Buderus MCM10 Installation Instructions Manual
For heating contractors
Pour le professionel
Please read carefully before
installing and servicing
A lire attentivement avant le
montage et l’entretien
MCM10
6 720 617 648 - 07.1O
en-us Installation Instructions 2
fr Notice d´installation 20
6 720 616 690 (08/2009)
Table of contents
MCM10
2
Table of contents
1 Explanation of symbols and safety instructions 3
1.1 Symbols, explanation of 3
1.2 Safety instructions 3
2 Details about the MCM10 module 4
2.1 Declaration of conformity 4
2.2 Information regarding the documentation 4
2.3 Proper use 4
2.4 Scope of delivery 4
2.5 Accessories 4
2.6 Technical specifications 5
2.6.1 General 5
2.6.2 Dimensions 5
2.6.3 Power connection parameters 5
2.6.4 Measurement values supply temperature sensor 5
2.6.5 Measurement values outdoor temperature sensor 5
2.7 System integration of the MCM10 6
2.7.1 Principles of cascade control 6
2.7.2 Heating controls for MCM10 cascade systems 6
2.7.3 Water heating with MCM10 cascade systems 6
2.7.4 Internal frost protection function 6
2.7.5 Control of one heating pump 7
2.7.6 External switching contact 7
2.7.7 System versions overview 7
2.7.8 Connection of additional modules in case of heating
system controls with 2-wire BUS control 9
3 Installation 10
3.1 Installation 10
3.1.1 Wall mounting 10
3.2 Making the electrical connections 11
3.2.1 Connection of the low voltage part with BUS
connections 11
3.2.2 120 V AC connection 11
3.2.3 Connection of a remote fault indication with optical
and acoustic signal 12
3.2.4 Electrical connection of the outdoor temperature
sensor 12
3.2.5 Electrical connection of the supply temperature
sensor 12
3.2.6 Electrical connection of the external switching
contact 12
3.2.7 Disposal 12
3.3 Installing other accessories 12
4 Start-up and shut-down 13
4.1 Configuration 13
4.2 Commissioning 13
4.3 Configuration reset 13
4.4 Shutting down 13
5 Operating and fault indications 14
5.1 Operating and fault indications via the heating appliance
displays 14
5.2 Fault message via the remote fault indication 14
5.3 Operating and fault indications via LED 14
5.4 Operating and fault indications via the RC35 16
5.5 Replacing the fuse for the heating zone pump
connection 17
6 Environmental protection 18
7Appendix 19
1
Explanation of symbols and safety information
MCM10
3
1 Explanation of symbols and safety information
1.1 Explanation of symbols
Warning symbols
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
• NOTICE indicates possible damage to property or
equipment, but where there is no risk of injury.
• CAUTION indicates possible injury.
• WARNING indicates possible severe injury.
• DANGER indicates possible risk to life.
Important information
Additional symbols
1.2 Safety precautions
B To ensure proper function, follow these instructions.
B Install and start up the heating appliance and all
accessories according to the associated instructions.
B Use this accessory exclusively in conjunction with the
controllers and heating appliances listed. Follow the
connection diagram!
B This accessory has inputs and outputs with different
voltages. Never connect the low voltage side to the
120 V power supply or vice-versa.
B In case of wall installation: never install this accessory
in wet areas.
B Work on electrical components only if you have the
required training and qualification.
B Before you start working on the system, disconnect the
heating system from electrical power by shutting off the
emergency shut-off switch or the heating system circuit
breaker.
B Secure against unintentional reconnection.
B It is not sufficient to simply shut off the controls.
B Observe all applicable electrical codes and
regulations.
Safety instructions in this document are
framed and identified by a warning triangle
which is printed on a grey background.
Electrical hazards are identified by a lightning
symbol surrounded by a warning triangle.
Notes contain important information in cases
where there is no risk of personal injury or
material losses and are identified by the
symbol shown on the left. They are bordered
by horizontal lines above and below the text.
Symbol Meaning
B a step in an action sequence
Æ a reference to a related part in the docu-
ment or to other related documents
•a list entry
– a list entry (second level)
2
Details about the MCM10 module
MCM10
4
2 Details about the MCM10 module
2.1 Declaration of conformity
2.2 Information regarding the
documentation
We reserve the right to make technical modifications!
2.3 Proper use
The MCM10 modules are designed to control cascade
systems. A cascade system is a heating system where
several smaller heating appliances are connected in
parallel to achieve a higher output (Æ Fig. 12, page 19).
The MCM10 modules are only suitable for controlling
heating appliances with Logamatic EMS BUS.
For floor-standing heaters, the MCM10 module is only
suitable for the activation of gas heaters with modulating
burners without operating conditions.
2.4 Scope of delivery
Fig. 1 Scope of delivery
1 MCM10
2 Duct connection box
3 Sensor well
4 Supply temperature sensor FV
5 Package with:
- 3 screws and 3 wall-plugs
- 4 strain relief clips and 8 screws
6 Installation and operating instructions
B Check that the delivery is complete.
2.5 Accessories
Here is a list with typical accessories. In order to get a
complete overview of all available accessories, please
contact the manufacturer.
• Outdoor temperature sensor FA for connection to
terminal F (only for system variant 1).
• RC35: Outdoor reset heating system controls with
plaintext display for controlling a heating system with
mixed or unmixed heating zones.
• WM10: Low loss header module for EMS.
• MM10: Mixer module for EMS.
• AM10: Outdoor reset controller with thermostat
connection.
The design and operation of this product
conform to the U.S. and Canadian Directives.
Its conformity is demonstrated by the CSA
designation.
The Declaration of conformity can be
claimed. See the address at the back of this
manual.
Hand all enclosed documents over to the user.
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2
4
3
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5
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Details about the MCM10 module
MCM10
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2.6 Technical specifications
2.6.1 General
2.6.2 Dimensions
Fig. 2 Dimensions
2.6.3 Power connection parameters
2.6.4 Measurement values supply temperature
sensor
2.6.5 Measurement values outdoor temperature
sensor
Designation Unit
Dimensions (Æ Fig. 2)
Weight (without packaging) lb (kg) 1.76 (0.8)
Rated voltage MCM10 AC … V 120
Frequency Hz 60
Max. on-site fuse protection of the
input voltage
Amp 10
Power draw MCM10 W 5
Rated voltage BUS DC … V 15
Internal appliance fuse, heating
pump output
Amp 5 AF, ceramic, filled
with sand
Measuring range, supply
temperature sensor
° F ( °C) 32 … 212
(0 … 100)
Measuring range, outside
temperature sensor
° F ( °C) – 40 … 122
( – 40 … 50)
Permissible ambient
temperature MCM10
° F ( °C) 32 … 122
(0 … 50)
Permissible ambient temperature,
supply temperature sensor
° F ( °C) 32 … 212
(0 … 100)
Permissible ambient temperature
outdoor temperature sensor
° F ( °C) – 58 … 212
( – 50 … 100)
Maximum cable length,
2-wire BUS connections
ft (m) (ÆTab. 6, page 11)
Maximum lead lengths,
sensor leads
ft (m) (ÆTab. 7, page 11)
EMC suppression level to IEC 60730
Enclosure rating II in accordance
with IEC 60730
NEMA definition Type 2
Tab. 1 General
2-1/2" (62mm)
6 720 616 690-03.1TD
2-1/2" (62mm)
9-1/4" (235mm)
2-1/4" (58mm)
1-1/2" (37mm)
5-9/16" (142mm)
6-1/2" (165mm)
Pos.
1)
1) (Æ Fig. 12, page 19)
Interface
A Input Power supply from the power
line or from the previous module MCM10
120 V AC,
max. 10 Amp.
B Output Power supply for additional
MCM10
120 V AC,
max. 10 Amp.
C Output Pump 120 V AC,
max. 250 W
D Output Remote fault indication zero volt,
max. 120 V,
2Amp.
E Input Supply temperature sensor NTC (ÆTab. 3)
F Input Outdoor temperature sensor NTC (ÆTab. 4)
G Input External switching contact Zero volt
H Input Heating controls
(ON/OFF contact)
24 V DC
I Input Heating controls (propor-
tional interface)
0-10 V DC
J 2-wire BUS to the heating controller
(RC35, WM10, MM10)
–
K 2-wire BUS from the previous MCM10
module
–
L 2-wire BUS to the next MCM10 module –
M 2-wire BUS to the heating appliance –
Tab. 2 Power connection parameters
°F ( °C) Ω °F ( °C) Ω
68 (20) 12490 140 (60) 2488
77 (25) 10000 149 (65) 2083
86 (30) 8057 158 (70) 1752
95 (35) 6531 167 (75) 1481
104 (40) 5327 176 (80) 1258
113 (45) 4369 185 (85) 1072
122 (50) 3603 194 (90) 917
131 (55) 2986 203 (95) 788
Tab. 3 Measurement values supply temperature sensor
°F ( °C) Ω °F ( °C) Ω
– 4 ( – 20) 97070 50 (10) 19900
5 ( – 15) 72929 59 (15) 15708
14 ( – 10) 55330 68 (20) 12490
23 ( – 5) 42315 77 (25) 10000
32 (0) 32650 86 (30) 8057
41 (5) 25388 95 (35) 6531
Tab. 4 Measurement values outdoor temperature
sensor
2
Details about the MCM10 module
MCM10
6
2.7 System integration of the MCM10
2.7.1 Principles of cascade control
When the heating appliance generates a heat demand
(Æ Tab. 5, system versions 1, 2, 3, and 4), initially one
heating appliance is started and, if required, its heat
output is raised to its maximum nominal power. Only then
will another heating appliance be started.
If excessive heat is being generated, heating appliances
are controlled one after another in sequence without
delay down to their respective minimum nominal power,
and then shut down until heat demand and generation
match. With system version 4 all appliances are shut
down simultaneously.
The MCM10 module automatically determines the
sequence in which the heating appliances are controlled.
The MCM10 module safeguards an even distribution of
the burner hours of operation for all heating appliances.
This takes into account heating and DHW. This increases
the heating appliance service life. If the power supply to
the MCM10 module is interrupted, the hours run meters
in the MCM10 module are reset to zero.
As soon as a heating appliance is not able to start (DHW
heating for a directly-connected hot water tank, heating
appliance fault, communication fault with MCM10
module), another heating appliance will be started
automatically to cover the heat demand.
2.7.2 Heating controls for MCM10 cascade
systems
The MCM10 modules stage the heating appliances
based on the heat demand calculated. For control
according to the heat demand, the MCM10 modules
always require heating system controls (Æ Fig. 12,
terminals H, I or J, page 19). Depending on the heating
system controls, there are four possible system versions
(ÆTab. 5).
One MCM10 module can control up to four heating
appliances. By connecting up to four MCM10 modules,
up to 16 heating appliances can be linked to form a single
cascade (Æ Fig. 12, page 19). In this case, one MCM10
module controls the cascade (MCM10 master).
Depending on the heating system controls used, a
cascade system with up to 4 or up to 16 heating
appliances can be created. The maximum number of
heating appliances that can be connected and the
number of MCM10 modules required for the different
systems are shown in Tab. 5, page 8.
The MCM10 module controls the entire boiler loop
(primary loop including the low loss header). All other
heating system components (secondary side of the low
loss header, such as the heating zones, hot water tank)
can be regulated by a weather-dependent heating
controller with a 2-wire BUS interface and additional
modules (WM10, MM10...). Contact the manufacturer for
further details. You will find the relevant address on the
back cover.
Heating appliances of any output can be part of a
cascade.
2.7.3 Water heating with MCM10 cascade
systems
Hot water tanks can be connected hydraulically and
electrically directly to a heating appliance (storage tank
model).
• Water heating is controlled by the heating appliance.
During a DHW demand, this heating appliance will not
be called by the MCM10 module. In case of demand,
another heating appliance may be started.
• If water heating is timed using a heating system control
with 2-wire BUS connection, the heating appliance
with the storage tank must be connected to the
MCM10 module (master) via terminals 17 and 18.
2.7.4 Internal frost protection function
The MCM10 module is equipped with an internal frost
protection function: if the supply temperature falls below
45 °F ( 7 °C ), a heating appliance starts and runs until a
supply temperature of 60 °F (15 °C) has been achieved.
Any heating pump that is connected to the MCM10
module will also run (Æ paragrahp 2.7.5).
B Connect the supply temperature sensor to the MCM10
master module if the internal frost protection function is
required.
Note that, for the correct function, only one
heating system control/building management
system may be connected.
The different system versions require the
connection of certain accessories (supply
temperature sensors, outdoor temperature
sensors, heating pumps, and heating system
controls) (Æ Tab. 5, page 8).
If the user wants to prepare hot water using
the 3-way valve of the heating appliance and
he wants to continue supplying the heating
zone, he must switch off the warm water
priority on the RC35 for all heating zones
since with the factory settings, hot water
priority is active by default.
The frost protection function of heating
system controls with 2-BUS interface
provides comprehensive system frost
protection. This requires the connection of an
outdoor temperature sensor.
2
Details about the MCM10 module
MCM10
7
2.7.5 Control of one heating pump
In heating systems with only one heating zone, the heating
pump can be connected directly to the MCM10 module
(master).
The heating pump runs:
• as long as at least one heating appliance pump is
running (if required, set the pump run-on time on the
heating appliance accordingly Æ heating appliance
installation instructions); or
• briefly after remaining idle for 24 hours (anti-seizing
protection).
2.7.6 External switching contact
The MCM10 module is equipped with an external
switching contact (Æ Fig. 12, pos. G). For the
characteristics of this switch, see Æ Tab. 2, page 5.
This external switching contact can be used optionally,
e.g. to connect a temperature switch for protecting the
radiant floor heating against a too-high water temperature.
If the switching contact is opened, all heating appliances
are switched off via the MCM10 module. As soon as the
switching contact is closed again, the heating appliances
are ready for operation again.
2.7.7 System versions overview
As a manufacturer of advanced heating technology, we
give high priority to the development and manufacture of
economical and clean-burning heating appliances. To
guarantee this, our heating appliances are equipped with
modulating burners. To make optimum use of the burner
characteristics, heating system controls with 2-wire BUS
control should be used.
The anti-seizing pump protection lets the
heating pump run at least once every day
even without a heat demand (e.g. during
summer).
B Leave your heating system switched on all
year to prevent the pump (in summer) from
seizing up.
2
Details about the MCM10 module
MCM10
8
System version 1: Modulating weathercompensated heating controller (RC35)
An advantage of this system is the ability of the modules
to communicate, enabling all heating zones to be
controlled (function module WM10 or MM10) with the
MCM10 module via a common BUS, parallel to terminal J
on the MCM10 module (Æ Fig. 12, page 19). This
ensures matching generated heat amount to the actual
heat demand of all heating zones in the system. With this
version, the heating system achieves optimum comfort
with maximum energy savings.
System version 2: Modulating weathercompensated heating controller (AM10)
The supply target temperature of the AM10 module
depends on the outdoor temperature. In contrast to
system version 1, it is not possible to use the WM10 and
MM10 modules.
System version 3: Modulating 0 - 10 V controller,
regulated acc. to output
In conjunction with a building management system with
0 - 10 V interface, the total output of the cascade can be
selected as control variable. Setting is achieved via a
jumper (Æ Fig. 3).
System version
Symbol forcontroller
connection
Heating controller to MCM10
master module
Type
Max. number MCM10
Max. number of heating
applianceswith BUS-enabled
Logamatic EMS
Required accessories with connection to MCM10
(Æ Fig. 12, page 19)
1 Modulating weather-compensated
controller 2-wire BUS control
RC35 4 16 • Outdoor temperature sensor.
• One WM10 module. The WM10 module is delivered with a
supply temperature sensor (see explanation on the following
page).
• Heating pump (secondary zone) is connected to the WM10
module.
2 Modulating weather-compensated
controller 2-wire BUS control
AM10
weathercompensated controller
4 16 • Connect outdoor temperature sensor to AM10.
• Common supply temperature sensor on terminal E (only for
internal frost protection).
• Heating pump (secondary zone) (Æ Fig. 12, [19]) on terminal C, only in case of one or several heating zones without
heating pump or in case of heating zones that do not communicate via BUS modules with the MCM10module.
3 Modulating
0 - 10 V controller,e.g. building management system;
control of the heat output
Any 4 16 • Common supply temperature sensor on terminal E (only for
internal frost protection).
• Heating pump (secondary zone) (Æ Fig. 12, [19]) on
terminal C, only with one or several heating zones without
heating pump or with heating zones that are not regulated
via the building management system.
4 Modulating
0 - 10 V controller, e.g. building management system;
supply temperature control
Any 4 16 • Common supply temperature sensor on terminal E
• Heating pump (secondary zone) (Æ Fig. 12, [19]) on
terminal C, only with one or several heating zones without
heating pump or with heating zones that are not regulated
via the building management system.
5 ON/OFF controller (zero volt) Any 4 16 • Common supply temperature sensor on terminal E (only for
internal frost protection).
• Heating pump (secondary zone) (Æ Fig. 12, [19]) on
terminal C.
Tab. 5 System versions overview
0 ... 10V
0 ... 10V
2
Details about the MCM10 module
MCM10
9
Fig. 3 Setting via jumper
Fig. 4 Correlation between the input voltage and heat
output
U Input voltage
P Output in % of the rated cascade output
System version 4: Modulating 0 - 10 V controller,
regulated to supply temperature
In conjunction with a building management system with
0 - 10 V interface, the supply temperature can be
selected as control variable. Setting is achieved via a
jumper (Æ Fig. 3).
Fig. 5 Correlation between the input voltage and the
supply temperature
U Input voltage
VT Supply temperature
System version 5: Heating control with ON/OFF
contact
In conjunction with a control unit with ON/OFF contact,
module MCM10 regulates the cascade output in
accordance with the contact closure respectively up to
maximum output, by starting one appliance after another.
When the contact is opened, all heating appliances are
shut down simultaneously.
The ON/OFF contact of the heating system controls must
be a dry contact.
2.7.8 Connection of additional modules in case of
heating system controls with 2-wire BUS
control
Any additional modules, such as the WM10 and MM10
modules (Æ Fig. 12, [21], page 19), must be connected
to the BUS of the heating controller (parallel to terminal J
on the MCM10 module).
6 720 617 648-001.1TD
VT [˚F]
P [%]
0246810
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0
30
50
70
90
U [V DC]
P [%]
194 (90)
167 (75)
140 (60)
113 (45)
86 (30)
59 (15)
0
0246810
6 720 617 648-10.1TD
U [V DC]
[˚F (˚C)] VT
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Installation
MCM10
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3 Installation
3.1 Installation
3.1.1 Wall mounting
B Determine the location on the wall in accordance with
the dimensions of the MCM10 module.
B Determine whether the main power cord is laid in stiff
or flexible ducts that require duct connection box and
appropriate free space under the MCM10.
B Undo two screws at the bottom of the MCM10 module,
pull the cover at the bottom forward and lift off upwards
(Æ Fig. 6).
Fig. 6 Removing the cover
B For the upper attachment screw, drill a Ø 1/4" (6 mm)
hole, insert an appropriate wall anchor, and insert the
screw until only 1/16" (1.5 mm) protrudes (Æ Fig. 7).
Fig. 7 Upper attachment screw
B In the back panel of the MCM10 module, create two
holes for the lower attachment screws using the
breakouts prepared.
B Attach the MCM10 module at the top attachment
screw.
B Mark the holes to be drilled on the wall through the
breakouts created.
B Remove the MCM10 module.
B Drill Ø 1/4" (6 mm) holes and insert wall anchors
(Æ Fig. 8).
Fig. 8 Insert wall anchor
DANGER: Risk of electric shock!
B Before connecting the power supply,
interrupt the power supply to the heating
appliances and to all other BUS
subscribers.
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1/4"
3,5 mm
0.05" (1,5mm)
6 720 617 648-02.1O
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4.
4.
2.
1.
1/4"
1/4"
3,5 mm
6 720 617 648-03.1O
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1/4"
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Installation
MCM10
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B Hook in the MCM10 module at the top attachment
screw and secure with the two lower screws.
B With the use of stiff or flexible ducts:
– Remove all plastic grommets from the slits on the
lower side of the MCM10;
– push the duct connection to the intended place;
– break out the required number of cable entries by
knocking cautiously with a screwdriver handle;
– mount the duct according to the manufacturer's
instructions.
Note: When using ducts, no plastic grommets are
required.
3.2 Making the electrical connections
B Observe electrical code for the connection and use at
least cable AWG14 for the main power cord.
B Always route cables through the preassembled
grommets and apply the strain relief supplied to protect
the system against the ingress of dripping water.
B Wiring preferably with single core cable. When using
multi-strand (flexible) cables, fit them with wire ferrules.
B Cables can be pulled off the contact strip for their
connection to the screw terminals. The connectors are
color-coded and keyed to prevent mismatch of cable
terminals.
3.2.1 Connection of the low voltage part with
BUS connections
The minimum permissible cable cross-section of the 2wire BUS connection arises from the cable length:
B Route all low-voltage cables separately from cables
carrying 120V to avoid inductive interference (minimum
separation 4 inches)(100 mm).
B In case of inductive external influences, use shielded
cables.
This way, the cables are screened against external
influences (e.g. high-voltage cables, contact wires,
transformer stations, radio and TV devices, amateur
radio stations, microwave devices, etc.).
B When sensor leads are extended, apply the following
lead cross-sections:
B To safeguard the splash-proof rating (IP):
Route cables so that the cable sheath protrudes at
least 0.8" (20 mm) into the cable grommet (Æ Fig. 9)
or the duct connection box.
Fig. 9 Splash-proof
3.2.2 120 V AC connection
B Only use electric cable of similar quality.
B Never connect additional controllers that regulate other
system components to outputs C (pump) and D (fault
signal).
CAUTION: Malfunction!
B Always wire in accordance with the wiring
diagram (Æ Fig. 12, page 19).
B Never connect one BUS to another.
Cable length Min. cross-section
< 325 ft (100 m) AWG 20
325 - 650 ft (100 - 200 m) AWG 18
Tab. 6 Minimum permissible cross-section of the
2-wire BUS connections
Cable length Min. cross-section
< 65 ft (20 m) AWG 20
65 - 100 ft (20 - 30 m) AWG 18
Tab. 7 Sensor lead extension
CAUTION: Risk of pole reversal.
Malfunction through interchanged
connection on the 0 - 10 V interface.
B Ensure connection to the correct poles
(9 = negative, 10 = positive).
CAUTION: The MCM10 module input is not
fuse-protected.
Overloading the outputs can damage the
MCM10 modules.
B Protect the MCM10 module power supply
(master) with a fuse with maximum rating
10 Amp.
CAUTION: Output C (pump) of the MCM10
module has a maximum load capacity of
250 W.
B Connect pumps drawing more current via
relays.
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Installation
MCM10
12
B Recommendation when using several MCM10
modules (cascade with more than four heating
appliances): Provide the additional modules with
power via the first MCM10 module (master). This
ensures simultaneous start-up.
3.2.3 Connection of a remote fault indication with
optical and acoustic signal
For example, a fault indicator can be connected to the
zero volt fault contact (Æ Fig. 12, terminal D, page 19).
The state of the fault contact is also indicated via an LED
on the MCM10 (Æ Tab. 9, page 14).
This is a dry contact that carries a maximum current of 2 A
at 120 V AC.
3.2.4 Electrical connection of the outdoor
temperature sensor
In conjunction with heating system controls with 2-wire
BUS control, always connect outdoor temperature sensor
to the MCM10 module (master) (Æ Fig. 12, page 19) and
not to the heating appliance.
3.2.5 Electrical connection of the supply
temperature sensor
For system version 1, the common supply temperature
sensor must be connected to the WM10 (Æ installation
instructions for WM10) and for the system versions 2, 3,
4, and 5, to the MCM10, terminal E (Æ Fig. 12, [18],
page 19).
3.2.6 Electrical connection of the external
switching contact
If an external switching contact must be connected, the
bridge on the plug must be removed first.
3.2.7 Disposal
B Dispose of packaging in an environmentally-
responsible manner.
B When replacing components, dispose of the old parts
in an environmentally-responsible manner.
3.3 Installing other accessories
B Install accessories according to the legal requirements
and the installation instructions supplied with them.
B The BUS subscribers RC35, WM10, and MM10 must
be connected to terminal J (Æ Fig. 12, page 19).
The maximum current drawn by the system
components (pump, etc.) must not exceed
specifications (Æ Tab. 2, page 5).
Situation Operating status contact
Current on, no fault
Current on, fault
No current
Tab. 8 Operating status contact
The remote fault indication is enabled when
the power supply to the MCM10 module is
interrupted (master) (function check).
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