Taconova FWCK Operating instructions

CONTACT AND FURTHER INFORMATION TACONOVA.COM
Taconova Group AG | Neunbrunnenstrasse 40 | CH-8050 Zurich | T [phone] | F [phone] | [email protected]
FWCK
CASCADE CONTROLLER
CONTROLLER MANUAL
V2.2014 | 07/2014 | Art.-Nr. 211059 | EA -Nr. 1156

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 Specications 5
B.2 About the controller 6
B.3 Scope of supply 6
B.4 Disposal and pollutants 6
B.5 Hydraulic variant 7
C.1 Wall installation 8
C.2 Electrical connection 9
D Electrical connections 10
E.1 Display and input 11
E.2 Menu sequence and menu structure 12
E.3 Commissioning help 13
E.4 Free commissioning 13
1. - Statistics 14
1.1. - Message log 14
1.2. - Reset/clear 14
2. - Operating modes 15
2.1. - Automatic 15
2.2. - Manual 15
2.3. - Off 15
3. - Settings 16
3.1. - VFS Type 16
3.2. - Threshold 1 16
3.3. - Threshold 2 17
3.4. - Threshold 3 17
3.5. - Threshold 4 17
4. - Special functions 18
4.1. - Time & date 18
4.2. - Sensor calibration 18
4.3. - Commissioning 18
4.4. - Factory settings 19
5. - Menu lock 20
6. - Service values 21
7. - Language 22
Z.1. Malfunctions with error messages 22
Z.2 Replacing the fuse 23
Z.3 Maintenance 23

3
Safety instructions
By af xing the CE mark to the unit the manufacturer declares that the FWCK 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 veri ed and the corresponding documentation and the EC decla-
ration of conformity are kept on  le by the manufacturer.
A.1 EC declaration of conformity
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, com-
missioning and operation of the unit.
The valid accident prevention regulations, VDE regulations, the regulations of the lo-
cal 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.2 General instructions
Danger
Caution
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 important for the function and optimal
use of the unit and the system.
It is essential that you read this!

4
Safety instructions
A.4 Changes to the unit
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
speci cations
- Force majeure
A.5 Warranty and liability
- Changes, additions to or conversion of the unit are not permitted without the writ-
ten 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 exam-
ple 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 the unit
or the entire system.
Danger

5
Electrical specications:
Mains voltage 230VAC +/- 10%
Mains frequency 50...60Hz
Power consumption 2VA
Switched power
overall 460VA (relay output 1-4)
per relay 460VA for AC1 / 185W for AC3
Internal fuse 2A slow-blow 250V
Protection category IP40
Protection class II
Sensor inputs 1x Vortex Flow Sensor (VFS)
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% rel. humidity at 25°C
for transport/storage no moisture condensation permitted
Other specications 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)
Vortex Flow Sensor (VFS) Flow rate and water temperature
Lead Vortex Flow sensor : prolongable to max. 3m
B.1 Specications
Description of controller

6
The FWCK can control the  ow to 4 more fresh water stations by means of stop valves.
The  rst fresh water station runs independently. The secondary fresh water stations
 own are controlled via stop valves. A  ow sensor is integrated into every single
station. The FWCK is monitoring the entire  ow. 4 On and Off limits are set in the
FWCK, at which the individual stations stop valves are switched.
To ensure an equal use of the fresh water stations the FWCK changes the station
switched  rst when the  ow reaches 0 L/min.
Important characteristics of the FWCK:
- Depiction of graphics and texts in a lighted display
- Simple viewing of the current measurement values
- Analysis 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
B.2 About the controller
Description of controller
- Temperature Difference Controller FWCK
- replacement fuse 2A slow-blow
- Installation and operating instructions
B.3 Scope of supply
B.4 Disposal and pollutants
The unit conforms to the European RoHS directive 2011/65/EU for the restriction of the
use of certain hazardous substances in electrical and electronic equipment.
Caution
Caution
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.
Every fresh water station has to be equipped with a  ow limiter to
prevent damage to the VFS.
Every fresh water station has to be con gured separately.

7
Description of controller
B.5 Hydraulic variant
Caution
The following illustration should be viewed only as schematic diagrams
showing the respective hydraulic system, and do not claim to be
complete. The controller does not replace safety devices under any
circumstances. Depending on the speci c 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.

8
C.1.1
C.1.2
Caution
C.1 Wall installation
Install the controller only in dry areas and under the ambient conditions de-
scribed under B.1 “Speci cations”. 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
Installation
C.2 Electrical connection
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 compli-
ance with the applicable regulations.
Do not use the controller if the housing shows visible damage.
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 as described under C.1.
2.Strip cables by 55mmmax., insert,  t the
strain relief devices, strip the last 8-9mm
of the wires (Fig. C.2.1)
3.Open the terminals using a suitable
screwdriver (Fig. C.2.1) and make electri-
cal connections on the controller
4.Re t upper part of housing and fasten
with screw.
5.Switch on mains voltage and place con-
troller in operation.
8...9
~30°
max. 55
C.2.1

10
Installation
Attention
low voltage max.
12VAC/DC Danger
Mains side
230VAC 50-60Hz
Low voltage max. 12VAC/DC connection in
the left-hand terminal compartment!
Terminal: Connection for:
S1 not used
S2 not used
S3 not used
S4 not used
S5 VFS temperature
(yellow)
S6 VFS  ow rate
(white)
+ VFS +5V DC (brown)
Z1 Option / additional function
Z2 Option / additional function
- jumper terminal block S-
e.g. VFS - (green)
Mains voltage 230VAC 50-60Hz
connection in the right-hand
terminal compartment!
Terminal: Connection for:
L Mains phase conductor L
R1 Valve 1
R2 Valve 2
R3 Valve 3
R4 Valve 4
R5 not used
R5I not used
N Jumper terminal block N
The PE protective conductor must be con-
nected to the PE metal terminal block!
Connection mains voltage compartmen:
• The PE protective conductor must be
connected to the PE metal terminal
block!
• Connection of relay lead N via
terminal block Sensor N
• Mains phase conductor terminal L
• Relay outputs terminals R1-R4
• Potential free terminal R5/R5I
Attention: only suitable for 230V!
Connections low voltage compartment:
• Temperature sensors terminal block
S1-S6 and terminal block S- (polarity
freely selectable)
• optional additional functions at
terminal Z1/Z2
D Electrical connections
Connection of sensor earths S1-S6 via terminal block sensor S.
The polarity of the sensors is freely selectable.
Terminal Block Terminal Block
A bridge from R2 to R1 must be placed by customer for the operation of a two
station cascade!
Caution

11
(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) ashes slowly red in the
operating mode “Manual”.
The LED (2) ashes quickly
red when an error is present.
Entries are made using four keys (3+4),
which are assigned to different functions
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 conrmation 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 di-
rectly above the keys; the right-hand key
is generally has a conrmation 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 = conrm selection
Conrm = conrm setting
Operation
E.1 Display and input

12
E.2 Menu sequence and menu structure
The graphics or overview mode appears
when no key has been press for 2 min-
utes, 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 avail-
able for selection there:
Function control of the system with
operating hours, etc
Automatic mode, manual mode or switch
unit off
Set parameters needed for normal
operation
Sensor calibration, clock, commissioning,
etc.
Against unintentional setting changes at
critical points
For diagnosis in the event of an error
Language selection
Operation
1. Statistics
2. Operating Mode
3. Settings
4. Special functions
5. Menu lock
6. Service data
7. Language

13
E.3 Commissioning help
E.4 Free commissioning
If you decide not to use the commissioning help, you should make the necessary
settings in the following sequence:
- Menu 4. Settings, all values
- Menu 3. Special functions if additional changes are necessary
Finally, menu 2.2 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.
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 2.2 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.
The  rst 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 necessary basic settings in the correct
Parametrisation
Caution
Observe the explanations for the the individual parameters on the
following pages, and check whether further settings are necessary for
your application.
Caution
Observe the explanations for the the individual parameters on the
following pages, and check whether further settings are necessary for
your application.

14
1.1. - Message log
Resetting and deleting the individual analyses. The function “All statistics” clears all
analyses but not the error messages.
1.2. - Reset/clear
Display of the last 10 events occurring in the system with indication of date and time.
1. - Statistics
Caution
The menu “1. Statistics” is used for func-
tion control and long-term monitoring of
the system.
The menu is closed by pressing “esc” or
selecting “Exit statistics”.
For analysis of the system data it is essential for the time to be set ac-
curately on the controller. Please note that the clock does not continue
to run if the mains voltage is interrupted, and must therefore be reset.
Improper operation or an incorrect time may result in data being deleted,
recorded incorrectly or overwritten.
The manufacturer accepts no liability for the recorded data!
Statistics

15
2. - Operating modes
In menu “2. Operating modes” the con-
troller can either be placed in automatic
mode, switched off, or placed in a manual
operating mode.
The menu is closed by pressing “esc” or
selecting “Exit operating modes”.
Automatic mode is the normal operating mode of the controller. Only automatic mode
provides proper controller function taking into account the current temperatures and
the parameters that have been set! After an interruption of the mains voltage the con-
troller automatically returns to the last operating mode selected!
2.1. - Automatic
Operating modes
2.2. - Manual
The relay 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. The measured temperatures are also shown to provide an overview and function
control. The high ef ciency pump is labeled “Relay 6” despite being connected to the Z
terminal clamps.
2.3. - Off
When the operating mode “Off” is activated, all controller functions are
switched off. This can lead, for example, to overheating on the solar
collector or other system components. The measured temperatures are
sstill displayed to provide an overview.
Caution
Danger
When operating mode “Manual” is activated, the current temperatures
and the selected parameters are no longer considered. There is a dan-
ger of scalding or serious damage to the system. The operating mode
“Manual” may only be used by specialists for brief function tests or dur-
ing commissioning!

16
3. - Settings
The necessary basic settings required for
the control function are made in menu “5.
Settings”.
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”.
Settings
Attention
3.1. - VFS Type
This menu is used to set the type of VFS sensor used.
VFS-Type- Settings range: 5-100, 10-200, 20-400 l/min / Default: 20-400 l/min
3.2. - Threshold 1
This menu is used to set the  ow rate, at which the relay is being switched.
Settings range:
Switch-on value: 1 to 400 l/min / Default: 30 l/min
Switch-off value: 1 to 400 l/min / Default: 20 l/min
The FWCK can control the  ow to 4 more fresh water stations by means of stop valves.
The  rst fresh water station runs independently. The secondary fresh water stations
 own are controlled via stop valves. A  ow sensor is integrated into every single
station. The FWCK is monitoring the entire  ow. 4 On and Off limits are set in the
FWCK, at which the individual stations stop valves are switched.
To ensure an equal use of the fresh water stations the FWCK changes the station
switched  rst when the  ow reaches 0 L/min.
To deactivate stations 2 to 4, the switch-on value can be set to „Off“.
Every Fresh water station has to be equipped with a  ow limiter to prevent
damage to the VFS sensor.

17
Settings
3.3. - Threshold 2
This menu is used to set the ow rate, at which the relay is being switched.
Settings range:
Switch-on value: 1 to 400 l/min / Default: 60 l/min
Switch-off value: 1 to 400 l/min / Default: 50 l/min
3.4. - Threshold 3
This menu is used to set the ow rate, at which the relay is being switched.
Settings range:
Switch-on value: 1 to 400 l/min / Default: 90 l/min
Switch-off value: 1 to 400 l/min / Default: 80 l/min
3.5. - Threshold 4
This menu is used to set the ow rate, at which the relay is being switched.
Settings range:
Switch-on value: 1 to 400 l/min / Default: 120 l/min
Switch-off value: 1 to 400 l/min / Default: 110 l/min

18
Special functions
Menu “4. Special functions” is used to set basic
items and expanded functions.
The menu is closed by pressing “esc” or
selecting “Exit special functions”.
4. - Special functions
Caution
Other than the time all settings may
only be made by a specialist.
This menu is used to set the current time and date.
4.1. - Time & date
Caution
For analysis of the system data it is essential for the time to be set accurately
on the controller. Please note that the clock does not continue to run if the mains
voltage is interrupted, and must therefore be reset.
Deviations in the temperature values displayed, for example due to cables which are to
long or sensors which are not positioned optimally, can be compensated for manually
here. The settings can be made for each individual sensor in steps of 0.5°C.
Offset S1...S3 per setting range: -100 to +100 (translates to -50°C...+50°C)
Default setting: 0
4.2. - Sensor calibration
Caution
Settings are only necessary in special cases at the time of initial com-
missioning by the specialist. Incorrect measurement values can lead to
unpredictable errors.
Starting the commissioning help guides you in the correct order through the basic set-
tings necessary for commissioning, 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 se-
lected setting again or adjust it if desired. Pressing the “esc” more than once takes you
back to the selection mode, thus cancelling the commissioning help. (see also E.2).
4.3. - Commissioning
Caution
May only be started by a specialist during commissioning! Observe the
explanations for the the individual parameters in these instructions, and
check whether further settings are necessary for your application.

19
Special functions
All of the settings that have been made can be reset, thus returning the controller to its delivery
state.
4.4. - Factory settings
Caution
The entire parametrisation, analyses, etc. of the controller will be lost
irrevocably. The controller must then be commissioned once again.

20
The menus listed below remain completely accessible despite the menu lock being
activated, and can be used to make adjustments if necessary:
1. Analysis
5. Menu lock
6. Service values
To lock the other menus, select “Menu lock on”.
To enable the menus again, select “Menu lock off”.
Setting range: on, off/default setting: off
Menu lock
Menu “5. Menu lock” can be used to secure
the controller against unintentional changing
of the set values.
The menu is closed by pressing “esc” or select-
ing “Exit menu lock”.
5. - Menu lock