Installation- and Operating Guide...

Installation- and Operating Guide

ThermoControl-4

www.danfoss.com

Warning!Read this Installation and Operating Guide prior to

starting any work. Prior to start-up ensure that the device is in fault-free condition and functioning smoothly.

Always keep the Installation and Operating Guide to hand near the device.

Original Installation and Operating Guide

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Installation and Operating Guide

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ThermoControl-4

1. Safety Information ................................................................................................................................................................................... 52. Hazard Warnings ....................................................................................................................................................................................... 63. General Information ............................................................................................................................................................................... 74. Installation .................................................................................................................................................................................................... 85. Electrical Installation .............................................................................................................................................................................. 9 5.1 Circuit Board Layout ................................................................................................................................................................. 9 5.2 Terminal Block Overview .................................................................................................................................................... 10 5.3 Terminal Assignment ............................................................................................................................................................. 11 5.4 Electrical connections ........................................................................................................................................................... 14 5.4.1 Sensor wiring .................................................................................................................................................................... 14 5.4.2 Flow Sensor ........................................................................................................................................................................ 14 5.4.3 Pump Wiring ...................................................................................................................................................................... 14 5.4.4 Power Supply .................................................................................................................................................................... 16 5.4.5 Valve Wiring ....................................................................................................................................................................... 176. Basic Operation ...................................................................................................................................................................................... 19 6.1 Device Overview ...................................................................................................................................................................... 19 6.2 Display ............................................................................................................................................................................................. 20 6.3 Switching on the Controller ............................................................................................................................................. 207. Operator Settings .................................................................................................................................................................................. 21 7.1 Setting the language ............................................................................................................................................................. 21 7.2 Setting the time ........................................................................................................................................................................ 21 7.3 Setting temperature setpoints ....................................................................................................................................... 22 7.4 Setting disinfection ................................................................................................................................................................ 23 7.5 Setting night shutoff circulation ................................................................................................................................... 248. Setting system status ......................................................................................................................................................................... 25 8.1 Status ................................................................................................................................................................................................ 25 8.2 Messages ........................................................................................................................................................................................ 25 8.3 Info ..................................................................................................................................................................................................... 26 9. Operator PIN ............................................................................................................................................................................................. 26 10. Definitions and abbreviations .................................................................................................................................................. 2711. Description of application and system types ................................................................................................................. 28 11.1 Tank charging system application (ThermoDual) ........................................................................................... 28 11.1.1 Function description ................................................................................................................................................ 28 11.1.1.1 General ........................................................................................................................................................................... 28 11.1.1.2 Charging ....................................................................................................................................................................... 28 11.1.1.3 Circulation .................................................................................................................................................................... 28 11.1.1.4 Tap water disinfection ......................................................................................................................................... 29 11.1.2 Hydraulic diagram ............................................................................................................................................................ 30 11.1.2.1 Heating circuit version ....................................................................................................................................... 30 11.1.2.2 Integration in circulation flow ....................................................................................................................... 31 11.1.2.2.1 Integration in circulation flow “Standard” or “Maintain” ................................................. 31 11.1.2.2.2 Integration in circulation flow “ZWN pump” or “ZWN valve” ....................................... 32 11.2 Anti-legionella system (ThermoClean) application ................... ..................................................................... 33 11.2.1 Function description ................................................................................................................................................ 33 11.2.1.1 General ................................................................................................................................................................... 33 11.2.1.2 Charging ................................................................................................................................................................ 33 11.2.1.3 Tapping ................................................................................................................................................................... 33 11.2.1.4 Circulation ............................................................................................................................................................ 33 11.2.1.5 Tap water disinfection .................................................................................................................................. 34 11.2.1.6 Protection against excessive tapping (optional) ...................................................................... 34 11.2.2 Hydraulic diagram ...................................................................................................................................................... 35 11.2.2.1 Heating circuit version ................................................................................................................................. 35

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11.3 Domestic instantaneous water heater application (ThermoDual-FLS) .................................................. 36 11.3.1 Function description ................................................................................................................................................ 36 11.3.1.1 General ..................................................................................................................................................................... 36 11.3.1.2 Tapping .................................................................................................................................................................... 36 11.3.1.3 Charging the heating buffer tank ......................................................................................................... 36 11.3.1.4 Circulation ............................................................................................................................................................. 36 11.3.1.5 Tap water disinfection ................................................................................................................................... 36 11.3.2 Hydraulic diagram system type ThermoDual FLS (FLS) ................................................................... 37 11.3.2.1 Heating circuit version .................................................................................................................................. 37 11.3.2.2 Optional expansion ThermoDual-FLS ................................................................................................ 38 11.4 Circulation reheating application (ZWN) ............................................................................................................. 39 11.4.1 Function description ................................................................................................................................................ 39 11.4.1.1 General ..................................................................................................................................................................... 39 11.4.1.2 Circulation ............................................................................................................................................................. 39 11.4.1.3 Tap water disinfection ................................................................................................................................... 39 11.4.2 Hydraulic diagram ............................................................................................................................................................ 4012. Expert settings ..................................................................................................................................................................................... 41 12.1 Selecting system type ........................................................................................................................................................ 41 12.1.1 Assigning pump signal ........................................................................................................................................... 42 12.1.2 Assigning minimum pump speed TMin ........................................................................................................ 43 12.1.3 Setting system-specific settings on ThermoDual (Dual) ............................................................... 44 12.1.4 Setting system-specific settings on ThermoClean (Clean) ........................................................... 44 12.1.5 Setting system-specific settings on ThermoDual-FLS (FLS) ........................................................ 44 12.1.6 Setting final settings under system type ................................................................................................... 44 12.2 Parameterization ................................................................................................................................................................... 45 12.2.1 Setting parameter 1 .................................................................................................................................................. 45 12.2.1.1 Setting ramp function PSL ......................................................................................................................... 45 12.2.1.2 Setting pump control .................................................................................................................................... 46 12.2.1.3 Setting valve control ..................................................................................................................................... 47 12.2.2 Setting parameter 2 ................................................................................................................................................. 47 12.2.2.1 Setting pump control ................................................................................................................................... 48 12.2.2.2 Setting valve control .................................................................................................................................... 4813. Setting default values ..................................................................................................................................................................... 4814. Running system test ........................................................................................................................................................................ 4915. Deleting messages ........................................................................................................................................................................... 4916. Expert PIN ................................................................................................................................................................................................ 5017. Error handling ....................................................................................................................................................................................... 50 17.1 Error handling table ............................................................................................................................................................ 5118. Flow sensor setting max. .............................................................................................................................................................. 5319. Guideline pump flow values (in %) ...................................................................................................................................... 53 19.1 Table system type ThermoDual (Dual) heating pump PHZG ................................................................. 53 19.2 Table system type ThermoDual (Dual) tank charging pump PSL ....................................................... 54 19.3 Table system type ThermoClean (Clean) tank charging pump PSL ................................................... 54 19.4 Table system type ZWN (ZWN) heating pump PZWN ................................................................................. 54 19.5 Table system type ThermoDual-FLS (FLS) heating pump PDF .............................................................. 55 19.6 Table assigning minimum pump speed TMin .................................................................................................. 5520. Relay heat demand KA and disinfection AUX ................................................................................................................ 5521. Technical data ....................................................................................................................................................................................... 5622. Malfunctions .......................................................................................................................................................................................... 5723. Table of parameters ......................................................................................................................................................................... 59


ThermoControl-4

Warning:All work involving transport, installation, start-up and servicing is to be carried out by qualified personnel (in compliance with IEC 364 and CENELEC HD 384 and IEC Report 664 as well as EN 50178, EN 60204, EN 60335/Part 1 and Part 51 and all local regulations)!

In so doing, observe prevailing country specific regulations, standards, accident prevention and local regulations. Connect power supply and outputs using flexible connecting cable or control line LIYY only!

Other standards apply:• Machinery Directive 2006/42/EC• EMC Directive 2004/108/EC• EMC Directive 2014/30/EU• Directive 1999/5/EC Radio equipment and

telecommunications terminal equipment• Directive 98/83/EC Quality of water intended for

human consumption• DIN EN 12897 Water supply - Specification for

indirectly heated unvented (closed) storage water heaters

• DIN EN 12828 Heating systems in buildings - Design for water-based heating systems

• DIN EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and risk reduction

• DIN EN 60204-1 Safety of machinery - Electrical machinery equipment

• DIN EN 60730-2-9 Automatic electrical controls• DIN EN 61000-6-1 Electromagnetic compatibility

(EMC)

• DIN EN 61000-6-3 Electromagnetic compatibility (EMC)

• DIN EN 61000-6-4 Electromagnetic compatibility (EMC)

• EN ISO 13849-1/2 Safety of machinery - Safety-related parts of control systems

• DIN EN 806-1/3 Technical regulations for drinking water installations

• DIN EN 806-1/3 Technical regulations for drinking water installations

Note: Aware of all other specific norms and legislations valid in your country

1. Safety information

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WARNING! Electrical hazard!Electrical energy can cause severe injury. Dama-ge to insulation or individual components can endanger life. Turn main switch off and secure against unintentional restart before performing maintenance, cleaning or repairs. Disconnect the device when working on the electrical system. Do not remove safety devices or render them inoperable through changes.

WARNING!Risk of injury!Stored residual energy, components with edges, edges and corners on and in the device or on the required tools can cause injury. For this reason only qualified personnel may install and uninstall the device.

ATTENTION!This symbol indicates information which if not observed may result in malfunction, damage and/or failure of the system .

ELECTRONIC WASTEElectrical and electronic components, lubricants and other excipients must be handled by haz-ardous waste treatment plants and may only be disposed by approved specialist companies

NOTE!This symbol highlights tips and information that will help operate the system smoothly and ef-ficiently.


ThermoControl-4

This Operating Guide describes the operation and function of the ThermoControl-4 electronic drink-ing water controller. In order to safely work with the controller and handle it properly, all of the specified safety information and handling instructions must be observed. The illustrations in this guide serve to better illustrate the content explained therein and are not necessarily to scale and may vary slightly from the actual design of the system. In addition to this Operating Guide, the operating instructions for other components used also apply. Observe the information contained within - particularly informa-tion - pertaining to safety.The ThermoControl-4 domestic water controller con-nects high-efficiency pumps to AC motors (230 V) that are compatible with the PWM (pulse width modulation) control signals or 0-10 V.

ATTENTION!Do not connect unregulated pumps to the Ther-moControl-4 controller. This may lead to mal-function, failure and/or damage to the system.

3. General information

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The ThermoControl-4 comes from the factory in-stalled on the respective domestic water system or installed on a mounting plate for final installation. In individual cases it may be installed outside of the do-mestic water system. In this case, the housing must be firmly attached to a solid, dry surface. The housing cover must also be removed. Carefully remove the housing cover from the housing. Ensure that the flat cable connects the housing cover to the circuit board in the housing. The flat cable can be removed from the circuit board.The following drawing illustrates the installation points on the housing base.The housing cover is on the front and is attached to the housing with six slotted screws. Loosen and remove the screws using a screwdriver.

ATTENTION!Make sure the cover does not slip when removing the screws.

4. Installation


ThermoControl-4

5. Electrical installation

5.1. Circuit board layout

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5.2. Overview of terminal blocks


ThermoControl-4

5.3. Terminal assignment

ATTENTION!All “Zxx” and “Axx” terminals have a maximum load of 12 V!

The terminal assignment diagram is located on the inside of the housing cover.

Terminal assignment for temperature sensorTerminal Name Description

Z 1-2 FHZ Heating supplyZ 3-4 FSL Domestic hot water chargingZ 5-6 FLE Tank charging onZ 7-8 FLA Tank charging off

Z 9-10 FZW CirculationZ 11-12 FRL Return temperature limitZ 13-14 FWW / FZWN Domestic hot waterZ 15-16 FRÜ Monitoring protection against excessive tappingZ 17-18 S9 not usedZ 19-20 S10 not used

Terminal assignment recirculation pump low voltageTerminal Name Description

Z 21 PHZG 0-10 V Heating pump control signal 0-10 VZ 22 PHZG GND Heating pump groundZ 23 PHZG malfunction Heating pump malfunction lineZ 24 PHZG PWM Heating pump control signal pulse width modulation PWM,

or on/off function at 0-10 V pump controlZ 25 PSL 0-10 V Tank charging pump control signal 0-10 VZ 26 PSL GND Tank charging groundZ 27 PSL malfunction Tank charging pump malfunction lineZ 28 PSL PWM Tank charging pump control signal pulse width modulation PWM,

or on/off function at 0-10 V pump controlZ 29 PZW 0-10 V Circulation pump control signal 0-10 VZ 30 PZW GND Circulation pump groundZ 31 PZW malfunction Circulation pump malfunction lineZ 32 PZW PWM Circulation pump control signal pulse width modulation PWM,

or on/off function at 0-10 V pump controlZ 33 PDF 0-10 V Heating pump control signal 0-10 V ThermoDual-FLSZ 34 PDF GND Heating pump ground ThermoDual-FLSZ 35 PDF malfunction Heating pump malfunction line ThermoDual-FLSZ 36 PDF PWM Heating pump control signal pulse width modulation PWM,

ThermoDual-FLSor on/off function at 0-10 V pump control

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Terminal assignment inputs and outputs additional functions low voltageTerminal Name Description

Z 37 Flow input Input pulse generator flow sensorZ 38 + 12 V Flow sensor power supply 12 V max. 50 mAZ 39 GND Flow sensor groundZ 40 0-10 V input not used

Terminal assignment inputs and outputs additional functions low voltageTerminal Name Description

A 1-2 TR Temperature controller TR and temperature monitor TWA 3-4 exDi Triggering of external disinfection or external temperature increaseA 5-6 TC-Bus not usedA 7-8 eBus not usedA 9-11 MODBus - / + / GND (iso))*

Terminal assignment loads supply voltage

Terminal Name Alternative name Description

Y 1 VSL openMKRÜ

VSL-storage charging valve ThermoDual-FLSMKRÜ valve protection against excessive tapping ThermoCleanY 2 VSL closed

Y 3 VWW openVRU, VZWN

VWW domestic hot water valve ThermoCleanVRU valve return stratification ThermoDual-FLS VZWN valve heating ZWNY 4 VWW closed

Y 5 VHZG openVHZG valve heating

Y 6 VHZG closedY 7 L -> STW

VHZG valve with emergency setting, live conductor in conjunction with safety temperature monitor (STW) or safety temperature limiterY 8 L <- STW

Y 9 L -> VHZGY10 N-supply

Supply 230 V / 50 Hz; PE on collective terminalY 11 L-supply

Terminal assignment power switch supply voltageTerminal Name Description

SW 1 Nto power switch

SW 2 LSW 3 N

from power switchSW 4 L

)* Modbus module required, available as separate accessory.


ThermoControl-4

Terminal assignment outputs additional functionsTerminal Name Description

R 1 KA NCPotential-free relay output for heat demand(C = center contact, NO = normally open, NC = normally closed)R 2 KA C

R 3 KA NOR 4 STM NC

Potential-free relay output for error message(C = center contact, NO = normally open, NC = normally closed)R 5 STM C

R 6 STM NOR 7 Aux NC

Potential-free relay output in disinfection mode(C = center contact, NO = normally open, NC = normally closed)R 8 Aux C

R 9 Aux NO

additional connections for pumps, valves and PETerminal block Description

L Fused and connected 230 V – pump supplyN Fused and connected 230 V – pump and valve supplyPE Protective earth - connections

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5.4 Electronic connections

5.4.1 Sensor wiring 5.4.2 Flow sensor

5.4.3 Pump wiring

The wiring for the factory-installed pumps is shown.

BU = blue BK = black BN = brown

PHZG

mal

func

.PH

ZG o

n-off

/ PW

M

PDF

mal

func

.PD

F on

-off

/ PW

M


ThermoControl-4

WI = white BU = blue BK = black BN = brown

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BU = blue BK = black BN = brown

5.4.4 Power supply


ThermoControl-4

5.4.5 Valve wiringThe wiring for the factory-installed valves is shown.

OPENCLOSE

OPE

N

CLO

SEOPENCLOSE

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OPE

N

CLO

SE

OPENCLOSE


ThermoControl-4

6. Basic operation

6.1. Device overview

Front

Underside

Legend(1) Power switch (2) Touch display (3) “Up” key (4) “Down” key (5) “Enter” key

(6) “Cancel/back” key (7) 3 × M20 cable glands with multiple sealing

inserts (4 × 5.0) for sensors and signal cables(8) 6 × M16 cable glands for supply voltage

(power supply, pumps, drives)

(1)

(2)

(3) (4) (5) (6)

(8)(7)

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6.2. DisplayThe display and the four touchscreen keys on the front of the ThermoControl-4 drinking water control-ler are used to call up information, enter information and make changes to the control parameters.

6.3 Switching on the controllerThe power switch turns on the controller (see Chap. 6.1, (1)). A self-test is then run and “Main Menu” appears on the display.

Settings 2Setpoints 2.1Disinfection 2.2Parameters 1 2.3Parameters 2 2.4Night shutoff 2.5Time/date 2.6

12:48

CLRSL KA TR Clean b

Actual Menu level

Menu level(sub)number

Actual Menulevel number

Cursor

Menu point

Next Menu level Actual

timeTank Charging active

Heat demand request

Disin-fection Tempera-

ture con-troller

System type

Keyupwards

Keydown

Key Keyreturn

DI i

Messagepointer

enter


ThermoControl-4

7. Operator settings

7.1. Setting the language

Choose the language selection menu [4] from the main menu and press Enter to open. The following languages are available for selection. Highlight the desired choice with the cursor:English [4.1] Deutsch [4.2] Francais [4.3]

The desired language is selected by placing the cursor and confirming the selection with the Enter key.

7.2. Setting the time

Select the Settings menu [2] from the main menu and then go to the Time/date menu [2.6]. Move the cursor to select the time or date to be set. Confirm with the Enter key. A PIN request appears. Changes can be made upon successful entry of the PIN. The 24-hour clock is used with the following format:hh : mm : ss hh = hour mm = minute ss = secondThe date has the following format: DD : MM : YY WD DD = day MM = month YY = year WD = day of the weekThe day of the week appears automatically. Use the Enter key to control the value ranges and the up and down keys to change the respective value. Confirm with Enter. Then place the cursor on “apply” and confirm with the Enter key. The values have now been changed. The switch between standard and daylight saving time takes place automatically.

Language selection 4English 4.1Deutsch 4.2Francais 4.3

12:51

CLRxxx

Time/date 2.6Time:Date:apply

10:23

10:23:00 14:01:16 Thu.

CLRxxx

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7.3. Setting temperature setpoints

Select the Settings [2] menu from the main menu and then go to the Setpoints [2.1] menu. Depending on the system application, only those sensors that are connected can perform control functions and be set to active if necessary.Any changes in the Setpoints menu must be author-ized by a PIN. Changes can be made upon successful entry of the PIN.Any changes to the default values have an impact on the function of the system and should be checked for plausibility. The tasks of each sensor are laid out in the function descriptions of the application.In the case of the ThermoDual (Dual) and Thermo-Clean (Clean) applications, the following appears: rel. to FSL: no/yesWhen “no” is selected, each sensor value is changed individually without affecting the other sensor values.When “yes” is selected, the change to the FSL sensor value directly affects the other sensor values. The value difference between the respective sensor and the FSL sensor value remains the same.Sensor values are changed individually for the Ther-moDual-FLS and ZWN applications.Change the values by selecting the respective value with the cursor and activating that value by press-ing the Enter key. The value flashes. Adjust the value using the Up and Down keys. Then accept the value with the Enter key.

Setpoints 2.1rel. to FSL: noFSL 60 °CFHZ 63 °CFLE 55 °CFLA 57 °CFZW 55 °C

12:51

CLRxxx


ThermoControl-4

7.4. Setting disinfection

The disinfection sequence is described in the func-tional description for the network disinfection of the respective applications. Select the Settings [2] menu from the main menu and then go to the Disinfection [2.2] menu.The Disinfection window opens displaying the current disinfection mode and its parameters, if re-quired. To change the mode or its parameters select “Change mode yes”.A PIN is required to make any changes within the Disinfection menu. Changes can be made upon suc-cessful entry of the PIN.The following selection is available in Disinfection mode:off, onetime, weekly, daily, external• off: the disinfection function is disabled• onetime: Disinfection is active once for a maximum

of the set duration. The temperature “Temp” less 5 degrees Kelvin must remain constant at the “FZW” sensor via the “Time” value in order to successfully complete disinfection. Once the disinfection time has been successfully completed, the program changes to the “off” mode.

• weekly: Disinfection sequence as described under “onetime” with the day of the week and time added as disinfection criteria.

• daily: Disinfection sequence as described under “onetime”, with the addition that it is activated daily by naming the start time.

• external: Disinfection is enabled or disabled via an external isolated contact (higher ranking MSR, key switch, etc.).

Change the values by selecting the respective value with the cursor and activating that value by pressing the Enter key. The value flashes. Adjust the value using the Up and Down keys. Then ac-cept the value with the Enter key.Only the selected option is carried out, multiple functions such as “on” and “external” are not possible.

Disinfection 2.2offonetimeweeklydailyexternal

12:51

CLRxxx

externalTemp.: 70 °CTime: 10 min

12:51

CLRxxx

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7.5. Setting night shutoff circulation

The night shutoff function makes it possible to shut off the circulation pump for a defined period of time.

ATTENTION!Shutting off the circulation pumpresults in stagnation of the domestic hot water and circulation water. The temperature may sink to a value that may critically affect hygiene.

A PIN is required to make any changes within the Night Shutoff menu. Changes can be made upon successful entry of the PIN.Select the Settings [2] menu from the main menu and then go to the Night Shutoff [2.5] menu. The following setting options are available for the night shutoff circulation pump:off, internal, external• off: The night shutoff for the circulation pump is

inactive.• internal: The night shutoff of the circulation pump

takes place within the defined window of time. The window of time is defined by the start and stop time. Confirm the settings with “accept”. Night shutoff takes place daily within the defined win-dow of time.

• external: The night shutoff occurs via a master MODbus interface (optional accessory).

Change the values by selecting the respective value with the cursor and activating that value by press-ing the Enter key. The value flashes. Adjust the value using the Up and Down keys. Then accept the value with the Enter key.

Night shutoff 2.5Mode: offStart: 22:00Stop: 05:00apply

12:51

CLRxxx


ThermoControl-4

8. View system status

8.1. Status

The menu enables the user/expert to view the current operating state of the drinking water station and to draw conclusions from the readable values. Select the System status [1] menu from the main menu and then go to the Status [1.1] menu. The Status menu is struc-tured with the loads as well as inputs/outputs and their current operating state on the left side. The right side of the display shows the current sensor values. In addi-tion, symbols may appear attached to the components. These symbols have the following meanings: + = setpoint has been reached or exceeded - - - = defective sensor = pump malfunction

8.2. Messages

Messages in the form of fault messages, time moni-toring and changes to the controller settings are listed chronologically. They are displayed with the consecutive number, date, time, error code and categorization by way of a symbol. The error codes and categories are described in detail in chapter 17. Select the System status [1] menu from the main menu and then go to the Messages [1.2] menu. New, unread messages are indicated with a symbol. The symbol is replaced by a “check” once the message has been read and acknowledged. = message acknowledged = Category 1 message = Category 2 message = Category 3 messageMessage acknowledgement requires a PIN to be entered. The acknowledgement is generated by using the cursor to select the respective message and opening it by pressing the Enter key. The mes-sage is displayed. Reply to the query as to whether the message should be acknowledged by pressing the Enter or CLR key.It is also possible to acknowledge all of the mes-sages. To do this, place the cursor at the bottom of the message list. “Acknowledge all” appears. Press

the Enter key and authorization is requested via PIN. If authorization is granted, all of the messages are checked as acknowledged.A maximum of 60 messages in the list are displayed.

NOTE!Acknowledging category 3 messages gets rid of the collective fault message (STM) relay.

Status 1.1PHZG 8% FHZ+ 67.5°CPSL 66% FSL 59.9°CPZW 15% FZW 54.8°CKA on FLE 47.4°CAux off FLA 51.9°CSTM off

12:51

CLRxxxSL KA

Messages 1.220 14.01.16 09:45:58 0119 14.01.17 09:45:45 0418 14.01.18 09:45:32 02 17 14.01.19 09:45:19 0516 14.01.20 09:40:11 61 15 14.01.21 08:15:35 21

12:51

CLRxxx

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8.3. Info

The Info window provides information about the system type, software version and date. Select the System status [1] menu from the main menu and then go to the Info [1.3] menu.

9. Operator PIN

The operator is responsible for operating a system that takes into account current regulations and standards and protects the user from harm. In or-der to meet these requirements, the system must be protected against unauthorized access and may only be operated by trained personnel.Changes to Message, Setpoints, Disinfection, Night Shutoff and Time/Date are PIN-protected. This PIN enables the operator to change those values. The operator PIN is: 1988This PIN also gives the operator access to other PIN-protected areas.The operator PIN is only valid for 30 minutes. After that, the PIN must be entered again to make changes or gain access.Switching the ThermoControl-4 on and off activates immediate PIN protection to protect against unau-thorized changes.

Info 1.3

Application: Dual bSoftware: V4.0

Date: Thu. 14. January 2016

12:51

CLRDual b

PIN request

Access PIN 0000

12:51

CLRxxx


ThermoControl-4

10. Definitions and abbreviations

The hydraulic diagrams of each system type contain abbreviations, the meaning of which is explained below:BTA = heating buffer tankDCIR = domestic water, circulationDF = flow sensorDHW = domestic hot waterDTA = domestic buffer tankDWC = domestic water, coldECD = electronic controller DHWFHZ = heating supply sensorFLA = tank charging sensor offFLE = tank charging sensor onFRL = return temperature sensorFRÜ = protection against excessive tapping sensorFSL = tank charging sensorFWW = domestic hot water network sensorFZW = sensor circulationFZWN = domestic hot water sensor Circulation reheatingHEA = heatingHEL = charging heat exchangerHEX = heat exchangerMKRÜ = shutoff protection against excessive tappingPDF = pump heating, flow system

PHZG = pump heatingPSL = Pump tank charging domestic water or

storage loading heatingPZW = pump circulationPZWN = Pump heating, circulation reheatingRET = returnRTA = reaction tankSTM = safety temperature monitorSUP = supplyTC = temperature controllerVHZG = control valve heatingVRU = return stratification valveVSL = storage charging valveVWW = mixed valve domestic hot water networkVZWN = Control heating, circulation reheating

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11. Description of application and system types

11.1 Tank charging system application (ThermoDual)

The ThermoControl-4 control device performs all of the relevant control functions required for the smooth operation of the tank charging system. The domestic water pumped by the PSL tank charging pump is heated by the heat exchanger and adjusted to the setpoint (e.g. 60°C) by regulating the quantity of hot water.Depending on whether it is system type “ThermoDual a”, “ThermoDual b” or “ThermoDual c”, regulation occurs via a motor valve “VHZG”, a heating pump “PHZG” or a mixed circuit control with motor valve “VHZG” and heating pump “PHZG” (see chap. 11.2.1). Maximum heat exchanger performance is attained by setting the pump speed to “PSL Max”. The volume control valve in the tank charging line is used for monitoring. This way, the entire system volume is heated to the preset setpoint (e.g. 60°C).

11.1.1 Function description

The controller initiates tank charging when the set-point temperature is undershot at the FLE and FLA sensors. The relay for the external heat demand KA switches on, i.e. the changeover contact is switched and the PHZG heating pump is switched on or VHZG is opened. When the heating supply temperature at the FHZ sensor is sufficient, the PSL tank charging pump is released and the actual tank charging begins.A software PI controller is used to adjust the domestic water heating to the setpoint (e.g. 60°C). Depending on the type of system, either the VHZG motor valve is controlled or the output of the PHZG heating pump is adjusted. Once the domestic water temperature in the tank reaches the preset setpoint at the FLA sensor, tank charging stops. The relay for the external heat demand KA drops off, the PHZG heating pump with adjustable post-run time is switched off or VHZG is closed. In order to purge the extra residual heat at the heat exchanger, the PSL tank charging pump at the adjustable post-run time (“PSL NL”) or until it falls below the adjustable shut-off threshold (“PSL off”). charging is then complete.

11.1.1.2 charging

Depending on the integration of the circulation line into the domestic water system and the required use, there are three distinct use cases: “Standard”, “Uphold” and “ZWN”.In all of these cases the circulation temperature is measured by the FZW sensor and in the event of setpoint deviations it is adjusted by changing the circulation volume flow using the PZW circulation pump.In the “Standard” case the circulation in the cold wa-ter line is integrated directly ahead of the domestic water tank.In the “Uphold” case, the circulation is directly inte-grated ahead of the heat exchanger in the charging line and is constantly reheated, monitored by the FSL sensor. The KA heat demand is set to permanent.During active tank charging (SL) in the “Standard” and “Uphold” cases, you can choose between two options for the circulation pump: “control” and mini-mum speed “min.”. Compared to “control”, minimum speed makes it possible to completely charge the domestic water tank more quickly.In the “ZWN valve” and “ZWN pump” cases, the cir-culation volume flow is reheated separately by an additional heat exchanger. This does not affect the tank charging.Reheating is monitored by the FZWN sensor and in the event of deviations it is adjusted by the heat-ing circuit control valves PZWN (heating pump) and VZWN (valve heating).

11.1.1.3 Circulation11.1.1.1 General


ThermoControl-4

11.1.1.4 Tap water disinfection

Disinfection mode includes heating/disinfection of downstream domestic hot water network distribu-tion. Disinfection mode is activated by an external, insulated contact or by an internal timer. During disinfection mode the relay switches on “Aux” for external heat requirements, i.e. the changeover switch is switched. The setpoints for hot water net-work temperature “FSL”, circulation temperature “FZW” and FZWN are increased according to the setting. FSL and, if necessary, FZWN are set to 70°C and FZW to 65°C.The control algorithm corresponds to the tank charg-ing, however the setpoints are higher. The PZW circu-lation pump is at the preset maximum speed. If the new setpoint has been reached at the FZW sensor, it is monitored for the preset time. Once the pre-set time interval for disinfection mode has expired, the setpoints are reset. The system now switches to normal mode. When shipped from the factory, disinfection mode is disabled

WARNING!Risk of scalding when tapping while disinfec-tion mode is activated! In order to avoid scal-ding, disinfection mode may only be activated upon consultation with the local operator.

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11.1.2 Hydraulic diagram

11.1.2.1 Heating circuit version

System type ThermoDual “a”, “b” or “c”

“ThermoDual a” (Dual a)

“ThermoDual b” (Dual b)

“ThermDual c” (Dual c)

)* = only with “ThermoDual a”


Uphold

ThermoControl-4

11.1.2.2 Integration in circulation flow

11.1.2.2.1 Integration in circulation flow “Standard” or “Maintain”

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11.2.2.2 Integration in ZWN pump circulation flow or ZWN valve

Integration in circulation flow parallel to the tank charging system.


ThermoControl-4

11.2 Anti-legionella system (ThermoClean) application


The “ThermoControl-4” control device performs all of the relevant control functions required to oper-ate the anti-legionella system ThermoClean® as intended. The domestic water pumped by the PSL tank charging pump is heated by the charging heat exchanger and adjusted to the setpoint (70°C).Depending on whether the system is type “Ther-moClean a”, “ThermoClean b” or “ThermoClean c”, adjustment at the FSL sensor occurs via a VHZG mo-tor valve, a PHZG heating pump or a mixed circuit control with VHZG motor valve and PHZG heating pump (see chap. 11.4). Maximum heat exchanger performance is attained by setting the pump speed to “PSL Max”. The volume control valve in the tank charging line is used for monitoring. This way, the entire system volume is heated to the preset set-point (70°C).

11.2.1.2 charging

The controller initiates tank charging when the set-point temperature is undershot at the FLE and FLA sensors. The heat demand KA is activated via a po-tential-free changeover relay and the PHZG heating pump is switched on and/or VHZG is opened. When the heating supply temperature at the FHZ sensor is sufficient, the PSL tank charging pump is released and the actual tank charging begins.A software PI controller is used to adjust the domes-tic water heating to the setpoint (70°C), monitored by the FSL sensor. Depending on the type of system, either the VHZG motor valve is controlled or the out-put of the PHZG heating pump is adjusted. Once the domestic water temperature in the tank reaches the preset setpoint, tank charging at the FLA sensor stops. The boiler demand is reset, and the PHZG heat-ing pump with adjustable post-run time is switched off. In order to purge the extra residual heat at the heat exchanger, the PSL tank charging pump runs at the adjustable post-run time (“PSL NL”) or until it falls below the adjustable shutoff threshold (“PSL off”). charging is then complete.

11.2.1.3 Tapping

The entire system volume is held at a disinfection temperature of 70°C. The extracted water (tapping or circulation flow) is fed to the domestic hot water network at a lower temperature. The back cooling heat exchanger along with the incoming cold water then cools the thermally disinfected domestic hot water and the setpoint (60°C) at the FWW sensor is adjusted by mixing in thermally disinfected domestic hot water at the VWW valve. This setpoint alone de-termines the temperature of the domestic hot water as it leaves the system and enters the home water supply network.

11.2.1.4 Circulation

The circulation temperature is measured by the FZW sensor and in the event of setpoint deviations it is adjusted by changing the circulation volume flow using the PZW circulation pump.

When shipped from the factory the sensor values for FLE and FLA are set to 75°C. This ensures continuous disinfection even during peak tapping periods.

11.2.1.1 General

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Disinfection mode includes heating/disinfection of downstream domestic hot water network distribu-tion. Disinfection mode is activated via a potential-free input contact or an internal timer. During dis-infection mode the heat demand is set to “Aux”. The setpoints for the hot water network temperature “FWW” and circulation temperature “FZW” are in-creased according to the setting. When shipped from the factory, FWW is set to 70°C and FZW is set to 65°C.The PZW circulation pump is at the preset maximum speed. If the new setpoint is reached at the FZW sen-sor, it is monitored for the preset time. Once the pre-set time interval for disinfection mode has elapsed, the setpoints are reset. The system now switches to normal mode. In its delivered state, disinfection mode is disabled.

WARNING!Risk of scalding when tapping while disinfecti-on mode is activated! In order to avoid scalding, disinfection mode may only be activated upon consultation with the local operator.

11.2.1.6 Protection against excessive tapping (optional)

If the amount taken out of the system in times of peak flow is greater than the amount charged, the existing tank volume of thermally disinfected do-mestic hot water is successively emptied.Thanks to the optional protection against excessive tapping and in the event of unexpected operation (e.g. peak flow lasting longer than the determined period of need), the cold water supply is limited until there is once again sufficient thermally disinfected domestic hot water available to the system through charging.To take advantage of this option, both the FRÜ sen-sor for monitoring the protection against excessive tapping (accessory) as well as a motorized shut-off valve “MKRÜ” (on-site, 230 V / 3-point-control) must be installed and the parameter “MKRÜ yes” activated in the controller (see chap. 12.1.4).


DH

W

Ther

moC

ontr

ol-4

App

licat

ion

"The

rmoC

lean

_ _

"

ThermoControl-4


System type ThermoClean “a”, “b” or “c”


“The

rmoC

lean

c” (

Clea

n c)

“The

rmoC

lean

a” (

Clea

n a)

othe

r app

licat

ions

see

belo

w

“The

rmoC

lean

b” (

Clea

n b)

36 | © Danfoss | 2017.03 VI.JM.Z4.02


11.3 Domestic instantaneous water heater application (ThermoDual-FLS)

11.3.1.1 General

The ThermoControl-4 control device performs all of the relevant control functions required for the smooth operation of a domestic instantaneous wa-ter heater. The domestic water pumped during tap-ping is heated by the heat exchanger and adjusted to the setpoint (e.g. 60°C) by regulating the quantity of hot water.Depending on whether it is system type “ThermoD-ual-FLS a”, “ThermoDual-FLS b” or “ThermoDual-FLS c”, regulation occurs via a VHZG motor valve, a PDF heating pump or a mixed circuit control with VHZG motor valve and PDF heating pump (see chap. 11.6.1).

11.3.1.2 Tapping

The controller monitors the domestic hot water tem-perature at the FWW sensor. During tapping, cold domestic water flows from the house connection and is measured by the flow sensor. The incoming domestic water is heated in the heat exchanger fol-lowing the counter flow principle. The flow sensor indicates a heat demand according to the amount of water drawn to the controller. The temperature of the domestic hot water is adjusted by way of the heating circuit control devices (PDF heating pump and VHZG control valve) in relation to the setpoint at the FWW sensor. In the heating supply of the ThermoDual®-FLS domestic instantaneous water heater, the FHZ sensor monitors whether the heating supply tem-perature is high enough to heat the domestic water.

11.3.1.3 charging the heating buffer tank

The heating buffer tank (optional) stores the required amount of heat to cover the need for domestic hot water. The required hot water temperature in the buffer tank is monitored by the FLE sensor (optional). When the setpoint temperature in the heating buffer tank is not met, the controller starts the PSL heating pump (optional) to charge the buffer tank at the pre-set speed “PSL max.” or the VSL valve opens.


The circulation temperature is measured by the FZW sensor and in the event of setpoint deviations it is adjusted by changing the circulation volume flow using the PZW circulation pump.

Charging of the heating buffer tank is complete when the temperature at the FLE sensor has reached the setpoint. The PSL heating pump switches off and the VSL valve closes. To prevent the buffer charging from continuously switching on and off, a switching hysteresis of 5 Kelvin is specified for the FLE sensor.


Disinfection mode includes heating/disinfection of downstream domestic hot water network distribu-tion. Disinfection mode is activated by an external isolated contact, or via an internal timer. During dis-infection the heat demand is set to “Aux”. The set-points for the hot water network temperature “FWW” and circulation temperature “FZW” are increased according to the setting. When shipped from the factory, FWW is set to 70°C and FZW is set to 65°C. If the buffer charging is activated via FLE, the setpoint temperature is raised to 75°C.The PZW circulation pump is set to the maximum speed. If the new setpoint has been reached at the FZW sensor, it is monitored for the preset time. The setpoints are reset once the preset time interval for disinfection mode has expired or the input contact has been reset. The system now switches to normal mode. In its delivered state, disinfection mode is disabled.




ThermoControl-4


System type ThermoDual-FLS “a”, “b” or “c”


“The

rmoD

ual-F

LS a

” (FL

S a)

“The

rmoD

ual-F

LS b

” (FL

S b)

“The

rmoD

ual-F

LS c

” (FL

S c)

38 | © Danfoss | 2017.03 VI.JM.Z4.02


Hot water buffer charging with control mechanism pump (PSL) or valve (VSL) and sensor (FLE).Stratification with directional ball valve (VRU) and sensors (FRL and FLA).

11.3.2.2 Optional extension ThermoDual-FLS

*) Place the FLE sensor in the lower portion of the buffer tank when not using the return stratification.


ThermoControl-4

11.4 Circulation reheating application (ZWN)

11.4.1.1 General

The ThermoControl-4 control device performs all of the relevant control functions required for the smooth operation of circulation reheating. The cir-culation quantity is heated by the heat exchanger and adjusted to the setpoint (e.g. 60°C) by regulating the amount of hot water.Depending on whether it is the “ZWN a” or “ZWN b” system, regulation takes place by way of a VZWN mo-torized valve or PZWN heating pump (see chap. 11.8).


The circulation temperature is measured by the FZW sensor and in the event of setpoint deviations it is adjusted by changing the circulation volume flow using the PZW circulation pump.The heat exchanger heats the circulation flow ac-cording to the principle of counter flow. The FZWN sensor monitors the circulation flow until it reaches the setpoint and the heating circuit control mecha-nisms pump PZWN or valve VZWN adjust the circula-tion flow. The reheated circulation flow is supplied to the domestic hot water supply in the house network.


Disinfection mode includes heating/disinfection of downstream domestic hot water network distribu-tion. Disinfection mode is activated by an external, isolated contact or by an internal timer. During the disinfection time the relay for external heat de-mand switches “Aux” on, i.e. the changeover con-tact is switched. The setpoints for hot water network temperature “FZWN” and circulation temperature “FZW” are increased according to the setting. When shipped from the factory, FZWN is set to 70°C and FZW to 65°C.The PZW circulation pump is at the preset maximum speed. If the new setpoint has been reached at the FZW sensor, it is monitored for the preset time. Once the preset time interval for disinfection mode has expired, the setpoints are reset. The system now switches to normal mode. In its delivered state, dis-infection mode is disabled.



40 | © Danfoss | 2017.03 VI.JM.Z4.02




)* TC/STM only with application ZWN a.

System type ZWN “a” or “b”


Application 3.1ThermoDualThermoCleanThermoDual-FLSZWN

13:19

CLRxxx x

ThermoDual FLSThermoDual FLS aThermoDual FLS bThermoDual FLS c

13:19

CLRxxx x

ThermoControl-4

12. Expert settings

The following settings should be adjusted or checked before starting up for the first time or when mainte-nance work is performed.Any changes in the System Type menu must be authorized by a PIN. Changes can be made upon successful entry of the PIN.

12.1 General

The ThermoControl-4 controller is predominantly installed in domestic water systems or preconfigured for tank charging systems. The controller must be reconfigured when spare parts are supplied. When shipped from the factory the system type is set to Service in the case of spare parts delivery.Select the system type that corresponds to the hy-draulic conditions. The system types are described in chapter 11.Select the System Maintenance [3] menu from the main menu and then go to the System Type [3.1] menu.In the System Type menu there are four system types including their respective type of heating cir-cuit control: • ThermoDual - ThermoDual a - ThermoDual b - ThermoDual c • ThermoClean - ThermoClean a - ThermoClean b - ThermoClean c • ThermoDual-FLS - ThermoDual-FLS a - ThermoDual-FLS b -o ThermoDual-FLS c • ZWN - ZWN a - ZWN bSelection is made by moving the cursor to the re-spective domestic water system and pressing the Enter key to open it. A sub-menu for the selected system type appears. Use the Up and Down keys to select the control type on the heating side and confirm by pressing the Enter key.

42 | © Danfoss | 2017.03 VI.JM.Z4.02

ThermoClean bPHZG Type: PWMPHZG TMin: 15%PSL Type: PWMinv.PSL TMin: 15%PZW Type: PWMinv.PZW TMin: 15%

13:19

CLRClean b


Once the system type including heating circuit con-trol type has been determined, a window in which the final configuration must be carried out opens, as described in chapters 12.1… through 12.2... :

12.1.1 Assigning pump signal

The individual pumps used in the respective system type are listed. The corresponding control signal is required for the ThermoControl-4 to control these pumps at their speed. Select between the types of control signal: • PWM • PWM inv • 0-10 VChange the values by selecting the respective type with the cursor and activating that type by pressing the Enter key. The value flashes. Use the Up and Down keys to change the type. Then accept the value with the Enter key.The default setting for the control signal is listed in chapter 23.Only high efficiency pumps with AC motors (230 V) and the PWM (pulse width modulation) control signals or 0-10 V may be used.

ATTENTION!Do not connect unregulated pumps to the Ther-moControl-4 controller. This may lead to mal-function, failure and/or damage to the system.

The pump signal PWM (pulse width modulation) is used for pumps provided on the heating side. If the cable breaks the pump remains idle.

ATTENTION!The supply voltage 230 V remains connected to the pump even if the signal cable breaks!


rotational speed

maximum

minimum

off 0% 100%

rotational speed

maximum

minimum

off 0% 100%

rotational speed

maximum

minimum

off 0 10

ThermoControl-4

Example: PWM signal for the circulator pump heating:

Grundfos: PWM profile C Wilo: PWM signal logic 2

The pump signal PWMinv (inverse pulse width mod-ulation) is used for pumps provided on the domestic water side. In the event of a cable break the pump runs at full load.

Example: PWMinv signal for the domestic water circulator pump:

Grundfos: PWM profile Wilo: PWM signal logic 1

The pump signal 0-10 V can be set when the pumps described above are not used. Ensure that the circu-lator pumps have an electrically controlled shutoff, e.g. by way of an add-on module. In addition, select the setting in the pump software that allows for the processing of the 0-10 V signal.

Example 0-10 V control signal for circulator pump:

In one system type, the operation of pumps with different control signals is allowed.

12.1.2 Assigning minimum pump speed TMin

The circulator pumps in the respective system types have a minimum speed specified by the manufac-turer. This are expressed in the ThermoControl-4 controller as the technical minimum speed “TMin”. Information regarding the minimum speed can be found in the documentation for the circulator pump in question. This information is required in order to take advantage of the complete performance range of the pump. The technical minimum speed is to be indicated in percent form.Change the values by selecting the respective type with the cursor and activating that type by press-ing the Enter key. The value flashes. Use the Up and Down keys to change the type. Then acknowledge the value with the Enter key.

44 | © Danfoss | 2017.03 VI.JM.Z4.02


12.1.3 Setting system-specific settings on ThermoDual (Dual)

The option return temperature limit “R.T. limiter” can be set under the ThermoDual (Dual) system type. This function must be activated (“enable”) when the heating return is to be limited to its maximum temperature. The maximum permissible return tem-perature is set at the FRL sensor under setpoints in the menu [2.1]. If the FRL sensor value is relatively low it can have a direct influence on the FSL sensor value so that the FSL sensor does not achieve the setpoint.The type of circulation integration - “Circulation” - is a required selection. The integration in the circulation flow is described in chap. 11.1.3 and 11.2.2. The avail-able choices are: “Standard”, “Uphold”, “ZWN Pump” and “ZWN Valve”.As a general rule, pay attention to the following criteria when integrating the circulation. During “Standard” integration the volume flow circulation should not exceed the volume flow tank charging. In many cases the heat source is a boiler (cyclical or priority circuit).During “Uphold” integration a continuous heat source is required (e.g. district heating). Here, too, the volume flow circulation should not exceed the charging volume current.When selecting ZWN, the circulation reheating is independent of the tank charging, and there is no limit as regards the relationship between volume flow, tank charging and circulation. There must also always be an available heat source.

12.1.4 Setting system-specific settings on ThermoClean (Clean)

The option return temperature limit “R.T. limiter” can be set under the ThermoClean (Clean) system type. This function must be activated (“enable”) when the heating return is to be limited to its maximum tem-perature. The maximum permissible return tempera-ture is set at the FRL sensor under setpoints in the menu [2.1]. If the FRL sensor value is relatively low it can have a direct influence on the FSL sensor value so that the FSL sensor does not achieve the setpoint.The protection against excessive tapping option “MKRÜ” can also be selected. The function is de-scribed in chap. 11.2.1.6. The triggering tempera-ture at the FRÜ sensor is set under Setpoints in the menu [2.1] and interrupts the cold water supply to the shutoff MKRÜ.

12.1.5 Setting system-specific settings on ThermoDual-FLS (FLS)

With the system type ThermoDual-FLS (FLS) there is the option of monitoring and controlling the hot water buffer charging with the ThermoControl-4. To do this, select menu point “Tank charging” and change the setting to valve “VSL” or pump “PSL” and confirm by pressing the Enter key. The functionali-ty and hydraulic connection are described in chap. 11.3.1.3 and 11.3.2.2You can also select return stratification “Ret. strati-ficat.”. To use the function, change the value to “en-able”. The return stratification (optional) contains the VRU valve and the FLA and FRL sensors. The hydraulic integration is shown in chap. 11.3.2.2 The tempera-ture difference is adjusted between the FRL sensor in the return and the FLA sensor in the hot water buffer tank. Depending on the relationship between the sensor values, the directional ball valve is connected. The hot water is then fed into the lower (open signal) or middle part (closed signal) of the hot water buffer tank. The temperature difference can be set in the Parameter menu 2 [2.4] under “VRU on”.

12.1.6 Setting final settings under system type

Once the settings for the pumps and system-specific settings have been made, select “apply” and confirm with the Enter key to successfully set the system type. The ThermoControl-4 controller restarts and remains in the main menu. Other settings to be adjusted for smooth functioning are described in chap. 12.2.


ThermoControl-4

12.2 Parameterization

In order to adapt the control mode of the respective system type to the requirements, settings for the connected loads must be adjusted and, in addition, the behavior in exceptional situations must be de-fined. The loads are defined in the hydraulic system diagram; see chap. 11.The default values are listed in chapter 23.Any changes in the Parameter 1 and Parameter 2 menu must be authorized by a PIN. Changes can be made upon successful entry of the PIN.

12.2.1 Setting parameter 1

Select the Settings [2] menu from the main menu and then go to the Parameter 1 [2.3] menu.Change the values by selecting the respective type with the cursor and activating that type by pressing the Enter key. The value flashes. Adjust the value using the Up and Down keys. Then accept the value with the Enter key.All of the setting options are described below. Pa-rameter 1 shows only those values required for the selected system type.HZG VL: This parameter takes effect under excepti-

onal circumstances if temperatures at the heating supply are not high enough. Tank charging is initiated once the time frame has elapsed.

12.2.1.1 Setting ramp function PSL

For the ThermoDual (Dual) and Thermo-Clean (Cle-an) system types, the PSL tank charging pump has a ramp function. This function takes into account the running time of the heating circuit control mechanis-ms and allows the tank charging pump to approach the maximum or minimum speed to maintain the charging temperature.PSL Kp: the value indicates the slope of the ascen-

ding ramp function (beginning of tank char-ging). A small value results in a slight slope in the ramp. A large value results in a steep slope in the ramp.

Value 0.2 0.5 1.0 1.5 2.0 5.0Time (s) 450 180 90 60 45 18

Parameters 1 2.3PSL min: 15%PSL max: 50%PSL off: -15KPSL NL: 180sHZG VL: 5minPZW Kp: 1.0

13:19

CLRClean b

Parameters 1 2.3PSL Kp: 2.0PSL Tn: 5.0sPSL min: 15%PSL max: 60%PSL off: -15KPSL NL: 180s

13:19

CLRDual b

46 | © Danfoss | 2017.03 VI.JM.Z4.02


PSL NL: the value indicates the slope of the descen-ding ramp function (end of tank charging). This value is expressed in seconds. This function cools the residual heat in the heat exchanger.

PSL off: when the temperature falls faster than specified by the descending ramp, the tank charging pump switches off early when the setpoint temperature of the tank charging minus the temperature difference is not met.

12.2.1.2 Setting pump control

The pump settings are valid for the following pumps if they have not already been stated in chapter 12.2.1.1:Pumps PSL, PZW, PHZG, PZWNKp: Amplification of the pulse length of the con-

trol signal.Tn: Reset time that specifies the pause between

control signals.Hy: Hysteresis, which does not result in any

control changes within the range around the setpoint.

min: Minimum speed in percent; this value should be equal to or greater than the technical mi-nimum; see chap. 12.1.2.

max: Maximum speed in percent required to cover the output of the circulator pump. Setting the speed too high can lead to inefficient functioning. Guidelines for the maximum values are found in the tables in chapter 19 and should be adapted to suit local regula-tions if necessary.

PZW Opt: The behavior of the circulation pump while the domestic water is being tapped (FLS) or during domestic water tank charging (Dual, Clean) can be defined using the pa-rameters “min”, “control” and “max”.

• min: during tank charging the circula-tion pump runs at the preset minimum speed. This results in quick charging.

• max: during tapping the circulation pump runs at the preset maximum speed. This supports the adjustment of the tapping temperature for the FLS sys-tem type.

• control: The circulation temperature is adjusted to the setpoint during tapping/tank charging. Select this option for circu-lation type ZWN and system type Clean.

Parameters 1 2.3HZG VL: 5minPZW Kp: 1.0PZW Tn: 5.0sPZW opt: min.PZW min: 15%PZW max: 100%

13:19

CLRDual b


ThermoControl-4

12.2.1.3 Setting valve control

The valve settings apply to the following valves:Valves VHZG, VZWNKp: Amplification of the pulse length of the

3-point signal. Tn: Reset time that specifies the pause between

control signals.Hy: Hysteresis, which does not result in any con-

trol changes within the range around the setpoint.

12.2.2 Setting parameter 2

Select the Settings [2] menu from the main menu and then go to the Parameter 2 [2.4] menu.Change the values by selecting the respective type with the cursor and activating that type by pressing the Enter key. The value flashes. Adjust the value using the Up and Down keys. Then acknowledge the value with the Enter key.All of the setting options are described below. Pa-rameter 2 shows only those values required for the selected system type.Flow (DF) max: The flow sensor measures the cold

water volume flow during tapping and de-termines the resulting heating circuit energy requirement. Set the maximum cold water volume flow in relation to the nominal capa-city of the ThermoDual-FLS domestic instan-taneous water heater. Calculate the values using the formula in chap. 18.

VRU on: The parameter is part of the return stratifica-tion set in the ThermoDual-FLS domestic in-stantaneous water heater. The functions are described in chapter 12.1.5. Open position = FLA > (FRL + VRU_on value) closed position = FLA < (FRL + VRU_on value)

Parameters 1 2.3PZW Tn: 5.0sPZW min: 15%PZW max: 100%VZWN Kp: 1.0VZWN Tn: 7.0sVZWN Hy: 0.5K

13:19

CLRZWN a

Parameters 2 2.4PDF Kp: 5.0PDF Tn: 5.0sPDF Hy: 0.5KPDF max: 100%DF max: 100l/minVRU on: +3K

13:19

CLRFLS b

48 | © Danfoss | 2017.03 VI.JM.Z4.02


12.2.2.1 Setting pump control

The pump settings are valid for the following pumps.Pumps PDF, PZWNKp: Amplification of the pulse length of the con-

trol signal. Tn: Reset time that specifies the pause between



max: Maximum speed in percent required to cover the output of the circulator pump. Setting the speed too high can lead to inefficient functioning. Guidelines for the maximum values are found in the tables in chapter 19 and should be adapted to suit local regu-lations if necessary (only visible for pump applications - all types).

12.2.2.2 Setting valve control

The valve settings apply to the following valves:Valves VWW, VZWNKp: Amplification of the pulse length of the

3-point signal.Tn: Reset time that specifies the pause between



13. Setting default values

Select the System Maintenance [3] menu from the main menu and then go to the Default values [3.2] menu.Setting the default values within the menu must be authorized by a PIN. Changes can be made upon successful entry of the PIN.You are asked whether you want to load the factory settings with the defaults for the specified system type. Confirm the menu selection “yes”. The controller restarts and any values changed by the user, except for the system type, are reset. The default values are described in chapter 23.

Parameters 2 2.4VWW Kp: 1.0VWW Tn: 7.0sVWW Hy: 0.5K

13:19

CLRFLS b

Default values 3.2

Restore the settings of the current application?

yes no13:19

CLRFLS b


ThermoControl-4

14. Run system test

Select the System maintenance [3] menu from the main menu and then go to the System test [3.3] menu.A PIN is required to authorize the use of the System test menu. It can be used once the PIN has been successfully entered.The electrical components (left display side) can be selected and their functions activated.The display contains information about current sen-sor values, externally activated disinfection (“exDI” off / on), temperature controllers (“TR” off / on) and connected pumps, valves and relays and their ac-tivation.Test the loads by selecting the respective type with the cursor and activating it by pressing the Enter key. The value flashes. Adjust the value using the Up and Down keys.The controller does not carry out any control func-tions in the System test menu level. The executed settings are only temporary. Once you leave the System test menu level the temporary settings are no longer valid and the ThermoControl-4 controls according to the system type.

15. Delete messages

The controller makes messages available as de-scribed in chapter 8.2. Messages are used to analyze for optimization and to remedy malfunctions. Once the messages are no longer required they may be deleted.Select the System maintenance [3] menu from the main menu and then go to the Delete messages [3.4] menu.A PIN is required to authorize the use of the Delete message menu. It can be used once the PIN has been successfully entered.The “Delete message” menu asks whether all mes-sages should be deleted. Press the Enter key to con-firm deletion. Once the message has been success-fully deleted you return to the System maintenance menu.Cancel the delete command using the CLR key and return to the System maintenance menu.

System test 3.3VHZG open FHZ+ 67.5°CPSL 66% FSL 59.9°CPZW 15% FZW 54.8°CKA on FLE 47.4°CAux off FLA 51.9°CSTM off

12:51

CLRxxx

current application? 3.4

Are you sure to deleteall messages?

yes no13:19

CLRxxx

50 | © Danfoss | 2017.03 VI.JM.Z4.02

16. Expert PIN

The expert is responsible for start-up and mainte-nance. Settings that guarantee the function of the system are to be carried out.Faulty settings can result in injury and damage to property.Changes to any adjustable areas of the ThermoCon-trol-4 are protected by a PIN.The expert PIN is: 7853This PIN also encompasses the authorization of the operator PIN.The PIN is valid for 30 minutes. After that, the PIN must be entered again to make changes or gain access.Switching the ThermoControl-4 on and off activates immediate PIN protection to protect against unau-thorized changes.

17. Error handling

The controller features a reporting system that chronologically records errors and events that oc-cur (see Messages menu [1.2]). The handling of these events can be adjusted.Select the System maintenance [3] menu from the main menu and then go to the Error handling [3.5] menu.A PIN is required to authorize the use of the Error handling menu. It can be used once the PIN has been successfully entered.The sub-menu covers• faulty sensors • controller events • pump malfunctions • system messagesCertain events should only create one message in the list (category 1), while others draw attention to themselves through additional displays at the foot of the display (category 2) and still others, e.g. defective sensors, also set the fault output STM (category 3). All of the message numbers, events, corresponding default categories and the obligatory responses on the part of the controller are listed in Table 17.1.


Explanation of symbols: = Category 1

= Category 2 = Category 3

PIN request

Access PIN 0000

12:51

CLRxxx

Controller events20 FHZ 20Min < setpoint21 FSL 20Min < setpoint22 FSL 20Min > setpoint23 Tank charging > 6h -25 FWW 20Min < setpoint 26 FZW 60Min > setpoint

12:51

CLR

xxx


ThermoControl-4

No. Error/event

CategoryComment/Action

Thermo Dual

(Dual)

Thermo Clean

(Clean)

Thermo Dual-FLS

(FLS)

ZWN (ZWN) (independent of category)

01 FHZ sensor defective –

The control mode is executed according to FSL/FWW or approved according to HZG VL (no. 28)

02 FSL sensor defective – – Abort tank charging, control mode terminated

03 FLE sensor defective –For Dual and Clean continuous tank charging, for FLS abort tank charging

04 FLA sensor defective –

For Dual and Clean continuous tank charging, for FLS VRU goes to “closed”

05 FZW sensor defective

PZW to max., regulate according to diagram

06 FRL sensor defective –For Dual and Clean ignore R.T. limiter, for FLS VRU goes to “closed”

07 FRÜ sensor defective – – – For Clean, MKRÜ received open signal

08 FWW sensor defective – – Energy supply stopped,

control terminated

08 FZWN sensor defective – – Energy supply stopped,

PZW adjusts to FZW

20 FHZ 20 min < setpoint – – regulate according to

diagram

21 FSL 20 min < setpoint – – regulate according to

diagram

22 FSL 20 min > setpoint – – regulate according to

diagram

23 SL duration > 6h (1 – – – regulate according to diagram

25 FWW 20 min < setpoint – – regulate according to

diagram

25 FZWN 20 min < setpoint – – regulate according to

diagram

26 FZW 60 min < setpoint

regulate according to diagram

28 Timeout HZG VL- (2 – – regulate according to diagram

17.1. Error handling table

52 | © Danfoss | 2017.03 VI.JM.Z4.02


No. Error/event

CategoryComment/Action

Thermo Dual

(Dual)

Thermo Clean

(Clean)

Thermo Dual-FLS

(FLS)

ZWN(ZWN) (independent of category)

29 12h no SL (1 – – regulate according to diagram

30 disinfection ok – – – – regulate according to diagram

31 Disinfectionnot ok

regulate according to diagram

40 TR triggered Energy supply stopped, control terminated.

41 FSL 5 min > setpoint +10K – – Energy supply stopped,

control terminated.

42FZW 20 min >

setpoint+ 15K

Energy supply stopped, control terminated.

43 FWW 20 min >setpoint + 10K – – Energy supply stopped,

control terminated.

43 FZWN 20 min >setpoint + 10K – – Control terminated.

45 Malfunctionremoved

51 PHZG malfunction (−)* (−)* – –52 PSL malfunction –53 PZW malfunction54 PDF malfunction – – (−)*54 PZWN malfunction – – (−)*

60 Restart – – – –The ThermoControl controller was switched on...

61 Settingschanged

62 Messagesdeleted

All messages were manually deleted

63 Time/dateinvalid

17.1. continued Error handling table

(–)* = The respective system picture a has no category as there is no pump.(1 = SL stands for tank charging(2 = meaning is explained in chap. 12.2.1 menu point HZG VL


ThermoControl-4

18. Flow sensor (DF) setting max.

The following formula determines the maximum volume flow to be set.Formula:

Q × 1000c × (Toff − Ton) × 60

V =

V = Volume flow in liters per minute Q = Heat output in kWh c = specific thermal capacity, 1.163 in Wh / (K × kg) Ton = domestic water inlet temperature in °C Toff = domestic water outlet temperature in °C

19. Guideline pump values (in %)

The ThermoControl-4 controller regulates the cir-culator pumps based on performance using the re-spective control signal. To further optimize control, the speed range of each circulator pump should be adapted to the output requirement by inputting the minimum and maximum speed. The minimum speed “P…. min: …%“ and maximum speed “P…. max: …%“ can be set in parameter 1 (menu 2.3) or parameter 2 (menu 2.4).The following tables contain guidelines for the mi-nimum and maximum speeds of the factory fitted circulator pumps for the different system types. For

Sample calculation:

150 × 10001.163 × (60 − 10) × 60

V =

Heat output 150 kW

V = 43 liters per minute

the circulation pump (PZW), we recommend using the default values (see chap. 23) as a starting point.The guidelines in the tables represent the basis for the commissioning of the system. Adjust the speed range in relation to the respective pump and system curve if necessary. For monitoring purposes, read the actual volume flow directly from the control valve on the domestic water side. Finally, check Menu 1.1 (Status) to ensure that the preset setpoint has been reached.

19.1. Table system type ThermoDual (Dual) heating pump PHZG

Capacity [kW]

Volume flow [l/min]

Heating pumpPHZG type

System type“ThermoDual b”

System type“ThermoDual c”

Max % Max %25 8

UPM GEO25-85 PWM

41 5340 13 41 5360 19 53 5380 26 53 76

100 32 53 65130 41 65 76140 45 65 76150 48 65 76210 67

Stratos-Para25/1-12 PWM

51 63280 89 57 66350 112 63 72420 134 Stratos-Para

30/1-12 PWM70 72

455 145 66 71

54 | © Danfoss | 2017.03 VI.JM.Z4.02


19.2. Table system type ThermoDual (Dual) tank charging pump PSL

Capacity [kW]

Volume flow [l/min]

Tank charging pump

PSL type

System type“ThermoDual”

Min. % Max %25 7

UPM2K25-40N PWM inv 15

4140 12 5360 17 6580 23 UPM2K

25-70N PWM inv 1553

100 29 65130 37

UPM GEO25-85N PWM inv 15

76140 40 65150 43 76210 60

MAGNA GEO25-100N PWM inv 15

59280 80 59350 100 67420 120 72455 130 72

19.3. Table system type ThermoClean (Clean) PSL tank charging pump

Volume flow [l/min]

PSL type tank charging pump

System type“ThermoClean”

Min. % Max %

Thermo-Clean-Combi

350 26 UPM2K 25-70 NPWM inv 15

65500 34 65750 42 UPM GEO

25-85N PWM inv 1576

1000 48 76

Thermo-Clean-DL

200 40MAGNA GEO

32-100N PWM inv 1556

350 70 59500 100 64750 150 MAGNA3

40-80 FN 0-10 V 2075

1000 200 86

1300 260 MAGNA340-100 FN 0-10 V 20 94

19.4. Table system type ZWN (ZWN) PZWN heating pump

Capacity [kW]

Volume flow [l/min]

Heating pump PZWN Type

System type“ZWN b” Max %

33 34 UPM GEO25-85 PWM

5352 53 63


ThermoControl-4

19.5. Table system type ThermoDual-FLS (FLS) heating pump PDF

Capacity [kW]

Volume flow [l/min]

Heating pump PDF type

System type“ThermoDual-FLS b”

Max %

System type“ThermoDual-FLS c”

Max %70 23

UPM GEO25-85 PWM

30 –135 43 50 –140 45 65 76210 67

MAGNA GEO25-100 PWM

60 67280 89 64 72350 112 67 75420 134 MAGNA GEO

32-100 PWM72 75

455 145 72 75

20. Relay heat demand KA and disinfection Aux

Relay heat demand (KA) Relay disinfection (Aux)Use System type Requirement Continuous Requirement

ThermoDual(Dual)

All + Standard × ×All + Maintain × ×All + ZWN… × ×

ThermoClean(Clean) All × ×

ThermoDual-FLS (FLS)

No buffer charging ×

Buffer charging × ×ZWN (ZWN) All ×

The table indicates when a relay is set.

19.6. Table assigning minimum pump speed TMin

Pump tMin* Valuation

Grundfos

UPM GEO / UPM2K 15% PWMUPM GEO -N / UPM2K -N 15% PWM inv.MAGNA GEO 15% PWMMAGNA GEO - N 15% PWM inv.MAGNA3 (N) 20% 0-10V

WiloSTRATOS (Z) 30% 0-10VStratos-Para 15% PWM

* = settings under Application [3.1] menu.

56 | © Danfoss | 2017.03 VI.JM.Z4.02


21. Technical data

Inputs

10 × Pt 1000 sensor in 2-wire-technology1 × potential-free circuit for external disinfection1 × potential-free circuit for temperature controller (TR)4 × potential-free circuit for malfunction inputs pump1 × frequency input for flow sensor

Outputs

3 × Three-step signal: Capacity max. 230 V AC, 0.5 A4 × Power supply pumps, switched: Capacity max. 230 V AC, 2 A4 × control signal pump PWM 5 V-level (100 Hz)4 × control signal pump 0-10 V DC, input signal > 100 kΩIncluding 4 switching outputs (on/off) 5 V-level1 × heat demand, potential-free changeover contact, capacity max. 230 V AC, 2 A1 × malfunction message output, potential-free changeover contact, capacity max. 230 V AC, 2 A1 × disinfection requirement, potential-free changeover contact, capacity max. 230 V AC, 2 A1 × 12 V DC: Capacity 50 mA

Bus ModBus RS485 half duplex, galvanically separated )*Operating voltage 230 V ± 10%, 50-60 Hz

Current consumption max. 6.3 AAmbient temperature 0-40°C

Protection class IP54Protection type II as per VDE 0106

Emission according to EN 61000-6-3according to EN 55011+A1: class B

emission according to EN 61000-6-2

FusePrimary 6.3 ATSecondary 1.0 AT

Battery 3 V Lithium coin cell 1225Dimensions (Height × Width × Depth): 159 × 248 × 124 mm

Weight 1.6 kg

)* Modbus module required, available as separate accessory.


ThermoControl-4

22. Malfunctions

Malfunctions in electrical equipment may only be repaired by appropriately qualified personnel in this field. Notify the manufacturer or the manufacturer’s authorized service partner in the event of malfun-ctions that cannot be repaired using the following measures.

NOTE!Messages generated by the controller (see chap. 8.2) are an important tool for troubleshooting and/or when analyzing malfunctions.

Malfunction Possible cause Troubleshooting CommentDomestic water temperature too low

Hygiene of domestic water at risk!

No power supply Switch on main switch, check supply, check fuses/contactor

No water supply, no cold water pressure, primary differential pressure too low, too little hot water

Establish and ensure operating conditions such as pressure, quantity and differential pressure

Supplier of heat or media

Incorrect controller setting(s)Check system type, check setpoints, pump settings, accept default settings

Consult Operating Guide

Closed shutoff mechanisms Open shut-off valve

Defective sensor

Sensor value displayed as “----” under Status.Check sensor wiring, replace sensor

Defective or not switched on charging pump

Check system type, check setpoints, pump settings, replace pump

Check connecting cable

Defective control valve Clean/make sure it moves freely, replace if necessary

Consult our experts

Defective drive or thermostat Replace drive/thermostat Consult our experts

System incorrectly sized - Check sizing- Expand / enlarge system

Consult our experts

Excessive water tapped from system

- Check sizing- Expand / enlarge system

Consult our experts

58 | © Danfoss | 2017.03 VI.JM.Z4.02


Malfunction Possible cause Troubleshooting CommentDomestic water temperature too high

Risk of scalding!

No power supply, electrical drive open

Take system out of operation, establish power supply, manually initiate emergency operation

Incorrect controller setting(s)Check system type, check setpoints, pump settings, accept default settings


Defective sensor

Sensor value displayed as “----” under Status.Check sensor wiring, replace sensor

Defective control valve Clean/make sure it moves freely, replace if necessary

Consult our experts

Defective drive or thermostat Replace drive/thermostat

Drive open or thermostat / capillary tube defective

Domestic water temperature fluctuates or is not constant

Risk of scalding!

Incorrect controller setting(s)

Correct settings- controller gain Kp- reset time Tn- valve running time


Fluctuation domestic water supply, fluctuating primary differential pressure, fluctuating heating water quantity

Establish and ensure operating conditions such as pressure, quantity and differential pressure

Supplier of heat or media


ThermoControl-4

23. Table of parametersM

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Dua

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Clean

Fact

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FLS

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2.1 Setpointsrel. to FSL no no – – yes / no

FSL 60°C 70°C – – 15 .. 80°CFHZ 63°C 73°C – – 15 .. 80°CFLE 55°C 75°C 70°C – 15 .. 80°CFLA 57°C 75°C – – 15 .. 80°CFZW 55°C 55°C 55°C 55°C 15 .. 80°CFWW – 60°C 60°C – 15 .. 80°CFZWN 60°C – – 60°C 15 .. 80°C

FRÜ – 50°C – – 15 .. 80°CFRL 65°C 75°C – – 15 .. 80°C

2.2 Disinfection

mode off off off off off, once, weekly, daily, external

2.3 Parameters 1VHZG Kp 1.0 1.0 1.0 – 0.1 .. 25.0VHZG Tn 7.0 s 7.0 s 5.0 s – 0.0 .. 300.0 sVHZG Hy 0.5 K 0.5 K 0.5 K – 0.0 .. 10.0 KPHZG Kp 1.0 1.0 – – 0.1 .. 25.0PHZG Tn 5.0 s 5.0 s – – 0.0 .. 300.0 sPHZG Hy 0.5 K 0.5 K – – 0.0 .. 10.0 K

PHZG max 100% 100% – – 5 .. 100%PHZG NL 30 s 30 s – – 0 .. 250 sPSL Kp: 1.0 1.0 – – 0.1 .. 25.0PSL Tn: 30.0 s 30.0 s – – 0.0 .. 300.0 s

PSL min 15% 15% – – 5 .. 100%PSL max 15% 15% 100% – 5 .. 100%PSL off −15 K −15 K – – −4 .. −15 KPSL NL 180 s 180 s – – 0 .. 250 sHZG VL 5 min 5 min – – 0 .. 240 minPZW Kp 1.0 1.0 1.0 1.0 0.1 .. 25.0PZW Tn 5.0 s 5.0 s 5.0 s 5.0 s 0.0 .. 300.0 s

PZW Opt min – max – min,regulate, maxPZW min 15% 15% 15% 15% 5 .. 100%PZW max 100% 100% 100% 100% 5 .. 100%

60 | © Danfoss | 2017.03 VI.JM.Z4.02

Installation and Operating GuideM

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Fact

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2.4 Parameters 2VWW Kp – 1.0 – – 0.1 .. 25.0VWW Tn – 7.0 s – – 0.0 .. 300.0 sVWW Hy – 0.5 K – – 0.0 .. 10.0 KPDF Kp – – 0.5 – 0.1 .. 25.0PDF Tn – – 5.0 s – 0.0 .. 300.0 sPDF Hy – – 0.5 K – 0.0 .. 10.0 K

PDF max – – 100% – 0 .. 100%Flow max – – 150 l/min – 10 .. 150 l/min

VRU on – – +3K – 3 .. 30KPZWN Kp 1.0 – – 1.0 0.1 .. 25.0PZWN Tn 5.0 s – – 5.0 s 0.0 .. 300.0 sPZWN Hy 0.5 K – – 0.5 K 0.0 .. 10.0 K

PZWN max 100% – – 100% 5 .. 100%VZWN Kp 1.0 – – 1.0 0.1 .. 25.0VZWN Tn 7.0 s – – 7.0 s 0.0 .. 300.0 sVZWN Hy 0.5 K – – 0.5 K 0.0 .. 10.0 K

2.5 Night shutoff

mode off off off off off, external, internal

Start 22:00 22:00 22:00 22:00Stop 05:00 05:00 05:00 05:00

3.1 System type

PHZG type PWM PWM – – PWM inv,PWM, 0 .. 10 V

PHZG TMin 15% 15% – – 5 .. 50%

PSL type PWM inv PWM inv PWM – PWM inv,PWM, 0 .. 10 V

PSL TMin 15% 15% 15% – 5 .. 50%

PZW Type PWM inv PWM inv PWM inv PWM inv PWM inv,PWM, 0 .. 10 V

PZW TMin 15% 15% 15% 15% 5 .. 50%

PDF Type – – PWM – PWM inv,PWM, 0 .. 10 V

PDF TMin – – 15% – 5 .. 50%

PZWN Type PWM – – PWM PWM inv,PWM, 0 .. 10 V

PZWN TMin 15% – – 15% 5 .. 50%


ThermoControl-4

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3.1 System type

Circulation Standard – – –Standard,

Uphold, ZWN valve, ZWN

pumpR.T. limiter disable disable – – disable, enableMKRÜ on – no – – no, yes

Heating buffer charging – – disable – disable, VSL, PSL

Ret. stratificat. – – disable – disable, enable

62 | © Danfoss | 2017.03 VI.JM.Z4.02



ThermoControl-4

64 | © Danfoss | DHS-SMCT/PL | 2017.03 VI.JM.Z4.02

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary eady agreed.All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

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