Danfoss ThermoControl-3 Installation instructions manual

Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL 1

Mounting Guide

ThermoControl–3

Contents

Warning!

Before beginning any work, read this mounting guide

and any associated installation guides. Before starting up the device,

make sure that it is free from defects and in perfect working order.

Always keep these installation instructions to hand near to the device.

Original Mounting Guide

1. Safety information ................................................................................................................................................................................................................. 2

2. Hazard warnings ..................................................................................................................................................................................................................... 2

3. General Information ............................................................................................................................................................................................................. 3

4. Device overview ...................................................................................................................................................................................................................... 4

5. Mounting points of housing ........................................................................................................................................................................................... 5

6. Installing the controller ...................................................................................................................................................................................................... 6

7. Layout of PCB ............................................................................................................................................................................................................................ 7

8. Overview of terminal blocks ........................................................................................................................................................................................... 8

9. Terminal assignment ............................................................................................................................................................................................................ 9

10. Technical data ...................................................................................................................................................................................................................... 12

Notes .................................................................................................................................................................................................................................................. 13

DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy

Mounting Guide ThermoControl–3

1. Safety information

Caution:

The tasks involved in transporting, installing commis-

sioning and maintaining the equipment may be per-

formed only by qualied technicians (who must comply

with IEC 364, CENELEC HD 384 or DIN VDE 0100 and

IECReport 664 or DIN VDE 0110, plus EN 50178, EN 60204,

EN 60335 parts 1 & 51, and any other local requirements)!

2. Hazard warnings

All valid VDE regulations, standards, accident prevention

regulations and any other local regulations must always

be complied with.

Only exible cables or LIYY control lines may be con-

nected to mains connections and power outputs!

WARNING! Risk of injury from electrical current.

Electrical energy can cause serious injuries. Damage on

insulation or individual components can endanger

life. Before performing any maintenance, cleaning or

repair work, switch the main switch o and secure it

against being switched back on again. Disconnect

the unit with all work on the electrical system. Do not

remove any safety units or put them out of operation

by making changes.

WARNING! Danger of injury!

Stored residual energies, sharp-edged components,

sharp points and edges on and in the device or on the

required tools may cause injury. All the tasks involved

in installing or dismantling the device may therefore

be carried out only by qualied personnel.

CAUTION!

This symbol highlights information, which, if ignored,

may result in malfunctions, damage and/or failure of

the entire system.

ELECTRICAL SCRAP

This device is subject to theWEEE directive (ElektroG)

and should not be disposed of with household waste.

After use it should be disposed of via the local recycling

collection point.

NOTE!

This symbol highlights hints that should be observed

to ensure ecient, problem-free operation of the

system.

Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL

Mounting Guide ThermoControl–3

3. General Information

These installation instructions describe the installation of

the electronic domestic hot-water temperature controller

ThermoControl-3

. You should also always refer to the

relevant installation guide for the chosen application.

Compliance with all the safety and handling instructions

is a requirement for working safely and using the system

properly. The graphics in this manual are intended to

illustrate the information content. They are not neces-

sarily to scale and may deviate slightly from the actual

system design.

In addition to this mounting guide, the installation

guides for other installed components also apply. The

information contained in these – especially in relation

to safety – must be complied with.

TheThermoControl-3 domestic hot-water temperature

controller is designed to be connected to high-ecien-

cy electric pumps (230V AC) that are compatible with

PWM (pulse width modulation) control signals or 0-10V.

CAUTION!

Unregulated pumps may not be connected to the

ThermoControl-3 controller. This would lead to mal-

functions, failures or damage to the system.

DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy

Mounting Guide ThermoControl–3

4. Device overview

Front

Underside

Legends

(1) Mains switch

(2) Display

(3) Membrane key“UP in the menu”

(4) Membrane key“DOWN in the menu”

(5) Membrane key“OK”

(6) Membrane key“Back”

(7) 3x M20 screwed cable entries with multiple seal

insert (4 x 5.0) for sensor and signal cables

(8) 6x M16 screwed cable entries for mains voltage

(power supply, pumps, actuators)

(9) Sub-D socket connection 15-pole (not used)

(1)

(2)

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

(8)

(9)

(7)

Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL

Mounting Guide ThermoControl–3

5. Mounting points of housing

DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy

Mounting Guide ThermoControl–3

6. Installing the controller

WARNING! Risk of injury from electrical current.

The housing cover is on the front and is fastened

to the housing by six Phillips screws. Use a suitable

screwdriver to loosen and remove the screws.

CAUTION!

While removing the screws, make sure the cover does

not slip.

NOTE!

The position of the 5-core ribbon cable is marked,

inserting the plug incorrectly causes the membrane

keys to malfunction. The 40-core cable is protected

against incorrect insertion.

The housing should be fastened to a rm dry surface.To

do this you will need to unscrew the cover.

Carefully release the cover from the housing. When

you do this, bear in mind that the (40-core and 5-core)

ribbon cables are connected to the PCB inside the housing

Both of these cables can be disconnected from the PCB.

Fig.: Positions of the (40-core and 5-core) ribbon cables on the PCB

Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL

Mounting Guide ThermoControl–3

7. Layout of PCB

DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy

Mounting Guide ThermoControl–3

8. Overview of terminal blocks

Pumps

Pumps and valves

L mains 230V.

N mains 230V.

VHZG closed

VHZG open

from STW

to STW

L (VHZG)

KA NC

KA NO

KA C

STM NC

STM NO

STM C

VWW closed

VWW open

MKRU open

MKRU closed

GND

FRU (FSLA / FVL)

GND

FWW(FSol / FZWN)

GND

exDi

GND

FRL

GND

FZW

GND

FLA

GND

FLE

GND

FSL

GND

FHZ

0...10V input

DF input

+12V

DF-input

PSol fault

PSol GND

PZW fault

PZW GND

PZW 0...10V

PSL fault

PSL GND

PSL 0...10V

PHZG fault

PHZG GND

PHZG 0...10V

Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL

Mounting Guide ThermoControl–3

9. Terminal assignment

CAUTION!

All the“Zxx”terminals can be loaded to at most 12V!

Not all terminals are assigned to functions in all

the possible applications.The devices that actually

need to be connected are shown in the electrical

wiring diagrams given in the installation guide for

the relevant application.

Terminal assignment of temperature sensors

Terminal Name Description

Z1, Z2 FHZ Heating supply

Z3, Z4 FSL Domestic hot-water charging

Z5, Z6 FLE Storage charging‘ON’

Z7, Z8 FLA Storage charging‘OFF’

Z9, Z10 FZW Domestic hot-water circulation

Z11, Z12 FRL Return temperature limiter

Z17, Z18

FWW

FSol

FZWN

Domestic hot-water network (applications ThermoClean, ThermoDual-FLS)

Solar storage tank (application MultiHeat)

Domestic hot-water network (application circulation reheating)

Z19, Z20 FRÜ

FSLS

Monitoring excessive extraction (application ThermoClean)

Solar storage charging (application MultiHeat)

Terminal assignment of additional functions

Terminal Name Description

Z13, Z14 exDi Initiation of external disinfection or external temperature increase

Z15, Z16 TR Temperature regulator TR or temperature monitor TW

DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy

Mounting Guide ThermoControl–3

Terminal assignment of circulation pumps

Terminal Name Description

Z21 PHZG 0..10V Heating pump control signal 0-10V

Z22 PHZG GND Heating pump ground

Z23 PHZG fault Heating pump fault line

Z24 PHZG PWM Heating pump control signal PWM (pulse-width modulation),

alternative: on/o function for 0-10V pump control

Z25 PSL 0...10V DHW storage charging pump control signal 0-10V

Z26 PSL GND DHW storage charging pump ground

Z27 PSL fault DHW storage charging pump fault line

Z28 PSL PWM

DHW storage charging pump control signal PWM (pulse-width modulation),

alternative on/o function for 0-10V pump control

Z29 PZW 0..10V DHW circulation pump control signal 0-10V

Z30 PZW GND DHW circulation pump ground

Z31 PZW fault DHW circulation pump fault line

Z32 PZW PWM

DHW circulation pump control signal PWM (pulse-width modulation),

alternative on/o function for 0-10V pump control

Z33 PDF 0..10V Heating pump control signal 0-10V (application ThermoDual-FLS)

or PSol (appl. MultiHeat) or PZWN (appl. Circulation reheating)

Z34 PDF GND Heating pump ground (application ThermoDual-FLS)

or PSol (appl. MultiHeat) or PZWN (appl. Circulation reheating)

Z35 PDF fault Heating pump fault line (application ThermoDual-FLS)

or PSol (appl. MultiHeat) or PZWN (appl. Circulation reheating)

Z36 PDF PWM

Heating pump control signal PWM (pulse-width modulation)

(application ThermoDual-FLS) or PSol (appl. MultiHeat) or PZWN

(appl. Circulation reheating), altern. on/o function for 0-10V pump control

Terminal assignment of inputs and outputs of additional functions

Terminal Name Description

Z37 DF input Input ow sensor pulse generator

Z38 +12V Flow sensor power supply 12V, maximum 50mA

Z39 GND Flow sensor ground

Z40 0..10V input not used

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