Danfoss CCR3 Installation guide

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Operating Guide

CCR3 Controller

CCR3 - CONTROLLER

ENGLISH

CCR3 Controller www.danfoss.com Page 4

Multilingual CCR3 instructions are provided on SD card included in CCR3 package or on http://www.danfoss.com

VI.D3.A3.02 | 1

CCR3 Controller

58 mm

158.5mm

Fig.1 CCR3 Controller Abb. 1 CCR3 Regler 1 pav. CCR3 reguliato rius

1. att. Regulat ors CCR3 Rys. 1 Sterow nik CCR3 Рис.1 Контроллер CCR3

CCR3 - CONTROLLER

SD FLASH CARD

Fig. 2 Dimens ions and installatio ns on DIN relay 35 mm Abb. 2 Abmessu ngen und Installat ionen auf 35 mm-DI N-Schiene 2 pav. Matmenys i r montavimas ant DIN re lės 35 mm

2. att. Izmē ri un uzstādīšana uz D IN 35 mm sliedes Rys. 2 Wymi ary i montaż na sz ynie DIN 35 mm Рис.2 Монтажные размеры контроллера на DIN-рейке

Do not in stall or remove SD c ard when connected to the current.

90 mm

Bei eingeschalteter Stromversorgung darf d ie SDSpeicherkarte weder eingesetzt noch entfernt werden.

35 mm

Neįdėkite ir neišimkite SD kortel ės, jei įjungta srovė.

31 mm

35 mm

62 mm

Neievietojiet un neiz ņemiet SD kart i, kad ierī ce ir pievienota strāvas avotam.

Nie nal eży wkładać ani wyjmować karty S D, gdy urządzenie jest podłączone do prądu.

Не устанавливайте и не удаля йте карту SD , если контр оллер CCR3 подкл ючен к сети питания.

Fig. 3 CCR3 Contolle r: scheme with 16 risers Abb. 3 CCR3 Regler : Anlage mit 16 Strängen 3 pav. CCR3 reguliato rius: schema su 16 stovų

3. att. Reg ulators CCR3: shēma ar 16 stāvva diem Rys. 3 Sterow nik CCR3: schemat z 16 pionami Рис.3 Контро ллер CCR3: Сзема с 16 стояками

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CCR3 Controller

Fig. 4 CCR3 Controll er: scheme with 32 rise rs Abb. 4 CCR3 Regler : Anlage mit 32 Strängen 4 pav. CCR3 reguliato rius: schema su 32 stovais

4. att. Reg ulators CCR3: shēma ar 32 stāv vadiem Rys. 4 Sterow nik CCR3: schemat z 32 piona mi Рис.4 Контролл ер CCR3: Схема с 32 стояками

Fig. 5 Wiring Abb. 5 Verdrahtun g 5 pav. Sujungim as

5. att. Vadojums Rys. 5 Podł ączenia elek tryczne Рис.5 Подключение силовых цепей

outlet: ac tuators 1-8

Triac output

Ausgang: Antriebe 1-8

Triac-Ausgang

Išėjimas: pavaros 1–8

TRIAC išė jimas

izeja: izpildmehānismi 1–8

TRIAC izvade

wylot: siłowniki 1–8

Wyjście triakowe

выход: прив оды 1-8

Триак-выход

V2 V3 V4 V5 V6 V7 V8

CCR3

CONTROLLER

V13

V10 V9

outlet: ac tuators 9-16

Triac output

Ausgang: Antriebe 9-16

Triac-Ausgang

Išėjimas: pavaros 9-16

TRIAC išė jimas

izeja: izpildmehānismi 9-16

wylot: siłowniki 9–16

Wyjście triakowe

выход: прив оды 9-16

Триак-выход

V11 V12

TRIAC izvade

V15 V16

V14

temperature sensors

S1-S8

Temperaturfühler

S1-S8

Temperatūros jutikliai

S1–S8

temperatūras sensori

S1–S8

czujniki temperatury

S1–S8

температурные датчики

S1-S8

M S1 S2 S3 S4 S5 S6 S7 S8

M S9 S10 S11 S12 S13 S14 S15 S16

temperature sensors

S9-S16

Temperaturfühler

S9-S16

Temperatūros jutikliai

S9–S16

temperatūras sensori

S9–S16

czujniki temperatury

S9–S16

температурные датчики

S9-S16

temp.

Free

sensor

contacts /

temp. fühler

Temp.

jutiklis

temp.

sensors

czujnik

bezpotencjałowych/

temp.

темп..

датчик

M B1 M B2 M M A

S0 B

NO T1

Input

Potentialfreie

Kontakte /

Eingabe

Nemokama

kontaktai/

įėjimas

Bezmaksas

kontakti /

Ievade

Styków

Wejście

Контакты

без / Ввод

„ModBus“ „do BMS“

0V 0V 24V

ModBus do BMS

ModBus un BMS

ModBus do BMS

шина ModBus

выполнить BMS

ALARM

Supplay voltage 24

Netzspannung

24 VAC

Maitinimo įtampa 24 V

kintamoji srovė

Padeves

spriegums 24 V

maiņstrāva

Napięcie zasilające

24 V AC

Напряжение питания 24 В

пер. тока

RS 485

Fbus

RS 485

Fbus

RS 485 „Fbus“

RS 485

FBus

RS 485

FBus

RS 485

FBus

VAC

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CCR3 Controller

ENGLISH

1. Product description

2. Application

The CCR3 Controller is a controller used to control return temperature in one pipe heating systems with functions such as temperature registration and monitoring riser temperature. The controller is connected to thermo actuators type TWA-Z (NO) and remote temperature sensors PT1000, type ESMC installed on each riser.

CCR 3 controller is part of AB-QTE solution for one-pipe heating systems. It converts one-pipe heating system (usually constant ﬂow system) into eﬃcient variable ﬂow system. This innovative solution dynamically controls the ﬂow in the riser according to the load in risers by return temperature control. There are few basic rules to be followed, even more valid in case of renovation:

• Set AB-QM according to the required heat load of the riser/loop.

• Ensure correct radiator a bypass ﬂow setting (typically around 25-35 %). If the resistance of the radiator is much too high compared to the bypass this may result in underﬂow through radiator if the ﬂow in riser/loop is reduced.

3. Technical data: CCR3 Controller

Temperature sensor (S0, S1-S16)

Temperature range (registration) –20 °C … +120 °C

Measuring accuracy +/- 0,5 K

Inputs: B1 and B2 Free contact (5 V 1 mA)

Number of control valves (risers)

Output signal to actuators (Triac t ype) 24 VAC max. 1 A

Alarm signal output (Triac type) 24 VAC max. 1 A

Relay output 0-24 VAC/DC max. 1A

OC output ( Transistor type) 0-20 VDC NPN Open collec tor max. 200 mA

Type of memor y card (included) SD

Maximum memory card 2 GB (included)

Timer: Real time clock

Ambient temperature 0 … +50 °C ( for CCR3 only. The ambient temperature for actuators

Transport temperature –10 … +60 °C

IP rating IP 20

Power supply 24 VAC

Power consumption 6 VA

Weight 0,9 kg

Installation DIN rail 35 mm

• Optimise ﬂow temperature that is driven by substation control (too high ﬂow temperature can inﬂuence eﬃciency of ﬁrst radiators in the riser/loop and result in oscillation of ﬂow).

• Optimise return temperature that is driven by CCR 3 (too high return temperature can result in lower energy eﬃciency).

• Install temperature sensor in front of AB-QM as close to last radiator in the riser/loop as possible.

Following above rules will ensure optimal control performance of CCR3 as well as energy eﬃciency and reliability of heating systems. For further application insights please contact Danfoss representative.

Pt1000, S0

16 basic, additional 16 with parallel connection ( 32 all together , one temperature sensor is used as common for two risers )

Built-in bat tery

– type ESMC/ESM11, S1-S16 – type ESMC

– powered for 10 years

TWA-Z (NO) should not be above 30 °C)

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CCR3 Controller

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LANGUAGE

4. Installation

For easy access the CCR3 Controller is installed in the technical box on DIN rail 35 mm. Box with DIN rail should be mounted in the wall (sub-station or boiler DIN rail to install same box as CCR3 (not supplied).

5. Switching the control on

Before switching the controller on for the ﬁrst time, disconnect all cables and connect a 24 VAC source to the disconnected power plug. Use a voltmeter to measure the voltage on the power cable plug before it is connected to the controller. If the voltage is correct:

1. Read the instructions before you operate the

2. Disconnect all cables

3. Connect the power to the transformer (not

4. Turn the power to the transformer on

5. Veriﬁed currency – 24 V

6. Connect the cable from the transformer to the

6. Control start menu

room) as close as possible to the heat source.

and box are not included. It is recommended

the standard 24 VAC transformer in the

controller

connected to CCR3 ”one”)

CCR3 Controller input

The transformer power depends on numbers of actuators (number of risers in heating installation). For standard application (16 actuators-16 risers) 30 W transformer is recommended, (for 32 actuators-32 risers) 60 W recommended. Do not install (and remove) SD card when the CCR3 is connected to the current. It must be turned oﬀ (risk of losing data).

The controller should display its name and the software version – CONTROLLER START MENU – display according to point 5.

Before any plugs are connected to the controllers, input and output connectors:

1. Set all parameters on the controller

Make sure that there is no external voltage on the temperature sensor plugs

3. Make sure that the voltage on the relay contacts is not too high (max. 24 VAC)

Start process

After switching the controller detected SD card on and veriﬁed card memory. If the card is placed correctly, the controller will verify the present ﬁles:

• access

• one set

• all set

If the above-mentioned ﬁle is detected, the controller

will ask whether it should be used or aborted. If no ﬁles (new card, used for the ﬁrst time) there will be no request. The next controller will automatically generate a folder with ﬁles:

• folder ACCESS:

allow change of access code to menu (details on request or www.danfoss.com side)

•

folder DATA: ﬁle with record date folder SETTINGS

No. LCD Dis play FUNCTION DESCRIPTION

1 Danfoss

OPCCR -3.20

2 SD Free

.....

3 SD Free

199 6 MB

4 NO

SD CARD!

5 072254

123 456

Welcome Menu Abbreviation: the type of the CCR3 Controller

Diagnosis: available SD card memory

Available memory In MB e.g.: 2 GB

No SD card in CCR3 Only when no card in CCR3

Series number of CCR3 and number of software. Code used for services.

with ﬁles

all set: file with settings. Each time the of control is switched on, setting parameters are archived. function provides verification history of all settings

- arch.set: file with archive of all settings.

Switching the controller on for the 2nd time with the above-mentioned record ﬁle the request procedure for setting change or abortion will start.

Display information during the start process

After switching the CCR3 Controller on, the LCD display automatically presents the start menu. The table below shows the various information and change possibilities during the operation of CCR3 Controller.

This

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7. Control reading menu

When the setup is complete, the reading display will be shown on the screen. Pressing the “+” key turns the subsequent reading display on. The “-” key turns the previous reading display on.

No. LCD Dis play FUNCTION DESCRIPTION

6 Sensor0

…………

7 Valv e1

…….

8 SetT R1

…….

9 Time

………

10 Archiver

AC xx

11 DayToE nd

……..

12 Alert T2

…….

8. Menu Access Code - access to settings

Pressing an arrow “▲” result in exit from the reading displays and enter to the ACCESS CODE menu, described in chapter 8. When exit from the menu the ﬁrst reading display is shown. A list of readings and possible displayed options are shown in the table below.

Current return temperature measure by sensors. Information: S0 – supply temperature, S1-S16 – return temperature measure in risers.

When info display Sensor .... Open ( no sensor ), when : Sensor ..... Closed ( short cut ).

Status of control valves, display from V1-V16 Information: 0 % ON no control signal for ac tuators (valve fully open when NO is used) or 100 % OFF (valves is closed). During the controlling intermediate status is displayed: e.g. 17 %

Information about setting return temperature correspondent to current ﬂow temperature, in C degree. Display for R1-R16, e.g.: 45,0 °C

Current date and time e.g .: 10- 04-27 17:45:10

Information about number of data storage in SD card(ﬁles) e.g.: 38 storage ﬁle, InProces xx = number of stored ﬁles; 1 ﬁle stored per day

Information how many days data can be stored on existing SD card. Please note that this is information valid for current archiving interval. e.g.: 884

Alarm output active or not . Function used for sensor and actuators circuit detection (for example shortcut detection) No Active or Active

To set the parameters, press the up arrow key “▲” from R

eading Menu

and enter the access code (three

digits) to enter the required settings group. The “+/-“ keys change the digit values in the code, the arrow keys “▲/▼”navigate the cursor through the code digits.

No LCD Display FUNCTION DESCRIPTION

13 AcceCode

***

Access codes to the controller’s setting menus. Available menus: – Install Menu (code: 427). Advanced settings – Real Time menu (code 576).Real time clock and date setting

- Control Menu (code 437): exp ert settings for PID control Quadruple pressing up arrow key “▲” without ente ring any code will give access to “SD Card Exchange”.

– SD card can be safely pulled out from CCR3 (process of date recording is interrupted).

The access codes are standard for the individual menus. It is possible to change the access codes by entering new codes through the SD memory card and restarting the controller. Detailed instructions are available on request. The controller’s settings can be entered using the keypad or globally through the SD memory card (controller restart required). Details are available on request.

To enter the required setting group press arrow key “▲” after last code digit. If the code is not correct, the display shows: SD Card Exchange – this means that the SD card can safely be pulled out from CCR3 "One pipe controller" (process of date recording is interrupted). The settings menu is closed automatically after four minutes of inactivity and the display returns to

Reading Menu.

The manufacturer reserves the right to change the controller’s settings and readings in production to improve handling and functionality. An up-to-date list of settings for the given software version is available on Danfoss’ web site. New settings can automatically upgrade CCR3 Controller through the SD memory card (controller restart required).

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CCR3 Controller

ENGLISH

9. INSTALL MENU SETTINGS (Code: 427)

From ACCESS CODE menu enter code: 427 (procedure in chapter 7). The Install Menu is displayed in details in the table below. The arrow keys “▲/▼” move the menu windows, the “+/ - “keys change the

To exit the setting menu, press the up arrow key “▲” after changing the last setting. The setting menu is closed automatically after 4 minutes of inactivity.

values in the window selected by the arrows.

No LCD Display FUNCTION DESCRIPTION

14 INSTALL

15 TRet (35)

.....

16 TRe t (40)

.....

17 TRet (45)

.....

18 TRet (50)

.....

19 TR et (55)

.....

20 TRet (63)

.....

21 TRet (70)

.....

22 TRet (80)

.....

23 TRet (90)

.....

24 Shift1

..0 °C..

25 RiserNr 16Number of risers used in the system: settings from: 1-16

26 V Type

…….

27 VCharact

…….

28 Cor Cal

S0 …. …. °C

29 Rel.Test

……….

Information about menu: Install Recommended for service.

Required return temperature for measure supply temperature: 35 °C Factory setting: 30 °C

Required return temperature for measure supply temperature: 40 °C Factory setting: 34 °C

Required return temperature for measure supply temperature: 45 °C Factory setting: 38 °C

Required return temperature for measure supply temperature: 50 °C Factory setting: 40 °C

Required return temperature for measure supply temperature: 55 °C Factory setting: 42 °C

Required return temperature for measure supply temperature: 63 °C Factory setting: 45 °C

Required return temperature for measure supply temperature: 70 °C Factory setting: 48 °C

Required return temperature for measure supply temperature: 80 °C Factory setting: 54 °C

Required return temperature for measure supply temperature: 90 °C Factory setting: 58 °C

Shift return temperature valid for all setting points. It can be adjusted up and down. The lowest shift setting is to 10 degrees (anti frost setting value). Each riser can be adjusted individually, riser by riser (from 1 to 16) Factory setting: 0 ºC; in range of ±10 °C

If more than 16 risers: choose 16 and connect selected risers parallel using one ac tuator’s output for t wo risers (for two actuators) (max additional 16 risers)

Factory setting: 16

Type of control valves: normal open or normal closed Option to choose: NO or NC

Factor y setting: NO

Type of valves characteristic Option to choose: Linear or Hyperbolic Factory setting: Linear (setting for 24 VAC actuator)

Sensor calibration: S0-S16 in range: ±9,9 °C Do not make calibration when sensor cables are shorter then:

- for cable 0,75 mm

- for cable 1,00 mm Correction factor total length

(two - core cable) in meter 0,5 0,75 1,00 1,5 10 - 0,2 - 0,1 - 0,1 - 0,1 15 - 0,5 - 0,3 - 0,2 - 0 ,1 20 - 0,4 - 0,3 - 0,2 - 0,1 25 - 0,5 - 0,3 - 0,3 - 0,1 30 - 0,6 - 0,4 - 0,3 - 0,2 35 - 0,7 - 0,5 - 0,4 - 0,2 40 - 0,8 - 0,5 - 0,4 - 0,2 45 - 0,9 - 0,6 - 0,5 - 0,2 50 - 1, 0 - 0,7 - 0,5 - 0,3 75 - 1,5 - 1,0 - 0,8 - 0,4 100 - 2,0 - 1,4 - 1, 0 - 0,5 125 - 2,5 - 1,7 - 1, 3 - 0,6 150 - 3,0 - 2,0 - 1, 5 - 0,8

Factory setting: 0 °C

Relay test (Triac output) AUTO – normal working operation V1-V16 – forced signal for valves output V1-V16 Rel C-NO - not used T1 Out – not used T2 Out – forced signal (24 VAC) for alarm T2.

Factory setting: Auto

– 10 meters,

– 15 meters.

cable cross section

(mm

)

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No LCD Display FUNCTION DESCRIPTION

30 AlertRel

... …

31 Archiver

...

32 ArchFreq

...

33 DateForm Form of date display:

34 Reset

…….

35 Ecs?

+ YES

10. REAL TIME CLOCK SETTINGS (code 576)

Alarm output (Triac) StillOn – continuos alarm signal: T2 – 24 VAC Pulse – pulse alarm signal 24 VAC every second

Factory setting: Pulse

Information about data archiving: Never – the feature is switched oﬀ, 1 File – data is stored in one ﬁle on the SD card, 2 Files – data is stored alternatively in two ﬁles to improve write reliability. This function decreases term of date storage (twice).

Factory setting: 1 File

Data archiving interval. The time can be set to any value between 10 seconds and 4 hours. The data from each day saved in diﬀerent ﬁles (with data name).

Factory setting: 1 min

YY-MM- DD – year, month, day YY-DD-MM – year, day, month DD-MM-YY – day, month, year MM-DD - YY – month, day, year

Factory setting: YY-MM-DD

Reset to factory settings Yes - return to factory settings No – keep adjust settings Note: To complete reset proced ure turn CCR3 oﬀ and back on.

Exit win dows from Install Men u. Enter “+” to closed set ting or basic menu will close automatically af ter 4 minutes

From ACCESS CODE menu enter code: 576 (procedure in chapter 7). The Real Time menu is displayed as detailed in the table below. The arrow keys “▲/▼”move the menu windows, the “+/-“keys change the values in the window selected by the arrows.

No LCD Display IN STALL MENU - FUNCTION DESCRI PTION

36 Real Time

37 RealTime

12:00:00

38 RealTime

12:00:00

39 RealTime

12:00:00

40 Year Sets the year for the current date

41 Month Sets the month for the current date

42 Day Sets the da y for the current date

43 Ecs?

+ YES

Information about menu: real Time

Sets the real time clock “hour”

Sets the real time clock “minute”

Sets the real time clock “second”

Exit win dows from Install Men u. Enter “+” to closed set ting or basic menu will close automatically af ter 4 minutes

To exit the setting menu, press the up arrow key after changing the last setting. The setting menu is closed automatically after 4 minutes of inactivity.

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CCR3 Controller

ENGLISH

11. CONTROL MENU (code 437)

From ACCESS CODE menu enter code: 437 (procedure in chapter 7). The Control menu is displayed as detailed in the table below. The arrow keys “▲/▼”move the menu windows, the “+/-“keys change the values in the window selected by the arrows. To exit the setting menu, press the up arrow key after changing the last setting. The setting menu is closed automatically after 4 minutes of inactivity.

No LCD Display FUNCTION DESCRIPTION

44 Prop. Fac ……Control gain of control signal (depend on actuators typ e). The higher gain control the bigger valves reac tion

45 Int.Time

46 Diﬀ.Ti me

47 PWM Per

48 PWM Min

49 PWM Max

50 BMSAdres

51 BMS TYPE

52 Ecs?

…….

…..

…….

+ YES

(no stable regulation). The lower gain control weak reaction for temperature change (stable regulation). Factory setting: 50 (for dedicated T WA-Z (NO) actuators); setting range 1-100

Integration time of the control signal (depend of actuators type). The shorter time, quicker temperature changes (no stable regulation). The longer time slower reaction for temperature change (stable regulation). Factory setting: 6 sec (for dedicated TWA-Z (NO) actuators); set ting range 1-100

Diﬀerential time of control signal. The longer the value, faster control in reaction to the control value change - approaching to the set value but not reaching it yet. Too high value resu lts in unstable control.

Factory setting: 15

Time period of pulse width madulation (PWM}.

Factory setting: 10s

At »close« signal to actuator, PWM describes minimum % of open period to the actuator. Lower the value, longer the reac tion time of the actuator. Too high value can result in not closed valve.

Factory setting: 10 %

At »open« signal to actuator, PWM describes maximum % of open period to the actuator. Higher the value, longer the reac tion time of the actuator. Too low value can resu lt in not opened valve.

Factory setting: 90 %

CCR3 address in BMS system

Factory setting: 1

Type of date transmission: ModBus 96 (9.600) Mod Bus 19 (19.000) ModBus 38 (38.400) FBus

Factory setting: Mod Bus 96

Exit win dows from Install Men u. Enter “+” to closed set ting or basic menu will close automatically af ter 4 minutes

12. USING THE DATA STORAGE CARD

The SD card may never be installed or removed from the CCR3 Controller when data is being written to it, this may lead to:

– data loss – SD card damage – CCR3 Controller damage.

INSTALLING THE SD CARD Disconnect the controller from the power supply for at least ﬁve seconds before inserting the SD card. The SD card may only be installed after this pause. REMOVING THE SD CARD

From ACCESS CODE menu quadruple press up arrow key “▲” without entering any code it will give access to “SD Card Exchange”. SD card can be pulled out safely from CCR3 Controller (process of date recording is interrupted). Power failures occur as data written to the SD card may also corrupt the archive or even damage ﬁles stored on the card. To reduce this risk, it is recommended to use a buﬀered power supply for a CCR3 Controller used with the data archiving function and to set the “Archive” setting to “2 Files.” The archive ﬁles will be doubled, but the storage space will drop by half.

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CCR3 Controller

Danf already on order pro All trademarks in this material are property of the respec

ENGLISH

13. CCR3 ModBus PROTOCOL

Data type: Coil [bool] Coil No. Description

MB_CoilOut [2 … 9] - open valves (0 … 7) MB_CoilOut [10 … 17] - risers with open valves (riser: 8 … 15)

Data type: Register [integer]

Baud rate:

MB_RegisterOut [0 … 8] - temperature sensors S0 … S8 (8000 <=> 80 °C) MB_RegisterOut [9 … 16] - temperature sensors S9 … S16 (8000 <=> 80 °C) MB_RegisterOut [17 … 24] - temperature setting for risers 1 … 8 MB_RegisterOut [25 … 32] - temperature setting for risers 9 … 16 MB_RegisterOut [36+0 … 7] - control signal (opening) in % for valve in risers: 1 … 8 MB_RegisterOut [44+0 … 7] - control signal (opening) % for valve in riser: 9 … 16

data bits stop bits parity

9.600 8+1 N

19.200 8+1 N

38.400 8+1 N

oss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products

vided that such alterations can be made without subsequential changes being necessary eady agreed.

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Danfoss CCR3 Installation guide

Specifications and Main Features

Frequently Asked Questions

User Manual