Danfoss ThermoControl-4 Operating instructions

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

2 | © Danfoss | 2017.03 VI.JM.Z4.02

Installation and Operating Guide

2 | © Danfoss | 2017.03 VI.JM.Z4.02

VI.JM.Z4.02 © Danfoss | 2017.03 | 3

ThermoControl-4

1. Safety Information ................................................................................................................................................................................... 5

2. Hazard Warnings ....................................................................................................................................................................................... 6

3. General Information ............................................................................................................................................................................... 7

4. Installation .................................................................................................................................................................................................... 8

5. 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 ....................................................................................................................................................................... 17

6. Basic Operation ...................................................................................................................................................................................... 19

6.1 Device Overview ...................................................................................................................................................................... 19

6.2 Display ............................................................................................................................................................................................. 20

6.3 Switching on the Controller ............................................................................................................................................. 20

7. 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 shuto circulation ................................................................................................................................... 24

8. Setting system status ......................................................................................................................................................................... 25

8.1 Status ................................................................................................................................................................................................ 25

8.2 Messages ........................................................................................................................................................................................ 25

8.3 Info ..................................................................................................................................................................................................... 26

9. Operator PIN ............................................................................................................................................................................................. 26

10. Denitions and abbreviations .................................................................................................................................................. 27

11. 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 ow ....................................................................................................................... 31

11.1.2.2.1 Integration in circulation ow “Standard” or “Maintain” ................................................. 31

11.1.2.2.2 Integration in circulation ow “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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Installation and Operating Guide

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 buer 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 ............................................................................................................................................................ 40

12. Expert settings ..................................................................................................................................................................................... 41

12.1 Selecting system type ........................................................................................................................................................ 41

12.1.1 Assigning pump signal ........................................................................................................................................... 42

12.1.2 Assigning minimum pump speed T

Min

........................................................................................................ 43

12.1.3 Setting system-specic settings on ThermoDual (Dual) ............................................................... 44

12.1.4 Setting system-specic settings on ThermoClean (Clean) ........................................................... 44

12.1.5 Setting system-specic settings on ThermoDual-FLS (FLS) ........................................................ 44

12.1.6 Setting nal 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 .................................................................................................................................... 48

13. Setting default values ..................................................................................................................................................................... 48

14. Running system test ........................................................................................................................................................................ 49

15. Deleting messages ........................................................................................................................................................................... 49

16. Expert PIN ................................................................................................................................................................................................ 50

17. Error handling ....................................................................................................................................................................................... 50

17.1 Error handling table ............................................................................................................................................................ 51

18. Flow sensor setting max. .............................................................................................................................................................. 53

19. Guideline pump ow 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 .................................................................................................. 55

20. Relay heat demand KA and disinfection AUX ................................................................................................................ 55

21. Technical data ....................................................................................................................................................................................... 56

22. Malfunctions .......................................................................................................................................................................................... 57

23. Table of parameters ......................................................................................................................................................................... 59

4 | © Danfoss | 2017.03 VI.JM.Z4.02 VI.JM.Z4.02 © Danfoss | 2017.03 | 5

ThermoControl-4

Warning:

All work involving transport, installation, start-

up and servicing is to be carried out by qualied

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 specic

regulations, standards, accident prevention and local

regulations. Connect power supply and outputs

using exible 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 - Specication 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 specic norms and

legislations valid in your country

1. Safety information

6 | © Danfoss | 2017.03 VI.JM.Z4.02

Installation and Operating Guide

WARNING!

Electrical hazard!

Electrical energy can cause severe injury. Dama-

ge to insulation or individual components can

endanger life. Turn main switch o 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 qualied 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 WASTE

Electrical 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-

ciently.

6 | © Danfoss | 2017.03 VI.JM.Z4.02 VI.JM.Z4.02 © Danfoss | 2017.03 | 7

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 specied

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-eciency 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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Installation and Operating Guide

The ThermoControl-4 comes from the factory in-

stalled on the respective domestic water system or

installed on a mounting plate for nal installation. In

individual cases it may be installed outside of the do-

mestic water system. In this case, the housing must

be rmly attached to a solid, dry surface. The housing

cover must also be removed. Carefully remove the

housing cover from the housing. Ensure that the at

cable connects the housing cover to the circuit board

in the housing. The at 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

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ThermoControl-4

5. Electrical installation

5.1. Circuit board layout

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Installation and Operating Guide

5.2. Overview of terminal blocks

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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 sensor

Terminal

Name Description

Z 1-2 FHZ Heating supply

Z 3-4 FSL Domestic hot water charging

Z 5-6 FLE Tank charging on

Z 7-8 FLA Tank charging o

Z 9-10 FZW Circulation

Z 11-12 FRL Return temperature limit

Z 13-14 FWW / FZWN Domestic hot water

Z 15-16 FRÜ Monitoring protection against excessive tapping

Z 17-18 S9 not used

Z 19-20 S10 not used

Terminal assignment recirculation pump low voltage

Terminal

Name Description

Z 21 PHZG 0-10 V Heating pump control signal 0-10 V

Z 22 PHZG GND Heating pump ground

Z 23 PHZG malfunction Heating pump malfunction line

Z 24 PHZG PWM Heating pump control signal pulse width modulation PWM,

or on/o function at 0-10 V pump control

Z 25 PSL 0-10 V Tank charging pump control signal 0-10 V

Z 26 PSL GND Tank charging ground

Z 27 PSL malfunction Tank charging pump malfunction line

Z 28 PSL PWM Tank charging pump control signal pulse width modulation PWM,

or on/o function at 0-10 V pump control

Z 29 PZW 0-10 V Circulation pump control signal 0-10 V

Z 30 PZW GND Circulation pump ground

Z 31 PZW malfunction Circulation pump malfunction line

Z 32 PZW PWM Circulation pump control signal pulse width modulation PWM,

or on/o function at 0-10 V pump control

Z 33 PDF 0-10 V Heating pump control signal 0-10 V ThermoDual-FLS

Z 34 PDF GND Heating pump ground ThermoDual-FLS

Z 35 PDF malfunction Heating pump malfunction line ThermoDual-FLS

Z 36 PDF PWM Heating pump control signal pulse width modulation PWM,

ThermoDual-FLS

or on/o function at 0-10 V pump control

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Installation and Operating Guide

Terminal assignment inputs and outputs additional functions low voltage

Terminal Name Description

Z 37 Flow input Input pulse generator ow sensor

Z 38 + 12 V Flow sensor power supply 12 V max. 50 mA

Z 39 GND Flow sensor ground

Z 40 0-10 V input not used

Terminal assignment inputs and outputs additional functions low voltage

Terminal Name Description

A 1-2 TR Temperature controller TR and temperature monitor TW

A 3-4 exDi Triggering of external disinfection or external temperature increase

A 5-6 TC-Bus not used

A 7-8 eBus not used

A 9-11 MODBus - / + / GND (iso))*

Terminal assignment loads supply voltage

Terminal Name Alternative name Description

Y 1 VSL open

MKRÜ

VSL-storage charging valve ThermoDual-FLS

MKRÜ valve protection against excessive

tapping ThermoClean

Y 2 VSL closed

Y 3 VWW open

VRU, VZWN

VWW domestic hot water valve ThermoClean

VRU valve return stratication ThermoDual-FLS

VZWN valve heating ZWN

Y 4 VWW closed

Y 5 VHZG open

VHZG valve heating

Y 6 VHZG closed

Y 7 L -> STW

VHZG valve with emergency setting, live conductor in conjunction

with safety temperature monitor (STW) or safety temperature limiter

Y 8 L <- STW

Y 9 L -> VHZG

Y10 N-supply

Supply 230 V / 50 Hz; PE on collective terminal

Y 11 L-supply

Terminal assignment power switch supply voltage

Terminal Name Description

SW 1 N

to power switch

SW 2 L

SW 3 N

from power switch

SW 4 L

)* Modbus module required, available as separate accessory.

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ThermoControl-4

Terminal assignment outputs additional functions

Terminal Name Description

R 1 KA NC

Potential-free relay output for heat demand

(C = center contact, NO = normally open, NC = normally closed)

R 2 KA C

R 3 KA NO

R 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 NO

R 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 PE

Terminal block Description

L Fused and connected 230 V – pump supply

N Fused and connected 230 V – pump and valve supply

PE Protective earth - connections

Installation and Operating Guide

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 malfunc.

PHZG on-o / PWM

PDF malfunc.

PDF on-o / PWM

ThermoControl-4

WI = white

BU = blue BK = black

BN = brown

Installation and Operating Guide

BU = blue BK = black

BN = brown

5.4.4 Power supply

ThermoControl-4

5.4.5 Valve wiring

The wiring for the factory-installed valves is shown.

OPENCLOSE

OPEN

CLOSE

OPENCLOSE

Installation and Operating Guide

OPEN

CLOSE

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)

Installation and Operating Guide

6.2. Display

The 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 controller

The 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 2

Setpoints 2.1

Disinfection 2.2

Parameters 1 2.3

Parameters 2 2.4

Night shutoff 2.5

Time/date 2.6

12:48

CLR

SL

KA

TR

Clean b

Actual Menu

level

Menu level

(sub)number

Actual Menu

level number

Cursor

Menu point

Next Menu

level

Actual

time

Tank

Charging

active

Heat demand

request

Disin-

fection

Tempera-

ture con-

troller

System type

Key

upwards

Key

down

Key

return

DI

i

Message

pointer

enter

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Danfoss ThermoControl-4 Operating instructions

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