Sorel HCC 3 User manual

Read carefully before installation, commissioning and operation
Heating-Controller HCC 3
Installation and operating instructions
Weathercontrolled heat circuit regulator

2
Table of content
Description of controller
2.1 Specifications
2.2 About the controller
2.3 Scope of supply
2.4 Disposal of pollutants
2.5 Hydraulic variants
2
5
6
6
6
7
Operation
4.1 Display and input
4.2 Menu sequence
4
12
13
Parametrisation
5.1 Commissioning help
5.2 Free commissioning
5
14
14
Malfunctions/Maintenance
17.1 Error messages
17.2 Replacing the fuse
17.3 Maintenance
16
29
30
30
Protective functions Menu 7
12.1 Anti seizing
12.2 Frost protection
12.3 Min. flow
12.4 Max. flow
11 22
22
22
23
Special functions Menu 8
12.1 Sensor calibration
12.2 Commissioning
12.3 Factory settings
12.4 Expansions
12.5 Mixer
12.6 Turn-time
12.7 Pause factor
12.8 Increase
12.9 Room controller
12
24
24
24
25
25
25
25
25
26
Useful notes/tips&tricks
17 31
Chapter Page Chapter Page
Measurement values
Menu 1
615
Statistics Menu 2
7.1 24 hours
7.2 28 days
7.3 Operating hours HC
7.4 Error messages
7.5 Reset/clear
7
16
16
16
16
16
Settings HC Menu 5
10.1 Su/Wi Day
10.2 Su/Wi Night
10.3 Curve
10.4 Day correction
10.5 Night correction
10.6 Comfort boost
10
19
19
20
21
21
21
Menu lock Menu 9 27
13
Language Menu11
14 27
Service values Menu 10
15 28
Safety instructions
1.1 EC conformity
1.2 General instructions
1.3 Explanation of symbols
1.4 Changes
1.5 Warranty
1
3
3
3
4
4
Operating modes Menu 4
9.1 Heat circuit
9.2 Manual
9
18
18
Installation
3.1 Wall installation
3.2 Electrical connection
3.3 Installing the sensors
3.4 Installing RS-485
3
8
9-10
11
11
17
17
17
Operating times Menu 3
8.1 time & date
8.2-8.4 Heat circuit day
8.5-8.7 Heat circuit comf.
8

3
1.1 EC declaration of conformity
By affixing the CE mark to the unit the manufacturer declares that the HCC3
conforms to the following relevant safety regulations:
- EC low voltage directive
73/23/EEC, as amended by 93/68/EEC
- EC electromagnetic compatibility directive
89/336/EEC version 92/31/EEC version 93/68/EEC
Conformity has been verified and the corresponding documentation and
the EC declaration of conformity are kept on file by the manufacturer.
1.2 General instructions It is essential that you read this!
These installation and operating instructions contain basic instructions
and important information regarding safety, installation, commissioning,
maintenance and the optimal use of the unit. Therefore these instructions
must be read completely and understood by the installation technician/
specialist and by the system user before installation, commissioning and
operation of the unit.
The valid accident prevention regulations, VDE regulations, the regulations
of the local power utility, the applicable DIN-EN standards and the
installation and operating instruction of the additional system components
must also be observed. The controller does not under any circumstances
replace any safety devices to be provided by the customer!
Installation, electrical connection, commissioning and maintenance of the unit
may only be carried out by specialists who possess the appropriate training.
For the user: Make sure that the specialist gives you detailed information on the
function and operation of the controller. Always keep these instructions
in the vicinity of the controller.
1.3 Explanation of symbols
Failure to observe these instructions can result in danger to life
from electric voltage.
Danger
Danger
Failure to observe these instructions can result in serious damage
to health such as scalding, or even life-threatening injuries.
Caution
Failure to observe these instructions can result in destruction of
the unit or the system, or damage to the environment.
Caution
Information which is especially importation for the function and
optimal use of the unit and the system.
Safety instructions
1 1

4
Safety instructions
1 1
1.4 Changes to the unit
1.5 Warranty and liability
The controller has been manufactured and tested with regard to high quality
and safety requirements. The unit is subject to the statutory guarantee
period of two years from the date of sale.
The warranty and liability shall not include, however, any injury to persons or
material damage that is attributable to one or more of the following causes:
- Failure to observe these installation and operating instructions
- Improper installation, commissioning, maintenance and operation
- Improperly executed repairs
- Unauthorised structural changes to the unit
- Installation of additional components that have not been tested
together with the unit
- Any damage resulting from continued use of the unit despite an
obvious defect
- Failure to use original spare parts and accessories
- Use of the device for other than its intended purpose
- Operation above or below the limit values listed in the specifications
- Force majeure
- Changes, additions to or conversion of the unit are not permitted without
written permission from the manufacturer
- It is likewise forbidden to install additional components that have not
been tested together with the unit
- If it becomes clear that safe operation of the unit is no longer possible,
for example because of damage to the housing, then turn the controller
off immediately
- Any parts of the unit or accessories that are not in perfect condition must
be exchanged immediately
- Use only original spare parts and accessories from the manufacturer.
- Markings made on the unit at the factory must not be altered, removed
or made illegible
- Only the settings actually described in these instructions may be made
on the controller
Gefahr
Changes to the unit can compromise the safety and function of the
unit or the entire system.

5
Description of controller
2 2
2.1 Specifications
Electrical specifications:
Mains Voltage 230VAC +/- 10%
Mains frequency 50...60Hz
Power consumption 2VA
Total switched power 460VA (Relay outputs 1-3)
Switched power per relay 460VA for AC1 / 185W for AC3
Internal fuse 2A slow blow 250V
Protection category IP40
Protection class II
Sensor inputs 5x Pt1000 temperature sensor
1x Room
Measuring range -40 to110°C
Permissible ambient conditions:
Ambient temperature
for controller operation 0°C...40°C
for transport/storage 0°C...60°C
Air humidity
for controller operation max. 85% humidity at 25°C
for transport/storage no moisture condensation permitted
Other specifications and dimensions
Housing design 2-part, ABS plastic
Installation methods Wall installation, optionally panel installation
Overall dimensions 163mm x 110mm x 52mm
Aperture installation dimensions 157mm x 106mm x 31mm
Display Fully graphical display 128 x 64 dots
Light diode Multicolour
Operation 4 entry keys
Temperature sensors: (may not be included in the scope of supp-
ly)
Immersion sensor Pt1000, e.g. immersion sensor TT/P4
Pipe-mounted sensor Pt1000, e.g. pipe-mounted sensor TR/P4
Outdoor sensor Pt1000, e.g. outdoor sensor TA52
Remote adjuster Pt1000, Typ RC21
Sensor leads 2x0.75mm² extendable up to 30m
Temperature resistance table for Pt1000 sensors
°C 0 102030405060708090100
Ω1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385

6
2.2 About the controller
The weather controlled Heat Circuit Controller HCC 3 facilitates efficient use
and function control of your heating system. The device is impressive
most of all for its functionality and simple, almost self-explanatory operation.
For each step in the input process the individual entry keys are assigned
to appropriate functions and explained. The controller menu contains
headwords for the measured values and settings, as well as help texts or
clearly-structured graphics.
Important characteristics of the HCC3:
- Depiction of graphics and texts in a lighted display
- Simple viewing of the current measurement values
- Statistics and monitoring of the system by means of statistical graphics, etc.
- Extensive setting menus with explanations
- Menu block can be activated to prevent unintentional setting changes
- Resetting to previously selected values or factory settings
Description of controller
2 2
2.3 Scope of supply
- Heating controller HCC3
- 3 screws 3,5x35mm and 3 plugs 6mm for wall installation
- 6 strain reliefs with 12 screws, replacement fuse 2AT
- installation and operating instructions HCC3
Optionally contained depending on design/order:
- 1x outdoor sensor e.g. TA52 (Pt1000)
- 1x pipe-mounted sensor e.g. TR/P4 (Pt1000)
- 1x Indoor sensor/remote adjuster with mode switch RC21
2.4 Disposal and pollutants
The unit conforms to the European RoHS directive 2002/95/EC for the
restriction of the use of certain hazardous substances in electrical and
electronic equipment.
Caution
The unit must not under any circumstances be disposed of with
ordinary household refuse. Dispose of the unit only at appropriate
collection points or ship it back to the seller or manufacturer.

7
Description of controller
2 2
2.5 Hydraulic variants
The following illustrations should be viewed only as schematic diagrams
showing the respective hydraulic systems, and do not claim to be
complete. The controller does not replace safety devices
under any circumstances. Depending on the specific application, additional
system components and safety components may be mandatory, such
as check valves, non-return valves, safety temperature limiters, scalding
protectors, etc., and must therefore be provided.
Caution
1Mixed heating circuit

8
3.1 Wall installation
Installation
3 3
Caution
Install the controller only in dry areas and under the ambient conditions
described under 2.1 „Specifications“. Carry out the following steps 1-8.
Fig.3.1.1
Fig.3.1.2
1. Unscrew cover screw completely
2. Carefully pull upper part of housing
from lower part.
3. Set upper part of housing aside,
being sure not to touch the electronics
when doing so.
4. Hold the lower part of the housing
up to the selected position
and mark the 3 mounting holes.
Make sure that the wall surface
is as even as possible so that
the housing does not become
distorted when it is screwed on.
5. Using a drill and size 6 bit, drill 3
holes at the points marked on the
wall and push in the plugs.
6. Insert the upper screw and screw
it in slightly.
7. Fit the upper part of the housing
and insert the other two screws.
8. Align the housing and tighten the
three screws.
Caution
For panel installation, a
special installation set is
available as an accessory.

9
Installation
3 3
3.2 Electrical connection
Before working on the unit, switch off the power supply and secure
it against being switched on again!
Check for the absence of power!
Electrical connections may only be made by a specialist and in
compliance with the applicable regulations. The controller may not be put
into operation if there is visible damage to the housing, e.g. cracks.
Caution
Danger
Low-voltage cables such as temperature sensor cables must be
routed separately from mains voltage cables. Feed temperature
sensor cables only into the left-hand side of the unit, and mains
voltage cables only into the right-hand side.
Caution
Fig.
3.2.1
Caution
The cables being connected to the unit must not be stripped by
more than 55mm, and the cable jacket must reach into the housing
just to the other side of the strain relief.
The customer must provide an all-pole disconnecting device, e.g.
a heating emergency switch.
1.Open controller housing (see 3.1)
2.Strip cables max. 55mm, insert, fit
the strain relief devices, strip the last
8-9 mm of the wires. (Fig.3.2.1)
3.Open the terminals using a suitable
screwdriver (Fig. 3.2.1) and make
electrical connections on the controller
(Pages 10)
4. Refit upper part of housing and
fasten with screw.
6. Switch on mains voltage and
place controller in operation
8...9
~30°
max. 55

10
Installation
3 3
3.2.2 Electrical terminals
Caution
Left-hand terminal compart-
ment only for low voltage if
max. 12VAC/DC Danger
Right-hand terminal compart-
ment only for mains voltages
of 230VAC 50-60Hz
Low voltage max. 12VAC/DC
connection in the left-hand terminal
compartment!
Terminal: Connection for:
- Jumper terminal block S-
S1 Sensor 1 outdoor
S2 Sensor 2 heating circuit
S3 not used
S4 not used
S5 Sensor 5 indoor sensor
S6 Sensor 6 remote adjuster
+not used
Z1 Option / add. function
Z2 Option / add. function
Use terminal block S- for connec-
ting the sensor earths of S1-S6.
The polarity of the sensors is freely
selectable.
Mains Voltage 230VAC 50-60Hz
connection in the right-hand terminal
compartment.
Terminal: Connection for:
R1 Heating pump L
N Heating pump N
L Mains phase conductorL
N Mains phase concuctorN
R2 Mixer open L
N not used N
R3 Mixer close L
N Mixer N
The PE protective conductor must
be connected to the PE metal terminal
block!
* Note: If the remote adjuster RC21 or
a different external floating thermostat
is connected, the bridge at S6 has to
be removed.

11
3.3 Installing the temperature sensors
The temperature sensor cables must be routed separately from
mains voltage cables, and must not, for example, be routed in the
same cable duct!
Caution
The controller operates with Pt1000 temperature sensors which are accurate
to the degree, thus ensuring optimal control of system functions.
Caution
If desired the sensor cables can be extended to a maximum of 30m
using a cable with a cross-section of at least 0.75mm². Make sure
that there is no contact resistance!
Position the sensor precisely in the area to be measured!
Only use immersion, pipe-mounted or flat-mounted sensor suitable
for the specific area of application with the appropriate permissible
temperature range.
3.4 Installation of the additional functions via clamps Z1/Z2
The instructions are supplied with the expansion board. The installa-
tion has to be commenced accordingly and all warnings have to be
observed.
Caution
Installation
3 3
S6 is by default connected by bridge with the terminal block S- to enable
the heating circuit functions. If the bridge is removed, the heating circuit
is switched off. When connecting the remote adjuster RC21 the bridge
has to be removed. If a third party external thermostat is connected, it’s
electrical contacts has to be floating and of low resistance = 0 Ohm.
Caution

12
Operation
4 4
4.1 Display and input
The display (1), with its extensive
text and graphics mode, is almost
self-explanatory, allowing easy
operation of the controller.
The LED (2) lights up green when a
relay is switched on.
The LED (2) lights up red when
operating mode „Off“ is set.
The LED (2) flashes slowly
red in the operating mode „Manual“.
The LED (2) flashes quickly
red when an error is present.
Entries are made using four keys
(3+4), to which different functions
are assigned depending on the
situation. The „esc“ key (3) is used
to cancel an entry or to exit a menu.
If applicable there will be a request
for confirmation as to whether the
changes which have been made
should be saved.
The function of each of the other
three keys (4) is shown in the display
line directly above the keys;
the right-hand key is generally
has a confirmation and selection
function.
Examples of key functions:
+/- = enlarge/shrink values
/ = scroll menu down/up
yes/no = approve/reject
Info = additional information
Back = to previous screen
ok = confirm selection
Confirm = confirm setting
Examples of display symbols:
Heating circuit pump
(rotates when active)
Heating circuit mixer
(black when active)
HC -Day mode (Time progr.)
HC-Night mode (Time progr.)
HC-Comfort mode (Time progr.)
Day mode
Night mode
Day mode due to RC21
Night mode due to RC21
Reference value mode
Reference value 14 day
Warning / Error message
New information available
(1)
(2)
(3)
(4)

13
Operation
4 4
4.2 Menu sequence and menu structure
The graphics or overview mode ap-
pears when no key has been pressed
for 2 minutes, or when the main menu
is exited by pressing „esc“.
Pressing a key in graphics or overview
mode takes you directly to the main
menu. The following menu
items are then available for selection
there:
Current temperature values with
explanations (see 6.)
Function control of the system with
operating hours, etc. (see 7.)
Operating times for heating circuit and hot
water, setting the clock (see 8.)
Operating times for heating circuit and hot
water, manual mode (see 9.)
Set parameters for the heating circuit
(see 10.)
Anti-seizing protection, Frost prot.,
Anti-Legionella activation (see 11.)
Sensor calibration, Remote adjuster,
Mixer, etc. (see 12.)
Against unintentional setting changes
at critical points (see 13.)
For diagnosis in the event of an
error (see 14.)
Selection of the menu language
(see 15.)

14
Parametrisation
5 5
The first time the controller is turned
on and after the language and time
are set, a query appears as to whether
you want to parametrise the
controller using the commissioning
help or not. The commissioning help
can also be terminated or called up
again at any time in the special
functions menu. The commissioning
help guides you through the neces-
5.1 Commissioning help
Caution
Observe the explanations for the the individual parameters on the
following pages, and check whether further settings are necessary
for your application.
5.2 Free commissioning
If you decide not to use the commissioning help, you should make the
necessary settings in the following sequence:
- Menu 10. Language (see 15.)
- Menu 3. Time, date and operating times (see 8.)
- Menu 5 Settings for heat circuit, all settings (see 10.)
- Menü 6. Protective functions if necessary (see 11.)
- Menü 7. Special functionsif necessary (see 13.)
Finally, menu 4.2 under operating mode „Manual“ should be used to test
the switch outputs with the consumers connected, and to check the sensor
values for plausibility. Then switch on automatic mode.
sary basic settings in the correct order, and provides brief descriptions of
each parameter in the display.Pressing the „esc“ key takes you back to the
previous value so you can look at the selected setting again or adjust it if
desired. Pressing the „esc“ more than once takes you back step by step to
the selection mode, thus cancelling the commissioning help. Finally, menu 4.3
under operating mode „Manual“ should be used to test the switch outputs with
the consumers connected, and to check the sensor values for plausibility. Then
switch on automatic mode.
Caution
Observe the explanations for the the individual parameters on the
following pages, and check whether further settings are necessary
for your application.

15
Menu “1. Measurement values”
serves to display the currently mea-
sured temperatures.
The menu is closed by pressing
“esc” or selecting “Exit measurement
values”.
Selecting “Info” leads to a brief help
text explaining the measurement
values.
Selecting “Overview” or “esc” exits
the Info mode.
If “Error” appears on the display instead of the measurement value,
then there may be a defective or incorrect temperature sensor.
Caution
Measurement values Menu 1
6 6
If the cables are too long or the sensors are not placed optimally, the result
may be small deviations in the measurement values. In this case the display
values can be compensated for by making entries on the controller.
Follow the instructions under 12.1.
What measurement values are displayed depends on the selected
program, the connected sensors and the specific device design.
6. Measurement values

16
Statistics Menu 2
7 7
7. Statistics
Menu “2. Statistics” is used for func-
tion control and long-term monitoring
of the system.
The submenus described under 7.1-
7.5 are available.
The menu is closed by pressing
“esc” or selecting “Exit statistics”.
7.1 Today Menu 2.1 (=Flow temperature for the present day)
In the graphical overview the characteristics of outdoor-and flow temperature
for the present day is shown from 0-24h. The right button changes the unit of
time and the two left buttons scroll through the diagram.
7.3 Operating hours Heat Circuit Menu 2.3
Display of operating hours of the heat pump connected to the controller, and
the date the measurement started.
7.4 Error messages Menu 2.4
Resetting and clearing the individual statistics. Selecting “All statistics”
clears everything except for the error log.
7.5 Reset / clear Menu 2.5
Display of the last three errors in the system with indication of date and time.
For system data statistics it is essential for the time to be set accurately
on the controller. Please note that the clock continues to
run for about 24 hours if the mains voltage is interrupted, and after
that has to be reset. Improper operation or an incorrect time may result
in data being cleared, recorded incorrectly or overwritten.
The manufacturer accepts no liability for the recorded data!
Caution
7.2 28-days Menu 2.2 (=Flow temperature during the last 28 days)
In the graphical overview the characteristics of the outdoor and flow tempera-
ture during the last 28 days is shown. The right button changes the unit of time
(Days) and the two left buttons scroll through the diagram.

17
Times Menu 3
8 8
8.Times
Menu “3. Times” is used to set the
time, date, operating times for the
heating circuit and hot water.
8.2 Heating circuit day Menu 3.2
This menu is used to select the daytime mode times for the heating circuit;
three time periods can be specified for each weekday and copied over to
the following days.
Setting range: Three time ranges for each day of the week
Default: Mo-Su 6:00-22:00
Note: See 10. for the associated temperature settings
8.1 Time & Date Menu 3.1
This menu is used to set the current time and date.
For proper functioning of the controller and statistics for the system
data it is essential for the time to be set accurately on the controller.
Please note that the clock continues to run for about 24 hours if the
mains voltage is interrupted, and after that has to be reset.
Caution
Caution
Times that are not specified are automatically considered to be
nighttime mode. The set times are only taken into account in the
heating circuit operating mode “Automatic”
8.3 Heating comfort Menu 3.3
This menu can be used to select a time range for each day of the week in
which the heating circuit is supplied with an increased comfort temperature,
e.g. for quick heating in the morning.
Setting range: One time range for each day of the week
Default: Mo-Su off
Note: See 10. for the associated temperature settings.
Caution
The menu is closed by pressing
“esc” or selecting “Exit display
mode”.
The associated temperature
reference values are speci-
fied in menu 5 “Settings”!

18
9. Operating modes
Menu “4. Operating modes” is used
to specify the operating modes for
the heating circuit.
After an interruption of the mains
voltage the controller automatically
returns to the last operating mode
selected!
The menu is closed by pressing
“esc” or selecting “Exit operating
modes”.
Operating modes Menu 4
9 9
.
The controller works with the set operating times and the corresponding
different reference flow temperature
values only in the automatic mode.
Caution
Auto = Automatic/Normal mode using the set times.
Continous Day = The set values for day mode are used.
Continous Night = The set values for night mode are used.
Reference Value = Fixed flow temperature regardless of the outdoor tempera-
ture. The desired flow temperature has to be set in menu 4.3.
14 day reference value = Specific fixed flow temperatures can be set for the
next 14 days in menu 4.4. After 14 days, the reference temperature of the 14th
day is used until the operating mode is changed.
Off = Heating circuit is switched off (except Frost protection)
Settings range: Auto, Continous day, Continous night, Reference value, 14
day reference, Off
Default: Automatic
9.1 Heat circuit Menu 4.1

19
The operating mode “Manual” may only be used by specialists for
brief function tests, e.g. during commissioning!
9.3 Manual Menu 4.2
In Manual mode the individual relay outputs and the connected consumers
can be checked for proper functioning and correct assignment.
Function in manual mode:
The relays and thus the connected consumer are switched on and off by
pressing a key, with no regard to the current temperatures and the parameters
which have been set. At the same time, the current measurement values of
temperature sensors are also shown in the display for the purposes of function
control.
Danger
9.4 14 day reference Menu 4.4
If operating mode “14 day reference value” is selected (Menu 4.1), the reference
flow temperature for each of the 14 days can be set here.
In the first menu 4.4.1 the starting time of the program is shown. To start the
program, hit restart.
Hitting “restart” again will reset the 14 day reference program and start it at
day 1.
9. Operating modes (continued)
9.3 Heat circuit reference Menu 4.3
If operating mode “Reference value” is selected, (Menu 4.1), the reference flow
temperature has to be set here, regardless of the curve/outdoor temperature.
Settings range: 10 °C to 75 °C
Default: 30 °C
Operating modes Menu 4
9 9

20
10. Settings HC
Settings Heating circuit Menu 5
10 10
Caution
This does not under any
circumstances replace the
safety facilities to be provided
by the customer!
The menu is closed by pressing
“esc” or selecting “Exit settings”.
The necessary basic settings required
for the control function of the heating
circuit are made in menu “5. Settings
HC”.
10.1 Su/Wi Day Menu 5.1 = Summer/Winter changeover in daytime mode
If this value is exceeded at outdoor sensor S1 during the daytime mode
times, the controller automatically switches the heating circuit off = Summer
mode.
If the outdoor temperature drops below this value, the heating circuit is
switched on again = Winter mode.
Setting range: from 0°C to 30°C / default setting: 18°C
10.2 Su/Wi Night Menu 5.2 = Summer/Winterchangeover in nighttime mode
If this value is exceeded at outdoor sensor S1 during the nighttime mode
times, the controller automatically switches the heating circuit off = Summer
mode.
If the outdoor temperature drops below this value, the heating circuit is
switched on again = Winter mode.
Settings range: 0°C to 30°C / Default: 12°C
In addition to the operating times in normal daytime operation, this
setting is also valid for times with activated comfort temperature
boost and activated low-rate period boost.
Caution