the combi storage tank The heater return is sent through the buffer or combination tank for preheating by the 3 way switching valve 7 3 Solar circuit heat meter The display shows the ...

Page 51: ... is not heated because the collector temperature is too high or the tank temperature is too high or tank 2 is deactivated or another tank is being heated or there is an error in the FM443 function module STAND STILL The solar yield of the collector is insufficient to load tank 2 HIGH FLOW Tank 2 is heated at a lower temperature difference high flow monitor SOLAR collector 230 F tank 2 BLOCKED Poss...

Page 52: ...g the tank is not present Under these conditions the solar control checks whether solar consumer 1 can be heated it has precedence This check is repeated at regular intervals factory setting WE 30 minutes until the solar consumer 1 can be loaded again MANUAL ON The control is in MANUAL ON mode This means that solar circuit 2 is actuated All control functions of the FM443 function module are deacti...

Page 53: ... as well as the operating mode of pumps and valves 7 4 3 Solar yield The display shows the total and momentary solar yield of solar circuit 2 monitor SOLAR SP2 bottom 86 F 3 way valve off sec circ SP2 off SP2 bottom Temperature of solar tank 2 3 way valve Status of the 3 way valve sec circ SP2 Solar circuit 2 secondary pump Possible displays 3 way valve SP1 tank 1 SP2 tank 2 off prim circ SP2 on o...

Page 54: ...Troubleshooting z Remove the sensor terminals z Check the resistance at the sensor lead ends using an ohmmeter z Check the sensor temperature with a thermometer Using the diagram you can check whether temperature and resistance correlate Collector sensor FSK curve Fig 5 Collector sensor FSK curve 6 720 618 330 01 1RS 482 250 392 200 302 150 212 100 122 50 58 50 32 0 F C ...

Page 55: ...R sensor 10 44 FV sensor 10 H HIGH FLOW 48 51 I Integrating FM443 function module 15 16 L Layout of solar modules 11 LOW FLOW 48 M Manual OFF 18 19 MANUAL ON 49 Manual ON 18 19 Manual switch 12 Maximum storage tank temperature 20 P Prim circ SP2 53 S Sec circ SP2 53 Sensor curve 54 Service level 15 Setting maximum tank temperature 40 Solar circuit heat meter 26 Solar consumer 1 20 Solar consumer 2...

Page 56: ...3 Tel 603 552 1100 Fax 603 584 1681 www buderus net U S A Products manufactured by Bosch Thermotechnik GmbH Sophienstraße 30 32 D 35576 Wetzlar www buderus de Bosch Thermotechnology Corp reverves the right to make changes without notice due to continuing engineering and technological advances ...

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