Samson TROVIS 5400 Series Service manual

Series 5400
District heating controller
TROVIS 5430
Edition July 1997
Firmwarerelease1.12
Mounting and operating instructions
EB 5430 EN
Figure1⋅TROVIS5430

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Notesfortheuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Technicaldata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Resistancevaluesofsensors . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Installingthecontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Installingthesensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Electricalconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Generalnotes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Connecting the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Connectingthe sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Connecting the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Connectingthe pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Terminalconnection diagrams . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Descriptionof controller functions . . . . . . . . . . . . . . . . . . . . . 11
4.1 Optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Flashadaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Reduced operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Summertimeoperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Delayedoutdoortemperature adaptation . . . . . . . . . . . . . . . . . . 13
4.6 Automaticclockreset,summertime/wintertime . . . . . . . . . . . . . . . . 13
4.7 Public holidays and vacations . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8 Thermaldisinfection of drinking water storage tank . . . . . . . . . . . . . . 14
4.9 Returnflow temperaturelimiting . . . . . . . . . . . . . . . . . . . . . . . . 14
4.10 Buildupofcharging temperature via the return flow sensor with . . . . . . . . 15
theheatingloop switchedoff
4.11 Limiting of controldeviationfortheOPENsignal . . . . . . . . . . . . . . . 15
4.12 Forcedcharging of the drinking water storage tank . . . . . . . . . . . . . . . 15
4.13 Room sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.14 Frostprotection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.15 Sensorfailure /operation errors . . . . . . . . . . . . . . . . . . . . . . . 16
4.16 Forcedactuationofpumps . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.17 Masterswitchoverforheating upofdrinking waterin
storagetank chargingsystem . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.18 Monitoringof aflowmaximum temperature forheatingupof drinkingwater . . . 17
5. System diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Systemcodenumber1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Systemcodenumber2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Systemcodenumber3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Systemcodenumber4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2

6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Operating mode selection . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 The operating levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7. Commissioning and adjusting the controller . . . . . . . . . . . . . . . . . 35
7.1 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1.1 Systemcodenumberadjustment . . . . . . . . . . . . . . . . . . . . . . . 35
7.1.2 Functionblockadjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Codenumbersetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1.3 Functionblock lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.4 Sensorcalibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2 Parameter entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.1 Defaultvalue adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2.2 Entry or modificationofuserdata - overview . . . . . . . . . . . . . . . . . 41
Heatingcharacteristicsandtemperatures . . . . . . . . . . . . . . . . . . 41
Heatingutilization periods . . . . . . . . . . . . . . . . . . . . . . . . . 44
Timedata,heating updrinkingwater . . . . . . . . . . . . . . . . . . . . 47
Timedata,circulationpump . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adjustmentof currenttime, dateandyear . . . . . . . . . . . . . . . . . . 48
Publicholidays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Vacations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8. Datasheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
The device may only be installed and put into operation by specialist per-
sonnel familiar with installation, commissioning and operation of this pro-
duct.It isassumedthat the device istransported andstoredcorrectly.
The controller is intended for use with high-voltage systems. For connection
andmaintenance therelevantsafety regulationsmustbe observed
!
3

1. General
The digital heating and district heating controller TROVIS 5430 is for weather-sensitive flow
temperature control of heating systems, i.e. by way of a heating characteristic the flow tempera-
ture of a heating loop is regulated in such a way that the desired room temperature is adjusted,
independent of the outside temperature. The return flow temperature can be limited depending
on the outside temperature. Furthermore, the controller is capable of regulating heating up of
drinkingwater.
The controller reads the respective temperature via a sensor and relays it to thecentral processor
via corresponding input units. This modulates a control signal for the closed control loop accor-
ding to the adjusted setpoint value. Depending on the configuration, the output unit converts this
signal into a three-step or two-step signal. In addition, the controller controls the heating circula-
tionpump, the heatexchangerchargingpumpas well asthestorageloading pump.
Validityof these mounting and operating instructions
asof firmware release 1.12
(currentfirmware release appearsfor 2 secs. whenpower isswitchedon)
Modifications to firmware release 1.01:
Supplementtosystem 4
1.1 Notes for the user
Theinstallation of the controller described in the followinganditselectricalconnections aretobe
carriedoutby authorized personnelonly.
The adjustments concerning the configuration described in chapter 7 also require a specialist
knowledge of heating systems and should only be carried out by a specialist. The function des-
criptionsandsystem configurations described inchapters4 and 5arealsointended for his use.
Commissioning of the controller is normally carried out by the specialist - all adjustment data
shouldbeenteredin thedatasheet inchapter8.
Temperature values and time programs are preset for the controller as default values and can be
alteredbythe user during commissioningor later on inchapter7.2(parameter entries).
4

1.2 Technical data
Inputs Accordingtoselected systemcodes,
2-phase circuit
Sensorinputs Maximumof 7 configurableinputs for sensors
(PTCorPt 1000)
(Heating/drinkingwaterloop)
2flowtemperature sensors
1room temperaturesensor
1outdoortemperaturesensor
1returnflow temperaturesensor
2storagetemperature sensors
Binaryinputs Storagethermostat
Additional inputs Room control device for adjusting room temperature
andselecting operatingmode,potentiometer
Outputs Accordingto selectedsystemcode number
Controlsignal Three-stepsignals:20to250 V~, 0.5 A~
On-offsignal:20 to 250 V~, 0.5 A~
NoDCvoltage circuits!
Binaryoutputs 4outputsforcontrolling pumps
Non-isolated: 230 V~, 2A~
Auxiliary power 230 V~ (+10 %/–15%),48to 62 Hz
Powersupply Approx.2VA
Temperaturerange 0to 50 °C (operation),–10to60 °C (storage)
Degreeof protection IP40 accordingtoIEC529
Classofprotection I accordingto VDE 0106
Degreeofcontamination 2 accordingto VDE 0110
Overvoltage category II accordingtoVDE0110
Humidity rating F accordingto VDE 40040
Noiseimmunity According to EN50082part 1
Noiseemission According to EN 50081part 1
Weight Approx. 0.6 kg
5

1.3 Resistance values of sensors
Resistance thermometer with PTC measuring element
Sensorresistanceelements(with controllerdisconnected)
Sensor for outdoor temperature type 5224, for flow and return flow temperature type 5264,
5265,forstoragetanktemperaturetype 5264
°C –20 –10 0 +10 +20 +25 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
Ω694 757 825 896 971 1010 1050 1132 1219 1309 1402 1500 1601 1706 1815 1925
Room control device type 5244 (remote control)
Switch at"Clock"position
Terminal1 and 2 °C +10 +15 +20 +25 +30
Ω679 699 720 741 762
Resistance thermometer with Pt 1000 measuring element
Sensor for outdoor temperature type 5227, for flow and return flow temperature type 5207-21,
5207-26, 5207-27, 5277 (thermowell required) and 5267 (contact sensor with 3 m cable), for
storagetanktemperaturetype5207-46, 5207-47 and 5207-48
Sensorforroomtemperaturetype5257
°C –35 –30 –25 –20 –15 –10 –5 0 5 10
Ohms 862.5 882.2 901.9 921.6 941.2 960.9 980.4 1000.0 1019.5 1039.0
°C 15 20 25 30 35 40 45 50 55 60
Ohms 1058.5 1077.9 1097.3 1116.7 1136.1 1155.4 1174.7 1194.0 1213.2 1232.4
°C 65 70 75 80 85 90 95 100 105 110
Ohms 1251.6 1270.7 1289.8 1308.9 1328.0 1347.0 1366.0 1385.0 1403.9 1422.9
°C 115 120 125 130 135 140 145 150
Ohms 1441.7 1460.6 1479.4 1498.2 1517.0 1535.8 1554.5 1573.1
6

2. Installation
2.1 Installing the controller
The controller consists of the controller housing with electronics and a housing rear panel with
terminalstrips.The housing rear panelcanbe ordered as a flatordeepversion.
To connect electrically, the front screws must be loosened and the controller housing must be se-
paratedfromthe rear panel.
In the case of a wall mounting, the housing rear panel must be mounted on a wall using three
screws.Hole spacing isgivenindiagram 2.
In the case of a panel mounting, the controller housing is inserted through the panel section and
the enclosed screw brackets inserted on the left and right housing sides (if necessary, turn out
screw completely before inserting). Then turn the screws in until the ends are firmly in contact
withthe rear sideofthepanel.
Thepanelsectionis138+1 mm widex92+0.8 mmhigh.
Figure2⋅Dimensiondiagramcontroller
16.5
63.5
Mounting bolts Screwedbracket
flat
Rearpaneldeep Rear panel flat
deep
7

2.2 Installing the sensors
2.2.1 Outdoor sensors
Mountoutdoor sensorsusingtwo screwsina suitablelocation onanoutside wall.Ensure thatthe
sensor is not mounted above any warm air exits (windows, ventilation slats etc.). In the case of a
detachedbuilding,ifpossible,mountthesensoronthe wall nexttothe preferred livingarea.
2.2.2 Flow/return flow sensor
Mount the sensor as a duct temperature sensor or as a contact sensor in an easily accessible lo-
cationin the vicinityoftheheat exchanger.
Duct temperature sensor: Insert the duct temperature sensor in an existing thermowell and push
inas farasit willgo.
Contact sensor: Remove insulation in the area of the flow line where the sensor is tobe mounted
and clean the pipe to the bare metal. Press the sensor firmly onto the pipe and fasten securely
usingthe accompanyingtensioner.
2.2.3 Room sensor
Mount the sensor in a suitable location on the wall, approx.150 cm high. Onno account should
aircirculationbe impeded bycupboards,curtains orsimilarobjects.
3. Electrical connections
3.1 General notes
When laying cables and connecting the controller, VDE regulations and local electric
company regulations must be observed. For this reason, the work must be carriedout
by a specialist.
Sensor and mains lines must be inseparate cables. If contactors are in the vicinity of the control-
ler or if inductive consumer circuits exist nearby, then these mustbe wired with noisesuppression
capacitorsto avoidinterference withthecontroller.
Radio interference suppression: The controller type 5430 with SAMSON actuators is interfe-
rence-suppressed according to EN 50081 part 1 and 50082 part 1 If other actuators are used,
or if other actuators with sources of radio interference are additionally used in a system, then the
operator/persons installing a non-standard system must, in compliance with legal duties con-
cerning radio interference suppression, ensure that the entire system complieswith the demands
inaccordancewiththeabove-listedstandards.
3.2 Connecting the controller
Electrical connections must be carried out in accordance with the system code number predefi-
ned in the configuration (see chapter 7) according to the terminal diagram, figures 3 to 6. For
the purpose of feeding cables, holes should be made at the locations marked on the housing
rearpaneland the enclosed cableglandsinserted.
3.3 Connecting the sensors
Connect cables with a minimum cross-section of 2 x 0.5 mm2at the terminal strip of the housing
rearpanel.
!
8

3.4 Connecting the actuator
Wire cables as humid area cables with a minimum cross-section of 1.5 mm2to the terminals of
the controller output. When commissioning, it is necessary to check the direction of rotation, i.e.
whetherconnections have been made correctlyby positioningtheoperatingswitch to + and-for
openingandclosingthe valve.
3.5 Connecting the pumps
Connect all cables with a minimum of 1.5 mm2to thecontroller terminals according to the corre-
spondingcircuitdiagram(system1,2,3 or 4).
3.6Terminal wiring diagrams
The terminal wiring diagrams listed in the following (figures 3, 4, 5 and 6) contain all possible
input and output connections for the respective system code number. If input or output connec-
tions are to remain unassigned, then this must be defined in the configuration, chapter 7.1 (level
CO1toCO SYS).
Legend:
FG Potentiometer (terminal3on room controldevice type 5244)
RF Roomsensor (terminal 1 onroom controldevice type 5244)
AF Outdoorsensor
RüF Returnflowsensor
VF Flowsensor
GNDF Sensor earth
UP Circulationpump
SLP Storageloadingpump
ZP Circulationpump
PE Groundingconductor
NRK andL RK powersupplyactuator
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE NRK
LRK
UP
GNDF
+
–
312
12 11
GNDF
Option
Type
5244
Figure3
Systemcode number1
9

Figure5
Systemcode number3
Figure6
Systemcode number4
Figure4
Systemcode number2
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE N
RK
L
RK
UP
+
–
312
SF 2
SF 1
SLPZP
GNDF
12 11
GNDF
Option
Type
5244
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE N
RK
L
RK
UP
GNDF
+
–
312
SF 2
SF 1
SLPZP
TLP
VF 2
GNDF
12 11
Option
Type
5244
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
FG
RF
RüF
VF1
AF
N
L
PE NRK
LRK
UP
GNDF
+
–
312
SLPZP
TLP
VF 2
GNDF
12 11
Option
Type
5244
10

4. Description of controller functions
The following function descriptions are intended to assist comprehension of the settings required
foroperation.
Thecontrollerfunctionsdepend on the selectedsystemcodenumber, 1, 2, 3, or 4, depictedand
describedinchapter 5.
The tables on pages 37 and 38 can be used to clarify the configuration levels (CO) and function
blocks(FB)describedin thefunctiondescriptions.
4.1 Optimizing
The controller is capable of independently establishing the most appropriate times for switching
the heating system on and off in periodically used buildings. For this purpose, the function block
settingFB 1 =ON(linked with FB2= ON) is selectedinconfiguration level CO1.
In contrast to reduced operation, the heating system is switched off at the latest at the beginning
oftheperiod ofnon-usage.
Aso-called reference room containing the necessary roomtemperaturesensor andrepresenting
the entire building is monitored with regard to an adjustable ”sustaining temperature”. If the
temperaturefalls below this value, the heating system will operate until the sustaining temperatu-
re (with approx. 0.5 °C added for differential gap) is exceeded, using the maximum permissible
flowtemperature.
The controller selects switch-on time for commencing rated operation in such a way that the
”room setpoint value” (temperature adjustable at controller) is just reached at the beginning of
rated operation (tolerance for comfort 0.5 °C). This switch-on time may be up to 6 hoursprior to
the time set for commencement of rated operation (this will for instance be the case when com-
missioning the function ”optimizing”, as the controller as yet has no information regarding the
characteristicsofthebuilding.
If no room sensor is connected, then heating system switch-on time can be postponed with re-
gardtothe outdoor temperature in CO1 by FB 2 = ON and Selection = 1. The maximumpermis-
siblepre-heatingtimeisadjustable,a referenceroomisomitted.
With all system code numbers, drinking water requirements are not taken into consideration du-
ringtheheating up period.
The controller selects heating system switch-off time in such a way that switching off the heating
before the end of rated operation has no noticeable effect on the desired room temperature
(comfort tolerance) towards the end of rated operation (for example sunlight can lead to an in-
crease in room temperature especially when flash adaptation is not used, and thus to premature
switching off). Switch-off time can be up to 2 hours before the time set for the end of the usage
period.
If no room sensor is connected, the controller reduces the flow temperature towards the end of
rated operation. If, at the beginning of reduced operation, the outdoor temperature exceeds
10°C (defaultvalue:adjustable),thentheheating systemremainsswitched off. If the temperatu-
re falls below this limiting value during reduced operation, then the reduced return flow tempe-
ratureisregulated.
If, in the course of one day, 2 or 3 rated operating times have been set, then a ”reduced room
setpoint value” (temperature adjustable at controller) is monitored instead of the ”sustaining
temperature”.
11

4.2 Flash adaptation
It is possible to achieve a direct reaction to deviations in room temperature via the function block
setting CO1 FB 3 = EIN (linked to FB 1 = ON): so-called flash adaptation counteracts deviations
in room temperature within time-controlled rated operation by raising or lowering the heating
characteristicby upto10°C (parallel adjustmentofthe heatingcharacteristic).
This takes place within a time lapse of 10 minutesif the room temperature deviates from the set-
point value by more than 0.5 K. The heating characteristic adjustment takes place in steps of 1K.
With flash adaptation, the possibility of correcting the setpoint value on the remote control does
not exist. Flash adaptation is terminated, i.e. the parallel adjustment is cancelled, at the end of
time-controlledrated operation.
Attention! Cooling such as draughts or open windows affect control! Short-term overheating of
roomsmay occur aftersuchcoolingisno longer effective!
4.3 Reduced operation
In the case of reduced operation, the heating loop generally operates a flow temperature set-
point value defined by the heating characteristic, being asetpoint reduced by the value entered
in”reductionof flow temperature for reduced operation”.
If however, during reduced operation, the outdoor temperature exceeds the value entered as the
”outdoor temperature limit for switching off during reduced operation”, then the heating loop is
automatically switched off by the controller; by the control valve being closed and the heating
circulation pump UP being switched off after two valve running periods (the control valve run-
ning period is adjustable at the controller). If the temperature falls below the limiting value (less
0.5°Cdifferential gap), then heating operation starts up again immediately.
4.4Summertimeoperation
During the summertime the heating loop is automatically switched off by the controller; the con-
trol valve is closed and the heating circulation pump UP is switched off after an adjustable time
period. The ”temperature and time-controlled summertime operation” function is linked to the
settingCO1 FB 6 =ON.These are twoindependentfunctions whose effectsmay overlap:
The outdoor temperature level is decisive for starting up exclusively temperature-controlled sum-
mertime operation. If the temperature exceeds the ”outdoor temperature limit for summertime
operation” (default setting 22 °C; adjustment range: 0 to 50 °C) adjustable in the parameter le-
vel,then summertimeoperationstarts upimmediately.
If the temperature falls belowthe limiting value (less1.0 °C differential gap), thenheating opera-
tion starts up again immediately. This function is independent of the function block setting CO1
FB6= ON.
Thefollowingisdecisive for startingup temperatureandtime-controlledsummertime operation
1.The daytimemeantemperaturelevel(calculatedbetween0700and2200hrs).If on 2 succes-
sive daysthetemperatureexceedstheoutdoortemperature limit adjustableinthe configurat-
ionlevel,linked to the function block setting CO1 FB=ON (defaultsetting 18 °C; adjustment
range: 0 to 50 °C), and if
2.The currentdateiswithintheeffective time periodlinkedtothe function blocksetting CO1
FB 6 = ON, adjustable in the configuration level (default setting 01/06 to 30/09), then sum-
12

mertime operation commences on the second day. If the daytime mean temperature level falls
below the outdoor temperature limit on two successive days, then summertime operation is ter-
minatedonthefollowingday.
4.5 Delayed outdoor temperature adaptation
Acalculatedoutdoor temperature is used to determine the flow temperature. This delayed adap-
tationoccurs
a) onlyif theoutdoortemperaturefalls, or
b) independentof outdoor temperaturevariations.
If the outdoor temperature varies within a very short period, e.g. by 12 °C, then the ”calculated
outdoor temperature” is adapted to the outdoor temperature in small steps over a period of
4hourswitha delayed settingof 3°C/h.
It is possible to avoid unnecessary heating central system overloads, overheating of buildings,
e.g. warm winds, (case a), or temporarily insufficient heating due to excessive sunlight to the
outdoorsensors(caseb)usingthe settingCO1FB= ON.
The selection immediately following the function block setting CO1 FB 5 = ON: Selection 1 me-
ansdelayingonly in thecaseoffalling outdoor temperatures.
Selection2 means delayingwhen the outdoortemperaturerisesand falls.
Subsequentlythedelay setting isentered (defaultsetting3 °C/h;adjustmentrange: 1to6 °C/h).
In the operating level , an active delayed adaptation to the outdoor temperature is indicated by
a flashing display. As long as the key is held down, the ”calculated outdoor temperature” is
displayed.
4.6 Automatic clock reset, summertime/wintertime
The clock time reset function is linked to the function block setting COSYS FB 3 = ON. The clocks
are automatically reset on the last Sunday in March at 0200 hrs and on the last Sunday in Oct-
oberat0300hrs.
4.7 Public holidays and vacations
The controller has the capability of defining 20 public holidays and 10 vacation periods (para-
meter level PASYS). The following public holidays are preset as standard: 01/01, 01/05,
25/12and26/12 (deletion isofcourse possible).
On public holidays the heating loop relies on time data as for Sundays (heating time data); du-
ring vacation periods reduced operation or standby operation occurs. Heating up of drinking
wateris not affectedbypublicholiday and vacationsettingswhenthe controller is onastandard
setting. Only if the function block setting is CO2 FB 7 = ON, will heating up of drinking water
functionas forSundaysettings(timedata,drinkingwater).
Subsequently, no heating up of drinking water occurs during a vacation period (frost protection
monitoringas of +5 °C).
13

4.8 Thermal disinfection of drinking water storage tank
Thisfunctioncannotbe usedinconjunctionwitha storagetankthermostat.
On all systems with heating up of drinking water the function block settingCO2 FB 5 = ON cau-
sesthestoragetanktobe charged at75°Cevery week on aselected dayat0000hrs.
The heat exchanger charging pump TLP is immediately switched on, regardless of the flow tem-
perature values which have been measured. If the charging temperature attains the current sto-
rage tank temperature at the storage tank sensor SF1 and if the master switchover is active
CO2 FB 3 = ON, then the controller switches over to the flow sensor in the storage tankcharging
loop, the storage tank charging pump SLP switches on and regulates a fixed value of 75 °C.
IfCO2FB 3isOFF,orsystem code number 2 is active, then the master switchover remainsinacti-
ve.
The circulation pump ZP is now switched off if in the configuration CO2 FB 4 OFF is set, i.e. ZP
doesnot runaccordingto time program duringstorage tankcharging.
If a temperature of 70 °C is attained at the storage tank sensor SF 1 or at the storage tank sensor
SF 2 (if two storage tank sensors are used), however at the latest at 0400 hrs, thermal disinfec-
tionis terminated(pumplagmayoccur).
If at the end of thermal disinfection, for instance due to reasons to do with hydraulics, the increa-
sed storage tank setpoint value is not attained, then the symbol ”operation error” willflash in the
display.
This warning is acknowledged manually by calling up the ”Error” level and confirming the error
message (error 02) with the enter key. This warning resets itself automatically when the increa-
sedstorage tanksetpointvalueis attainedduringalaterdisinfectionphase.
4.9 Return flow temperature limiting
In order to be able to operate a district heating system economically, it is necessary to extract as
much heat as possible from the heat conductor (water) coming from the heating supplier. The
temperature difference between network flow and return flow is an energy efficiency indicator.
Alarge differenceintemperatureindicatesahigh efficiency level, asmalldifference in tempera-
ture indicates a low efficiency level. With preset network flow temperatures a return flow sensor
issufficientforevaluating thedifference in temperature.
The function is as follows: Limiting of the return flow temperature can depend either on the out-
door temperature (floating) or be fixed. If the return flow temperature measured at the return
flow sensor RüF exceeds the value calculated as a result of the preset return flow characteristic or
the fixed limiting value by , say, 2 °C, then the respective calculated setpoint value or the fixed
setpoint value setting (return flow temperature heating, charging temperature) is reduced by 2
°C. In this way the primary flow will be reduced andthe return flow temperature will drop. In the
case of limiting, both the measured value display ”return flow temperature” as well as the set-
point value display (return flow temperature heating, charging temperature) will blink. The
functionis already activatedby thefunctionblock settingCOSYS FB 1=ON.
Inthecaseofsystemcodenumbers2 and3(heatedup drinkingwaterfrom the secondaryloop),
itisstandardduring heating up of drinkingwaterto switchoverfrom the heatingsidereturnflow
temperature limiting value (usually calculated from the return flow temperature limiting charac-
teristic) to the limiting value ”return flow limiting temperature during heating up of drinking wa-
ter” (temperature adjustable at controller). In this way it is safe to run low return flow limiting
temperatures during the seasonal interim between summer and winter (or vice-versa) without
endangeringproper chargingof the storagetank.
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4.10 Buildup of charging temperature via the return flow sensor with the heating
loop switched off
This function is only active with system code number 2. If, during the usage period, the heating
loop is switched off, then in the case of storage tank charging the storage loading pump is only
switched on when the temperature at the return flow sensor attains the temperature level measu-
red at storage tank sensor 1. This preventscold water entering the storage tank when loading be-
gins. During this time, return flow temperature limiting is adjusted to the flow temperature setpoint
value.ThefunctionblocksettingCO2FB8= OFFallowsthisfunctiontobedeselected.
4.11 Limiting of control deviation for the OPEN signal
When using the controller to regulate steam pressure it is advisable to activate limiting of control
deviation for the OPEN signal. This function can be used to dampen the reaction of the control-
ler to setpoint deviations which result in opening the primary control valve, thus allowing in par-
ticular the starting up process of such systems to be less problematic. The reaction of the control-
lerto setpointvaluedeviationsresultingin closingof the controlvalveisnot influenced.
ThisfunctionisactivatedviaCOSYS FB6= ON for allsystemcode numbers.
The entry for limiting the standard deviation to between 2 and 10 °C (standardsetting 2 °C)im-
mediatelyfollows thefunctionblock settingCOSYS FB6.
4.12 Forced charging of the drinking water storage tank
Thisfunctionis implemented as standard onallsystem code numberswithheatingupof drinking
water, can however not be used in conjunction with a storage tank thermostat (CO2 FB 1 und
FB2= OFF).
In order to guarantee sufficient charging of the drinking water storage tank at the beginning of
theratedoperationaltime (oratthe beginningoftheheating upphaseduringoptimizingopera-
tion), forced charging commences one hour prior to the time set for the start of the heating loop
usage period (or one hour prior to the calculated beginning of heating up in optimizing opera-
tion), insofar as the utilization period of the drinking water loop does not terminate at the begin-
ningofthe utilization periodofthe heating loop.
Chargingof the storage tank is terminated, as usual, by the differentialgapforstoragetanksen-
sor SF 1 being exceeded, or by the temperature ”drinking water requirement OFF” at storage
tanksensor SF2 beingexceeded.
4.13 Room sensor
If the room sensor is activated by CO1 FB 1, but neither optimizing nor flash adaptation is acti-
vated,theroom temperaturesetpointvalue is displayedbutnot usedforcontrollingpurposes.
4.14 Frost protection
As a rule, the heating circulation pump UP is switched on when the outdoor temperature falls below
0°C.ThecirculationpumpZPisalsoswitchedonaslongasnostoragetankchargingoccurs.
If the flow temperature falls below 5 °C, then a setpoint value of 20 °Cis regulated for5 minutes.
If the drinking water storage tank temperature falls below 5°C outdoor ratedoperating timesof
the drinking water loop, then storage tank charging commences (exception: systems with a sto-
rage tank thermostat). Storage tank charging terminates when the warm water temperature ex-
ceeds10 °C.
Frostprotection is notactiveinmanualoperation.
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4.15 Sensor failure/operation errors
Interruptions or a short circuit of the sensor lines as well as other operational errors are display-
ed in the operating level by an ”ERROR” message. If this level is opened, then thecontroller indi-
cates the defective sensors by corresponding combinations of symbols. Operational errors are
displayedusingthe followingnumbercodes:
Err1: New reading in ofcoldstart values.Acknowledgmentintheerrorlevelvia the key.
Err2: Increasedstoragetanksetpoint valueduring thermaldisinfectionnot attained.
Acknowledgment in the error level via the key.
Err3: Device not calibrated.No acknowledgmentpossible.
Err4: The operatingswitchwasina non-valid positionfor more than10seconds, e.g.
betweentwo switch positions,oris defective.
Outdoor temperature sensor AF: in the case of a defective outdoor sensor, a flow temperature
setpoint value of 50 °C or the value set under ”max. flow temperature” is run (if the temperature
value”max.flowtemperature” is less than50°C).
Flow temperature sensor VF 1: in the case of flow sensor failure the controller continues to
functionin the lastvalveposition.
Flow temperature sensor drinking water storage tank VF 2: A failure of this sensor only leads
to regulation of the flow temperature setpoint value for the drinking water exchanger on the
VF1. The warningdisplaywillblink all thesame.
Return flow temperature sensor RüF: In the case of a defective return flow sensor the controller
continuestofunctionwithoutreturnflowtemperaturelimiting.
Room temperature sensor RF: In the case of room sensor failure the controller functions in ac-
cordance with the settings for operation with no room sensor, e.g. is switched over from optimi-
zing to reduced operation. In the case of adapted operation, this is cancelled; the most recently
determinedheating characteristicremainsunaltered.
Storage tank temperature sensor SF 1 and SF 2: if one of the two sensors fails, storage tank
chargingno longeroccurs.
4.16 Forced actuation of pumps
The circulation pump is activated by program once a day between 1200 and 1201 hrs. Forced
running of the storage loading pump or of the heat exchanger charging pump commences be-
tween 1201and1202hrs.
4.17 Master switchover for heating up of drinking water in storage tank charging system
Ifundersystem code number3anadditional flow sensor (VF2) downstreamofthe heat exchan-
ger for heating up of drinking water is desired in addition to the standard flow sensor (VF1),
then CO2 FB 3 must be set to ON on the controller. This has the effect of mastering of the closed
control loop being switched over from VF1 to VF2 one minuteafter the storageloading pump is
beingswitched on.
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4.18 Monitoring of a flowmaximum temperature for heating up of drinking water
If heating up of drinking water with master switchover is selected (possible only on system code
number3),the controllermonitorsthe flow temperatureat the flowsensorfor theheatexchanger
duringstorage charging.
If this, for instance, exceeds an adjustable maximum value due to increased warm water usage
on the drinking water side, the controller uses this value until this increase in requirements is no
longervalid.
Attention! Under certain circumstances (e.g. scale deposits in the heat exchanger) it is possible
thatthis maximumvaluesettingmaynotbe terminated.
To prevent unintentional limiting, the default value is set to 120 °C by the manufacturer and must
bemodifiedaccording to requirements.
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5. System diagrams
Preliminary remarks:
The system diagrams depicted contain only the system components relevant to the control, not
howeversafetyrelevantsystem components.
If a temperature regulator (TR) or a safety temperature monitor (STW) or additionally a pressure
limiter (DB) is required, a control device with a safety function according to DIN 32730 must be
used.
If a TR/STW combination according to DIN 4747 part 1 is required, a DB (if necessary) accor-
dingto DIN4751 should be selected.
A TR/STB combination according to DIN 4753 should, if necessary, be selected for heating up
ofdrinkingwater.
Heating control (all systems)
The circulation pump UP runs in rated operation. The flow temperature setpoint valueis calcula-
tedfrom the heatingcharacteristic(gradientor4-point characteristicCO1 FB4 =ON).
Thecirculation pumpUPrunsin reduced operation. Theflowtemperaturesetpointvalue iscalcu-
lated from the heating characteristic (gradient or 4-point characteristic) less the value entered
under ”reduction of flow temperature for reduced operation” (in the case of a 4-point heating
characteristic,areduction value forcharacteristicpoints2 and 3eachshouldbe entered).
5.1 System code number 1
(Thissystemdoes not process heating upofdrinking water.)
VL RL AF
UP
RüF
VF
M
Figure7 ⋅Anl 1 (System 1) Weather-sensitiveflow temperature regulator withvariable
returnflow temperaturelimiting
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5.2 System code number 2
Processing heating up of drinking water
Four different cases are distinguished:
A) The temperature at the flow sensor is higher than the charging temperature setpoint value
If the temperature in the storage tank fallsbelow the value for drinking water requirementON at
sensor SF1 or if the temperature falls below the value set at the storage tank thermostat, comen-
cement of storage tank charging initially only leadsto a reduction of the excessive flow tempera-
tureviathe heatingloop.
At 5K above the charging setpoint value (measured at flowsensor VF), at the latestafter 3 minu-
tes, the storage loading pump (described as SLP in the following) starts up. At the same time the
circulation pump (in the following described as UP) is switched off; the circulation pump (in the
followingdescribed asZP)runsaccordingto the functionblock setting.
If the requirement is terminated by exceeding theadjustable differential gap at sensorSF1 or the
preset differential gap at the storage tank thermostat, the controller initially runs at a fixed defi-
nable value at sensor VF. When this is attained, at the latest after two running periodsof the con-
trol valve, the UP is switched on and the SLP is switched off. The ZP runs according to a time pro-
gram.
Figure8⋅Anl 2 (System 2) Weather-sensitive flow temperatureregulatorwithvariable re-
turnflow temperaturelimitingand heatingupof drinkingwaterin thestoragetanksystem
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B) The temperature at the flow sensor is less than the charging temperature setpoint value, but
higher than 40 °C
If the temperature in the storage tank falls belowthe value for drinking water requirement ONat
sensor SF1 or if the temperature falls below the value set at the storage tank thermostat, com-
mencement of storage tank charging initially only leads to abuildup of the chargingtemperatu-
reviathe heatingloop.
At 5K below the charging setpoint value (measured at flow sensor VF), the SLP starts up. At the
sametime the UPis switchedoff; theZP runsaccordingtothefunctionblocksetting.
If the requirement is terminated by exceeding theadjustable differential gap at sensor SF1or the
preset differential gap at the storage tank thermostat, the controller initially runs at a fixed defi-
nable value at sensor VF. When this is attained, at the latest after two running periodsof the con-
trol valve, the UP is switched on and the SLP is switchedoff. The ZP runsaccording to a time pro-
gram.
C) The temperature at the flow sensor is less than 40 °C
If the temperature in the storage tank falls belowthe value for drinking water requirement ONat
sensor SF1 or if the temperature falls below the value set at the storage tank thermostat, com-
mencement of storage tankchargingleadstoan immediate buildupofthecharging temperature
via the storage tank, i.e. the UP is switched off and the SLPis switched on. TheZP runs according
tothefunction blocksetting.
If the requirement is terminated by exceeding theadjustable differential gap at sensor SF1or the
preset differential gap at the storage tank thermostat, the controller operates again according to
the heating characteristic; while the control valve is closing, the flow temperature is monitored at
sensor VF. If this is reduced down to a fixed definable value, at the latest however after two run-
ning periods of the control valve, the UP is switched on and the SLP is switched off. The ZP runs
accordingtoa time program.
D) Summertime operation or switched off operation
If the temperature in the storage tank falls belowthe value for drinking water requirement ONat
sensor SF1 or if the temperature falls below the value set at the storage tank thermostat, com-
mencement of storage tankchargingleadstoan immediate buildupofthecharging temperature
via the storage tank, i.e. the SLP is switched on. The ZP runs according to the function block set-
ting.
If CO2 FB 8 = ON, the SLP is only switched on when the temperature atsensor RüF ishigher than
thetemperatureatsensorSF1.
When the requirement is terminated, the control valve is closed. While the control valve is clo-
sing, the flow temperature is monitored at sensor VF. If this is reduced down to a fixed definable
value, at the latest however after two running periods of the control valve, the UP is switched on
andthe SLPisswitchedoff. The ZPruns accordingtoa time program.
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