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

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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.

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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.

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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)

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Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL
Mounting Guide ThermoControl–3
5. Mounting points of housing

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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

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Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL
Mounting Guide ThermoControl–3
7. Layout of PCB

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DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy
Mounting Guide ThermoControl–3
8. Overview of terminal blocks
Pumps
Pumps and valves
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
TR
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
PZW 0...10V
PSL fault
PSL GND
PSL 0...10V
PHZG fault
PHZG GND
PHZG 0...10V

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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

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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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Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL
Mounting Guide ThermoControl–3
Terminal assignment of circulation pumps
Terminal Name Description
Y1 MKRÜ closed Excessive extraction protection shut-o
Y2 MKRÜ open
Y3 (VWW) open VWW – valve domestic hot water (appl. ThermoClean)
VRU – valve stratication (appl. ThermoDual-FLS)
VSol – valve preheating (appl. MultiHeat)
VZWN – valve heating (appl. Circulation reheating)
Y4 (VWW) closed
Y5 STM C
Potential-free relay output for fault indication
(C=center contact, NO=normally open contact, NC=normally closed contact)
Y6 STM NO
Y7 STM NC
Y8 KA C
Potential-free relay output for heat request
(C=center contact, NO=normally open contact, NC=normally closed contact)
Y9 KA NO
Y10 KA NC
Y11 L (VHZG) Heating control valve with safety function, conductor
Y12 to STW Thermostat with safety monitor (STW) or
temperature safety limiter (STB)
Y13 from STW
Y14 VHZG open Heating control valve
Y15 VHZG closed
Y16 N Mains power 230V / 50Hz
Y17 L
Y18 N to mains switch (wired internally)
Y19 L
Y20 N from mains switch (wired internally)
Y21 L
Additional connections for pumps, valves and PE
Terminal Description
LFused and switched 230V power supply to the pumps
N Neutral conductor (pumps and valves)
PE Protective earth conductor
You will also nd the terminal assignment diagram
on the inside of the housing cover

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DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy
Mounting Guide ThermoControl–3
10. Technical data
Inputs
8 x Pt1000 two-wire sensors
1 x potential-free circuit for external disinfection
1 x potential-free circuit for temperature regulator (TR)
4 x potential-free circuits for pump fault inputs
1 x frequency input for ow sensor
Outputs
3 x 3-point signal maximum load 230V AC, 2A
4 x pump power supplies, switched: maximum load 230V AC, 2A
4 x pump control signals PWM 5V level (100Hz)
4 x pump control signals 0-10V DC, input resistance >100kΩ
including four switch outputs (on/o) 5V level
1 x heat request, potential-free two-way contact, maximum load
230V AC, 2A
1 x fault message output, potential-free two-way contact, maximum load
230V AC, 2A
1 x 12V DC: maximum load 50mA
Operating voltage (V) 230V ±10%, 50-60Hz
Current consumption max. 6.3A
Ambient temperature 0-40°C
Protection class IP 54
Protection class II as per VDE 0106
Interference emission as per EN 61000-6-3
as per EN55011 + A1 : class B
Resistance to interference as per EN 61000-6-2
Dimensions (height x width x depth): 159 x 248 x 124 mm
Weight 1.6 kg

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Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL
Mounting Guide ThermoControl–3
Notes

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DEN-SMT/PL VM.GU.A1.02 Danfoss District Energy
Mounting Guide ThermoControl–3
Notes

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Danfoss District Energy VM.GU.A1.02 DEN-SMT/PL
Mounting Guide ThermoControl–3
Notes

VM.GU.A1.02
Mounting Guide ThermoControl–3
Danfoss
District Energy Division
www.danfoss.com
Produced by Danfoss A/S © 02/2014