Schwank ThermoControl Plus M2 Specification sheet

ThermoControl Plus M2
2-stage or modulating controller
with two control zones
(alternative: four control zones 1-stage)
Operating and
Installation Manual
Schwank GmbH - Bremerhavener Str. 43 - 50735 Cologne - Germany
Tel: [phone] Fax: [phone]
E-mail: [e-mail]
Internet: www.schwank.de
Subject to technical changes. Version 09/10

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Content:
1 INTRODUCTION ................................................................................................. 3
2 YOUR SAFETY ................................................................................................... 4
3 STRUCTURE AND FUNCTION .......................................................................... 5
4 OPERATION ....................................................................................................... 6
4.1 Basic knowledge of operation ...................................................................... 6
4.1.1 Further readable information..................................................................... 6
4.1.2 Selection of the control zone..................................................................... 7
4.1.3 Activation and deactivation of the shown control-zone.............................. 7
4.1.4 Special information in the base display ..................................................... 7
4.2 Display and change of day- and night temperature...................................... 8
4.3. How to read and modify time and date........................................................ 9
4.4 Timing ........................................................................................................ 11
4.4.1 How to read a time program.................................................................... 11
4.4.2 How to clear a switching point................................................................. 12
4.4.3 How to clear a whole time program......................................................... 12
4.4.4 How to protect the time program ............................................................. 12
4.4.5 How to program the switching points....................................................... 13
4.5 Holiday program ......................................................................................... 14
4.6 Manual operation
FIX
.............................................................................. 15
4.7 Button for chimney-sweep mode................................................................ 15
5 SET UP THE OPERATING PARAMETERS ..................................................... 16
5.1 Enter the number of control zones ............................................................. 16
5.2 Set up the parameters in the display.......................................................... 17
5.3 The warm up time optimiser....................................................................... 18
5.4 COPY ......................................................................................................... 19
5.5 How to do a security save and how to reload all parameters: .................... 20
6 INSTALLATION................................................................................................. 21
6.1 General security instructions ...................................................................... 21
6.2 Sensor connections.................................................................................... 21
6.3 Connection of the heaters .......................................................................... 21
6.4 Maximum load............................................................................................ 22
6.5 Wiring connections..................................................................................... 22
6.6 Flue fan connection.................................................................................... 22
6.7 Alarm contact input .................................................................................... 22
6.8 Remote-Control .................................................................................... 23
6.9 Signal input fault......................................................................................... 23
6.10 Common fault signal ................................................................................ 24
7 TECHNICAL PARAMETERS ............................................................................ 25
8 APPENDIX ........................................................................................................ 26

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1 Introduction
The Schwank ThermoControl Plus M2 is suitable for 1-stage, 2-stage or modulating gas-
infrared heating systems as well as for gas-fired warm air heaters.
Dependant upon its operation the controller has two or four control zones.
Please read this manual carefully before installing or using the control-unit. Failure to follow the
notes and warnings will affect your guarantees. They are also a prerequisite for a professional
installation and correct handling.
Please pay special attention to chapter 2 „Your Safety“.
The ThermoControl Plus M2 is designed to be used for industrial/commercial building heating
systems only. Other or further uses are not permitted.
Schwank GmbH will not be held responsible for any damages whatsoever resulting from
incorrect use.
- The controller measures the room temperature and switches the heater on/off by relays.
- The controller features four operating programs.
P0: single-stage control mode for gas fired air heater
P1: single-stage controller for luminous gas-infrared heaters and tube heaters
P2, P3: single-stage, two-stage or modulating control for gas-infrared heaters
Override day temperature mode +h
Available as a special feature is the extension of the programmed heating period by a manually
operated button. This button can be installed parallel to the sensor. By pushing the button (~1
sec.), the nominal value of the programmed temperature in the selected control circuit is
maintained for an additional programmable time period. (Standard 1h)
Programmed temperature values and operating programs
The temperatures and operating programs of every single control circuit are independently
selectable.
- Day- , night- or anti-freezing temperature , selected by a week program
- Continuous day-( FIX) night-( FIX) or anti freezing temperature ( FIX).
- Holiday program: the controller is able to save eight holiday periods, which are programmed
according to the calendar.
Other Tools/Features:
– Illuminated display
– Button for chimney-sweep operation mode
– Real-time clock with calendar, including automatic summer- / wintertime correction
– Outdoor temperature sensor (ATF)
– Optimised warm-up: the heater starts/switches on earlier to ensure that the
desired temperature is achieved at the programmed time.
– Remote controlled day-mode operation
– Working-hour/time-counter at every relay output
– Error-relay: relay switches on in any case of error

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2 Your Safety
Installation details
Danger!
Note that electric shocks can be
highly dangerous. Pay attention while
working on electrical equipment. The
electrical installation must be carried
out by a qualified engineer to the
current national and international
standards. Check the electrical
equipment regularly. Defective wires
etc. must be replaced immediately.
The appliance must be isolated from
power supply before working with
the electrics. Make sure that nobody
can connect appliance to the power
supply while you are working.
.
The Schwank ThermoControl Plus 2
has to be mounted on/at a place,
where it’s not affected by vibrations
or shocks.
The feed/supply line has to be
protected by a fuse with max. 16 A
on the part of the builder.
Please install the ThermoControl
Plus M2 ensuring conformity to the
wiring diagram, which is located in
the switchboard.
Ensure that the controller and
consumer are connected by a 1.5
mm
2
cable, further on controller and
sensor have to be connected by a
telephone cable.
Install the room-temperature-
sensor between the radiation
area of two heaters at a height of
2.5 m. Therefore the controller
receives an optimal value of the
nominal temperature.
+ If the controller is installed in a
large sized building or in a building
with extreme temperature
differences (temperature gradiants),
you can also average over, instead
of using room-temperature-sensors
for every single control circuit.
Settins and modification of the
function parameters can be carried
out only by Schwank service
technicians.

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3 Structure and Function
Front panel layout:
1. I/O Main switch on / off
2. LCD Display: All functional- and operating-information is shown in the base display mode
(upper picture).The control-unit switches back to the base display, if no button is
pushed for more than one minute.
3. If you push the button or the button the day or night set value will be
shown/displayed immediately. By using the
+/- buttons the values can be modified.
4. + / - With these buttons the display values can be increased or decreased.
5. DISP "“Display-button“: To change the display. This button also offers the ability to switch
back to the main menu immediately.
6. SEL „SELECT”: This button allows you to select a certain parameter out of every
parameter shown in the display. The chosen/selected parameter can be modified by
the +/- buttons.
7. Clock-button: Can be used to display and modify time and date.
8.
FIX
To change between programmed and FIX modes and back.
9. PR To check and modify the weekly time program in the displayed control circuit.
10. CLR „Clear-button“: To delete a switch-point or a complete time program.
11. Copy This button can be used to copy time- and temperature programs.
12. ERROR The system-error lamp flashes for any kind of error. An arrow will provide
information about the cause.
13. ZONE To switch between different control circuits.
14. To turn on/off the single control circuits.
15. SERVICE „Maintenance”: If this sign appears the system needs maintenance, please call
the official Schwank service.
16. Button to program holiday operation mode.
17. Button for chimney-sweep operation mode: all control circuits heat full load.

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4 Operation
4.1 Basic knowledge of operation
By starting the ThermoControl Plus M with the I/O -button an automatic display-test is activated.
The controller starts up with the factory-made standard-program. Afterwards the display
switches to the base-program, which shows all the important operational information.
4.1.1 Further readable information
Actual control mode, in
this case: day
mode Present status of the heater:
full load or modulation
partial load
heater is turned off
Measured temperature
in the room/zone
(18.2°C)
The extract fan is
working (optional)
Recording device of the
chosen control circuit
This number informs: which relay output
and which sensor inputs are used in the
specific control circuit.
Display of the outside temperature (only in case of an
outdoor temperature sensor ATF).
The main/base display gives all important operating
data, further information can be received by pushing
the DISP button.
Value of the entered anti-freezing temperature . The
displayed value can be changed by the
+/- buttons.
Range of setting: +3… +20°C
Working-time counter: At 2-stage/modulating control
the circuit time of both stages (1,2) will be shown.
Push the SEL button to
switch between the stages.
The shown data cannot be
deleted, after 199999 hours
the display switches back to
zero.
Display of the actual heating power in %

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4.1.2 Selection of the control zone
4.1.3 Activation and deactivation of the shown control-zone
If you want to stop heating a certain zone push the button. The symbol will sign the
deactivation of the zone. In the deactivated zone only temperature measurement and display
are still working. You can activate the control zone again by pushing the button.
4.1.4 Special information in the base display
The display of the controller and its
usage is based on the display of the
control circuit. The control zone can
be chosen by pushing the ZONE
button. Now, all settings of the control
zones can be managed and
progressed.
During the optimised warm up time you will notice the OPT
symbol. The activation time of a specific zone is
accelerated in dependency of the preheating performance
compared to the entered heating time. This function can be
deactivated only in the setup-menu. An outside sensor
ATF is necessary.
While using the holiday-mode the
sign will be
marked.
To stop or modify the holiday program, please push
the button (chap. 4.5).
Option: By pushing the override button the day mode starts
for a pre-programmed time (0:00-24:00h; standard 1h). At
the same time the +h symbol will be marked. The mode
can be stopped by using the
FIX
button.

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4.2 Display and change of day- and night temperature
The desired temperature for every control circuit can be programmed separately.
Pushing the DISP button, (automatically after one
minute, without pushing a button) the current
display switches back to the main display.
The current day- or night-
temperatures can be
displayed, if you push or
button.
The displayed values can be
modified by pushing
+/- .
All modifications are saved
immediately.
The temperatures can be
changed on a scale of:
+3 up to +35°C

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4.3. How to read and modify time and date
To read and modify time and date, the button has to be pushed.
All control circuits include a separate time-program. This function takes place at the collective
clock. At first the time is shown (in the picture: 14:03). Afterwards you have to use the button
again, to be able to change the year (2007), after pushing the button for the third time month
and day (in this case: 3 = March 21) are announced. „3 Day” stands for the third day in the
ongoing week, in other words: Wednesday. ( 1= Monday, etc.)
After using the button once more the display switches back to the normal clock.
The display ends at the base display, if you press the DISP button.
Setting the time
To change the time, the
SEL button has to be
pressed. At first the
minutes start to blink
(03), which can be
modified by using
+/- .
After pushing the SEL
button again, the hours
will start to blink. (14)
The hours can also be
changed with the +/-
buttons.
The setting of the time
can be finished by using
the button.
Afterwards the display
goes back to the year.
Remark: symbols or figures, which are framed are
blinking ones!

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Setting the year
After the time has been modified, you have to set the right year, month and day as well.
Otherwise the automatic summer- / wintertime correction won’t work correctly.
Setting the month and day
To change the year, you have
to press the SEL button. The
last two figures will start to
blink (06), they can be
modified with the
+/- buttons.
Afterwards the button has
to be pushed and month and
day respectively will be
shown on the display. When
the year has been modified,
the day of the week might be
changing, according to the
calendar (in this case 3).
To change the setting you have
to press SEL. At first the month
(5) will start to blink, the setting
can be modified with
+/- .
To change the day please push
the SEL button again. Now, the
day starts to blink (21). The day
can also be modified with the
buttons +/- .
Once more the day of the week
changes according to the
calendar (first from 3 to 6, then
from to 7).
If the setting is completed push
DISP. After pushing the button,
the display switches back to the
base display.

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4.4 Timing
Every control circuit has an independent time program, which is able to be modified.
The time program is a series of different circuit times. The controller changes automatically
from day- , to night- or antifreeze mode-
A circuit/switching point of time can be described as:
- time (hour and minute)
- temperature mode , or , which will start at this point of time
- day of the week, or couple of days, when the switching time should work
(1 = Monday, 2 = Tuesday ……7=Sunday)
- number of switching points of time (max. 19 times in one program)
4.4.1 How to read a time program
After you have pushed the PR button, the number of
free and available switching points shows up.
(here: still 17 switching points available).
In the next step the display changes to the first
switching point. In this case the display shows: At 6.00
o’clock in the morning on every day of the week (1 2 3
4 5 6 7 Day) the controller is instructed to change to
day temperature The small number on the display
(1) is the program number of the switching point.
To read off the second switching point of time (2) you
have to press the PR button. In the picture: 9.00
o’clock in the evening on every day in the week (1 2 3
4 5 6 7 Day) the controller switches to night
temperature .
If you repeat the process again and again by pushing
the PR button the picture with a free switching point
shows up (for example 3). The horizontal lines stand
for a free switching point, that can be modified.
After a free switching point all following ones are
available as well. (here: 4 … 19).
To quit the menu you have to push the DISP button. To
get back to the first switching point push the PR button.
To read off the program, please press PR.

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4.4.2 How to clear a switching point
The numeric of a switching point is not fixed. If a switching point is deleted the numbers of the
remaining points will be assigned again, thus there is no chance of holes in the time program.
4.4.3 How to clear a whole time program
4.4.4 How to protect the time program
The function of the time program is based on the clock and calendar data.
The clock is supplied by a battery (1,5 V AA). A warning signal shows, when the battery has
to be changed. The exact time and date won’t get lost while the battery is getting changed (for 2
minutes).
In case of not using the control-unit for a long time, including a complete discharge of the
batteries, you will have to check, if time and date are still correct after a battery change, to avoid
problems.
The saved switching points are independent of the battery charge, because the program is
saved on a secured EEPRON-memory card. Thus time programs cannot get lost as a
consequence of a battery change or in the case of any other mistake.
If you want to clear a switching
point, you have to push and
hold the CLR button. The
symbol CLR will blink in the
display, so that you are warned
you are going to clear a
switching point. If the CLR
button is released immediately
the cancellation will be stopped.
If the cancellation is completed
horizontal lines are visible.
Afterwards the new number of
free switching points is
displayed.
To clear a whole time program
you have to push and hold the
CLR button while the number of
free spaces are shown in the
display (FrEE).
The symbol CLR will start to
blink, to warn you. If the button
is released immediately the
cancellation of the program will
be stopped.
The cancellation is completed, if
horizontal lines become visible.
That is followed by the new
number of free spaces (19).

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4.4.5 How to program the switching points
In this example we program the following circumstance: The day
temperature should start every morning at 7:35 from Monday
till Friday. First of all we are searching for a free switching point by
using the PR button. Then we press the SEL button to modify the
new data. The same procedure can be used for existing switching
points.
At first the type of
temperature starts to blink.
Now you are able to chose
between and button
by using the
+/- buttons.
Now you can select the
day program with the
SEL button. Then the
whole week appears:
1234567
Pressing
+/- you are
able to select different
day groups or only
single days
(1=Monday).
Afterwards you can modify the
hour by pushing the SEL
button (12). The requested
time (7) can be achieved with
+/- .
After that you select the
minutes with SEL (00). The
requested time (35) can be
adjusted with
+/- .
Finally the PR button has to
be pushed. The SET –
symbol starts to blink shortly,
while the data is being saved.
Afterwards the display
switches to the next free
switching point.
It is not possible to program two different switching points with the same time parameter. In
case of a saving mistake of two switching points for the same time, the time of the last
programmed point will be corrected by one minute.
In this case a new switching
point was programmed with a
time parameter of 7:35.
Unfortunately this time
parameter was used already in
switching point 3. Thus the time
changes automatically to 7:36.

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4.5 Holiday program
The controller gives you the opportunity to program 8 holiday phases. Beginning and ending of
the holidays is displayed with exact data (year, month, day). The programs can be changed and
also stopped at every point of time.
During the holiday program the anti-freezing temperature will be maintained.
To program the holiday periods push the
button.
At first the number of the holiday program HOL 1 (holiday 1) appears. The numeric above the
holiday number shows which program is activated. A programmed holiday period starts
automatically at the programmed date. Within the SEL button you are able to start or stop the
programmed holiday period. If the program is switched off(program number does not appear)
it won’t start, a running program would be shut down respectively. By using +/- you are able to
choose one of the 8 holiday programs.
The holiday program starts in all control circuits, which are working in the automatic mode .If
a control circuit is working on a fixed mode FIX, the holiday program has no effect on this
function.
If you push the
button again, the start of the holiday
period can be modified(A): by pressing
+/- you can set
up year, month and day.
The holiday program starts off at 0.00 o’clock on the
desired date.
After you have modified the start (A), you will have to
set up the end (B) of the holiday period. To fix the date
please use the
+/- button. The completed program
ends at 0.00 o’clock on programmed day.
Press
button to finish programming, the display
switches back to HOL.1. Now you can select the next
holiday program and start its modification, otherwise
you can get back to the main display by pushing the
DISP button.
It is possible, that the ERR symbol appears, while you
are programming the holidays:
- if start date Ais later than the programmed end of the
holiday period B
- if the end of the period Bis earlier than the present
date.
A program, that indicates one of these problems,
wouldn’t start.
If all errors are eliminated the ERR –symbol
disappears.

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4.6 Manual operation
FIX
If you use the
FIX
button, you are able to select different operating modes.
4.7 Button for chimney-sweep mode
To change the FIX
mode you have to
push the
FIX
button.
Press DISP, if the desired operation mode appears
(for example: continuous FIX mode). The control-
unit switches back to the main display and the
selected mode is activated.
night-temperature mode
day-temperature mode
anti-freezing temperature
By pushing the button the heater runs with full power
independent of the current room temperature. You can
switch back to the base display mode by pushing this
button again.
Push
FIX
to get back to the main display.

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5 Set up the operating parameters
The set up is made with the buttons on the front. To modify the parameters you
have to have technical knowledge, otherwise a faultless function might not be
maintained. To avoid unwanted modifications a special procedure must be carried
out to open parameter settings. Without this procedure the parameters can be
displayed but modification is not possible.
Before you open the control unit, please read the security advice in chapter 2! The
selection of the control mode (Two-stage/Modulation) or the application program P0, P1,
P2 and P3 must only be carried out in a zero-potential state.
:
The application program can be selected at the controller unit (P0, P1, P2, P3). A small
“jumper“ has to be placed in the correct position. Only one program can be chosen at any one
time. Please be careful by choosing the right electrical connection for the desired application
program!
In case of changing the application program(P0, P1, P2, P3) all parameters switch back to the
factory setting (chapter 5.1 und 5.2) !
P0 - 4 Control zones gas fired air heater
P1 - 4 Control zones, single-stage
P2 - 1 Control zone, two-stage or modulating control; 2 control zones, single-stage
P3 - 2 Control zones, two-stage or modulation
Control mode can be selected by a small separate jumper:
Upper position: modulating control mode
Lower position: two-stage control mode
Modulating control mode selection is possible only if the relay outputs are
connected to modulating heaters through the special Modulation Box. Modulating
control mode selection when 1- or 2-stage heaters are connected
to the unit will cause bad operation.
5.1 Enter the number of control zones
The controller is able to manage one to four control zones, depending on the chosen
application. In the following example we try to fix the actual number of control zones.
Get back to the normal functions by pushing the DISP button.
Hold the ZONE button for
about 3 sec. The number of
available control zones
appears in the display (for
example: 1-4: four control
zones).
The desired number of control
zones can be selected if you
push +/- (1-3).
Protected function !

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5.2 Set up the parameters in the display
Parameter set up is a protected function. A special process must be carried out to
enable modification. In basic mode parameters can be displayed by DISP and SEL
buttons but modification is not allowed.
To set up the parameters please hold
the DISP button for circa 3 seconds.
The „Par” symbol appears for a short
time. The parameters can be
selected with the SEL button.
Hysteresis , can be activated by
0.2 … 2.0°C
Sensor correction: if the sensor could
not be mounted at an optimal place,
the measured temperature can be
revised: -9.9 … +9.9°C
t1: After starting the heater, it runs
with full power until it stops at the
programmed time, in this case: 0…5
minute.
t2: For the displayed time, the heater
stops completely (5..60 Sec). it only
appears, if the t1 doesn’t equal zero.
Min. turn on time of the heater
(0...15 min)
Ability of a restart:
t3: The heater starts off with full load
for 1 minute, afterwards the controller
switches to the regular mode (0: off).
It does not appear unless the two-
stage control is selected.
Integration band:
Modulating: 1,5 … 9,9°C
2-stage: 0,5 … 3,0°C
single-stage: --.--
Integration time: 10 … 99 minutes
(only in two-stage/modulation mode),
in single-stage mode, or in off-state
(--.--) appears.

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5.3 The warm up time optimiser
The optimised warm up time only works out well, if the sensor ATF is connected to the
controller. The program works automatically and doesn’t need to be adjusted. The optimised
warm up time follows an easy principal: the controller switches on the heater earlier than it
is programmed, so the desired temperature is achieved at the favoured time. Temperature
differences and the current outside temperature are integrated in the calculation for the warm
up time. The control-unit incorporates the heating characteristics of the building and adjusts the
starting point of the warm up time to the effective situation. Every control circuit has an separate
optimised warm up time.
Extract fan follow-up-time : After
the heating circuits have been
switched off, the extract fan continues
until the programmed time is achieved.
From 0 up to 60 minutes can be
programmed (it appears only in the
”AUt” ventilation mode).
The optimised warm up time can be
switched on (AUt) or off(OFF). The
effective warm up time is shown.
Automatic switch from summer- over
to wintertime (+/- 1h).
This function can be activated (AUt)
and deactivated (OFF).
If the controller is integrated into a communication module, other parameters will follow.
Switch off the extract fans:
’AUt’: extract fan in use,
’OFF’’: the extract fan is switched off
(also the symbol doesn’t appear).
The illumination of the display can be
programmed: 1…9 minutes, switched
on (ON) or switched off (OFF).
Feature selection of the contact input
no. 72-73:
: remote contact
RES-ERR: signal input - Error
Programmable time for the override
button +h (0:00-24:00)
Start value of heating power display
0…90% (only at 2-stage or
modulating control mode).

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5.4 COPY
The COPY button offers you the opportunity to copy all parameters of a certain circuit or the
omplete time program and insert it into the program of one or many other control circuits.
ZONE, signal and number of Zone 2 start to blink. „COPY“
appears in the display to signalise the copy mode. Push
COPY to paste the data of Zone 2 (heating area 2). The
data of ZONE 1 are now copied into ZONE 2, The numeric
2is signalling the completion of the copy process.
Now ZONE 3 is selected and starts to blink. Push COPY to
paste the data of ZONE 2 into ZONE 3.
The numeric 2 and 3 are signalling the completion of the
copy process.
Now push the SEL button to select a new zone.
In the next step ZONE 4 is selected (4 starts to blink).
Push the COPY button to paste the data into ZONE 4.
The display is signalling the completion of the copy
process. The data of ZONE 1 has now been pasted into
ZONE 2-3-4. To finish the copying of the parameters you
have to press DISP, while you have to use the PR-button
to finish the copying of time programs.
To copy parameters hold DISP
(approx. 3 sec., chapter 3.11).
Protected function!
To copy time programs use the PR button
(chapter. 2.2).
To exemplify the procedure, we try to copy data
of ZONE1.

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5.5 How to do a security save and how to reload all parameters:
The Schwank-service technician can save all operational parameters as a
package on a save memory card. In case of changing the parameters
unintentionally and a resulting functional damage causes problems in the
system, the system can be modified to the old parameters easily, according to
the purpose built memory card. It is also possible to reload the factory settings.
Protected function!
Press CLR and +
simultaneously. The „SAVE”
symbol will appear in the
display. Now push DISP, the
display will start to blink, the
parameters are saved,
afterwards the display switches
back to the main menu.
If you press CLR and SEL simultaneously, the „LOAd”
symbol appears in the display. Then press the DISP button
and the parameters, that were saved by the Schwank-
service technician, will start to reload. Switch from „LOAd” to
„FACt“, by using the +/- button. If „FACt” appears in the
display push the DISP button and the factory parameters
are reconstructed.