Fasel Elektronik FCU2000 Series User manual

Important
documents:
Please add these documents to the device documents, they
must be kept in the immediate vicinity of the control unit, so
that they are always accessible.
Technical changes and errors excepted, illustration similar
Series FCU2x00/FCU3x00/FCU4x00
Installation instructions
Sauna control
Series FCU2000/FCU2200
Series FCU3000/FCU3200/FCU3400
Series FCU4000/FCU4200/FCU4400
Doc-ID: M_FCUxxxx _EN
Version: V 2.18
certificated

2 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
FASEL GmbH
Germany

Table of contents
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 3
Table of contents
1 Safety................................................................................................................................5
1.1 Explanations of symbols .........................................................................................5
1.2 Technical safety notes for assembly and installation .............................................6
1.3 Intended use ...........................................................................................................6
1.4 Modifications and alterations ..................................................................................6
1.5 Demands on technical personnel ...........................................................................7
1.6 Operational safety and special dangers .................................................................8
2 Technical Data .................................................................................................................9
2.1 Cables.....................................................................................................................9
2.2 Voltage and switching capacity - electrical load ...................................................10
2.3 If the sauna control device is installed in the technical room ...............................11
2.4 General information ..............................................................................................12
3 Identification ..................................................................................................................13
3.1 Nameplate.............................................................................................................13
4 Goods receipt, Transport and Storage .......................................................................14
4.1 Safety....................................................................................................................14
4.2 Goods receipt........................................................................................................14
4.3 Packing .................................................................................................................14
4.4 Storage .................................................................................................................14
5 Installation .....................................................................................................................15
5.1 ESD protection......................................................................................................15
5.2 Installation of sauna control device FCUxxxx .......................................................15
5.3 Installation of the operating control of FCUxxxx-Design und FCUxxxx-Design-
Glas.......................................................................................................................15
5.4 Installation opening of operating control FCUxxxx-Design and FCUxxxx-Design-
Glas.......................................................................................................................16
5.5 Assembly (I) / disassembly (II) of operating control FCUxxxx-Design .................17
5.6 Installing the temperature and humidity sensor....................................................18
5.6.1 Temperature sensor ..............................................................................19
5.6.2 Humidity sensor.....................................................................................20
5.7 Installation of internal display in cabin ..................................................................22
6 Electrical connection ....................................................................................................24
6.1 Safety....................................................................................................................24
6.2 Connecting the control device, consumers and sensor........................................25
6.3 Electrical circuit diagram .......................................................................................28
6.4 Checking the electrical connection .......................................................................29
7 Commissioning .............................................................................................................29
7.1 Safety instructions.................................................................................................29
7.2 Checks before the initial commissioning...............................................................30
7.3 Switching on and switching off the sauna control.................................................30
7.4 Functional test of the sauna control device and the electrical consumers ...........31

Table of contents
4 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
7.5 Functional test of the sensor.................................................................................32
8 General Information ......................................................................................................33
8.1 Liability limitation...................................................................................................33
8.2 Copyright...............................................................................................................33
8.3 Scope of delivery ..................................................................................................33
8.4 Spare parts ...........................................................................................................34
8.5 Customer service ..................................................................................................34
8.6 Light and fan .........................................................................................................35
8.6.1 Disable light brightness or fan speed, or exchange triac ......................35
Index.......................................................................................................................................36
Notes:.....................................................................................................................................37

Safety
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 5
1 Safety
1.1 Explanations of symbols
Warnings Warnings in this operating manual are indicated through symbols. The instructions are
introduced through signal words, which express the degree of danger.
Follow these instructions strictly and take care to avoid accidents, personal injuries and
property damage.
DANGER!
…indicates an imminent dangerous situation, which could lead to loss
of life or cause serious injuries if not avoided.
WARNING!
…indicates a possible dangerous situation, which can be fatal or cause
serious injuries if not avoided.
CAUTION!
…indicates a possible dangerous situation, which could lead to small or
slight injuries if not avoided.
ATTENTION!
…indicates a possible dangerous situation, which could lead to property
damage if not avoided.
Tips and
recommen-
dations
NOTE!
…highlights useful tips and recommendations as well as information for
an efficient and smooth operation.

Safety
6 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
1.2 Technical safety notes for assembly and installation
DANGER!
The control device can be installed directly on the outer side of the
cabin or at another location, however not within the cabin
Use the sauna control device only with a cover guard for sauna heaters
if one of the following option is enabled:
timer option (lockable in service menu)
remote start via option input or WEB-Control
Appropriate VDE applies to public saunas, that a control lamp, showing,
that the heater is switched on, is to install in the room of the supervisor.
This lamp can be connected to the clamp (FLE-STB).
For switching off the mains, the power supply cable must be equipped
with a fuse with a contact opening width corresponding to the
requirements of the excess voltage category III for total disconnection.
At FCUxxxx-Design-Glas the main switch of the control unit must be
accessible.
The sensor of the thermostat must be installed in such a way that it is
not affected by the incoming cool air.
1.3 Intended use
Depending on the version, the FASEL sauna controls of the series FCU2x00, FCU3x00 and FCU4x00 are
exclusively meant for operation and control of saunas, saunas with moisture and infrared cabins. The control
devices are permitted for operation in houses and commercial facilities.
Intended use
WARNING!
Danger if not used correctly
Any improper use of the sauna control can lead to dangerous situations.
Therefore:
Use the sauna control correctly.
Operate the sauna control only within the permissible room temperature
and moisture range. →See technical data
All the specifications in the operating manual and the installation
manual must be strictly adhered to.
Claims of any type due to damages caused by improper use will not be accepted. Only the user is
responsible for damages caused by improper use.
1.4 Modifications and alterations
Modifications and alterations of the sauna control or installation can lead to unforeseen dangers.
All technical modifications and add-ons to the sauna control require the written permission of the
manufacturer.

Safety
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 7
1.5 Demands on technical personnel
The assembly, installation, commissioning as well as rectification of defects and repairs
must be carried out by qualified persons only unless otherwise mentioned.
Inadequate
Qualification
WARNING!
Danger of injury due to inadequate qualification
Improper handling can lead to significant personal injuries and material
damage.
Therefore:
– The assembly, installation, commissioning as well as rectification of
defects, maintenance and repairs must be carried out by qualified
persons only unless otherwise mentioned.
 Technical personnel
Due to their technical training, knowledge and experience as well as the knowledge
of the relevant regulations these persons are in a position to carry out the tasks
assigned to them and to identify possible dangers on their own. Also they are
familiar in handling with ESD sensitive devices.
 Certified electricians
Due to their technical training, knowledge and experience as well as the knowledge
of the relevant standard specifications and regulations these experts are in a position
to carry out jobs on the electrical unit and to identify possible dangers on their own.
In Germany certified electricians have to fulfill the stipulations of the accident
prevention regulation BGV A3 (e.g. master electrician). In other countries
corresponding stipulations are applicable that have to be followed.

Safety
8 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
1.6 Operational safety and special dangers
Pay attention to the safety and warning notes in the following chapters of this manual to
minimize health hazards and to avoid dangerous situations.
The following instructions are to be adhered for your own safety and the safety of
the unit:
Electric
potential
DANGER!
Danger to life due to electric potential!
Contact with live components can be fatal.
Damage of the insulation of the individual components can be
dangerous to life.
Therefore:
For switching off the mains, the power supply cable must be equipped
with a fuse with a contact opening width corresponding to the
requirements of the excess voltage category III for total
disconnection.
Disconnect the unit from the mains before carrying out any work on it
(switch off the fuse in the distribution box) and secure against
restarting. Check for zero potential. The control device should be
disconnected from the mains before opening the casing.
In case of damage to the insulation, switch off the power supply
immediately and carry out the repair.
Work on electrical unit should be carried out by certified electricians
only.
Never bypass fuses or put them out of operation.
While replacing fuses, pay attention to correct current specifications.
Keep moisture away from live components, since it can lead to short
circuit.
WARNING!
If a short circuit occurs in a 230V/400V load, the relay contact can
be welded by the high short-circuit current. Is turned on before
removing the short circuit, the safety relay can be also welded.
This can lead to the continuous operation of the load. Turn off the
circuit breaker in the distribuition box. Send the unit back to the
factory for check/repair.
Improper
operation
WARNING!
Improper operation can result in serious injuries!
Therefore:
read and note the operating manual.

Technical Data
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 9
2 Technical Data
2.1 Cables
Use of
inappropriate
cables –
Electric
potential
DANGER!
Danger to life due to electric potential
Use of inappropriate cables can lead to short circuits and subsequent
fires.
Damage to the insulation can be dangerous to life.
Therefore:
– All the cables, which lead to the sauna, must be designed for at least
150 °C.
– Use cables as per specifications in Table 1 and electrical circuit
diagram (see annexure). The specified cross sections are designed
for copper cables. In case of aluminum cables the cross sections
should be appropriately increased.
– The cross sections can increase due to the length of the cables, the
type of cable laying or special regulations.
Designation Type
FCU2x00 FCU3x00 FCU4x00
Power supply cables Type / Cross
section /
Number of
leads
H07RN-FG2,5 (heavy rubber hose 2,5 mm
2
)
Power supply cables must be polychloroprene-coated and
should not be lighter than heavy polychloroprene-coated
flexible cables.
Type Heat resistant, at least 150 °C230 / 400V cables for
supply to oven,
evaporator, fan, light etc. Cross section
Number of
leads
→See electrical circuit diagram.
Type In case of longer distances: LiYCY
(flexible, shielded cable)
Within the cabin: heat resistant,
minimum 150 °C
Signal cables for sensors
Cross section
Number of
leads
→See electrical circuit diagram.
Connecting cable
Control device to
operating element or
interior display
The patch cable can be delivered with a standard length of 5 or 10m. If
another length is desired then the cable must be configured by the
electrician. Another option would be to bridge a stretch by installing two
network sockets (CAT 5).
Specification of the patch
cable Minimum CAT 5, minimum AWG26
Plugs should have no rubber covering over the locking mechanism
Pin 1 to Pin 1 cable configuration (straight through)
Conduit for patch cable Min. M32 (inner diameter min. 24mm), smallest bending radius 30 cm
Table 1: Technical data – cables

Technical Data
10 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
2.2 Voltage and switching capacity - electrical load
Designation Type
FCU2x00 FCU3x00 FCU4x00
Nominal voltage 400 V 3 N ~ 50Hz
Oven 3x 230 V~ max. 3x 3 kW (AC1) / 3x 0,55kW (AC3) / 3x 0,75kW (AC15)
(Inrush current max. 30A for 5ms)
Evaporator
1)
230 V~ max. 3 kW (Inrush current max. 30A for 5ms)
Infrared
2)
230 V~ max. 3 kW (Inrush current max. 30A for 5ms)
PS1 (FLE-STB) 230 V~ max. 60 W (Inrush current max. 10A for 5ms)
Fan 230 V~ max. 120 W (Inrush current max. 10A for 5ms)
Cabin light 230 V~ max. 120 W (Inrush current max. 10A for 5ms)
Cleaning light 230 V~ max. 120 W (Inrush current max. 10A for 5ms)
Coloured light 230 V~ / max. 120 W per relay / total capacity see circuit diagram
(Inrush current max. 80A for 20ms)
OUT 1 … OUT 4
3)
OUT 5 … OUT 12
3)
Potential free, safety extra low voltage max. 50 V / 1 A,
230 V~ / max. 120 W per relay; total capacity see circuit diagram (Inrush
current max. 6A for 5ms)
IN 1 … IN 4, IN 9 … 12
3)
IN 5 … IN 8
3)
safety extra low voltage approx. 15 V, switching current approx. 10 mA ,
230 V~ 50 Hz, all inputs same phase
Table 2: Technical data – voltages and switching capacity consumer
1) Only in controls with the bathing option "Sauna with humidity" (Series FCU2200, FCU3200, FCU3400, FCU4200 and
FCU4400)
2) Only in controls with the bathing option "Infrared" (Series FCU3400 and FCU4400)
3) Optional
Maximum
capacity
Sauna oven and
evaporator
EN 60335-2-53 allows the following capacity for sauna oven (Sauna heating device)
and evaporator. Prefabricated sauna equipment is checked as per this standard
specification.
Cabin cubatore [m
3
] Maximum
capacity
Sauna oven [kW]
Maximum
capacity
evaporator [kW]
6 5 1,5
7,5 6 2
11 9 3
26 21 7
Table 3: Maximum capacity of sauna oven and evaporator

Technical Data
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 11
NOTE!
FASEL additionally offers a extension power unit for loads of 9 kW, 18
kW and 24 kW.
2.3 If the sauna control device is installed in the technical room
If the sauna
control device
is not directly
installed on the
outer wall of the
cabin
The control device can be installed directly on the outer side of the cabin or at another
location, however not within the cabin. If the installation is not done directly on the outer
wall of the cabin then the following points should be noted:
Lay the signal cables separately from the power line.
Do not lay the signal cables parallel to the power line.
Install a distribution box for the signal lines and another one for the power lines as per
Figure 1
Note EN 60335-2-53 for remote start
Figure 1: Cabling while installing the sauna control device not directly on the outer wall of the cabin

Technical Data
12 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
2.4 General information
Designation Unit Type
FCU2x00 FCU3x00 FCU4x00
Dimensions basic device
FCUxxxx
FCUxxxx DESIGN and
FCUxxxx DESIGN-GLAS
[mm] (H x W x D) 247 x 285 x 86,5
Dimensions operating element
FCUxxxx DESIGN
[mm] (H x W x D) 198,5 x 124 x 30,5
Dimensions operating element
FCUxxxx DESIGN-GLAS
[mm] (H x W x D) 197,5 x 122,5 x 35
Max. Distance
Basic device to operating element
FCUxxxx DESIGN, FCUxxxx
DESIGN-GLAS or interior display
[m] 100
Voltage supply [V AC / Hz] see nameplate
safety OFF [°C] Sensor interruption (at ca. >138°C)
sensor short circuit (at ca. < -25°C)
STB interruption (at ca. 140°C
accordingly to DIN EN 60335-2-53 section 19)
Ambient temperature [°C] 0 to +40
Rel. humidity [% r.F.] max.80 % r. humidity, non-condensing
Storage temperature [°C] –10 to +60
Storage rel. humidity, [% r.F.] max.80 % r. humidity, non-condensing
Insulation type [–] see nameplate
Table 4: Technical Data – General

Identification
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 13
3 Identification
3.1 Nameplate
The nameplate is located on the control unit on the left side:
2
1
8
5
3
4
7
6
Art Nr
Spg.:
Geräte Nr.: RoHS
conform
9
10 11
12
Fig.2 Control unit nameplate
1 Type designation
2 Company logo
3 Article number
4 Voltage and max. power
5 Device number
6 Barcode
7 article number
8 Barcode article number
9 VDE mark (for devices that are approved by VDE)
10 RoHS marking
11 CE mark
12 Protection category

Goods receipt, Transport and Storage
14 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
4 Goods receipt, Transport and Storage
4.1 Safety
Inappropriate
Transport
ATTENTION!
Damage to the control due to inappropriate transport
The control is a highly sensitive electronic device. It can get damaged
due to inappropriate transport.
Therefore:
– Remove the packing only just before starting the installation
4.2 Goods receipt
After receipt, the consignment should be immediately checked for any transport
damages.
In case of damages, which are visible from outside, the following course of action
should be taken:
The consignment should not be accepted or accepted conditionally only.
Note down the scope of damage on the transport documents or on the delivery note
of the transporter.
Initiate claim.
NOTE!
Claim damages as soon as they are identified. Claims for damages can
be lodged only within the valid claim period.
4.3 Packing
The packaging should provide protection against transport damages to the individual
components till the time of installation. Therefore remove the packaging only just before
installation.
4.4 Storage
Store the control device under the following conditions:
Do not store in open place, store in a dry dust free place.
Avoid contact with any aggressive media.
Protect against sunlight.
Avoid mechanical shocks.
Storage temperature: –10 to +60 °C
Relative humidity: max. 80 %, non-condensing

Installation
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 15
5 Installation
5.1 ESD protection
ATTENTION!
Note ESD protection!
Do not touch on electrical parts because of ESD protection reasons.
When assembling only touch the circuit board at the plastic case or at
the edge of the board.
Also only touch the connection cable to the circuit board, on the
connector. Thereby do not touch the contact surfaces.
Therefore:
Take appropriate protections. Touch a grounded piece of metal as a
minimum protection.
5.2 Installation of sauna control device FCUxxxx
Installation The sauna control device should be installed sideways, above and below at a distance
of at least 5 cm from the walls or other equipment. There should be a distance of 10 cm
between other electrical devices.
The control unit must be mounted so that it is at any time accessible! (e.g. for service,
wear parts, fuses, etc.)
Note!
At FCUxxxx-Design-Glas the main switch of the control unit must be
accessible.
5.3 Installation of the operating control of FCUxxxx-Design und FCUxxxx-
Design-Glas
Installation The operating control can be installed maximum 100 m away from the basic control
device.
ATTENTION!
Damage or malfunction of the operating control FCUxxxx-Design-
Glas by steam, humidity or water!
Therefore:
It must be ensured, that neither steam, humiditiy or water can occur at
or in the keyboard.

Installation
16 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
5.4 Installation opening of operating control FCUxxxx-Design and FCUxxxx-
Design-Glas
Figure 3:Installation opening for operating control FCUxxxx-Design and FCUxxxx-Design-Glas

Installation
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 17
5.5 Assembly (I) / disassembly (II) of operating control FCUxxxx-Design
Figure 4:Assembly / disassembly of operating control FCUxxxx-Design

Installation
18 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
5.6 Installing the temperature and humidity sensor
Note!
An installation of a humidity sensor with humidity control is necessary
only for the bathing option "Sauna with humidity ". If a time controlled
humidity control is provided then a humidity sensor is not necessary.
Note!
The sensor of the thermostat must be installed in such a way that it is
not affected by the cool incoming air.
Note!
The temperature and humidity values displayed on additional
thermometers and hygrometers in the cabin can deviate from the
displayed values on the control. This could be due to the following
reasons:
Depending on the cabin, the temperature differences from the floor to
the ceiling or from the oven to the opposite wall can be up to 60 K and
the differences in the relative humidity can be up to 40%.
Instruments with indicator needles react slower than electrical
measuring and display systems used for the control.
Dimensions of
temperature
sensor,
humidity sensor
as well as the
combined
temperature
and humidity
sensor
Figure 5: Dimensions of the sensors

Installation
Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18 19
5.6.1 Temperature sensor
The following temperature sensor variants are available:
Oven sensor for temperature (FCU-SENSOR-OVEN-A)
Bench sensor for temperature (FCU-SENSOR-BENCH-A)
Combined bench sensor for temperature and humidity
(FCU-SENSOR-HUMIDITY-BENCH-A)
Installation site
Figure 6 : Installation site of oven sensor / bench sensor / combined bench sensor
Oven sensor for temperature
If the oven manufacturer has not specified any other position, the sensor should be
installed on the wall behind the sauna oven (middle of sauna oven) 20 cm below the
ceiling.
Bench sensor for temperature
Install the bench sensor on the opposite side of the oven and 20 cm below the
ceiling or at shoulder height of the topmost bench. This position for the sensor is only
a recommendation for standard cabins.
Attention: The system installer has to consider cabin-specific conditions, such as
the position of the steam outlet, the supply and outlet air, the door (s), the shape of
the ceiling, etc., and mount the sensor at the appropriate place for this cabin!.
Combined bench sensor for temperature and humidity
Install the combined sensor for temperature and humidity like the bench sensor.
For all sensors
Ensure unrestricted air circulation.
Do not install the sensors in the immediate vicinity of the door or a window.
Limiter sensor for IR
The limiter sensor for the IR system is only required if the manufacturer of the IR
system a maximum temperature for their system dictates, which is smaller than our
room temperature of max. 70°C or limiter temperature of 130°C.
If a sensor is needed, it shall be installed according to specifications of the IR system
manufacturer.

Installation
20 Installation instructions Sauna control Series FCU2x00/FCU3x00/FCU4x00 / Version V 2.18
5.6.2 Humidity sensor
Following variants of the humidity sensor are available:
Bench sensor for humidity (FCU-SENSOR-HUMIDITY-A)
Combined bench sensor for temperature and humidity
(FCU-SENSOR-HUMIDITY-BENCH-A)
Installation
location
Figure 7: Installation location for humidity sensor/combined bench sensor
Humidity sensor
Install the humidity sensor on the wall on the opposite side of the evaporator at
approximately 1,35 …1,60 m height; this position of the sensor is only a
recommendation for standard cabins.
Attention: The system installer has to consider cabin-specific conditions, such as
the position of the steam outlet, the supply and outlet air, the door (s), the shape of
the ceiling, etc., and mount the sensor at the appropriate place for this cabin!.
Combined bench sensor for temperature and humidity
Install the combined sensor for temperature and humidity like the bench sensor.