MCDonald Electraflow Installation Instructions Manual

Brand: MCDonald

Model: Electraflow

Category: Thermostats

Type: Installation Instructions Manual

1 of 31 3MUI042 Rev16.09.16

Electraflow - Multi-Channel Timer

2 of 31 3MUI042 Rev16.09.16

Controller (3MF042_1) Remote Boost Button (3MF042_2)

1. Product Summary ........................................................................................................... 3

2. Specification ................................................................................................................... 4

3. Installation ...................................................................................................................... 5

3.1. Mounting .................................................................................................................... 5

3.2. Connections ................................................................................................................ 6

3.2.1. Heater and Control Supply Connections .................................................................. 6

3.2.2. Central Heating Pump Connection ........................................................................ 10

3.2.3. Central Heating Room Thermostat Connection ..................................................... 10

3.2.4. Tariff Detector Connection.................................................................................... 10

3.2.5. Control Sensor Connections .................................... Error! Bookmark not defined.

3.2.6. Heater Configurations ........................................................................................... 12

4. Operating Instructions ................................................................................................... 14

4.1. General Use .............................................................................................................. 14

4.2. General Functionality ................................................................................................ 15

4.2.1. HW & CH Mode Selection.................................................................................... 16

4.2.2. HW Boost Control ................................................................................................ 16

4.2.3. Remote Boost Button ............................................................................................ 17

4.2.4. CH Advance Control ............................................................................................. 18

4.2.5. Tariff Detector Input ............................................................................................. 18

4.3. Configuration ............................................................................................................ 19

4.3.1. Setting Timer Items ............................................................................................... 19

4.3.1.1. Selecting On and Off Times .............................................................................. 20

4.3.2. Users Menu ........................................................................................................... 20

4.3.2.1. Date .................................................................................................................. 21

4.3.2.2. Time ................................................................................................................. 21

4.3.2.3. CH Timer .......................................................................................................... 21

4.3.2.4. Exit ................................................................................................................... 22

4.3.3. Engineers Menu .................................................................................................... 24

4.3.3.1 Presets .................................................................................................................. 24

4.3.3.2 Tariff .................................................................................................................... 25

4.3.3.3 TimeBase .............................................................................................................. 25

4.3.3.4 CH Timer .............................................................................................................. 26

4.3.3.5 HW Timer ............................................................................................................. 26

4.3.3.6 Exit ....................................................................................................................... 26

5. Internal Operating Temperature .................................................................................... 28

6. Repair and Service ........................................................................................................ 28

This product complies with the following EC Directives:

Electro-Magnetic Compatibility Directive.

(EMC) (89\336\EEC), (92\31\EEC)

Low Voltage Directive.

(LVD) (72\23\EEC), (93\68\EEC)

3 of 31 3MUI042 Rev16.09.16

1. Product Summary

The Electraflow Controller provides connections for up to five 3KW immersion heaters.

These outputs are implemented as two isolated groups to allow for single or dual supply

systems. In addition the Controller provides control of the central heating pump.

Each individual immersion heater is selectable to provide heat for either the Hot Water (HW)

or the Central Heating (CH) sections of the system. This allows the Controller to be used in a

range of configurations.

The Controller functionality provides a 7day programmable timer for the CH heaters, giving

three time periods for each day of the week. A timer Advance feature is also provided for

the CH heaters.

The Controller also provides a 24hr timer for the HW heaters, which allows for three

programmable time periods. A manual Boost button provides selection of 30, 60 or 120

minutes boost duration for the HW heaters.

The Electraflow Controller provides maximum flexibility in system configuration which may

include the following functionality:

• Dual (Economy and Standard tariff) or single metered supplies.

• Intelligent heater control such that only one heater is turned on or off at a time,

minimising large instantaneous loading of the input supplies.

• Tariff detection to allow for remote tele-switch (RTS) meter installations.

Below is shown an example system configuration using the Controller. It is a single supply

arrangement, with one 3KW HW immersion heater and three 3KW CH heaters.

Fig. 1 Example System

Consumer

Unit

Electraflow

Controller

Key:

- 3kW heater (inbuilt control & high

limit Tstat)

Group 2

Group 1

Heater3

Heater2

Heater1

Controller supply

Heater

Room

thermostat

CH Pump

4 of 31 3MUI042 Rev16.09.16

2. Specification

Purpose of control

Sensing control

Classification

Type 1.B Action, micro-disconnection on operation

Contact rating

230VAC Suitable for heating element up to 3KW

Control power supply

230V AC 50Hz 4W

Load power supply

230V AC 50Hz 5 x 3KW + 700W (heating pump)

Boost duration

30, 60 and 120 min

Operating

temperature range

0OC to 40OC

Control pollution

situation

Pollution degree 2

Shock protection

Class II

Rated impulse

voltage

4000V

Ball pressure test

75OC

Enclosure protection

IP30

Contacts

Micro-disconnection

Construction

Independently mounted control for surface mounting

Case material

Flame resistant Polycarbonate

Overall Dimensions

Width 220mm (including cable glands)

Height 254mm

Depth 63mm

Mounting

Surface mounting

Warning - Installation and connection should only be carried out by a suitably

qualified person and in accordance with the current edition of the IEE wiring

regulations. Warning: Isolate all the mains supplies before commencing

installation.

Caution – Installation and connection requires that the enclosure lid is removed

(using a suitable tool). The lid is also attached via the Timer control cable, which

may be disconnected at the printed circuit board (PCB). To disconnect, ensure

the connector is pulled away by gripping the plastic housing and not the cable

itself.

5 of 31 3MUI042 Rev16.09.16

3. Installation

3.1. Mounting

Fig. 2 Enclosure dimensions and mounting points

Fix the unit securely in place using the 4 off 5mm dia. mounting holes in the enclosure. The

mounting holes are located directly behind the enclosure lid screws. The drawing above

shows the location and fixing centres of the holes.

The Controller should be located in close proximity to the cylinder in a position where it will

remain dry. The unit should be mounted on a suitable solid surface (e.g. wall or metal plate),

however ensure that:

• the mounting surface is flat to avoid distortion of the case.

• clearance is provided for mounting the enclosure and that there is sufficient access

for wiring to the unit.

• ensure a minimum of 50mm free air space around the unit (excluding the rear face).

Do not mount directly to any heat source.

• avoid tight radius bends on all external cables to the unit.

165mm

254mm

Ø5mm x 4off

239mm

180mm

6 of 31 3MUI042 Rev16.09.16

3.2. Connections

3.2.1. Heater and Control Supply Connections

The connection of the heater supplies to the power distribution equipment is dependent on

the required system configuration. As such it is the responsibility of the system designer and

the installation engineer to ensure that the installation wiring and associated switchgear is

arranged logically for the intended application.

The heaters are divided into two groups:

- Group 1 3 x 3KW heaters

- Group 2 2 x 3KW heaters

Each heater group in the Controller is electrically isolated. At the end of this section Fig.4

shows a schematic of the grouping arrangement.

The supply circuit for each heater group should have an independent connection to the

power distribution equipment and be protected by a suitably rated HRC fuse or circuit

breaker. An appropriately rated isolation switch (minimum contact air gap of 3mm) should be

used close to the control.

Three-core cable should be used for each of the heater connections, with a minimum

conductor size of 1.5mm2 for a 2KW heater or 2.5mm2 for a 3KW heater. For the 6KW and

9KW mains supplies, three core cables should be used, with a minimum conductor size of

4.0mm2 and 6.0mm2 respectively. All cables must pass through the cable glands provided

and be secured on completion of wiring.

Note. The Controller must be powered from a single independently fused and switched

supply which is not derived from the heater circuits. This will allow the unit to operate during

programming with the heater supplies switched off for safety. The supply must also always

be present and cannot be powered by an externally switched economy supply.

Warning –each control unit is class II and as such has no provision for protective earth

(PE). However provision is made within the units for common earth connections for

earth continuity of each heater and the CH pump.

If a protective earth is joined through the control, the impedance of the PE conductor

path must be tested during installation to ensure it does not exceed the specifications

required.

The cables should be heat resistant to 85OC where applicable. The suggested conductor

sizes provided should be checked by applying the relevant temperature de-rating factors

for all cables used prior to selection and fitting.

Ensure all conductors are securely clamped in the connectors. Only a single cable must

be used with each connector terminal. None of the terminals in the units are to be used

as a wiring junction.

Poor cable connections can cause localised heating of the connectors and may result in

damage to the unit.

7 of 31 3MUI042 Rev16.09.16

Fig. 3 General wiring diagram of the Controller:

Note. If the Controller has been configured to not provide all the possible connectivity, then

the respective cable glands will have been replaced with blanking plugs.

If for any reason any of the fitted glands are not used for a particular installation then these

must be also be blocked off using suitable blanking plugs to prevent any access to the inside

of the enclosure.

8 of 31 3MUI042 Rev16.09.16

Location of heater connections inside the Controller:

Note. Each of the immersion heater outputs is internally fused, using a standard 1”x¼” 15A

fuse in a PCB mounted fuse holder.

Location of the Controller power supply, CH pump and room thermostat connections inside

the unit:

Warning – All immersion heaters must have their in-built high limit thermostat

connected directly in-series with the element to provide safety protection.

9 of 31 3MUI042 Rev16.09.16

Connections on Base Board:

PCB

Connector

Fig1.

Ref

Connection Description

Location

Heater1A Lout

Lout1A

Live OUT terminal for Heater1A

Heater1A W

E1A

Common earth connection for earth continuity of

Heater1A

Heater1A N

Nout1A

Neutral OUT terminal for Heater1A

Heater1B Lout

Lout1B

Live OUT terminal for Heater1B

Heater1B W

E1B

Common earth connection for earth continuity of

Heater1B

Heater1B N

Nout1B

Neutral OUT terminal for Heater1B

Supply Lin

Lin1

Live IN terminal for heater Group 1 – 9KW max

Supply W

Common earth connection for earth continuity of

heater Group 1

Supply N

Nin1

Neutral IN terminal for heater Group 1

Heater1C Lout

Lout1C

Live OUT terminal for Heater1C

Heater1C W

E1C

Common earth connection for earth continuity of

Heater1C

Heater1C N

Nout1C

Neutral OUT terminal for Heater1C

Heater2A Lout

Lout2A

Live OUT terminal for Heater2A

J11

Heater2A W

E2A

Common earth connection for earth continuity of

Heater2A

Heater2A N

Nout2A

Neutral OUT terminal for Heater2A

Heater2B Lout

Lout2B

Live OUT terminal for Heater2B

J12

Heater2B W

E2B

Common earth connection for earth continuity of

Heater2B

Heater2B N

Nout2B

Neutral OUT terminal for Heater2B

Supply Lin

Lin2

Live IN terminal for heater Group 2 – 6KW max

J13

Supply W

Common earth connection for earth continuity of

heater Group 2

Supply N

Nin2

Neutral IN terminal for heater Group 2

Controller L

Lin3

Live IN terminal for Controller supply

J14

Controller N

Nin3

Neutral IN terminal for Controller supply

Controller W

Common earth connection for earth continuity of

CH pump

Pump Lout

Lout3A

Live out terminal for Central Heating Pump

J15

Pump N

Nout3A

Neutral out terminal for Central Heating Pump

Pump W

E3A

Common earth connection for earth continuity of

Central Heating Pump

R.Stat L1

LRC

Live out terminal to Room Thermostat

J17

R.Stat L2

LRS

Live in terminal from Room Thermostat

R.Stat N

Neutral out terminal to Room Thermostat

10 of 31 3MUI042 Rev16.09.16

3.2.2. Central Heating Pump Connection

The Controller provides connection for a CH pump (up to 700W). The heating pump is

connected directly to the Controller, the supply being derived internally from the Controller’s

power supply.

The CH pump connection is independent of the room thermostat interface so that the

Controller can provide a pump overrun period (fixed time period of 5 mins).

The CH pump output is not internally fused. The supply circuit for the Controller should be

protected by a suitably rated HRC fuse or circuit breaker for the combined power

requirements of the Controller, CH pump and room thermostat.

3.2.3. Central Heating Room Thermostat Connection

The Controller provides for a CH room thermostat which is connected directly.

The room thermostat may be powered by the Controller (230Vac), the supply being derived

internally from the Controller’s power supply. The power supply for the room thermostat is

not internally fused.

The room thermostat must have contacts (rated for 230Vac) which are closed when calling

for heat such as the Danfoss RMT 230 Part No 087N.110000 or equivalent.

3.2.4. Tariff Detector Connection

The Controller provides a tariff detector input (230VAC) that may be used with a remote tele-

switch (RTS) meter.

Note when Tariff Detection is used the CH control thermostat is disabled and the CH

control thermostat input terminals must be linked together.

3.2.5. Control Connections on Base Board (right hand side; top to bottom):

See Page 11.

11 of 31 3MUI042 Rev16.09.16

PCB

Connector

Fig1.

Ref

Connection Description

Location

Gnd

Remote boost switch Gnd return

Remote boost switch input.

Note this is only intended for use with dedicated

Boost switch.

N/A

J10

TCH

Location of control connections inside unit:

12 of 31 3MUI042 Rev16.09.16

3.2.6. Heater Configurations

We would recommend, for a thermal store type installation, to have the system pre-set

to CH1 HW4, with the CH immersion wired in the Terminal – Heater 1A.

This means the Heating Immersions will keep the tank up to temperature which is a

requirement for hot water. They will switch off automatically when the tank reaches

temperature. When a boost is required the CH1 Immersion will come on to ensure full

kW input to the unit.

The Electraflow Controller provides connections for up to five 3KW immersion heaters.

The functionality of each immersion heater is determined by the Presets item in the

Engineers Menu. This gives a choice of four possible CH / HW immersion heater

combinations:

Preset

Group 1

Group 2

Heater 1A

Heater 1B

Heater 1C

Heater 2A

Heater 2B

CH1

HW4

CH2

HW3

CH3

HW2

CH4

HW1

Note only the presets CH2 HW3 and CH3 HW2 may be used with a dual supply

system where each heater group is provided from separate power supplies.

For each preset combination it is not necessary to have an immersion heater connected to

every output. For example if the required system configuration is for 3 x CH / 1 x HW, then

preset CH1 HW3 would be used with one of the heater outputs unused.

13 of 31 3MUI042 Rev16.09.16

Fig. 4 Controller Wiring Schematic

14 of 31 3MUI042 Rev16.09.16

4. Operating Instructions

4.1. General Use

The Controller provides a 2 line by 8 character backlit display and two LED’s to show the

system status. The display is used to show the operating status of the unit whilst in Status

display mode and is also used to show configuration information whilst in either the Users

Menu or Engineers Menu.

In normal operation the display backlighting is set to a low level. Any key press will bring the

backlighting up to full brightness, which will remain active for 30 secs if there are no further

key presses. Whilst in either the Users Menu or Engineers Menu the backlighting will

remain at full brightness.

Five keys are also provided below the display. Left and Right keys are used to traverse menu

items (they are also used to set the operating mode of the CH and HW respectively). Up and

Down keys scroll through selection options (the Up key is also used to provide the CH

Advance function). The Boost key is used to select items and also provide the HW Boost

function.

The Controller has three display modes:

Mode

Description

Status display

Standard display mode

Users Menu

Used to configure basic settings generally required by the user

Engineers Menu

Used to configure system settings, generally only done by the

engineer during installation of the Control unit

15 of 31 3MUI042 Rev16.09.16

4.2. General Functionality

The unit normally operates in Status display mode. In this mode the first line of the display

shows the current time, whilst the second line displays various changing status messages.

The following table lists the standard status messages that the controller may display:

Status

Display

Description

HW Status

Off

Hot Water heater/s off

Hot Water 24hr timer is active. HW control stat is

not calling for heat.

Hot Water 24hr timer is active. HW control stat

calling for heat.

XXX

Hot Water Manual Boost on for ‘xxx’ remaining

minutes. HW control stat is not calling for heat.

XXX

Hot Water Manual Boost on for ‘xxx’ remaining

minutes. HW control stat calling for heat.

CH Status

Off

Central Heating heater/s off

Central Heating 7day timer is active. CH control

stat is not calling for heat.

Central Heating 7 day timer is active. CH control

stat calling for heat.

CH Adv

Central Heating 7day timer has been advanced.

CH control stat is not calling for heat.

Adv

Central Heating 7day timer has been advanced.

CH control stat calling for heat.

Day

Saturday

Current day

Date

1st Jan

Current date

Under certain conditions both display lines will be used to inform the user of the Controller’s

status:

Condition

Display

Description

Setting Boost

period

Boost!

OFF

HW Boost heater/s off

Boost!

ON 30

HW Boost heater/s on for 30

minutes

Boost!

ON 60

HW Boost heater/s on for 60

minutes

Boost!

ON 120

HW Boost heater/s on for 120

minutes

Setting timers

1st 6:30

LIMIT

Time period cannot overlap next

time period.

Boost timer on

period

Timed

HW on

HW timer is active. Boost button

is disabled.

Function not

available

Wrong

Mode!

The function trying to be

selected is not available. Check

CH and HW operating modes.

Communication

fault

WARNING!

Comms.error.Reset?

Temporary communication fault,

- will restart automatically after

30s.

High ambient

temperature

WARNING!

High.Ambent.Reset?

Ambient temperature has

exceeded safety limit.

16 of 31 3MUI042 Rev16.09.16

In addition to the display, two indicators labelled ‘CH’ and ‘HW’ provide status information.

The ‘CH’ indicator is on when the CH 7day timer is on or the CH has been manually

advanced. The ‘HW’ indicator is on when the HW 24hr timer is on or the HW has been

manually boosted.

4.2.1. HW & CH Mode Selection

The operation of the CH and HW timers are set independently. Each may be set to one of

three operating modes.

The CH mode of operation is selected using the Left key, with each key press changing the

operating mode to the next available setting:

CH Mode

Description

OFF

Disables all the CH 7 day timers. The CH Advance is still functional.

Timed

The CH 7 day timers and CH Advance are functional

Constant

The CH is on continuously

The HW mode of operation is selected using the Right key, with each key press changing the

operating mode to the next available setting:

HW Mode

Description

OFF

Disables the HW 24hr timer. The HW Boost is still functional.

Timed

The HW 24hr timer and HW Boost are functional

Constant

The HW is on continuously

Note: When the CH Mode or HW Mode is set to Constant all the associated

heaters are constantly on and directly controlled by the systems control thermostat/s. The

related timers are disabled.

4.2.2. HW Boost Control

The HW heater/s may be turned on for a fixed time period using the HW Boost button. The

Controller’s HW Mode must be set to OFF or Timed to use the HW boost function. Note

that the HW boost button is disabled during a HW 24hr Timer on period.

To set the Boost duration:-

Each press of the HW boost Button will change the time period to the next available setting

as shown below.

17 of 31 3MUI042 Rev16.09.16

Fig. 5 Boost Button Operation

After each boost key-press the display will briefly show the duration period set. The display

will then revert back to showing the normal alternating status messages. The boost function

can be cleared at a later time by a single press of the boost button.

During the boost period the Controller will display as part of the standard status messages

the remaining time in minutes before the HW heater/s will switch off. If the optional Remote

Boost Button is connected this will also be illuminated to indicate the boost function has

been activated.

4.2.3. Remote Boost Button

In addition to the standard HW boost Button on the Controller, the unit also allows for the

connection of a dedicated ‘Remote’ Boost Button (RBB).

The RBB can be mounted in a more convenient position away from the Controller, and uses

a simple 2-wire cable (low voltage).

The RBB gives a fixed boost period of 60 minutes. Whilst the manual boost is active the

RBB will be illuminated and pressing the button will cancel the boost period. The boost

period may alternatively be cancelled using the boost button on the Controller.

The Controller’s HW Mode must be set to OFF or HW timed to use the RBB. The RBB

is disabled whilst the HW 24hr Timer is on and the button will remain un-illuminated.

The RBB will flash to indicate Controller fault conditions (Over temperature tripped). Note

also that the button is faintly lit when the manual boost is not set which shows the RBB has

been installed correctly and can be useful in locating it in low light conditions.

Off

120 min

30 min

60 min

18 of 31 3MUI042 Rev16.09.16

4.2.4. CH Advance Control

The Controller’s CH Mode must be set to OFF or CH timed to use the CH advance

function.

The CH 7day timer settings may be manually advanced using the CH advance button (Up

key). The function is initiated by briefly pressing the UP key.

The action of the CH advance is to pre-empt the next switching state of the CH 7day timer.

The CH Advance will turn the Central Heating on if it was in an off period and vice versa. It

will stay in this state until either the CH advance key is pressed again or until the next timed

On/Off event.

4.2.5. Tariff Detector Input

The Controller provides a tariff detector input (230VAC) that allows the HW heaters to be

directly controlled by the detection of an economy supply instead of using the HW 24 hr

timer. Whilst enabled the heaters will be on whenever the Controller detects a mains supply

across the Tariff Detector terminals.

The Tariff Detector input is only functional when the Tariff item in the Engineers Menu is set

to RTSmeter and HW Mode is set to Timed.

19 of 31 3MUI042 Rev16.09.16

4.3. Configuration

The various Controller settings which determine its operation are configured using the two

menus; Users Menu and Engineers Menu. Once in either of these menus, the four cursor

keys together with the Boost key are used to review and revise the settings.

The left and right cursor keys are used to traverse across the menu items and sub-menu

items (where applicable).

The Boost key is used to view a menu item and it is also used to select sub-menus (where

applicable).

When a menu item is viewed the current option setting will appear flashing on the first line of

the display. The second line of the display will show descriptive text for the item. The up and

down cursor keys are used to scroll through the selection options available.

To select an option, press the Boost key. After selecting an option, the next item in the menu

or sub-menu will be displayed.

At any time whilst viewing the menus, pressing the up and down cursor keys simultaneously

will exit the menu, and place the controller back in Status display mode. Any changes made

to options prior to exiting will be implemented.

Whilst in either of the menus, if at any point no keys are used for a period of approximately

30 seconds, then the menu will automatically exit back to Status display mode. Again any

changes made to options prior to exiting will be implemented.

4.3.1. Setting Timer Items

Within the User and Engineer Menus several items require times to be entered instead of

scrolling through selection options. The same procedure is used for setting the On and Off

times for both the HW 24hr timer and the CH 7day timer.

On selecting a specific time setting from the menus with the Boost key, the display shows the

time period number (‘1st’,‘2nd’ or ‘3rd’) and the start time setting on the first line. The

period end time is displayed on the second line.

Use the Left and Right cursor keys to move between each of the On and Off times. As each

time becomes the current item, the digits will be flashing and the symbol ‘

‘will be

positioned next to it. Using the Left and Right keys also moves between each available time

period as shown below:

Fig. 6 Timer Settings

The Up and Down cursor keys are used to increase or decrease the selected time in 5

minute intervals. N.B. holding either key down will cause the numbers to auto-scroll.

1st 6:30