Sorel HCC 5 User manual

Read carefully before installation, commissioning and operation
Heating-Controller HCC 5
Installation and operating instructions
Weather controlled heat circuit regulator

2
pagepage
Content
A.1 EC declaration of conformity 3
A.2 General instructions 3
A.3 Explanation of symbols 3
A.4 Changes to the unit 4
A.5 Warranty and liability 4
B.1 Specifications 5
B.2 Temperature resistance table
for Pt1000 sensors 5
B.3 About the controller 6
B.4 Scope of supply 6
B.5 Disposal and pollutants 6
B.6 Hydraulic variants 7
C.1 Wall installation 8
C.2 Electrical connection 9
C.3 Installing the temperature sensors 10
C.4 Installation of the additional functions
via clamps Z1/Z2 10
D Electrical terminals 11
E.1 Display and input 12
E.2 Commissioning help 13
E.3 Free commissioning 13
E.4 Menu sequence and menu structure 14
1. Measurement values 15
2. Statistics 16
2.1 Today 16
2.2 28-days 16
2.3 Operating hours Heat Circuit 16
2.4 Operating hours DHW 16
2.5 Operating hours heating 16
2.6 Error messages 16
2.7 Reset / clear 16
3. Times 17
3.1 Time & Date 17
3.2 Heating circuit day 17
3.3 Heating comfort 17
3.4 Hot water enable 18
4. Operating modes 19
4.1 Heat circuit 19
4.2 Manual 20
4.3 Heat circuit reference 20
4.4 14 day reference 20
4.5 Domestic Hot Water 20
5. Settings Heating circuit 21
5.1 Su/Wi Day 21
5.2 Su/Wi Night 21
5.3 Curve 22
5.4 Day correction 23
5.5 Night correction 23
5.6 Comfort temperature boost 23
5.7 Reference/actual - 24
5.8 Reference/actual + 24
6. DHW settings 25
6.1 DHW min 25
6.2 DHW reference 25
6.3 DHW hysteresis 25
6.4 Buffer HW load 25
6.5 DHW priority 25
7. Protective functions 26
7.1 Anti-seizing protection 26
7.2 Frost protection 26
7.3 min. flow temperature 26
7.4 max. flow 27
7.5 Anti legionella 27
7.6 Discharge protection 27
8. Special functions 28
8.1 Sensor calibration 28
8.2 Commissioning 28
8.3 Factory settings 28
8.4 Expansions 29
8.5 Mixer 29
8.6 Room controller 30
9. Menu lock 31
11. Language 31
10. Service values 32
Z.1. Malfunctions with error messages 33
Z.2 Replacing the fuse 34
Z.3 Maintenance 34

3
Safety instructions
Danger
Caution
A.1 EC declaration of conformity
By affixing the CE mark to the unit the manufacturer declares that the HCC 5 conforms
to the following relevant safety regulations:
- EC low voltage directive 2006/95/EC
- EC electromagnetic compatibility directive 2004/108/EC
Conformity has been verified and the corresponding documentation and
the EC declaration of conformity are kept on file by the manufacturer.
A.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 func-
tion and operation of the controller. Always keep these instructions
in the vicinity of the controller.
A.3 Explanation of symbols
Failure to observe these instructions can result in danger to life from
electric voltage.
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.
Information which is especially importation for the function and optimal
use of the unit and the system.

4
A.4 Changes to the unit
A.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
Changes to the unit can compromise the safety and function of theunit
or the entire system.
Safety instructions
Danger

5
B.2 Temperature resistance table for Pt1000 sensors
B.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 supply)
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
°C 0 102030405060708090100
Ω1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385
Description of controller

6
B.4 Scope of supply
• Heating controller HCC 5
• 3 screws 3,5x35mm and 3 plugs 6mm for wall installation
• 6 strain reliefs with 12 screws, replacement fuse 2AT
• installation and operating instructions HCC 5
Optionally contained depending on design/order:
• 1x outdoor sensor e.g. TA52 (Pt1000)
• 1-2x pipe-mounted sensor e.g. TR/P4 (Pt1000)
• 1x buffer sensor e.g. TT/P4 (Pt1000)
• 1x Indoor sensor/remote adjuster with mode switch RC21
• 1x Immersion sleeve e.g. TH150
• various additional functions expansion boards
B.5 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 ordina-
ry household refuse. Dispose of the unit only at appropriate collection
points or ship it back to the seller or manufacturer.
B.3 About the controller
The weather controlled Heat Circuit Controller HCC 5 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 HCC 5:
• 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
• various additional functions are available e.g. 0...10V connection for boiler control
Description of controller

7
1
2
3
Mixed heat circuit with buffer
Mixed heat circuit with buffer and domestic hot water buffer
Mixed heat circuit and domestic hot water buffer
Caution
M
M
M
In heating installations where domestic hot water is not needed, the DHW heat-
ing can be deactivated in menu 4 „Operating mode“.
In heating installations without buffer the buffer sensor has to installed in an ap-
propriate position ahead of the mixer.
B.6 Hydraulic variants
Description of controller
Caution
The following illustrations should be viewed only as schematic dia-
grams 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 protec-
tors, etc., and must therefore be provided.

8
C.1.1
C.1.2
Caution
C.1 Wall installation
Install the controller only in dry areas and under the ambient conditions descri-
bed under B.1 „Specifications“. Carry out the following steps 1-8.
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.
Installation

9
C.2 Electrical connection
Installation
Danger
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 comp-
liance with the applicable regulations. The controller may not be put into
operation if there is visible damage to the housing, e.g. cracks.
Caution
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
The customer must provide an all-pole disconnecting device, e.g. a
heating emergency switch.
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.
1. Open controller housing (see C.1.1)
2. Strip cables max. 55mm, insert, fit the
strain relief devices, strip the last 8-9
mm of the wires. (Fig.C.2.1)
3. Open the terminals using a suitable
screwdriver (Fig. C.2.1) and make
electrical connections on the controller
(see section D)
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
C.2.1

10
Installation
C.3 Installing the temperature sensors
C.4 Installation of the additional functions via clamps Z1/Z2
Der Regler arbeitet mit Pt1000-Temperaturfühlern, die für eine gradgenaue Tempera-
turerfassung sorgen, um die Anlagenfunktion regeltechnisch optimal sicherzustellen.
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 tempe-
rature range.
Caution
S6 is by default connected by jumper with the terminal block S- to ena-
ble the heating circuit functions. If the jumper is removed, the heating
circuit is switched off. When connecting the remote adjuster RC21 the
jumper has to be removed. If a third party external thermostat is con-
nected, it’s electrical contacts has to be floating and of low resistance =
0 Ohm.
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 instructions are supplied with the expansion board. The installation
has to be commenced accordingly and all warnings have to be obser-
ved.
Caution

11
Caution
Left-hand terminal compartment
only for low voltage if max. 12VAC/
DC Danger
Right-hand terminal com-
partment only for mains volt-
ages of 230VAC 50-60Hz
Low voltage max. 12VAC/DC
connection in the left-hand terminal compart-
ment!
Terminal: Connection for:
- Jumper terminal block S-
S1 outdoor
S2 heating circuit
S3 Domestic hot water
S4 buffer
S5 indoor sensor
S6 remote adjuster*
+ not used
Z1 Option / add. function
Z2 Option / add. function
Use terminal block S- for connecting the
sensor earths of S1-S6.
The polarity of the sensors is freely selecta-
ble.
The sensors S4-S6 are optional, depending
on the hydraulic variant chosen.
Mains Voltage 230VAC 50-60Hz connec-
tion in the right-hand terminal compartment.
Terminal: Connection for:
N Jumper terminal block N
L Mains phase conductor L
R1 Heat circuit pump
R2 Mixer open
R3 Mixer close
R4 Valve/DHW pump
R5 add. heating
R5I add. heating
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 con-
nected, the bridge at S6 has to be removed.
Connections Mains Voltage:
- Protective conductor PE metal terminal
block
- Neutral conductor terminal block N
- Mains phase conductor L
- Switch output R1-R4
- Floating contact at R5/R5I
Caution: Only suitable for 230V!
Connections low voltage:
- Temperature sensors S1 - S6
(polarity freely selectable)
- Optional additional functions Z1/Z2
D Electrical terminals
Installation

12
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
Additional heating
Reference value mode
Reference value 14 day
external thermostat off
Warning / Error message
New information available
(1)
(2)
(3)
(4)
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 de-
pending 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 con-
firmation 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 direct-
ly above the keys; the right-hand key is
generally has a confirmation and selec-
tion 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
Operation
E.1 Display and input

13
Operation
E.2 Commissioning help
E.3 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.)
- Menu 6. Protective functions if necessary (see 11.)
- Menu 7. Special functions if 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.
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 selec-
tion 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 connec-
ted, and to check the sensor values for plausibility. Then switch on automatic mode.
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 commis-
sioning help can also be terminated or
called up again at any time in the special
functions menu. The commissioning help
guides you through the necessary basic
settings in the correct order, and provides
Caution
Observe the explanations for the the individual parameters on the follo-
wing pages, and check whether further settings are necessary for your
application.
Caution
Observe the explanations for the the individual parameters on the follo-
wing pages, and check whether further settings are necessary for your
application.

14
1. Measurements
4. Operating
7. Protections
2. Statistics
5. HC settings
8. Special functions
3. Times
6. DHW settings
9. Menu lock
10. Service Data
11. Language
E.4 Menu sequence and menu structure
Operation
The graphics or overview mode appears
when no key has been pressed for 2 mi-
nutes, 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 availa-
ble for selection there:
Current temperature values with
explanations
Function control of the system with operating
hours, etc.
Operating times for heating circuit and hot water,
setting the clock
Operating times for heating circuit and hot water,
manual mode
Set parameters for the heating circuit
Anti-seizing protection, Frost prot.,
Anti-Legionella activation
Sensor calibration, Remote adjuster, Mixer,
etc.
Against unintentional setting changes at
critical points
For diagnosis in the event of an error
Selection of the menu language
Set parameters for Domestic Hot Water

15
Menu “1. Measurement values” serves to
display the currently measured tempera-
tures.
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.
Caution
If “Error” appears on the display instead of the measurement value, then
there may be a defective or incorrect temperature sensor.
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 8.1.
What measurement values are displayed depends on the selected pro-
gram, the connected sensors and the specific device design.
Measurement values
1. Measurement values

16
2. Statistics
Menu “2. Statistics” is used for function
control and long-term monitoring of the
system.
The menu is closed by pressing “esc” or
selecting “Exit statistics”.
2.1 Today
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.
2.2 28-days
Flow temperature during the last 28 days
In the graphical overview the characteristics of the outdoor and flow temperature du-
ring the last 28 days is shown. The right button changes the unit of time (Days) and the
two left buttons scroll through the diagram.
2.3 Operating hours Heat Circuit
Display of operating hours of the heat pump connected to the controller, and the date
the measurement started.
2.4 Operating hours DHW
Display of operating hours of Domestic Hot Water pump connected to the controller,
and the date the measurement started.
2.5 Operating hours heating
Display of operating hours of additional heating, and the date the measurement star-
ted.
2.6 Error messages
Display of the last three errors in the system with indication of date and time.
2.7 Reset / clear
Resetting and clearing the individual statistics. Selecting “All statistics” clears eve-
rything except for the error log.
Statistics
Caution
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!

17
3. Times
Caution
Menu “3. Times” is used to set the time,
date, operating times for the heating cir-
cuit and hot water.
The menu is closed by pressing “esc” or
selecting “Exit times”.
The associated temperature
reference values are specified in
menu 5 “Settings”!
3.1 Time & Date
This menu is used to set the current time and date.
3.2 Heating circuit day
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 5. for the associated temperature settings
3.3 Heating comfort
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 5. for the associated temperature settings.
Times
Caution
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 volta-
ge is interrupted, and after that has to be reset.
Caution
Times that are not specified are automatically considered to be night-
time mode. The set times are only taken into account in the heating
circuit operating mode “Automatic”

18
Times
3.4 Hot water enable
This menu is used to select the times when the domestic hot water heating is enabled
(sensor 3); 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 11. for the associated temperature settings
Caution
Times that are not specified are set to “disabled”.

19
4. Operating modes
Menu “4. Operating modes” is used to
specify the operating modes for the hea-
ting circuit.
After an interruption of the mains
voltage the controller automatically re-
turns to the last operating mode selected!
The menu is closed by pressing “esc” or
selecting “Exit operating modes”.
Auto = Automatic/Normal mode using the set times.
Continuous Day = The set values for day mode are used.
Continuous Night = The set values for night mode are used.
Reference Value = Fixed flow temperature regardless of the outdoor temperature. 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, Continuous day, Continuous night, Reference value, 14 day reference,
Off
Default: Automatic
4.1 Heat circuit
Operating modes
The controller works with the set operating times and the corresponding
different reference flow temperature values only in the automatic mode.
Caution

20
Operating modes
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.
If operating mode “Reference value” is selected, (Menu 4.1), the reference flow tempe-
rature has to be set here, regardless of the curve/outdoor temperature.
Settings range: 10 °C to 75 °C
Default: 30 °C
4.2 Manual
4.3 Heat circuit reference
Danger
The operating mode “Manual” may only be used by specialists for
brief function tests, e.g. during commissioning!
The domestic hot water heating can be activated here. “Auto” makes use of the times
set in the “times” menu (see menu 3.4), “On” activates continuously, and “Off” switches
the DHW heating off.
Settings range: Auto, On, Off
Default: Auto
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.
4.5 Domestic Hot Water
4.4 14 day reference