Danfoss ECL 2000 Operating instructions

Type
Operating instructions
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Danfoss A/S
EU.65.D1.02
ECL 2000
EU.65.G1.02
LL
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed materials.
Danfoss reserves the right to alter its products without notice. This also applies to products already on order pro-
vided that such alterations can be made without subsequent changes being necessary in specifications already
agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logo-
type are trademarks of Danfoss A/S.
Danfoss A/S ID: EU.65.G1.02
DK-6430 Nordborg Date: September 1998
Denmark
Phone: +45 74 88 22 22
Copyright 1998 Danfoss A/S. All Rights Reserved
Contents
EU.65.G1.02
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1.1 Scope 1
1.2 About this Manual 1
1.3 Typographical Conventions 1
1.4 Overview of Components 2
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2.1 Enclosure 3
2.1.1 Top Part 3
2.1.2 Inside the Enclosure 5
Opening the Enclosure 5
Removing the I/O Board 6
Disconnecting Ribbon Cables 6
Removing the CPU Board 7
2.1.3 Bottom Part 7
2.2 Base Plate and Case 8
2.2.1 Base Plate 8
2.2.2 Terminal Blocks 9
2.2.3 Case 10
2.3 Maintenance 10
2.4 Electronics 11
2.4.1 I/O Board 11
I/O Board Type 1 11
I/O Board Type 2 17
2.4.2 CPU Board 20
2.4.3 LON Board 21
2.4.4 Graphical Display 22
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3.1 Diagram Symbols 24
3.2 Application 1 25
3.3 Application 2 27
3.4 Application 3 29
3.5 Application 4 31
3.6 Application 5 32
3.7 Application 6 34
3.8 Application 7 36
3.9 Application 8 37
3.10 Application 9 39
3.11 Application 10 41
3.12 Application 11 43
3.13 Application 12 46
3.14 Application 13 47
3.15 Application 14 48
3.16 Application 15 52
Contents
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3.17 Application 16 53
3.18 Application 17 55
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4.1 Heat Circuit Types 57
4.1.1 Heat Circuit Type a 57
4.1.2 Heat Circuit Type b 58
4.1.3 Heat Circuit Type c 59
4.1.4 Heat Circuit Type d 60
4.2 General Heat Circuit Functions 61
4.2.1 Calculating the Reference Flow Temperature 61
No Room Temperature Sensor Installed 61
Room Temperature Sensor Installed 62
4.2.2 Return Temperature Limiting 68
4.2.3 Summer Cut-off 69
4.2.4 Optimizer 71
Function of the Optimizer 71
4.2.5 Motor Control (PI-Control) 74
Voltage Control (ECL 2000 Type 2) 74
3-Point Control (ECL 2000 Type 1) 75
Running Time of Motor Valve 78
4.2.6 Pump Control 78
Overrun 78
Night Stop 79
4.2.7 Remote Control 80
Connecting the ESMF 81
4.2.8 Frost Protection 82
4.2.9 Limiter 82
Flow Limiter 83
Flow Cut-off 84
Energy Limiter 84
Wind Velocity Limiter 85
Sun Intensity Limiter 86
Universal Limiter 87
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5.1 Hot-Water Circuit Types 89
5.1.1 Hot-Water Circuit Type A 89
5.1.2 Hot-Water Circuit Type B 90
5.1.3 Hot-Water Circuit Type C 91
5.1.4 Hot-Water Circuit Type D 93
5.1.5 Hot-Water Circuit Type E 95
5.1.6 Hot-Water Circuit Type F 97
5.1.7 Hot-Water Circuit Type G 99
5.1.8 Hot-Water Circuit Type H 101
5.1.9 Hot-Water Circuit Type I 103
5.1.10Hot-Water Circuit Type J 105
5.1.11Hot-Water Circuit Type K 107
5.1.12Hot-Water Circuit Type L 109
Contents
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5.2 General Hot-Water Functions 110
5.2.1 Anti-bacteria function 110
5.2.2 Return Temperature Limiting 110
5.2.3 Motor Control (PI-control) 111
5.2.4 Limiter 111
Flow Limiter 111
Energy Limiter 112
Universal Limiter 112
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6.1 Alarm 113
6.1.1 Alarm Setup 113
6.1.2 Alarm Status 115
6.2 Sensor Time Constants 115
6.3 Software Version 116
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Contents
EU.65.G1.02
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Introduction
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This Technical Manual is for the ECL 2000 district heating temperature controller.
The manual is intended for project and service engineers, as well as sales staff
seeking detailed information about the controller. The manual describes:
ECL 2000 hardware
ECL 2000 automatic control procedures.
Detailed operating instructions are not included in this manual. These are provided
in the ECL 2000 User’s Guide (ref. [3]).
Instructions for installing the controller are provided in the ECL 2000 Installation
Guide (ref. [2]).
You may also want to refer to the overview of user displays and service menus in-
cluded in the appendix of the ECL 2000 User’s Guide and Installation Guide.
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Chapter 2 describes the ECL 2000 hardware: The enclosure and mounting appli-
ances, as well as the printed circuit boards.
Chapter 3 briefly describes each of the ECL 2000’s pre-programmed applications.
Chapter 4 describes heat circuit control.
Chapter 5 describes hot-water circuit control.
Chapter 6 describes the Common Functions of the ECL 2000’s service menus.
At the end of the manual, you find a list of references and an index.
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The following conventions are used:
%ROG Terms that are found in display pictures appear in bold when mentioned in the
text.
,WDOLF Introduces new terms.
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Indicates a note to which you should pay attention.
Introduction
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The list below provides an overview of the various ECL 2000 products including
code numbers. In the following chapters, the individual products and their instal-
lation are described. See also data sheet on ECL 2000, ref. [4].
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ECL 2000 Temperature controller 230V AC. Type 1 without LON communication 087B8000
ECL 2000 Temperature controller 230V AC. Type 1 with LON communication 087B8001
ECL 2000 Temperature controller 24V AC. Type 1 without LON communication 087B8002
ECL 2000 Temperature controller 24V AC. Type 1 with LON communication 087B8003
ECL 2000 Temperature controller 24V AC. Type 2 without LON communication 087B8006
ECL 2000 Temperature controller 24V AC. Type 2 with LON communication 087B8007
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Base plate Base plate including terminal blocks and case in black plastic 087B8099
Panel spring acces-
sory
4 retainer springs and two terminal blocks. Used when controller is placed in
a panel cut-out.
087B3076
DIN rail spring
accessory
Spring for DIN rail mounting 087B3077
IP65 Mounting kit IP65 protection 087B3064
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ESMA Pt 1000 flow temperature sensor, surface type, for mounting on pipe
Provided with screw terminals
084N1004
ESMU Pt 1000 flow temperature sensor, 100 mm immersion type, copper 084N1052
ESMU Pt 1000 flow temperature sensor, 100 mm immersion type, stainless steel 084N1050
ESMU Pt 1000 flow temperature sensor, 250 mm immersion type, copper 084N1053
ESMU Pt 1000 flow temperature sensor, 250 mm immersion type, stainless steel 084N1051
ESMT Pt 1000 outdoor temperature sensor 084N1012
ESMR Pt 1000 room temperature sensor 084N1016
ESMF
Remote control including room temperature sensor. Displacement:
±
10 K
087B3132
ESMB Pt 1000 hot water temperature sensor, cable type 087N0010
ESMC Pt 1000 flow temperature sensor, surface type, for mounting on pipe
Provided with 2 m wire connection
087N0011
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LON LON communication module to be fitted in controller 087B8098
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ECL 2000 Hardware
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Figure 1 shows the ECL 2000 enclosure.
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The ECL 2000 enclosure consists of two parts: a top part and a bottom part. These
are described in the following sections.
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Figure 2 below and Figure 3 on page 4 show the top part of the ECL 2000 enclo-
sure.
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ECL 2000 Hardware
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The service terminal connector shown in Figure 3 is an EIA 232 interface of type
RJ45 (modular jack).
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When the ECL 2000 is delivered, the service terminal connector is protected by a
small cover plate. This cover plate should be left in place during normal operation
of the controller.
To remove the cover and access the connector, carefully lift the right-hand side of
the cover plate with the tip of a screwdriver, at the same time sliding the cover
plate to the right. See Figure 4.
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Service terminal connector
Keyboard 1
Keyboard 2
Fixing screw
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The diagram in Figure 5 illustrates the components of the ECL 2000: Enclosure
and printed circuit boards (the abbreviation ‘PCB’ is used in the following text).
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To open the cabinet, you remove the bottom part of the enclosure, taking out the
front panel and PCBs as one block.
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Before opening the ECL 2000’s enclosure, make sure that the controller is pow-
ered off.
 Ensure that the fixing screw is removed from the front panel (see
Figure 3, page 4).
The bottom part of the enclosure is fixed to the top part by two sets of release ac-
tuators on either side of the enclosure.
ECL 2000 Hardware
EU.65.G1.02
 Insert the tip of a screwdriver between the top part and the bottom part,
for example on the left side and carefully lift the edge of the front panel
out and up to release the actuators.
 Repeat on the opposite side of the enclosure.
Now the bottom part can be removed by carefully sliding it off across the connec-
tors on the I/O board.
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When the bottom part of the enclosure is removed, and the controller is placed in a
horizontal position with its front panel down, the I/O board is upward (see
Figure 5, page 5). A ribbon cable connects the I/O board to the CPU board. How-
ever, it is possible to remove the I/O board without loosening the ribbon cable:
The I/O board is mounted on three guide pins placed through holes drilled in the
printed circuit board, 1 in the middle and 1 on either side of the board (see
Figure 7, page 7).
 Carefully press the top of the 2 guide pins down through the holes of the
printed circuit board while lifting the I/O board.
 Turn over the I/O board so that it is placed next to the CPU board.
Now you can get access to the CPU board to replace the EPROM, for example (see
Figure 19, page 20).
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Figure 6 shows one of the ECL 2000’s ribbon cable connectors.
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A connector lock, which is provided with one release key on either side, secures
the ribbon cable. If necessary, the ribbon cable can be removed:
 Pull the keys in the direction indicated by the arrows in Figure 6. The
best thing is to release both keys at once.
The ribbon cable is now loose and can be pulled out in the direction of the arrows.
To connect the ribbon cable again:
Connector
Ribbon cable
Connector lock
ECL 2000 Hardware
EU.65.G1.02
 Insert the cable in the connector.
 Push the keys in the opposite direction of the arrows in Figure 6. The
best thing is to push both keys at once.
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The CPU board is secured to the front panel by 3 release actuators positioned in
the corners of the board. Moreover, the board is secured by a release actuator
placed through a rectangular hole approximately in the centre of the board. See
Figure 7.
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The CPU board is removed from the front panel in the following way:
 Remove the ribbon cable to the I/O board, as well as the two ribbon ca-
bles connecting the CPU board to the front panel (see instructions
page 6).
 Carefully pull each release actuator in the corners outwards, and disen-
gage the CPU board from the front panel.
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Figure 13 (page 12), Figure 14 (page 13) and Figure 18 (page 18) show the rear
panels of the ECL 2000 Type 1 and 2, including the EIA 232 modem connector.
ECL 2000 Hardware
EU.65.G1.02
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When the ECL 2000 is mounted on a wall, a base plate and case (Order no.
087B8099) are used.
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Figure 8 shows the base plate.
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The bottom and rear sides of the base plate are provided with a number of knock-
outs, which are removed to allow cable entry. Inside the case, cables are connected
to two terminal blocks. See following pages for further details.
ECL 2000 Hardware
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Two terminal blocks with screw terminals are used to connect cables to the con-
troller. The terminal blocks can be mounted on the inside of the base plate, as il-
lustrated in Figure 9.
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If the ECL 2000 is mounted in a panel, the case and base plate are not used. In this
case, cables are connected to a set of loose terminal blocks, which are then
mounted on the controller’s rear side, as illustrated in Figure 10.
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Terminal block
ECL 2000 Hardware
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Figure 11 shows the case used for mounting the ECL 2000 on a wall.
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The enclosure of the ECL2000 can be cleaned using a mild detergent applied to a
damp cloth.
ECL 2000 Hardware
EU.65.G1.02
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The I/O board of the ECL 2000 is equipped with a microprocessor which handles
all tasks related to I/O. The following functions are located on this board:
Sensor input
Motor valve control output
Power supply
EIA232 interface.
The ECL 2000 exists in two versions: Type 1 and type 2. The type of the controller
is determined by the I/O board: An ECL 2000 Type 1 has a type 1 I/O board, a
type 2 has a type 2 I/O board.
There are three types of I/O board:
A type 1 I/O board for 230 V power supply
A type 1 I/O board for 24 V power supply
The type 2 I/O board for 24 power supply.
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Figure 12 is a schematic diagram of the type 1 I/O board seen from the controller’s
rear (component side).
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Connector for ribbon cable
to CPU board
Connector for modem
(EIA232) cable
Transformer
ECL 2000 Hardware
EU.65.G1.02
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The purpose of the diagram in Figure 12 is to help you recognize the Type 1 I/O
board. Thus, the diagram does not show all of the components on the I/O board.
The side of the transformer is provided with a label stating the supply voltage (230
V or 24 V) required for the PCB in question.
The diagram in Figure 13 shows the rear panel of an ECL 2000 Type 1 for 230 V
power supply. Table 2 gives additional detail about inputs and outputs.
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I Relay output (pump), 230V AC (NO) 4 (2)A 250V AC
1
II Relay output (pump), 230V AC (NO) 4 (2)A 250V AC
III Relay output (pump), 230V AC (NO) 4 (2)A 250V AC
I
3-point output (gear motor for valve) 0.15 A/250V AC
II
3-point output (gear motor for valve) 0.15 A/250V AC
S1-S7 Input: Pt 1000 temperature sensor
S8-S9 Input: Pt 1000, ESMF, 0-10V, pulse or digital
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4 A at resistive load, 2 A at inductive load.
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Danfoss ECL 2000 Operating instructions

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