Danfoss ECL 2000 Operating instructions

Technical Manual

ECL 2000

03-2000 EU.65.G3.02

Technical Manual

ECL 2000

Danfoss A/S

EU.65.G3.02

ECL 2000

EU.65.G3.02

ii

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.

This manual replaces the ECL 2000 Technical Manual EU.65.G2.02 of June 1999.

Danfoss A/S ID: EU.65.G3.02

DK-6430 Nordborg Date: March 2000

Denmark

Phone: +45 74 88 22 22

Contents

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TABLE OF CONTENTS

1. INTRODUCTION 1

1.1 Scope 1

1.2 About this Manual 1

1.3 Typographical Conventions 2

1.4 Overview of Components 2

2. ECL 2000 HARDWARE 5

2.1 Enclosure 5

2.1.1 Top Part 5

2.1.2 Inside the Enclosure 7

2.1.2.1 Opening the Enclosure 7

2.1.2.2 Removing the I/O Board 8

2.1.2.3 Disconnecting Ribbon Cables 8

2.1.2.4 Removing the CPU Board 9

2.1.3 Bottom Part 9

2.2 Base Plate and Case 10

2.2.1 Base Plate 10

2.2.2 Terminal Blocks 11

2.2.3 Case 12

2.3 Maintenance 12

2.4 Electronics 13

2.4.1 I/O Board 13

2.4.1.1 I/O Board Type 1 13

2.4.1.2 I/O Board Type 2 19

2.4.2 CPU Board 22

2.4.3 LON Board TP/XF-78 23

2.4.4 LON Board FTT-10A 24

2.4.5 Graphical Display 25

3. ECL 2000 APPLICATIONS 27

3.1 Diagram Symbols 28

3.2 Application 1 29

3.3 Application 2 31

3.4 Application 3 33

3.5 Application 4 35

3.6 Application 5 36

3.7 Application 6 38

3.8 Application 7 40

3.9 Application 8 41

3.10 Application 9 43

3.11 Application 10 45

3.12 Application 11 47

3.13 Application 12 50

3.14 Application 13 51

3.15 Application 14 52

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3.16 Application 15 55

3.17 Application 16 56

3.18 Application 17 58

4. HEAT CIRCUIT CONTROL 61

4.1 Heat Circuit Types 61

4.1.1 Heat Circuit Type a 61

4.1.2 Heat Circuit Type b 62

4.1.3 Heat Circuit Type c 63

4.1.4 Heat Circuit Type d 64

4.2 General Heat Circuit Functions 65

4.2.1 Calculating the Reference Flow Temperature 65

4.2.1.1 No Room Temperature Sensor Installed 65

4.2.1.2 Room Temperature Sensor Installed 66

4.2.2 Return Temperature Limiting 72

4.2.3 Summer Cut-off 73

4.2.4 Optimizer 75

4.2.4.1 Function of the Optimizer 75

4.2.4.2 Recommended Settings 77

4.2.5 Motor Control (PI-Control) 78

4.2.5.1 Voltage Control (ECL 2000 Type 2) 78

4.2.5.2 3-Point Control (ECL 2000 Type 1) 79

4.2.5.3 Running Time of Motor Valve 82

4.2.6 Pump Control 82

4.2.6.1 Overrun 82

4.2.6.2 Night Stop 83

4.2.7 Remote Control 84

4.2.7.1 Connecting the ESMF 85

4.2.8 Frost Protection 86

4.2.9 Limiter 86

4.2.9.1 Flow Limiter 87

4.2.9.2 Flow Cut-off 88

4.2.9.3 Energy Limiter 88

4.2.9.4 Wind Velocity Limiter 89

4.2.9.5 Sun Intensity Limiter 90

4.2.9.6 Universal Limiter 91

5. HOT-WATER CIRCUIT CONTROL 93

5.1 Hot-Water Circuit Types 93

5.1.1 Hot-Water Circuit Type A 93

5.1.2 Hot-Water Circuit Type B 94

5.1.3 Hot-Water Circuit Type C 95

5.1.4 Hot-Water Circuit Type D 97

5.1.5 Hot-Water Circuit Type E 99

5.1.6 Hot-Water Circuit Type F 101

5.1.7 Hot-Water Circuit Type G 103

5.1.8 Hot-Water Circuit Type H 105

5.1.9 Hot-Water Circuit Type I 107

5.1.10Hot-Water Circuit Type J 109

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5.1.11Hot-Water Circuit Type K 111

5.1.12Hot-Water Circuit Type L 113

5.2 General Hot-Water Functions 114

5.2.1 Anti-bacteria function 114

5.2.2 Return Temperature Limiting 114

5.2.3 Motor Control (PI-control) 115

5.2.4 Limiter 115

5.2.4.1 Flow Limiter 115

5.2.4.2 Energy Limiter 116

5.2.4.3 Universal Limiter 116

6. COMMON FUNCTIONS 117

6.1 Alarm 117

6.1.1 Alarm Setup 117

6.1.2 Alarm Status 119

6.2 Sensor Time Constants 119

6.3 Software Version 120

LITERATURE 121

INDEX 123

Contents

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Introduction

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1. INTRODUCTION

1.1 Scope

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]).

The ECL 2000 LON communication is described in the Technical Manual for the

ECL 2000 LON Option (ref. [6]). The ECL 2000’s EIA 232 interface is described

in the Technical Manual for the ECL 2000 Serial Interface (ref. [5]).

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.

1.2 About this Manual

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.

Introduction

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1.3 Typographical Conventions

The following conventions are used:

Bold Terms that are found in display pictures appear in bold when mentioned in the

text.

Italic Introduces new terms.

Note:

Indicates a note to which you should pay attention.

1.4 Overview of Components

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].

Controllers Description Code No.

ECL 2000 Temperature controller 230V AC. Type 1 without LON communication 087B8000

ECL 2000 Temperature controller 230V AC. Type 1 with LON TP/XF-78 087B8001

ECL 2000 Temperature controller 230V AC. Type 1 with LON FTT-10A 087B8011

ECL 2000 Temperature controller 24V AC. Type 1 without LON communication 087B8002

ECL 2000 Temperature controller 24V AC. Type 1 with LON TP/XF-78 087B8003

ECL 2000 Temperature controller 24V AC. Type 1 with LON FTT-10A 087B8013

ECL 2000 Temperature controller 24V AC. Type 2 without LON communication 087B8006

ECL 2000 Temperature controller 24V AC. Type 2 with LON TP/XF-78 087B8007

ECL 2000 Temperature controller 24V AC. Type 2 with LON FTT-10A 087B8017

Mounting Description Code No.

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

Sensors Description Code No.

ESMA Pt 1000 flow temperature sensor, surface type, for mounting on pipe

Provided with screw terminals

084N1004

Introduction

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Sensors Description

Code No.

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

Other Description Code No.

LON LON communication module to be fitted in controller, LON TP/XF-78 087B8098

LON LON communication module to be fitted in controller, LON FTT-10A 087B8097

Service software PC software package for diagnostics and service of controller 087B8063

Service cable Serial interface cable for connecting controller to service PC 087B8062

Table 1. ECL 2000 components and order numbers

Introduction

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ECL 2000 Hardware

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2. ECL 2000 HARDWARE

2.1 Enclosure

Figure 1 shows the ECL 2000 enclosure.

Figure 1. The ECL 2000 enclosure

The ECL 2000 enclosure consists of two parts: a top part and a bottom part. These

are described in the following sections.

2.1.1 Top Part

Figure 2 below and Figure 3 on page 6 show the top part of the ECL 2000 enclo-

sure.

Figure 2. The top part of the ECL 2000 enclosure, closed

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The service terminal connector shown in Figure 3 is an EIA 232 interface of type

RJ45 (modular jack).

Figure 3. The top part of the ECL 2000 enclosure, open

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.

Figure 4. Removing the cover plate from the service terminal connector

Service terminal connector

Keyboard 1

Keyboard 2

Fixing screw

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2.1.2 Inside the Enclosure

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).

Figure 5. Inside the ECL 2000

2.1.2.1 Opening the Enclosure

To open the cabinet, you remove the bottom part of the enclosure, taking out the

front panel and PCBs as one block.

Note:

Before opening the ECL 2000’s enclosure, make sure that the controller is pow-

ered off.

1. Ensure that the fixing screw is removed from the front panel (see

Figure 3, page 6).

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.

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2. 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.

3. 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.

2.1.2.2 Removing the I/O Board

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 7). 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 9).

1. Carefully press the top of the 2 guide pins down through the holes of the

printed circuit board while lifting the I/O board.

2. 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 20, page 22).

2.1.2.3 Disconnecting Ribbon Cables

Figure 6 shows one of the ECL 2000’s ribbon cable connectors.

Figure 6. Ribbon cable connector

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:

1. 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

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1. Insert the cable in the connector.

2. Push the keys in the opposite direction of the arrows in Figure 6. The

best thing is to push both keys at once.

2.1.2.4 Removing the CPU Board

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.

Figure 7. The CPU board mounted on the rear side of the controller’s front panel

The CPU board is removed from the front panel in the following way:

1. 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 8).

2. Carefully pull each release actuator in the corners outwards, and disen-

gage the CPU board from the front panel.

2.1.3 Bottom Part

Figure 13 (page 14), Figure 15 (page 15) and Figure 21 (page 20) show the rear

panels of the ECL 2000 Type 1 and 2, including the EIA 232 modem connector.

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2.2 Base Plate and Case

When the ECL 2000 is mounted on a wall, a base plate and case (Order no.

087B8099) are used.

2.2.1 Base Plate

Figure 8 shows the base plate.

Figure 8. Base plate

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.

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2.2.2 Terminal Blocks

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.

Figure 9. Base plate with terminal blocks fastened

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.

Figure 10. Mounting terminal strips on the controller’s rear side

Terminal block

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2.2.3 Case

Figure 11 shows the case used for mounting the ECL 2000 on a wall.

Figure 11. The ECL 2000 is inserted in the case

2.3 Maintenance

The enclosure of the ECL2000 can be cleaned using a mild detergent applied to a

damp cloth.

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Danfoss ECL 2000 Operating instructions

Danfoss ECL 2000 Operating instructions

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