ThermoControl Plus 4 Eight controller circuits 1-stage Four controller circuit 2-stage Operating and Installation Manual Schwank Group P.O.Box 988 2 Schwank Way @ Hwy. 56N Tel:1-877-446-3727 Fax: 1-866-361-0523 tsa@schwankgroup.com www.schwankgroup.
Content: 1 INTRODUCTION ............................................................................................... 4 2 SAFETY............................................................................................................. 5 3 Display and Button Function .............................................................................. 6 4 OPERATION ..................................................................................................... 7 4.1 Basic operation .......................
6.7 6.8 Exhaust Fan Output - Two-stage Luminous Zones .................................. 29 Alarm Contact Input ................................................................................. 29 6.9 6.10 6.11 6.10 6.11 Remote-Control .................................................................................. 29 Signal input fault ...................................................................................... 29 Temperature display ºF / ºC selection ........................................
1 Introduction The Schwank ThermoControl Plus 4 is suitable for single or two-stage gas-infrared heating systems. Dependant upon its operation the controller has one or two controller circuits. 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 “Safety“.
2 Safety This is a 24VAC Class 2 low voltage (24Vac) temperature controller. Use only Class 2 rated power supply. Do not install on voltages higher than 30Vac. Minimum Wiring Connection: It is the installer’s responsibility to ensure that wire gauge is sufficient to provide 24Vac from the transformer to the controller, and from the controller 24Vac outputs to the external relays that power heaters and exhaust fans. The distance between the power source and equipment must be considered.
3 Display and Button 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). If no button is pushed for more than one minute, the control unit switches back to the base display. 3. 4. 5. 6. Push the button or the button to display the day or night set value. Use the +/buttons to modify the values. + / - With these buttons the display values can be increased or decreased.
4 Operation 4.1 Basic operation When starting the ThermoControl wit h the I/O -button an automatic disp lay-test is activated. The controller starts with the factor y default program. The display then switches to the base-program, which shows all the important operation information. Indication of which relay output and which sensor inputs are used in the specific control circuit. Measured temperature Indication of the chosen control circuit in the space/zone (18.
4.1.2 Selection of a control zone The controller display and its usage is based on the display of the control circuit. The control zone can be selected by pushing the ZONE button. All settings of the control zone can be managed. 4.1.3 Activation and deactivation of a control-zone To stop heating in a certain zone: select the zone, and push the button. The symbol will indicate the deactivation of the zone. In the deactivated zone only temperature measurement and display continue to work.
4.2 Display and change of occupied/unoccupied temperature The desired temperature for each control circuit can be programmed separately The current occupied/unoccupied temperatures can be displayed by pushing or button. The values can be modified by pushing +/-. All modifications are saved immediately. The temperatures can be changed within the range: +3…+35 °C / 37 ...95 ºF Push the DISP button to switch the current display back to the main displa y (automatic after one minute if no button pushed).
4.3. To display or modify the base time and date of the controller Cycle through the base time and date of the controller with the button. Modify any time or date using +/-. This function affects the base controller clock (all control circuits have a separate time program). button to display/modify time of day (in the picture: 14:03). Push the button again Push the to display/change the year (2007). Push the button a third time and the month and day (in this case: 3rd month = March, 21 st day) is displayed.
Set the year After the time of day has been modified, set the correct year, month and day as well. Otherwise the automatic summer / winter time correction won’t work properly. To change the year press the SEL button. The last two figures will start to blink (06). Modify with the +/- buttons. Next push the button and month and day of the month respectively will be shown on the display. When the year has been modified, the day of the week may change according to the calendar (in this case 3).
4.4 Circuit/Zone Times Each control circuit has an independent time program, which can be set or modified. The time program is a series of different circui t times.
4.4.2 How to clear a switch point To clear or erase a switch time point: select the point, push and hold the CLR button. The symbol CLR will blink in the display, warning that a switch time point is to be cleared. If the CLR button is released immediately, then the erasure procedure will be stopped. If the erasure is completed horizontal lines are visible. Then the new number of free switch points is displayed. The numeric of a switch point is not fixed.
4.4.5 To program the switch points In this example we program the following criteria: The day temperature should start every morning at 7:35 from Monday through Friday. First search for a free switch point ( - -:- -) by using the PR button. Then press the SEL button and +/- to modify the new data. The same procedure ca n be used to modify existing switch points. At first the temperature mode starts to blink. The mode or can be selected using the +/- buttons.
4.5 Holiday program The controller provides the opport unity to program 8 holidays. Start and end of the holiday is displayed with exact data (year, month, day). The programs can be c hanged and also stopped at every point of time. During the holiday program the freeze protection temperature will be maintained. To program holiday periods push the button. First the number of the holiday program HOL 1 (holiday 1) appears. The numeric above the holiday number shows which of the 8 holiday programs is activated.
4.6 Manual operation Use the FIX FIX button to select different operating modes. To change the FIX mode push the FIX button. Press DISP when 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. day-temperature mode night-temperature mode freeze protection temperature Push FIX to return to the main display. 4.
5 Set up the operating parameters The “setup” switch as well as the jumper selection of the program P1 … P5 may only be changed after the main power to the controller has been switched off. Before you open the control unit read the important information in chapter 2! The set up of operation parameters can be modified from the front panel with the “setup” switch in the “On” position. Only a trained and knowledgeable technician should modify the operating parameters.
5.2 Set up system operation parameters To set up the parameters hold the DISP button for approximately 3 seconds. The “PAr” symbol appears briefly. The operation parameters can be selected with the SEL button. Integration band: Two-stage mode only: 0.5...3.0 °C / 1.0...5.5 ºF In single-stage mode: (--.--) appears Integration time: Two-stage mode only: 10 … 99 minutes In single-stage mode, or in off-state (--.--) appears. Hysteresis , can be activated by 0.2 … 2.0 °C / 0.4...3.
Refer to sections 6.4 to 6.7 for exhaust fan output use Switch off exhaust fans: ’AUto’: exhaust fan in use = for twostage luminous zones ONLY, ’OFF’’: exhaust fan output is switched off for all tube heater zones, and single stage luminous zones (the symbol disappears). Exhaust fan post-purge time : After a heating zone (two-stage luminous) has been switched off, the exhaust fan can continue to run until the set time is achieved: 0 to 60 minutes (available only in the ”AUto” ventilation mode).
5.4 COPY The COPY button offers the opportunity to copy all parameters of a certain circuit or the complete time program and insert it into the program of one or many other control circuits. To copy parameters hold DISP (approx. 3 sec., chapter 5.2). To copy time programs use the PR button (chapter. 4.4.1). This example copies data from Zone 1 to Zone 2. Push either the DISP (parameters) or program) button PR (time Zone 2 symbol start to blink. “COPY“ appears in the display to indicate the copy mode.
6 Installation & Configuration Bracket Lower part 140 25 96 265 244 Door Lock Upper part Screw 180 205 6.1 Electrical Supply The controller must be electr ically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1. Appliance and control wiring must be in accordance with all applicable local codes.
6.2 Sensor connections The sensor is connected with two wires. The sensor does not require shielded cable, because the controller includes effective protection. The l ength of wire up to 650 ft (200 m) does not influence the accuracy of the temperature measurement. Do not run the s ensor lead next to high voltage wires. The sensor connection must match the selected operating program (single- and/or two-stage zones). Unused inputs must be kept free of usage! 6.
6.5 Zone Configuration – Two Stage Tube Heaters For two-stage tube heaters: All heater zones are set up as two-stage only. Pairs of controller outputs control low and high fire. The location of the jumper in P5 establishes four two-stage zones. A 100VA 120V/24V transformer is supplied to power the controller, and eight 24Vac external relays are also supplied.
6.6.1 Zone Configuration – Luminous (high intensity) Heaters JUMPER IN POSITION 1 (P1): Up to eight single stage zones (all single-stage) The jumper pins P1 to P5 are located inside the controller cover to the right side of the battery. The location of the jumper in P1 … P5 determines the quantity of single-stage and two-stage zones. With the jumper in position P1, all zones are single stage.
6.6.2 Zone Configuration – Luminous (high intensity) Heaters JUMPER IN POSITION 2 (P2): One two-stage zones + up to six single-stage zones The jumper pins P1 to P5 are located inside the controller cover to the right side of the battery. The location of the jumper in P1 … P5 determines the quantity of single-stage and two-stage zones. With the jumper in position P2, one zone is two-stage, and the balance of the zones are single stage.
6.6.3 Zone Configuration – Luminous (high intensity) Heaters JUMPER IN POSITION 3 (P3): Two two-stage zones + up to four single-stage zones The jumper pins P1 to P5 are located inside the controller cover to the right side of the battery. The location of the jumper in P1 … P5 determines the quantity of single-stage and two-stage zones. With the jumper in position P3, two zones are two-stage, and the balance of the zones are single stage.
6.6.4 Zone Configuration – Luminous (high intensity) Heaters JUMPER IN POSITION 4 (P4): Three two-stage zones + two single-stage zones The jumper pins P1 to P5 are located inside the controller cover to the right side of the battery. The location of the jumper in P1 … P5 determines the quantity of single-stage and two-stage zones. With the jumper in position P4, three zones are two-stage, and two zones remain for single stage.
6.6.4 Zone Configuration – Luminous (high intensity) Heaters JUMPER IN POSITION 5 (P5): Four two-stage zones The jumper pins P1 to P5 are located inside the controller cover to the right side of the battery. The location of the jumper in P1 … P5 determines the quantity of single-stage and two-stage zones. With the jumper in position P5, all four zones are two-stage. Eight relay switches are supplied with the controller to switch line voltage to the zone transformers (field supplied).
6.7 Exhaust fan output connection – For Two-stage Luminous Zone ONLY REFER TO ZONE AND EXHAUST FAN SCHEMES IN 6.6 AND LUMINOUS HEATER WIRING DIAGRAM. Exhaust fan output connections (10 to 17) are reserved for luminous two-stage zones ONLY! Use 24VAC Class 2 rated power relay (field supplied) to switch line voltage to an exhaust fan that serves both the proportion of heater in the low-stage zone, and the balance of the heaters in the high-stage zone.
6.12 Communication connection Two types of optional communication cards can be used and connected to the "Communication" terminal (only one type can be used at a time): -CM485 card: Modbus (RS485) output, standard interface to building and industrial supervisory systems. The output of this card is optically isolated from the controller. -CM232 card: RS232 output, built-in 3-weeks data logger. Direct connection to telephone modem or PC.
Holiday Programming: When modifying the holiday program the “ERROR“ signal will appear if the starting(A) or ending(B) dates or calendar data are in conflict. (for example: the end date is earlier than the start date of a holiday period) In case of data entry error, the holiday program won’t activate. This display represents a very rare error: a button on the front panel is jammed in the depressed position.
7 Technical Relay outputs: 8 control relays - up to 8 heating zones, (4 flue fan relays – Reserved – Do Not Use). Relays switch out 24Vac to connection terminals (wet contact). 1 error relay: connected as voltage-free contact to connection terminals Relay load: max. 6.
8 WIRING DIAGRAMS - ThermoControl Plus 1, 2, 4 8.1 Standard Tube Heaters: Single-stage zone; 1-8 Zones Two-stage zones; 1-4 Zones (refer to section 5 and 5.
8.2 Two-Stage Tube Heaters: 1-4 two-stage zones (refer to section 5 and 5.
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8.5 Wiring diagram, accessories Option 1: Override Button Override Button (or other override input) IR / Ambient Temperature Sensor NOTE: For humidity control (steel storage facilities, etc.) a humidity sensor can be connected in parallel to the SR to operate the heaters if humidity rises above humidity set-point even though temperature set-point may be satisfied. Other inputs such as coin-operated equipment can also be connected in parallel to the SR.
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