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Table of Contents
Related Manuals for Schwank ThermoControl Plus 4
Summary of Contents for Schwank ThermoControl Plus 4
- Page 1 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.com IM100630 RL:2 JUNE2010...
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Page 2: Table Of Contents
Content: 1 INTRODUCTION ....................4 2 SAFETY ......................5 3 Display and Button Function ................6 4 OPERATION ..................... 7 Basic operation ..................7 4.1.1 Further display information ................ 7 4.1.2 Selection of a control zone ................. 8 4.1.3 Activation and deactivation of a control-zone ..........8 4.1.4 Special information in the base display ............ - Page 3 Exhaust Fan Output - Two-stage Luminous Zones ........29 Alarm Contact Input ................. 29 Remote-Control .................. 29 6.10 Signal input fault ..................29 6.11 Temperature display ºF / ºC selection ............29 6.10 Communication connection (CM232, CM485) ......... 30 6.11 Common fault signals ................
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Page 4: Introduction
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. -
Page 5: Safety
Connect sensor to controller with minimum 18 AWG wire Install the IR temperature sensor The Schwank ThermoControl Plus 4 between the radiant area of two must be mounted where it is not heaters at a height of 6 ft (2 m) affected by vibration or shock. -
Page 6: Display And Button Function
3 Display and Button Function Front panel layout: Main switch on / off 1. I/O 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. -
Page 7: Operation
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. -
Page 8: Selection Of A Control Zone
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. -
Page 9: Display And Change Of Occupied/Unoccupied Temperature
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 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... -
Page 10: Display And Modify Time And Date
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). - Page 11 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).
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Page 12: Circuit/Zone Times
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. The controller changes automatically from occupied (day) mode , to unoccupied (night) mode or freeze protection mode- A circuit/zone point of time to switch modes can be described as: - time of day (hour and minute) -
Page 13: How To Clear A Switch Point
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. -
Page 14: Program The Switch Points
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. -
Page 15: Holiday Program
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. -
Page 16: Manual Operation
4.6 Manual operation Use the button to select different operating modes. To change the FIX mode push the 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. -
Page 17: Set Up The Operating Parameters
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”... -
Page 18: Set Up System Operation Parameters
5.2 Set up system operation parameters (suggested settings are circled) DISP To set up the parameters hold the button for approximately 3 seconds. The “PAr” symbol appears briefly. The operation parameters can be selected with the button. Proportional Gain: Two-stage mode only: 0.5...3.0 °C / 1.0...5.5 ºF Suggested Setting: 1.0°C / 1.8°F °F... -
Page 19: Adaptive Heat Recovery Time
Refer to sections 6.4 to 6.7 for Switch off exhaust fans: exhaust fan output use ’AUto’: exhaust fan in use = for two- stage luminous zones ONLY, ’OFF’’: exhaust fan output is switched off for all tube heater zones, and single stage luminous zones (the symbol disappears). -
Page 20: Copy
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). -
Page 21: Installation
6 Installation & Configuration Bracket Lower part Door Upper part Screw Lock 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. -
Page 22: Sensor Connections
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. -
Page 23: Two-Stage Tube Heaters
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. -
Page 24: Luminous Heaters - Jumper P1
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 …... -
Page 25: Luminous Heaters - Jumper P2
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 …... -
Page 26: Luminous Heaters - Jumper P3
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 …... -
Page 27: Luminous Heaters - Jumper P4
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 …... -
Page 28: Luminous Heaters - Jumper P5
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. -
Page 29: Exhaust Fan Output - Two-Stage Luminous Zones
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. -
Page 30: Communication Connection (Cm232, Cm485)
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. -
Page 31: Technical Parameters
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. - Page 32 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.
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Page 33: Wiring Diagrams
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 5.2) Wire each of the low- and high-stage zones as below ... -
Page 34: Two-Stage Tube Heaters: Two-Stage Zones
8.2 Two-Stage Tube Heaters: 1-4 two-stage zones (refer to section 5 and 5.2) See internal burner wiring diagram next page - 34 -... -
Page 35: Two-Stage Tube Heaters: Internal Burner Wiring
8.2.1 Two-Stage Tube Heater Internal Burner Wiring See zone wiring diagram previous page - 35 -... -
Page 36: Luminous Heaters: Single-Stage Zones
8.3 Luminous Heaters: single-stage; 1-8 Zones - 36 -... -
Page 37: Luminous Heaters: Two-Stage Zones
8.4 Luminous Heaters: Two-stage Zones; 1-4 Zones - 37 -... -
Page 38: Wiring Diagrams: Overrides, Humidity Control, Temp. Averaging
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. -
Page 39: Temperature Sensor Characteristics
8.6 Temperature Sensor-Characteristics °F Temperature Sensor-Characteristic 32 14324 34 13539 16000 36 12802 14000 38 12110 12000 40 11460 10000 42 10848 8000 44 10273 6000 46 9732 4000 48 9223 2000 50 8744 52 8293 54 7867 °F 56 7466 58 7088 60 6732 °C...