Viessmann Versatronik 503 NR2/Analog Bridge Operating instructions

Brand: Viessmann

Model: Versatronik 503 NR2/Analog Bridge

Type: Operating instructions

Please file in Service Binder6204788 - 02 11/2023

NR2/Analog Bridge

Installation and

Operating Instructions

for use by heating contractor

Versatronik 503 Communication Module

Part Number: 7984983

Product may not be exactly as shown

Read and save these instructions

for future reference.

IMPORTANT

LR 102874

6204788 - 02

Versatronik 503 NR2/Analog Bridge

HDangerous Conditions

- Deactivate main power immediately.

- Close gas supply valve.

HIn Emergencies

Immediately switch off the external power supply to

the panel. e.g. at the separate fuse or power supply

HInstallation of additional Components

The installation of additional components which

have not been tested together with the panel can

adversely affect the function and performance of

the panel.

Our warranty does not cover and we accept no

liability for damage attributable to the installation of

such components.

Safety, Installation and Warranty Requirements

Safety

fProduct documentation fLicensed professional heating contractor

Read all applicable documentation before

commencing installation. Store documentation

near heat pump in a readily accessible

location for reference in the future by service

personnel.

The installation, adjustment, service and

maintenance of this equipment must be

performed by a licensed professional heating

contractor.

u For a listing of applicable

literature, please see section entitled

“Important Regulatory and Safety

Requirements”.

u Please see section entitled “Im-

portant Regulatory and Installation

Requirements”.

fAdvice to owner fWarranty

Once the installation work is complete, the heating

contractor must familiarize the system operator/

ultimate owner with all equipment, as well as safety

precautions/requirements, shutdown procedure, and

the need for professional service annually before the

heating season begins.

Information contained in this and

related product documentation must

be read and followed. Failure to do so

renders the warranty null and void.

Please ensure that these instructions are read and understood before commencing installation. Failure to

comply with the instructions listed below and details printed in this manual can cause product/property

damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and

fulfilled (including detailed information found in manual subsections).

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Table of Contents

Index

Safety

Safety, Installation and Warranty Requirements ................................... 2

Table of Contents

Index .............................................................................................. 3

Important Precautions

Important Regulatory and Installation Requirements .............................. 4

General Information

About these Installation Instructions ................................................... 5

Intended Use ................................................................................... 5

Installation

Mounting the Communication Module ................................................. 6

Overview of Electrical Connections ..................................................... 7

Connections

Setting the Rotary Switch S1 ............................................................ 8

Setting the DIP Switches S2 .............................................................. 9

Boiler Connections ........................................................................... 11

LON Connections ............................................................................. 12

Power Supply .................................................................................. 13

Configuration

Configuring the Boilers ...................................................................... 14

Specifications

Specifications .................................................................................. 15

Troubleshooting

Troubleshooting ............................................................................... 16

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Approvals

Viessmann boilers, burners and controls are

approved for sale in North America by CSA

International.

Codes

The installation of this unit shall be in accordance

with local codes. In the absence of local codes, use:

- CSA C22.1 Part 1 and/or local codes in Canada

- National Electrical Code ANSI/NFPA 70 in the U.S.

Always use latest editions of codes.

The heating contractor must comply with the

Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1

where required by the authority having jurisdiction.

Working on the equipment

The installation, adjustment, service, and

maintenance of this product must be done by a

licensed professional heating contractor who is

qualified and experienced in the installation, service,

and maintenance of hot water boilers. There are

no user serviceable parts on the boiler, burner, or

control.

Power supply

Install power supply in accordance with the

regulations of the authorities having jurisdiction or,

in absence of such requirements, in accordance

with National Codes. Viessmann recommends the

installation of a disconnect switch to the 120V

power supply outside of the boiler room.

Ensure main power supply to equipment, the

heating system, and all external controls have

been deactivated. Close main oil or gas supply

valve. Take precautions in both instances to avoid

accidental activation of power during service work.

fPlease carefully read this manual prior to

attempting installation. Any warranty is null and

void if these instructions are not followed.

For information regarding other Viessmann System

Technology componentry, please reference

documentation of the respective product.

We offer frequent installation and service seminars

to familiarize our partners with our products.

Please inquire.

fThe completeness and functionality of field

supplied electrical controls and components must

be verified by the heating contractor. These

include low water cut-offs, flow switches (if

used), staging controls, pumps, motorized valves,

air vents, thermostats, etc.

1 WARNING

Turn off electric power supply

before servicing. Contact with live

electric components can cause

shock or loss of life.

Important Regulatory and Installation Requirements

Important Precautions

1 CAUTION

HField modifications of this control panel

manufactured by Viessmann Manufacturing

Company Inc. will void factory CSA certification!

HIf modifications are performed, electrical safety

field inspection is required according to local

codes.

HViessmann Manufacturing Company Inc. is not

responsible for any damage, injury or loss of life

resulting from field modifications

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Intended use of the Versatronik 503 NR2/Analog

Bridge is to integrate a boiler equipped with a One

Base control into a pre-existing NR2/LON cascade

system.

On the LON communication side, the Versatronik

503 behaves like any other boiler in the cascade. It

then communicates this information, in analog, to

the target boiler.

More specifically, the cascade control sends these

commands to a boiler: Temperature setpoint and on/

off command. This, in turn, is then communicated

with the target boiler as a 0-10V signal.

The Versatronik 503 equipped boiler is responsible

for relaying the following parameters back to the

cascade: Boiler Temperature, Modulation rate,

and fault status. This is achieved through analog

outputs from the boiler, and a strap-on sensor

(included) that must be mounted on the supply

side of the boiler being integrated into the cascade

system.

About these Installation Instructions

General Information

uThis symbol indicates that additional, pertinent

Information is to be found.

1 WARNING

Indicates an imminently hazardous situation

which, if not avoided, could result in death,

serious injury or substantial product/property

damage.

1 CAUTION

Indicates an imminently hazardous situation

which, if not avoided, may result in minor injury or

product/property damage.

IMPORTANT

1Take note of all symbols and notations intended to draw attention to potential hazards or important

product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.

uWarnings draw your attention to the presence of

potential hazards or important product information.

uCautions draw your attention to the presence of

potential hazards or important product information.

uHelpful hints for installation, operation or

maintenance which pertain to the product.

u uThis symbol indicates that additional, pertinent

Information is to be found.

Intended Use

6204788 - 02

Versatronik 503 NR2/Analog Bridge

1. Mount Versatronik 503 in a convenient location

near the One Base boiler. Remove cover by

loosening the two screws on either side of the

base to release the cover.

2. Fasten base to wall, or back of boiler, using

field-supplied screws/fasteners.

3. Remove knockout and install wire strain relief or

box connector. Removal of remaining knockouts

is required to make further connections.

4. Once all of the 120VAC and low voltage

connections are complete and verified, reinstall

the cover from Step 1.

Mounting the Communication Module

Installation

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Legend

A Power Supply (120VAC) with preinstalled 6 ft (2

meter) convenience plug

B LON Connection (LON1)

C LON Connection (LON2)

D 0-10VDC Boiler Temperature Setpoint Output to

boiler (BLR CMD)

E Fault Message Input from Boiler (FAULT)

F Boiler Temperature Input from boiler (BLR TEMP)

G 0-10VDC Boiler Temperature Input from boiler

(BLR STS)

H Rotary Dial (S1)

I DIP Switches (S2)

Note:

Apply strain relief to on-site cables. Secure

individual wires directly to each plug using cable

ties. Seal any unnecessary apertures with cable

grommets (not cut open).

1 CAUTION

The electronic modules are static

sensitive. To avoid damage

caused by static discharge, follow

Electrostatic Discharge safety

procedures.

LON 1

LON 2

1212

LN1

R41

R17

1212

1 5

1234567

3 4

1 2 345 6 7

IC4

R14

IC5

C15

C16

C10

C11

C12

C13

C14

R16

R15

IC6

R22

C17

C19

R20

R26

C21

R40

C25

D2 D1

R42

LED2

D10D11

D17

D18

D19

J1 J2

C31

R25

C30

IC9

SV1

R12 LED3

R13 LED4

R18 LED5

R19 LED6

OK2

R10

IC3

G F E D C

Installation

Overview of Electrical Connections

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Setting the Rotary Switch

The rotary dial sets the LON participant address of the

device.

Position 1-8: Boiler LON participant address. The

Vitotronic Cascade control will recognize this boiler

as this address.

Note:

You must power cycle the device after an address

change.

Position 0: Test mode, this mode is used for factory

testing, the unit will not function as intended when

left in this position.

Position 9: Autobinding reset is used to change LON

participant # without power cycle. Or breaking

a tool binding configuration (this is not used in a

typical application).

Position LON Participant Number

0 Do not use

1 Boiler Address 1

2 Boiler Address 2

3 Boiler Address 3

4 Boiler Address 4

5 Boiler Address 5

6 Boiler Address 6

7 Boiler Address 7

8 Boiler Address 8

9 Autobinding reset

Adjust dial switch to position 9

Wait 10s

Press and hold service button for 2s

Wait 10s

Adjust dial switch to desired boiler #

New address is set after another 10s

LON 1

LON 2

1212

LN1

R41

R17

1212

1 5

1234567

3 4

1 2 345 6 7

IC4

R14

IC5

C15

C16

C10

C11

C12

C13

C14

R16

R15

IC6

R22

C17

C19

R20

R26

C21

R40

C25

D2 D1

R42

LED2

D10D11

D17

D18

D19

J1 J2

C31

R25

C30

IC9

SV1

R12 LED3

R13 LED4

R18 LED5

R19 LED6

OK2

R10

IC3

Connections

Setting the Rotary Switch S1

6204788 - 02

Versatronik 503 NR2/Analog Bridge

LON 1

LON 2

1212

LN1

R41

R17

1212

1 5

1234567

3 4

1 2 345 6 7

IC4

R14

IC5

C15

C16

C10

C11

C12

C13

C14

R16

R15

IC6

R22

C17

C19

R20

R26

C21

R40

C25

D2 D1

R42

LED2

D10D11

D17

D18

D19

J1 J2

C31

R25

C30

IC9

SV1

R12 LED3

R13 LED4

R18 LED5

R19 LED6

OK2

R10

IC3

1234567

1 2 345 6 7

Setting the Dip Switches

The DIP Switch settings are used to configure device

options and target boiler maximum power output.

DIP switches 1-6 are used for selecting the power

input of the connected boiler.

The calculation for power (in kW) is the binary value

squared, then divided by 5.

P = (x^2)/5

See table 1 below.

DIP switch #7 is used in case there is no 0-10V

feedback (Feedback disabled) In this case the

Versatronik 503 cannot provide accurate feedback

information to the cascade.

Position ON OFF

DIP 7 0-10V feedback

Disabled

0-10V feedback

Enabled

Boiler Input

MBH (kW)

Boiler

Model

Switch Setting

1 2 3 4 5 6

0 (0) OFF OFF OFF OFF OFF OFF

0.6 (0.2) ON OFF OFF OFF OFF OFF

2.7 (0.8) OFF ON OFF OFF OFF OFF

6.1 (1.8) ON ON OFF OFF OFF OFF

10.9 (3.2) OFF OFF ON OFF OFF OFF

17.0 (5.0) ON OFF ON OFF OFF OFF

24.6 (7.2) OFF ON ON OFF OFF OFF

33.4 (9.8) ON ON ON OFF OFF OFF

43.6 (12.8) OFF OFF OFF ON OFF OFF

55.3 (16.2) ON OFF OFF ON OFF OFF

68.2 (20.0) OFF ON OFF ON OFF OFF

82.6 (24.2) B2HE 85 ON ON OFF ON OFF OFF

98.3 (28.8) OFF OFF ON ON OFF OFF

115.3 (33.8) B2HE 120 ON OFF ON ON OFF OFF

133.8 (39.2) B2HE 150 OFF ON ON ON OFF OFF

153.8 (45.1) ON ON ON ON OFF OFF

174.7 (51.2) OFF OFF OFF OFF ON OFF

197.2 (57.8) B2HE 199 ON OFF OFF OFF ON OFF

221.1 (64.8) OFF ON OFF OFF ON OFF

246.4 (72.2) ON ON OFF OFF ON OFF

273.0 (80.0) OFF OFF ON OFF ON OFF

Connections

Setting the DIP Switches S2

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Boiler Input MBH (kW) Boiler Model Switch Setting

1 2 3 4 5 6

301.0 (88.2) ON OFF ON OFF ON OFF

330.3 (96.8) OFF ON ON OFF ON OFF

361.0 (105.8) ON ON ON OFF ON OFF

393.1 (115.2) CI2 399 OFF OFF OFF ON ON OFF

426.5 (125.0) ON OFF OFF ON ON OFF

461.3 (135.2) OFF ON OFF ON ON OFF

497.5 (145.8) CI2 500 ON ON OFF ON ON OFF

535.0 (156.8) OFF OFF ON ON ON OFF

573.9 (168.2) ON OFF ON ON ON OFF

614.2 (180.0) OFF ON ON ON ON OFF

655.8 (192.2) ON ON ON ON ON OFF

698.8 (204.8) OFF OFF OFF OFF ON ON

743.2 (217.8) CI2 750 ON OFF OFF OFF OFF ON

788.9 (231.2) OFF ON OFF OFF OFF ON

836.0 (245.0) ON ON OFF OFF OFF ON

884.4 (259.2) OFF OFF ON OFF OFF ON

934.2 (273.8) ON OFF ON OFF OFF ON

985.4 (288.8) CI2 1000 OFF ON ON OFF OFF ON

1037.8 (304.1) ON ON ON OFF OFF ON

1091.9 (320.0) OFF OFF OFF ON OFF ON

1147.1 (336.2) ON OFF OFF ON OFF ON

1203.8 (352.8) OFF ON OFF ON OFF ON

1261.8 (369.8) ON ON OFF ON OFF ON

1321.2 (387.2) OFF OFF ON ON OFF ON

1381.9 (405.0) ON OFF ON ON OFF ON

1444.0 (423.2) CI2 1500 OFF ON ON ON OFF ON

1507.5 (441.8) ON ON ON ON OFF ON

1572.3 (460.8) OFF OFF OFF OFF OFF ON

1638.5 (480.2) ON OFF OFF OFF ON ON

1706.1 (500.0) OFF ON OFF OFF ON ON

1775.0 (520.2) ON ON OFF OFF ON ON

1845.3 (540.8) OFF OFF ON OFF ON ON

1917.0 (561.8) ON OFF ON OFF ON ON

1990.0 (583.2) CI2 2000 OFF ON ON OFF ON ON

2064.3 (605.0) ON ON ON OFF ON ON

2140.1 (627.2) OFF OFF OFF ON ON ON

2217.2 (649.8) ON OFF OFF ON ON ON

2295.7 (672.8) OFF ON OFF ON ON ON

2375.5 (696.2) ON ON OFF ON ON ON

2456.7 (720.0) OFF OFF ON ON ON ON

2539.3 (744.2) ON OFF ON ON ON ON

2623.3 (768.8) OFF ON ON ON ON ON

2708.6 (793.8) ON ON ON ON ON ON

Connections

Setting the DIP Switches S2

6204788 - 02

Versatronik 503 NR2/Analog Bridge

CD E

Terminal

Designation

Boiler Terminal Description

Blr Sts 0-10V Out Boiler Modulation

Feedback

Blr Temp N/A Boiler Temp

Sensor (10K)

Fault 66 (S and P) Boiler Fault Status

Blr Cmd 0-10V In (0-

100°C)

Boiler Setpoint

Demand Signal

Setting the Rotary Switch

The Versatronik 503 requires three analog

connections to be made to the boiler control board.

As well as a 10K boiler temp sensor (provided)

Legend

A Boiler MZIO

B Verstaronik 503

C NTC 10K Sensor (Supplied)

D LON Connection 2

E LON Connection 1

Connections

Boiler Connections

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Setting the Rotary Switch

The Versatronik 503 is wired into a Vitotronic NR2

LON daisy chain. There are two RJ45 (8P8C) jacks

for this connection.

They are electrically connected internally, it does

not matter in which order they are connected. If

only one connection is required (end of bus) insert a

LON end resistor into the other port (not provided)

Consideration when using Vitogate 300

The Vitogate 300 will not recognise the Versatronik

503. It can therefore not directly communicate with

the target boiler. However, there are a few data

points that can be learned from the cascade control.

For example, in the case of a GW6B lead control.

The following useful points can be learned about

boiler 3 (via the Versatronik 503)

AI:1085 - 1.1 (Boiler 3) Boiler output - value

AI:1050 - 1.1 (Boiler 3) Boiler water temperature

AI:1059 - 1.1 (Boiler 3) Set boiler water

temperature

MI:1033 - 1.1 (Boiler 3) Boiler fault

MI:1013 - 1.1 (Boiler 3) Operating mode

Connections

LON Connections

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Direct power supply

The Versatronik 503 comes complete with a 6 ft. (2

m) power cord with convenience plug for simplified

installation.

1 WARNING

Incorrectly executed electrical installations can result

in injuries from electrical current and in equipment

damage.

Connect the power supply and implement all

grounding measures (e.g. RCD circuit) in accordance

with the following regulations:

HIn Canada all electrical wiring is to be done in

accordance with the latest edition of CSA C22.1

Part 1 and/or local codes. In the U.S. use the

National Electrical Code ANSI/NFPA 70. The

heating contractor must also comply with both

the Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1,

and the Installation Code for Hydronic Heating

Systems, CSA B214-01, where required by the

authority having jurisdiction.

HConnection requirements specified by your local

power supply utility

HProtect the power cable with max. 15A

Connections

Power Supply

1 WARNING

The absence of component grounding in the system

can lead to serious injury from electrical current if

an electrical fault occurs. Connect the appliance and

pipework to the equipotential bonding of the building

in question.

1 WARNING

Incorrect core allocation can result in serious injury

and damage to the appliance.

Never interchange cores “L” and “N”.

1 WARNING

An incorrect phase sequence can cause damage

to the appliance. Check for phase equality with

the power supply connection of the control unit.

1 WARNING

When extending wire there is the possibility of

exposure to electromagnetic interference. Avoid

running wires beside or near high voltage 120/240

VAC conductors. If proximity to high voltage

conductors cannot be avoided, use stranded,

twisted pair of shield design wire. Ensure that only

one end of the shielding is grounded.

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Application Boiler Configuration Settings

Operating Mode Not weather compensated

without room temperature

controller

Heating Circuit

1-4

Not available

DHW Not available

Low Loss Header/

Buffer Tank

Not available

Heating Zone 1-3 Not available

Function Plug 96 “No Function”

This is preferred so that only

the Versatronik 503 controls

the appliance. However other

options will work as well.

Setting the Rotary Switch

It is recommended that the E-series appliance

should be commissioned as a standalone unit with

no zones, heating circuits, DHW, or outdoor reset

enabled.

This can be configured during the Commissioning

process.

Note:

Basic configuration required for Versatronik 503

compatibility. The installation manual / startup

procedure for the boiler should still be followed

VDD 1706

Description Function Selection MZIO

Value 06

Description Fault Message Output and

Temperature Demand

Setting the Rotary Switch

The heating appliance should also be configured

with 0-10VDC setpoint controls, and fault output

(VDD 1706) This is done using the following steps:

Service -> Service Functions -> Boiler -> 1706.0

Configuring the Boilers

Configuration

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Rated voltage 120VAC

Rated frequency 60 Hz

Rated current 63 mA

Power consumption 22 mA

Permissible ambient

temperature

HOperation 32 to 104°F

(0 to +40°C)

HStorage and transport -4 to 149°F

(–20°C to +65°C)

Specifications

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Function ON OFF BLINK

LED1 Power Power Supply is

Functioning

No Power Not Applicable

LED2 Service PIN LED may flash during

participant check from

the cascade

LED3 LON Communication

Status

Not Applicable No Communication 1/second indicates

communication with

the cascade is active

LED4 Cascade Demand Setpoint requested

from Cascade

Standby requested

from Cascade

Not Applicable

LED5 Boiler Fault Boiler Fault Output is

active

Boiler Fault is inactive 1/second temperature

sensor is missing

4/second LON module

communication fault

LED6 Boiler Status Boiler Status 100%

(10VDC)

Boiler Status is 0%

(0VDC)

Flashes faster as

modulation increases

(0-9.8VDC)

LED Indication

It is recommended that the E-series appliance should

be There are six LEDs on the PCB that can be used

for information feedback and troubleshooting.

LON 1

LON 2

1212

LN1

R41

R17

1212

1 5

1234567

3 4

1 2 345 6 7

IC4

R14

IC5

C15

C16

C10

C11

C12

C13

C14

R16

R15

IC6

R22

C17

C19

R20

R26

C21

R40

C25

D2 D1

R42

LED2

D10D11

D17

D18

D19

J1 J2

C31

R25

C30

IC9

SV1

R12 LED3

R13 LED4

R18 LED5

R19 LED6

OK2

R10

IC3

LED3

LED4

LED5

LED6

LED2

Troubleshooting

6204788 - 02

Versatronik 503 NR2/Analog Bridge

6204788 - 02

Versatronik 503 NR2/Analog Bridge

6204788 - 02

Versatronik 503 NR2/Analog Bridge

6204788 - 02

Versatronik 503 NR2/Analog Bridge

Technical information subject to change without notice. Printed on environmentally friendly

(recycled and recyclable) paper.

Viessmann Manufacturing Company (U.S.) Inc.

45 Access Road

Warwick, Rhode Island · 02886 · USA

TechInfo Line 1-888-484-8643

1-800-288-0667 · Fax (401) 732-0590

www.viessmann-us.com · [email protected]

Viessmann Manufacturing Company Inc.

750 McMurray Road

Waterloo, Ontario · N2V 2G5 · Canada

TechInfo Line 1-888-484-8643

1-800-387-7373 · Fax (519) 885-0887

www.viessmann.ca · [email protected]

Viessmann Versatronik 503 NR2/Analog Bridge Operating instructions

Viessmann Versatronik 503 NR2/Analog Bridge Operating instructions

Viessmann Versatronik 503 NR2/Analog Bridge Operating instructions

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