Honeywell MCR 200 SERVICE INSTRUCTIONS

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MCR 200 - SERVICE INSTRUCTIONS

CONTENTS

HEATING CONTROL

HEAT CONSUMERS........................................................................................................................................................... 3

HEATING CIRCUIT CONTROL........................................................................................................................................... 5

Time program ........................................................................................................... 3

Outside temperature controlled cut-off ..................................................................... 3

Room temperature controlled cut-off........................................................................ 4

Optimization.............................................................................................................. 4

Outside temperature controlled flow temperature control......................................... 5

Heating characteristic .......................................................................................... 5

Automatic adaptation of the heating characteristic .............................................. 7

Room temperature control......................................................................................13

Limitation of the heating up speed.....................................................................14

Maximum limitation of the room temperature..................................................... 14

Minimum limitation of the room temperature...................................................... 14

Overtime compensation with TF 26 ................................................................... 14

Overtime compensation via room sensor input.................................................. 15

Statistics................................................................................................................. 15

Determining the number of degree days............................................................ 15

Counter for operating hours ............................................................................... 15

External temperature demand ................................................................................ 16

Overlapping mixing circuit functions, sensors, device connections ................... 17

Passing on the outside temperature sensor value through the C bus ............... 17

Signal: Hot water priority switching and system overheating,

corrosion protection .............................................................................. 17

Janitor function, heating limits ................................................................................ 18

Flow temperature control........................................................................................ 19

Setpoint ramp (flow temperature)....................................................................... 19

Limitations, special functions.................................................................................. 20

Limitation of the heating flow temperature - minimum and maximum................ 20

Pump logic ......................................................................................................... 20

Boiler excess...................................................................................................... 20

Screed drying heating function according to DIN 4725/T4................................. 20

Protective functions................................................................................................ 21

Frost protection.................................................................................................. 21

Pump actuation.................................................................................................. 21

Mixing valve and pump forced operation ........................................................... 21

Domestic hot water control ..................................................................................... 22

Standard control................................................................................................. 22

Domestic hot water priority settings ................................................................... 22

Domestic hot water charging pump.................................................................... 22

Pump forced operation....................................................................................... 23

BOILER / BOILER SEQUENCE CONTROL ..................................................................................................................... 24

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Setpoint setting....................................................................................................... 24

1. Flow temperature demand from other MCR 200 controllers

through the LC or C bus................................................................................. 24

2. Flow temperature demand through analog voltage signal

(only for MCR 200-71).................................................................................... 24

3. Flow temperature demand by floating normally open contact

(only for MCR 200-71).................................................................................... 25

4. Minimum demand (only MCR 200-71) ........................................................... 27

5. Flow demand by EXCEL 5000 system.......................................................... 27

6. Flow demand by an internal heating circuit program HKZ ............................ 27

Setpoint formation .................................................................................................. 28

Excess................................................................................................................ 28

Limitations.......................................................................................................... 28

Minimum limitation / Boiler corrosion protection ................................................ 28

Maximum limitation / Boiler overheating (for single boiler)................................. 28

Boiler overheating for boiler sequence (MCR 200-71 only ................................ 28

Return temperature limitation control ..................................................................... 29

Minimum switch-on time of the burner (Code 706 / 806) ................................... 29

Minimum switch-off time of the burner (Code 707 / 807) ................................... 29

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MCR 200 - SERVICE INSTRUCTIONS

Total shutdown of the boiler (Code 703 / 802) ................................................... 29

Boiler sequence exchange (only MCR 200-71).................................................. 29

Leading boiler .................................................................................................... 30

Parallel / sequential boiler sequence ................................................................. 30

Outside temperature blockage of the 2nd boiler................................................ 30

Strategy function (only MCR 200-71) ..................................................................... 31

Heating up time (Code 921)............................................................................... 31

Gradient waiting time (Code 708 / 808) ............................................................. 31

Overheating of strategy temperature ................................................................. 31

Control range strategy (Code 914)..................................................................... 32

PID method (only MCR 200-71) ............................................................................. 34

Starting circuit for modulating burner (MCR 200-71/22)......................................... 34

Boiler control for single-boiler systems:.................................................................. 35

Boiler sensor / Sensor detection:....................................................................... 35

Outside sensor:.................................................................................................. 35

Pump run-on time (only MCR 200-71) ............................................................... 35

Using a heating controller as boiler return temperature controller ..................... 35

Alarms / Faults........................................................................................................ 36

Burner fault ........................................................................................................ 36

Boiler pump fault ................................................................................................ 36

Status displays in the.............................................................................................. 36

operating sequence................................................................................................ 36

WE (total heat generator / strategy) only for MCR 200-71................................. 36

WE1 / WE2 ........................................................................................................ 36

DISTRICT HEATING CONTROLLER...................................................................................................... .......................... 37

Return temperature limitation ................................................................................. 37

Return interval flushing........................................................................................... 38

100 % function........................................................................................................ 38

Control parameters for district heating valve.......................................................... 39

Unmixed domestic hot water storage tank control.................................................. 39

Manuelle Warmwasserladung............................................................................ 39

Switch on conditions for the secondary loading pump....................................... 39

Sollwertbegrenzung Warmwasserladung........................................................... 39

Protection against calcification........................................................................... 40

Boiler or flow temperature requirement of the hot water control ....................... 40

Minimum valve lift for incidental amount suppression........................................ 40

Heat meter connection ........................................................................................... 41

Electrical connection.......................................................................................... 41

Computing the heat power and the volume flow.................................................... 42

AIR CONDITION CONTROL........................................................................................................................................................ 43

HARDWARE ................................................................................................................................................................................ 44

COMMUNICATION

CONTROLLER TO CONTROLLER SIGNALS .................................................................................................................. 45

MCR 200 Fax  Controller...................................................................................... 46

MCR 200 Voice  Controller................................................................................... 47

MCR 200  EXCEL................................................................................................. 47

C-Bus................................................................................................................. 47

Outside temperature indications............................................................................. 48

INSTALLATION CHECKLIST ...................................................................................................................................................... 49

CODE TABLES............................................................................................................................................................................ 50

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MCR 200 - SERVICE INSTRUCTIONS

HEATING CONTROL

Heat consumers

Time program

Different room temperatures can be selected in the time program of the MCR 200. According to setting, one refers to heating operation (normal operation), tempera- ture reduction (reduced operation) or cut-off. MCR 200 has time programs for every mixing circuit for the switching points of which an individual setpoint can be set.

Example:

gymnastics hour in a multipurpose building (heating operation). In school sports events on the other hand, a setpoint of 18 °C can be set. The heating is then oper- ated reduced.

The corresponding time program looks like the following:

09:00 Setpoint 21 °C 10:00 Setpoint 18 °C

The heating can also be switched off with the time program for optimizing the en- ergy consumption. The heating circuit pump is switched off and the mixing valve closed for this purpose. If the heating is switched off, only frost protection functions which prevent the heating system freezing are active.

So that the heating is switched off, the optimization for heating up must be switched on in the time program.

Example:

09:00 Setpoint 21 °C Opt: yes

10:00 Setpoint 18 °C Opt: no

12:00 Setpoint 15 °C Opt: yes

According to the temperature sensors present, the controller switches off outside temperature controlled or room temperature controlled.

A room temperature of 21 °C should be guaranteed in the senior citizens

after the school sports, the heating is switched off completely.

optimized heating up, so that 21°C are reached by 9.00 am only reducing the room setpoint to 18 °C early cut-off

Outside temperature controlled cut-off

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So that the residual heat of the building is utilized optimally, the heating switches on or off already before the switching points. Naturally the time period for optimization with room temperature sensor is calculated depending upon the momentary tem- peratures. In the case of optimization without room temperature sensor, the time period is calculated only depending upon the outside temperature.

The outside temperature controlled cut-off function is activated if no room tempera- ture sensor is present and "

If the outside temperature drops below the frost protection limit of 2 °C, for in- stance, the heating circuit pump is switched on. The flow temperature is controlled so that the heating system does not freeze.

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Opt: yes

" is selected.

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MCR 200 - SERVICE INSTRUCTIONS

Room temperature controlled cut-off

Optimization

The room temperature controlled cut-off function is activated automatically if a room temperature sensor is connected to the corresponding heating circuit and "

Opt:yes"

If the time program switches the heating off, the control is switched over to room temperature control. In this way the heating is switched off in the night until the temperature has dropped to the corresponding setpoint. To avoid the room cooling down too much, the pump is switched on and the mixing valve opened. If the outside temperature drops below the frost protection limit of 0 °C, for in- stance, the heating circuit pump is switched on continuously.

The switching times of the time program can be shifted corresponding to the tem- peratures to opimize the energy consumption. Since there can be heating circuits without room temperature sensors, a distinction is made between optimization with room temperature sensor and optimization without room temperature sensor.

CODE - 133 - 233 - 333 - 433 Room temperature sensor for optimization

=1 =0

is selected. (The

→ →

Optimization with room temperature sensor Optimization without room temperature sensor

Code No. 133, 233, 333, 433

must also stand at 1).

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MCR 200 - SERVICE INSTRUCTIONS

Heating circuit control

Outside temperature controlled flow temperature control

The heating circuits serve for temperature control with a mixing valve. The following controls can be implemented by setting code values:

CODE 117 - 217 - 317 - 417 Type of control

=2 =1 =3

The MCR 200 control units are set in the factory as outside temperature controlled flow temperature control, i.e. a certain flow temperature is assigned to each outside temperature by the heating characteristic. If a room temperature sensor is con- nected in addition, then the controller can automatically set (adapt) its heating characteristic. The room temperature can be set for different requirements with a time program. The night cut-off and optimizing the switching times enables energy to be utilized optimally.

→ → →

→ →

Outside temperature controlled flow temperature control Room temperature control Constant flow temperature control, internal 0...10 V signal External requirement with switching contact, outside temperature controlled External requirement with switching contact, independent of outside temperature

Heating characteristic

In addition, the maximum room temperature can be limited by connecting a room temperature sensor. This adjustable limiting function ensures that heating energy is not consumed unnecessarily.

The outside temperature controlled flow temperature controller requires a heating characteristic according to which it can provide the correct flow temperature for the mixing circuit concerned corresponding to the outside temperature. The heating characteristic shows the relationship between the outside temperature and the associated flow temperature.

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Fig. Heating characteristic Basic setting for heating circuit 1 Slope 1.6, curvature 1.33

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MCR 200 - SERVICE INSTRUCTIONS

Basic setting

Setting recommendation

After start-up, the controller works initially with a basic setting made in the factory.

The slope of this characteristics is 1.6. The curvature of this characteristic is 1.33 and applies for DIN radiators.

The selected room temperature of this heating characteristic is 20 °C

Both the slope and the curvature can be changed in the settings menu with the in- dex key.

The room temperature can be changed in the time program or through the external remote control.

IMPORTANT NOTE:

The basic factory setting must be changed for a part of the system which is designed as floor heating. Otherwise damage due to too high flow temperatures could arise at low outside temperatures. We there- fore basically recommend a limiting thermostat which switches off the mixing valve at too high flow temperatures.

Fig. Heating characteristic Curvature for floor heating approx. 1.1 DIN radiators or plate heaters approx. 1.3 Convectors approx. 1.5

Setting recommendation for floor heating:

•

Slope of the heating characteristic: 0.8

•

Curvature of the heating characteristic: 1.1

•

Maximum limitation of the flow temperature to design value, e.g. 50 °C. This maximum limitation does not replace any safety measures such as the safety temperature limiter required for floor heating systems

(CODE No. 102, 202, 302 and 402)

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MCR 200 - SERVICE INSTRUCTIONS

Automatic adaptation of the heating characteristic

The basic setting does not have to be changed for all other types of system in which higher flow temperatures are permitted. The controller corrects the heating characteristic by the adaptation automatically.

The curvature depends exclusively upon the type of heating system or upon the type of the radiators. The larger the numerical value, the more is the heating char- acteristic curved.

CODE 102 - 202 - 302 - 402 Maximum limitation [°C]

The ability of the controller to adapt the default heating characteristic (heating curve) step by step automatically to the building heating characteristic is called ad- aptation. The mean values of the room temperature, of the outside and flow tem- perature are the working variables for the adaptation.

Adaptation with room temperature sensor

If a room temperature sensor is connected, then the adaptation for the control loop concerned is automatic. The temperature is measured during the entire daily opera- tion.

The correction of the heating characteristic by adaptation is not made until the 3rd day. If the basic setting (1.6) is too high, it can be that too high flow temperatures occur in the first days. If the adaptation has already been running over a longer pe- riod, a well adapted heating characteristic has become established.

No thermostatic valve may be effective in the room (test room) in which the room sensor is installed. The radiator in the test room must always be fully opened, oth- erwise the automatic adaptation cannot work or leads to faulty interpretations. Open fire places, tile stoves and too frequent airing in the initial phase after starting the application can lead to faulty interpretations.

Prerequisites for each mixing circuit are:

•

A room sensor must be connected.

•

The room temperature setpoint must be higher than 18 °C and the heating circuit pump running time must be at least 6 hours per day.

•

The outside temperature averaged during the heating circuit pump running time must be below 15 °C.

•

The adaptation must be allowed

(CODE No. 131, 231, 331, 431)

If these conditions are fulfilled, then automatic adaptation takes place.

Adaptation must have taken place at least three times before the basic setting of the heating characteristic can be changed.

The controller corrects the heating characteristic around midnight. In this case the corrections for each following adaptation day are always weaker.

Note

The curvature can be changed only manually through the operating unit and is preallocated with 1.33 for all heating circuits (DIN radiators).

The curvature depends exclusively upon the type of the heating system or upon the type of the radiators. The larger the numerical value, the more is the heating char- acteristic curved.

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CODE 131 - 231 - 331 - 431 Allow / prevent adaptation

=0 =1 =2

→ → →

Adaptation not allowed Adaptation allowed New start of the adaptation

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MCR 200 - SERVICE INSTRUCTIONS

Optimization without room sensor (floor heating, ...)

(Code 133 = 0)

Heating up

The controller works in the heating up process with a fixed adjustable room tem- perature excess (CODE No. 136, 236, 336, 436) and varies the heating up time with the outside temperature. The heating time at 0 °C outside temperature (Fig. on the left) can be set in the Code Table (CODE No. 137, 237, 337, 437).

CODE 136 - 236 - 336 - 436 Room temperature excess [°C]

CODE 137 - 237 - 337 - 437 Heating up time at 0 °C [min]

The flow temperature for heating up is established according to the heating charac- teristic plus the set room temperature excess. The settings of the time constants and dead times are not relevant for this heating up optimization. If the target time is reached (as in the example diagram 8.00 am), then the controller switches back to normal control.

This type of optimization is recommended for floor heating systems, for instance. Large dead times, as are customary in floor heating systems, have no influence on the switch-on time in this method.

Cut-off

On cut-off, the outside temperature influences the cut-off time. Thus all relation- ships are determined by the diagram without it being possible to take account of the room temperature. The maximum early cut-off is 2 hours. The switching point must always be set at the latest possible cut-off.

The limiting value of the outside temperature, t

can be used for the early cut-off

a min

in the Code Table (CODE No. 138, 238, 338, 438).

This means that the controller cuts off the heating earlier between this limiting value and the current room setpoint.

CODE 138 - 238 - 338 - 438 Minimum outside temperature for early cut-off [°C]

If the outside temperature is below the set limiting value, there is no early cut-off.

The heating is switched off during the set back period (pump off, mixing valve closed). A minimum limitation which may be set (CODE No. 101, 201, 301, 401) has higher priority on the other hand and remains valid during the cut-off.

The controller switches the pumps on and the control circuit works with the current night setpoint from the time program (supporting mode) only if the temperature drops below the frost protection limit (CODE No. 109, 209, 309, 409).

CODE 109 - 209 - 309 - 409 Frost protection limit [°C]

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MCR 200 - SERVICE INSTRUCTIONS

Optimization with room sensor

(Code 133 = 1)

It is possible to record the residual heat in a building only if a room sensor is instal- led. Thus the controller can determine the heating up time with the additional informa- tion of dead time and time constant and the values of outside temperature, maxi- mum flow temperature and room temperature. There are two possibilities of heating up the system optimally in heating up optimization with room sensor.

Temperature-variable heating up

The heating up time is constant in this case (CODE No. 134, 234, 334, 434). The flow temperature is calculated depending upon the required energy.

CODE 134 - 234 - 334 - 434 Heating up time [min]

Time-variable heating up

If the maximum flow temperature is required for heating up, then with growing heat demand the controller can only shift the heating up time towards earlier times. This transition is influenced by a setting in the Code Table (CODE No. 134, 234, 334, 434 and 135, 235, 335, 435). Here the minimum heating up time and the maximum flow temperature available are determined for heating up. The heating up process starts at the calculated time with the maximum flow temperature for heating up (CODE No. 135, 235, 335, 435).

CODE 134 - 234 - 334 - 434 Heating up time [min]

CODE 135 - 235 - 335 - 435 max. flow temperature for heating up [°C]

The heating system is switched off before heating up (pump off, mixing valve closed). A minimum limitation which may be set (CODE No. 101, 201, 301, 401) has on the other hand higher priority and remains valid during the cut-off. If the room temperature drops below the set night setpoint during the temperature reduc- tion time, then the controller switches automatically over to room temperature con- trol.

If the room temperature reaches the setpoint before the target time, then the sys- tem switches over to room control.

If the target time is reached, the controller works basically for a further 30 minutes as room temperature controller. It then switches back to outside temperature con- trol.

CODE 101 - 201 - 301 - 401 Minimum limitation [°C]

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MCR 200 - SERVICE INSTRUCTIONS

Cut-off with room sensor

In the cut-off with room sensor, the current room temperature is included in the calculation of the early cut-off.

•

If the room temperature tRis equal to the setpoint tRS, then the early cut-off

applies

•

If the room temperature tRis greater than the setpoint tRS(solar radiation, per-

sonal heat, then the set characteristic becomes steeper, i.e. the heating

switches off earlier (max. 2 hours).

as in the case without room sensor.

Identification of time constant and dead time

NOTE:

In the code Table, the limiting value of the outer temperature t early cut-off (CODE No. 138, 238, 338, 438). This means that at this limiting value, the controller cuts off the heating earlier. If the outside temperature is below the set limiting value, then there is no early cut- off.

CODE 138 - 238 - 338 - 438 Minimum outside temperature for early cut-off [°C]

The program identifies the necessary time constants and dead times for heating up optimization with room sensor.

Two parameter set are identified:

•

Dead time 1 (CODE No. 140, 240, 340, 440) and time constant 1

(CODE No. 141, 241, 341, 441) of the room model for short temperature reduc-

tions

(shorter than 24 hours).

CODE 140 - 240 - 340 - 440 Dead time for short temperature reduction [min]

If the room temperature t characteristic becomes flatter. The heating remains switched on lon- ger, as a maximum up to the programmed cut-off point.

is smaller than the setpoint tRS, then the set

can be set via the

a min

CODE 141 - 241 - 341 - 441 Time constant for short temperature reduction [min]

•

Dead time 2 (CODE No. 142, 242, 342, 442) and time constant 2 (CODE No. 143, 243, 343, 443) for temperature reductions lasting longer than 24 hours.

CODE 142 - 242 - 342 - 442 Dead time for long temperature reduction [min]

CODE 143 - 243 - 343 - 443 Time constant for long temperature reduction [min]

Dead times and time constants are determined in the heating up process. Proceed- ing from the basic settings, the parameters are corrected automatically in each heating up process. After the end of the dead time, the room temperature is measured every 15 min- utes and the new time constant is estimated. The identification is completed when the room temperature controller starts. Before the newly determined parameter set is made use of, there is a plausibility check. The value present in the memory is then replaced by a mean value formed from the old and new value.

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MCR 200 - SERVICE INSTRUCTIONS

Solar compensation

Depending upon the cut-off time of the heating system, the controller uses in each case the first or second parameter set for calculating the heating up time.

The parameters can be identified only if the following conditions are fulfilled:

•

The identification is not disabled (CODE No. 132, 232, 332, 432).

CODE 132 - 232 - 332 - 432 Identification

=0 =1 =2

•

The basic setting values for the two parameter sets (dead time, time constant) rep- resent the starting point of the identification.

The solar radiation influences the value of the damped outside temperature through the SAF20. A radiation power of 500 W/m2has around the same effects as an out- side temperature which is 20 K warmer. The influence of the compensation can be adjusted between 0 and -1 for all heating circuits (CODE No. 116, 216, 316, 416).

→→ →→ →→

A room sensor is connected. The temperature difference between room temperature on switching on the

heating and room temperature setpoint at the target time is greater than 2 K. The outside temperature is less than 10 °C.

disabled enabled New start

CODE 116 - 216 - 316 - 416 Solar compensation

=0 =-1

→ →

off on

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MCR 200 - SERVICE INSTRUCTIONS

Wind compensation

The wind compensation acts exactly in the opposite way as the solar compensa- tion. At maximum wind loading (15 m/sec.), the value of the outside temperature is reduced by max. 20 K. The influence of the wind compensation can be set between 0 and +1 for all three heating circuits (CODE No. 116, 216, 316, 416).

CODE 116 - 216 - 316 - 416 Wind compensation

=0 =+1

→ →

off on

Dynamic outside temperature adaptation

To take account of residual heat in the building, the outside temperature control does not work with the current outside temperature, but with a delayed outside temperature. The effect of this is that the delayed outside temperature passes on fast outside temperature changes later and also weaker to the controller, just as in the case of the wind influence.

The building parameter T (CODE No. 112, 212, 312, 412) is a direct measure for the delay.

CODE 113 - 213 - 313 - 413 Building parameter T [h]

Typical values: very light construction approx. 0.5 h light construction approx. 2 h medium heavy construction approx. 5 h heavy construction approx. 10 h

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MCR 200 - SERVICE INSTRUCTIONS

Room temperature control

If wanted, the controller can also work as room temperature controller. Set the CODE No. 117, 217, 317, 417 to "1" for this purpose.

In room temperature control, the controller decides by reference to the actual room temperature and the room temperature set point the flow temperature which the mixing valve must set. If room temperature control is wanted, no thermostatic valve may be attached to the radiator in the room in which the room sensor is installed. All radiator valves must be fully opened.

The room temperature controller is designed as cascade controller, whereby the main controller is the room temperature controller and the auxiliary controller is the flow temperature controller.

The sensitivity of the room temperature controller is set with the proportional band. The proportional band changes the flow temperature setpoint immediately if the room temperature changes.

A change of the room temperature by 1 K results (at P band X

= 5 K; CODE No.

122, 222, 322, 422) in a change of the flow setpoint by 20 K.

At Xp= 2 K, the flow setpoint changes by 50 K.

It applies that: 1 / XPx100K=∆t

flow

The working point of the room temperature controller is determined by the heating characteristic (heating curve).

An outside temperature sensor is also required for the room temperature control.

The integral action time (CODE No. 123, 223, 323, 423) states the time after which, with unchanging system deviation, the controller increases the flow setpoint by the same amount as it reaches due to the P component. The control circuit works as pure P controller with integral action times < 15 s.

In most cases, the P controller is sufficient for the room temperature control, since the working point is determined by the heating characteristic and thus a low P de- viation can be expected.

So that not too high setpoint temperature requirements are placed on the boiler during the morning heating up, the P controller is set as basic setting for the room control.

A response threshold (CODE No. 124, 224, 324, 424) prevents continuous inter- vention for small changes.

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CODE 122 - 222 - 322 - 422 Proportional band of the room temperature control [K/K]

CODE 123 - 223 - 323 - 423 Integral action time [sec]

CODE 124 - 224 - 324 - 424 Response threshold [K]

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MCR 200 - SERVICE INSTRUCTIONS

Limitation of the heating up speed

Maximum limitation of the room temperature

The user can reduce the heating up speed for special applications. By setting a room temperature setpoint ramp (CODE No. 106, 206, 306,406) it is possible to let the room setpoint rise slowly. The cooling down speed is limited correspondingly. The room equipment and building are conserved by limiting the heating up speed (application e.g. in church buildings, museums etc.). The switching point is always the starting point of the ramp.

CODE 106 - 206 - 306 - 406 Room temperature setpoint ramp [K/h]

This function requires a room sensor!

With connected room sensor and if an adjustable room temperature limitation is exceeded, the flow temperature setpoint is lowered.

Example:

Room temperature setpoint 20 °C, maximum limitation of the room temperature to 22 °C. It results from this that starting from a room temperature of 22 °C, the flow temperature of the heating circuit constantly starts to decrease. The maximum permissible room limitation setpoint must be set under the CODE No. 105, 205, 305, 405. If the room temperature (actual value) exceeds the room limitation set- point, then the heating flow temperature setpoint is decreased via the shift factor (CODE No. 122, 222, 322, 422) and the momentary deviation (actual value of the room temperature - room limitation setpoint).

Minimum limitation of the room temperature

Overtime compensation with TF 26

CODE 105 - 205 - 305 - 405 Maximum limitation of the room temperature [°C]

CODE 122 - 222 - 322 - 422 Proportional band of the room temperature control [K/K]

If the flow temperature does not reach the room setpoint with connected room sen- sor and if this is below the set room temperature limit, the flow temperature setpoint is set to 0 °C.

CODE 104 - 204 - 304 - 404 Minimum limitation of the room temperature [°C]

The set overtime setpoint (CODE No. 107, 207, 307, 407) is active if the TF 26 be- longing to the mixing circuit stands at the "Sun" symbol. "TW day" then appears on the operating unit, since the timer no longer has any influence. The night setpoint (CODE No. 108, 208, 308, 408) is used if the TF 26 stands at "NIGHT".

Note:

The maximum permissible room temperature always has priority, i.e. overtime setpoints which are larger than the max. permissible room temperature (CODE No. 105, 205, 305, 405) cannot be maintained. The minimum limitation of the room temperature has the same functi- on. The minimum room temperature is set in CODE 104, 204, 304, 404.

CODE 107 - 207 - 307 - 407

→

Overtime setpoint for TW intervention [°C]

CODE 108 - 208 - 308 - 408 CODE 104 - 204 - 304 - 404 CODE 105 - 205 - 305 - 405

→ → →

Night setpoint for TW intervention Minimum room temperature Maximum room temperature

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MCR 200 - SERVICE INSTRUCTIONS

Overtime compensation via room sensor input

Statistics

Determining the number of degree days

In order to start the overtime function, the room sensor input of the control circuit has to be short circuited for at least 10 seconds. This will start a timer, starts coun- ting back to zero from the time set under

CODE 129 - 229 - 329 - 429 time for overtime function

During this period of time the overtime setpoint under Code 107 - 207 - 307 - 407 is activated.

The number of degree days is required for determining the energy consumption of an appliance for a heating period. The MCR200 controllers can determine the real, system-specific number of degree days. The number of degree days is the product of the heating days of a heating period and the temperature difference between the fixed room setpoint of 18 °C and the mean outside temperature (the base tempera- ture is adjustable, Code 1650).

The calculations required for this are performed by the controller. The correspond- ing information can be called up in the text field of the operating unit. For this pur- pose the computer measures the outside temperature every five minutes and aver- ages these measurements at the end of the day.

Counter for operating hours

These measurements are made in the time window from September 1 to May 31, provided the outside temperature is below +15 °C (time window according to VDI 2067 BL 1).

In code 1650 the basic outdoor temperature for the degree day calculation can be set:

CODE 1650 degree day calculation: basic temperature [°C]

One counter each is available in the MCR200 for recording the operating hours of the individual control circuits. The counter registers all times in which the pumps or burners are in operation.

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MCR 200 - SERVICE INSTRUCTIONS

External temperature demand

The heating circuit control system also offers the possibility of reacting to external setpoint demand. This external setpoint demand can be triggered by different func- tions:

1. by a temperature selector

2. by a 0...10 V signal

3. by a switching contact (e.g. of a ventilation device)

The settings for the relevant function must be made in Code 117.

External room setpoint

(Code 117, 217, 317, 417=1or2) The room setpoint setting of the time program can be overwritten by a temperature selector (TF 26). The TF 26 has a selector switch with the following functions: auto automatic operation according to time program Day constant day setpoint (overtime) Night constant night setpoint The setpoints for "Day" and "Night" can be set in the Code Table. The setpoint of the time program and the overtime setpoint can be changed in 1 °C steps with the setting knob of the TF 26. The TF 26 can be used only for room controlled and outside temperature controlled control.

External temperature demand by 0...10V signal

(Code 117, 217, 317, 417 = 3)

The MCR 200 can be used as pre-control for arbitrary heat consumers. For this purpose a flow setpoint is calculated from a 0...10 V signal (117, 217, 317, 417 = 3) or queried by a contact (117, 217, 317, 417 = 4).

It applies for this that the flow setpoint varies between min. and max. limitation ac- cording to the level of the input signal. There is a switch-on threshold of 0.3V. The switching program is not in operation here.

On connection of the 0...10 V signal, the voltage signal of 0.3 to 10 V is converted to minimum flow temperature (101, 201, 301, 401) up to maximum flow tempera- ture (102, 202, 302, 402) (see adjacent Fig.). The heating circuit pump always runs if the flow setpoint is > 20°C. The janitor function is in operation.

External switching contact mode 1

(Code 117, 217, 317, 417 = 4) On connection of a contact, the setpoint is calculated by a heating characteristic. With a closed contact, the heating characteristic is calculated according to 107, 207, 307, 407 according to the room setpoint. The temperature limitations 101, 201, 301, 401 and 102, 202, 302, 402 always apply.

The external switching contact has the following meaning:

Closed contact The controller works without switching program with the

setpoint from Code No. 107, 207, 307, 407 as outside temperature controlled controller

Open contact The controller works without switching program with the

setpoint from Code 108 , 208, 308, 408 as outside temperature controlled controller.

External switching contact mode 2

(Code 117, 217, 317, 417 = 5) The external switching contact has the following meaning:

Closed contact The controller works without switching program

Open contact The controller works without switching program

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with the setpoint from Code No. 102

with the setpoint from Code 101

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The heating circuit pump always runs if the flow setpoint is > 20°C. The janitor function is in operation.

Overlapping mixing circuit functions, sensors, device connections

Passing on the outside temperature sensor value through the C bus

CODE 101 - 201 - 301 - 401 CODE 102 - 202 - 302 - 402 CODE 107 - 207 - 307 - 407 CODE 108 - 208 - 308 - 408

→ → → →

Minimum limitation [°C] Maximum limitation [°C] Overtime setpoint TW Night setpoint for TW intervention [°C]

In an extensive system with several control groups, different sensors can be used jointly. This means: a common outside sensor can be used for several MCR 200. The same applies, for instance, also for the wind or the solar sensor.

The MCR 200 allows the boiler to be controlled according to a maximum selection; i.e. the MCR 200 control circuit which requires currently the highest setpoint con- trols the boiler.

For the signal transmission, the MCR 200 must be equipped in each case with a plug-in module GV1, for longer distances (> 2 m) also with GV2 and be connected with one another through a cable.

If several MCR 200 are connected through GV1 (GV2), the measured outside tem- perature of a device is passed on to all other MCR 200. If outside temperature sen- sors are connected to several devices, the locally connected outside temperature sensor is used as standard for the control system. Should a certain sensor be se- lected for several outside temperature sensors, CODE No. 115, 215, 315, 415 must be changed. The

highest

of all values in each case is transmitted through the de-

vice connection (GV1/GV2).

Signal: Hot water priority switching and system overheating, corrosion protection

CODE 115 - 215- 315 - 415 Number of the valid outside temperature sensor

=0 =1 =2

→ → →

local bus automatic

Signals can be branched in an extensive system with several control groups. This means that the hot water priority of a MCR 200 acts on all connected MCR 200. Since individual mixing circuits must also continue to be supplied with hot water priority, the influence (CODE No. 114, 214, 314, 414) of the hot water priority can be changed continuously.

CODE 114 - 214- 314 - 414 Hot water priority

=0 =1 >2

The priority signal is also used simultaneously as

corrosion protection signal

→ → →

off on intensified

overheating signal

and

boiler

. In the case of boiler overheating, the allowed heating circuits open (see also Maxi- mum limitation / Boiler overheating). In the case of boiler corrosion protection (boiler temperature < boiler minimum temperature), the allowed heating circuits close (see also Maximum limitation / Boiler corrosion protecting).

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Janitor function, heating limits

Because of the storage masses of the building, a reduction of the outside tempera- ture does not immediately affect the room temperature. Thus not only the momen- tary outside temperature is a measure for switching on but in addition the outside temperature delayed by the storage masses of the building. Under this we under- stand averaging the outside temperature or assessment of the time constant of the building.

For instance, the limiting value of the delayed outside temperature prevents the heating switching on too early and thus unnecessary energy consumption if it be- comes colder outside. A building no longer loses heat if the room temperatures are just as high as the outside temperatures. Heating energy is no longer required at the latest at this time. However, external heat is always available in a residential building: direct or diffuse solar radiation, personal heat, heat from lighting or possibly existing electri- cal machines.

Since these internal heat loads cover the losses starting from an outside tempera- ture of approx. 17...18 °C, the heating can be switched off correspondingly already at around this outside temperature. This cut-off point is defined as heating limit.

The momentary and the delayed outside temperature run differently and are phase- shifted. Therefore both temperatures must also be set separately.

For switching on and off it applies that:

•

If one of the two temperatures rises above the relevant set value, then the heating switches off (e.g. point A).

•

If the momentary outside temperature (ta- CODE No. 110, 210, 310, 410) and the delayed outside temperature (t low its relevant set value, then the heating is switched on (e.g. point B).

- CODE No. 111, 211, 311, 411) drops be-

Caution: Hysteresis??

CODE 110 - 210 - 310 - 410 Momentary outside temperature heating limit [°C]

CODE 111 - 211 - 311- 411 Delayed outside temperature heating limit [°C]

Example:

set value and the heating is switched off (point A). At around 2.45 am, the delayed outside temperature drops below the set value, the momentary outside temperature has already been below the set value since 6.45 pm, the heating is switched on (point B).

At around 10.30 am, the momentary outside temperature ta exceeds the

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Flow temperature control

The controller computes the setpoint for the flow temperature control from several variables. Flow setpoints of heating characteristic, optimization, room temperature control, room temperature limitation, 0...10 V input or contact requirement are available for selection. The controller decides which of the flow setpoints is valid.

The current flow setpoint for each heating circuit is stated in the system status menu (index key and 2).

The sensitivity of the flow temperature controller is set with the proportional band and the integral action time. The proportional band has a basic setting of 100 K, i.e. a system deviation of 2K, for instance, means that the servomotor opens or closes the mixing valve by 2 %.

To pass the manipulated variable on to the mixing valve motor, the controller con- verts the manipulated variable into an actuating time. The motor running time of the servomotor used (CODE No. 121, 221, 321, 421) must be set for this purpose.

Deviations between the actual and the set motor running time are critical only if the set motor running time is significantly larger (or shorter) than the actual motor run- ning time. The calculated actuating time is then too long; oscillations of the control system occur. If the deviation is significantly smaller, the control response of the control system becomes more inert.

CODE 118 - 218 - 318 - 418 Proportional band of the flow temperature controller [%/K]

Setpoint ramp (flow temperature)

CODE 121 - 221 - 321 - 421 Motor running time [sec]

The integral action time (CODE No. 119, 219, 319, 419) states the time after which with unchanging system deviation the controller increases the manipulated value by the same amount which is given by the gain factor multiplied by the system de- viation. Integral action times < 15 sec are not taken into account, the controller then works as pure P controller. A response threshold (CODE No. 120, 220, 320, 420) prevents continuous inter- vention for small changes of the system deviation.

CODE 119 - 219 - 319 - 419 Integral action time [sec]

CODE 120 - 220 - 320 - 420 Response threshold [K]

Limiting the heating up speed

The user can reduce the heating up speed for special applications and to reduce crackling noises in the pipelines. It is possible by setting a flow temperature set- point ramp (CODE No. 103, 203, 303, 403) to let the flow setpoint rise slowly (12...500 K/h). The cooling down speed is limited correspondingly.

CODE 103 - 203 - 303 - 403 Flow temperature setpoint ramp [K/h]

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Limitations, special functions

Limitation of the heating flow temperature minimum and maximum

In some systems, the heating flow temperature must not be less than or exceed certain limits. For example, the maximum limitation of the heating flow temperature is very expedient in floor heating systems. An additional temperature sensor is not required, since the limiting temperature is acquired with the existing flow tempera- ture sensor. If minimum limitation is set, then it is constantly effective. Only the heating limits determined by the controller can put the minimum limitation out of force.

Pump logic

Boiler excess

Screed drying heating function according to DIN4725/T4

Note:

CODE 101 - 201 - 301 - 401 Heating flow temperature minimum limitation [°C]

CODE 102 - 202 - 302 - 402 Heating flow temperature maximum limitation [°C]

To prevent the heating pump running unnecessarily, the controller decides whether heat is required or not. The pump is switched off if heat is no longer required. When the last heating circuit pump switches off, it runs on for 15 minutes (CODE No. 128, 228, 328, 428) to utilize the residual heat from the hydraulic network.

CODE 128 - 228 - 328 - 428 Pump cut-off delay [min]

The highest of all temperature demands is passed on to the boiler controller (in the case of several MCR 200 controllers through GV1 / GV2). An adjustable excess ensures simultaneously that pipe losses up to the consumers are compensated for.

Screeds must be dried before starting up the floor heating. They are dried by con- trolled heating up according to DIN 4725 / T4. In this case the flow temperature in the first days is regulated to 25 °C for instance (CODE No. 130, 230, 330, 430 =

25). After 72 h, the flow setpoint is raised to the maximum allowed value (CODE No. 102, 202, 302, 402).

The limitation does not replace safety measures, such as the limiting thermostat of a floor heating system.

The screed drying heating function starts as soon as CODE No. 130, 230, 330, 430 is > 2 °C.

Note

: Do not forget to set the maximum flow temperature

(CODE 102, 202, 302, 402).

CODE 130 - 230 - 330 - 430 Flow temperature for floor heating function [°C]

CODE 102 - 202 - 302 - 402 Maximum limitation [°C]

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Protective functions

Frost protection

Pump actuation

Mixing valve and pump forced operation

Important note:

To avoid the heating circuit freezing at unfavourable places of the piping system, the frost protection function bypasses the

If the outside temperature drops below a value to be set (frost limit), the circulating pump is switched on forcibly, even if there is no heat demand. If the flow temperature drops below 10 °C (CODE 101, 201, 301, 401) or below the minimum room temperature setpoint (CODE 104, 204, 304, 404), the flow tempera- ture is regulated to the setpoint from the time program according to the heating characteristic. The flow temperature control is switched off again after two hours until the flow temperature drops below one of the limiting values again.

To avoid the mixing valve seizing (e.g. during the summer), the mixing valve is opened once daily and closed again in heating breaks. To avoid the heating circuit pump seizing, it is switched on if it has been switched off for one week (= 168 h). The pump switches on for 60 sec (CODE H26 and H27, see also pump forced op- eration).

The protective functions are always active. The protective functions are not performed only in the 0 position of the operating mode switch.

demand driven pump actuation.

CODE 126 - 226 - 326 - 426 Pump protection interval [h]

CODE 127 - 227 - 327 - 427 Running time of the pump protective function [sec]

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Domestic hot water control

Standard control

Domestic hot water priority settings

If a standard hot water storage tank (hot water storage tank with integrated heat exchanger) is installed in the heating system, the charging pump is switched on as soon as the temperature drops below the temperature set point.

So that the hot water charging process takes place as quickly as possible, the set- point of the heat generator for the time of hot water charging is raised to a value 15 K above the hot water setpoint (CODE No. 504, 604, and 503, 603).

CODE 504 - 604 Hot water charging excess [°C]

CODE 503 - 603 Switching hysteresis [°C]

It is possible to choose between three types of hot water priority (see "Settings" operating instructions):

•

Absolute hot water priority: As long as hot water charging is taking place, the mixers are closed continuously. If the hot water temperature rises, the mixers open again.

•

Parallel operation: Hot water charging has no influence on the mixing circuits.

•

Time-dependent hot water priority parallel operation e.g. for 20 minutes. If the set hot water temperature is not reached within this time, the system switches over to absolute hot water priority.

Domestic hot water charging pump

Switch-on conditions

Cut-off condition

In the factory setting, the MCR 200 works with time-dependent hot water priority. The hot water priority is switched off in all cases 60 minutes after starting hot water charging.

Example:

means no priority, "40 min." means 40 minutes priority. Thus the priority circuit starts 20 minutes after start of hot water charging.

CODE 501 - 601 Hot water priority [min]

Prerequisites for switching on the hot water charging pumps are:

•

CODE 506 - 606 Boiler temperature influence

=0 =1

The hot water temperature must be greater than or equal to the water temperature plus a switching difference (CODE No. 503, 603).

The duration of the hot water priority can be set in CODE 501, 601. "0"

The hot water setpoint must be higher than the current water temperature at the sensor

The boiler temperature must be higher than the measured water temperature at the sensor (only for MCR 200-12, -13, -22, -32 and CODE No. 506 = 1).

→ →

off on

CODE 503 - 603 Switching difference [°C]

Charging pump run-on

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Boiler setpoint for hot water charging

Automatic anti-legionnaire's bacteria system

This function enables the boiler residual heat to be utilized in hot water charging in summer operation and in the transitional period. The charging pump runs on until the temperature in the storage tank no longer rises. The charging pump does not run on if other control circuits require heat. There is an additional max. running time to be set under Code 521. If this time has elapsed, the pump will stop even the temperature in the tank is still rising.

The boiler temperature setpoint required for hot water charging is calculated from the hot water setpoint plus a boiler temperature excess (CODE No. 504, 604) plus the switching difference (CODE No. 503, 603).

CODE 503 - 603 Switching hysteresis [°C]

CODE 504 - 604 Hot water charging temperature excess [°C]

To kill off legionnaire's bacteria, DVGW Worksheet 551 for hot water heaters > 400 litres water contents requires certain heating up temperatures which must be reached once daily. The temperatures are set in the time program of the hot water temperature. To avoid the risk of scalding in smaller systems, no heating up to high temperature is preset as standard.

Hot water heating with separately heated hot water storage tank (special application)

Pump forced operation

There are heating systems in which the hot water is not heated by the boiler, e.g. with a free standing hot water storage tank with its own atmospheric gas burner or with an electrical heating element. In the case of hot water charging, the gas burner is actuated instead of the charging pump. The requirements for an increased boiler temperature setpoint is thus not applica- ble. It can be set with CODE 505, 605 of the MCR 200 whether the boiler temperature setpoint is influenced or not during hot water charging.

CODE 505 - 605 Boiler requirement

=0 =1

→ →

off on

To prevent the charging pump seizing, it is switched on if it was off for one week (Code 507). The pump switches on for 60 sec (Code 508).

CODE 507 - 607 Pump protection interval [h]

CODE 508 - 608 Running time of the pump protective function [sec]

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MCR 200 - SERVICE INSTRUCTIONS

Boiler / Boiler sequence control

Setpoint setting

1. Flow temperature demand from other MCR 200 controllers through the LC or C bus.

2. Flow temperature demand through analog voltage signal (only for MCR 200-71)

The setpoint setting can be made in 6 different ways.

Each of these possibilities can also arise simultaneously in an arbitrary combina- tion. The highest value from the flow temperature demands described below is processed.

The highest demand in each case of a heat consumer is automatically transmitted through GV 1. The controller with the heat generator(s) controls according to the highest demand which is received through GV 1.

An analog voltage signal which is connected through the input EX1 to the MCR 200-71. This signal places a demand on the heat generator(s) according to the simple rela- tionship:

The boiler pumps switch off if the analog signal is < 0.3 V.

0...10 V input

E.g. all MCR 32 / 33 or other controllers installed in the field can pass on their heat demand through a 0...10 V signal (see also MCR 32 operating instructions). This signal can be impressed at the MCR 200-71, input EX1 to pass on a flow set- point to the boiler controller.

Note:

To quickly pass on from the outside a higher demand to the boiler controller, it is important to activate its output through Code 922. With activated input and open contact, the demand is automatically approx. 80 °C. There is no demand with closed contact. This function can be used, for instance, for an external hot water heater.

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3. Flow temperature demand by floating normally open contact (only for MCR 200-71)

A floating normally open contact, which is connected through the input EX2. (E.g. from MCR 52 or ZG devices). In this case the demand is calculated using an addi- tional integral function.

A heating characteristic serves as basis for determining the common flow setpoint. This heating characteristic is set with Code 904 - 905 - 906.

The maximum shift of the setpoint from this heating characteristic, up or down, is set by Code 907.

From this results a "Working band" outside the set heating characteristic, which is also restricted by the min. and max. limitation of the common flow temperature.

A minimum setpoint can be determined by the MCR 200-71 time program (day-year program) or via the code table Code 901. The setpoint applies for the common flow temperature in the hydraulic crossover.

What happens when the floating contact closes?

1. The demand for the boiler sequence circuit starts on the heating charac-

teristic (I).

2. According to the time the contact is closed, the setpoint is increased con-

stantly with Code 908 until the next burner stage switches on (II).

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3. The setpoint remains constant as long as either the gradient waiting time

or minimum on or minimum off time are active (III).

4. The setpoint increases further with the same slope only after the waiting

time has elapsed  provided the external contact is still closed.

5. If the demand contact is open (IV), then the setpoint requirement de-

creases initially slowly and then increasingly faster.

6. If the burner switches off during this phase, only the minimum off time runs

down and the setpoint remains constant for this time (V).

7. After each waiting time, the setpoint demand decreases further with the

last slope (VI). The setpoint requirement is limited by strategy minimum temperature and the maximum shift of the heating characteristic (Code

907).

Setting recommendations when using the switching contact:

Code Setting

904 20 °C 905 1.6 (maximum selection) 906 1.3 907 20 °C (without hot water charging) 908 1

Note:

We recommend a separate connection through the input EX

for the

hot water charging of the external controllers to improve the dynamic response

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4. Minimum demand (only MCR 200-71)

5. Flow demand by EXCEL 5000 system.

A minimum demand can be determined through the MCR 200-71 time program WEZ (day/year program). The setpoint applies for the common flow temperature in the hydraulic crossover. These setpoints are always fixed flow setpoints and

not

outside temperature dependent.

A data point of an EXCEL 5000 system can transfer the setpoint to the MCR 200- 71 heat generator, so that the MCR 200 heat generator receives the correct flow setpoint. For this purpose there is a user adress defined as VA_EXCEL________XX, where- by XX is the controller number.

6. Flow demand by an internal heating circuit program HKZ

An outside temperature controlled demand can be determined through the MCR 200-71 time program HKZ.

This internal heating circuit program also works with an independent year timer and serves for generating an internal flow demand if the controller should work "alone".

The heating circuit therefore has no outputs for mixing valve and pump and also no inputs for room sensor and flow temperature sensor.

Functions such as switching on and off optimization, janitor function, room control, adaptation of the heating characteristic, solar and wind influence, delayed outside temperature and number of degree days calculation are not integrated.

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Setpoint formation

Excess

Limitations

Minimum limitation / Boiler corrosion protection

The setpoint of the boiler or of the boiler sequence results from the maximum heat demand of the consumers and an adjustable excess. For the single boiler controllers this is Code 709 and for the boiler sequence Code

903. The excess takes account of piping losses.

In all boiler controllers, both the minimum (701 / 801) and maximum (702 / 802) boiler setpoint temperature can be limited. In addition, in the boiler sequence circuit, the minimum (901) and maximum (902) common flow setpoint can be limited.

If there is a condition in which the minimum boiler temperature is not reached, then the actuators in the series connected control circuits close constantly. The reaction depends upon the setting under Code 114 / 214 / 314 / 414 and the temperature difference between setpoint and actual value.

Example:

If the actual boiler temperature drops by 10 K below the minimum setpoint and if the setting is Code 114 = 5, then the momentary output signal of this heating circuit is reduced by 10 K×5=50%. At the same time as this proportional reaction, there is an adjustable integrating time under CODE 753. To obtain stable operation, the boiler corrosion protection function can be delayed with CODE 754 (overheating function).

Maximum limitation / Boiler overheating (for single boiler)

Boiler overheating for boiler sequence (MCR 200-71 only

If there is a condition in which the maximum boiler temperature is exceeded, then the actuators in the connected control circuits open constantly. The reaction depends upon the setting under Code 114, 214, 314, 414 and the temperature difference between setpoint and actual value.

Example:

If the actual boiler temperature rises by 10 K above the max. setpoint and if the setting is Code 114 = 5, then the momentary output signal of this heating circuit is increased by 10 K×5=50%. At the same time as this proportional reaction, there is an adjustable integrating time under CODE 753. To obtain stable operation, the boiler overheating function can be delayed with CODE 754 (overheating function).

If the boiler temperature is above the max. limit then the following will happen:

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Return temperature limitation control

Minimum switch-on time of the burner (Code 706 / 806)

Minimum switch-off time of the burner (Code 707 / 807)

Total shutdown of the boiler (Code 703 / 802)

Boiler sequence exchange (only MCR 200-71)

A constant return temperature control is provided for the boilers of the boiler se- quence circuit in controller MCR 200-71. The setpoint is entered under Code 717 /

817. The controller is a fixed value controller with adjustable P band and fixed inte- grating time(2 min.). (The working point is the setpoint and corresponds to 0 % output). This return limitation can be switched off through Code 718 / 818, i.e. the output can be used for a butterfly valve. The butterfly valve opens if the minimum tempera- ture is reached after heating up the boiler. If the temperature drops below the mini- mum temperature in further operation, then the butterfly valve remains open. However, the actuators of the heat consumers react through the "boiler corrosion protection" function.

To ensure economic combustion, for the safe drying out of the combustion space and to avoid chimney sooting, it is expedient to set the burner a longer running time. The minimum switch-on times and / or minimum exhaust gas temperatures can be set for this. After switching on, the burner remains in operation until the minimum switch-on time has ended. The minimum exhaust gas temperature must also be reached before it switches off. Switching off earlier is possible only on reaching the maximum permissible boiler temperature.

The adjustable minimum switch-off time for the burner ensures that the switching frequency is reduced. Even if the temperature is below the temperature setpoint, the burner cannot start before the minimum switch-off time has ended. Thus too frequent pulsing around the setpoint is reduced and uneconomic heating operation is avoided.

If the boiler is suitable for low or extra low temperature operation, it can also shut down heat generation completely to save energy outside the times of use. This must be notified to the controller at start-up through the parameter. If because of the temperature conditions the conditions for total shutdown are fulfilled, the con- troller ensures that the possibly set minimum limitation is ineffective in the shut- down times. However, the controller constantly performs the frost protection func- tion, it has absolute priority. As soon as the heat generation plant has to switch on because of the frost protection function, the minimum limitations are also in opera- tion again (Code 913). When heat is required by the consumer circuits, the boiler, as long as it has not reached the minimum temperature, will send a priority signal (influence adjustable under Code 114, 214, 314, 414) to the consumers, which at a high setting results in the consumers not receiving heat until the boiler minimum temperature is reached.

Code 909 determines the conditions for the boiler sequence exchange:

0 = no exchange i.e. the sequence of the boilers always remains the same. Boiler 1 is required firstly; if the heat output is not reached, boiler 2 switches on.

1 = according to operating hours If the set operating time (Code 716, 816) of the base load boiler has ended, the se- quence of the boiler requirement changes at the next switch-on and the previous following boiler becomes the base load boiler.

2 = according to outside temperature If the 72h mean value of the outside temperature exceeds the set limit of Code 912, then the 1st boiler becomes the base load boiler and the 2nd boiler the following boiler. The sequence of the requirement is the other way round below this outside temperature limit.

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CAUTION:

If boilers are of different size, the summer boiler must always be con- nected to the electrical connections for boiler 1.

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Leading boiler

In systems without hydraulic crossover, it is necessary that system water can circulate through a boiler (the heating circuit pump runs with flow temperature de- mands > 15°C). For this reason a leading boiler is defined under Code 920, i.e. the base load boiler is always connected hydraulically with the heating circuit distributor, so that system water can flow through it. In the case of boilers which are shut off with butterfly valves, the butterfly valve is open. In boilers with return temperature control, the three-way valve opens. This means that cold system water may come into the boiler return since the return temperature control for the leading boiler is not in operation.

Parallel / sequential boiler sequence

Outside temperature blockage of the 2nd boiler

NOTE:

We therefore urgently recommend installing a hydraulic crossover for each boiler sequence circuit, since without hydraulic crossover, relia- ble control of the return temperature and all flow temperatures is not possible in all operating conditions.

In special cases it is possible with Code 910 to change the sequence of the stages from sequential to parallel. In parallel operation, the stages are called up in the fol- lowing sequence:

Boiler 1, stage a Boiler 2, stage a Boiler 1, stage b Boiler 2, stage b

NOTE:

Manual sequence exchange: If the second boiler must always start first for technical reasons, then this is possible by setting Code 912 to "100" and Code 909 to "2". In this way the winter condition is always simulated (boiler 2 = base load). The summer / winter switch-over has a hysteresis of 2 K.

CAUTION:

An hydraulic crossover is not always the ideal solution with regard to energy for condensing boilers.

If the 72-hour mean value of the outside temperature exceeds the temperature set in Code 919, then the following boiler is blocked in each case.

Code 919 Outside temperature blockage of 2nd boiler

This blockage is cancelled if there is a fault in the 1st boiler (see also alarms / faults).

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Strategy function (only MCR 200-71)

Heating up time (Code 921)

Gradient waiting time (Code 708 / 808)

If Code 911 is 0 (= strategy), then the following settings are important for the op- eration of the boiler sequence circuit:

As long as the system deviation is larger than set via Code 914, and increases, the target time for heating up shifts continuously, i.e. the target time is always 60 min. (Code 921) in the future. The target time is not fixed until the system deviation starts to become smaller.

To acquire an accurate temperature gradient with the heat generation running, the gradient waiting time must first have ended, to balance out the effect of all storage processes.

After the end of this gradient waiting time, the controller determines the tempera- ture gradient which is compared with the target point to be reached.

Overheating of strategy temperature

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If the strategy temperature exceeds the value of Code 902 the overheating function is activated, that means that the temperature difference between strategy tempera- ture and Code 902 is sent via the bus to all heat consumers, which will react ac- cording to their settings in Code 114 / 214 / 314 / 414 (priority settings). If there is no overheating, this bussignal (code 1612) displays -888.

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Control range strategy (Code 914)

This setting above and below the setpoint to be reached is used to define the cut-in and cut-out of burner stages.

When must the next burner stage cut in?

1. The gradient leads to larger deviation of the setpoint at the target time

than defined in Code 914 (see Figure), i.e. the next stage or the next boiler can cut in. (Case I)

2. The gradient leads to a deviation below the setpoint but within the strategy

control range, i.e. the next stage may cut in, but a second boiler not. (Case II)

When must the next burner stage cut out?

1. The last switched on burner stage cuts out if the setpoint is exceeded by

3 K and the waiting times have elapsed (Case III).

2. The last switched on boiler can cut out if the setpoint + Code 914 is

reached and the waiting times have elapsed (Case IV). The same applies if the maximum boiler temperature is reached.

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MCR 200 - SERVICE INSTRUCTIONS

What happens in the strategy control range?

1. Actual value<setpoint

If there is a system deviation within the strategy, then the next stage can be switched on. If this system deviation is present for longer than the heating up time Code 921, then the next boiler can also be called up. All the waiting times apply at the same time.

2. If the actual value moves between setpoint and setpoint +3 K, then nothing

happens.

3. If the actual value>setpoint+3Kthelast stage switched on will cut out.

4. If the actual value>setpoint + Code 914 (control range) the las boiler swithed

on will cut out.

5. The modulating stage controls with the PID settings.

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MCR 200 - SERVICE INSTRUCTIONS

PID method (only MCR 200-71)

If Code No. 911 is at 1 = PID, then the following settings are important for opera- tion:

Code 915 P band

916 Integral action time 917 Derivative action time 918 Response threshold

The stages switch on and off for the following output signal (shown here as P controller):

Starting circuit for modulating burner (MCR 200-71/22)

A maximum duty cycle is switched on for the modulating burner through Code 713 (factory setting 50 %). This means that at 100 % signal, the time for reaching the steady stage condition is twice as long as if Code 713 is at 100 %.

In this way fast, modulating stages work slower and more stably.

At the first runup, this value is set fixed to 20 % deviating from the setting of Code 713, i.e. it lasts five times as long as would be possible with maximum speed.

The modulating stage of boiler 1 can start only when the first stage of burner 1 has been running for at least the minimum running time. If then the internal PID signal

25 % the modulating output signal will increase also.

During this time all other stages of the second boiler are disabled. Only when the modulating output is 100 % and all delay times have elapsed a decision can be made (depending on the PID signal) if a further stage will be switched on.

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MCR 200 - SERVICE INSTRUCTIONS

Boiler control for single-boiler systems:

The modulating component cannot be switched in until the gradient waiting time (minimum switch-on time + delay time for 2nd stage) has ended, if controller output with running stage > 0.

The second modulating stage is set by the PI controller (Code 711 / 712).

Output is 0...100 %

Code No. 710-714 Settings!

Boiler sensor / Sensor detection:

If the boiler sensor is not present, then the functions of boiler control and its limita- tions are not activated. So that unnecessary sensor breakage alarm messages do not arise, the final sensor configuration should be confirmed through the operating sequence.

Outside sensor:

Pump run-on time (only MCR 200-71)

Using a heating controller as boiler return temperature controller

If no outside sensor is connected, and if there is no outside sensor information on the C bus, then the controllers work with a fixed outside temperature of 0° C. Here as well the final sensor configuration should be confirmed through the operat- ing sequence.

The condition for the pump run-on time can be set individually for each boiler of the boiler sequence circuit.

Code 722 / 822: Maximum run-on time Code 723 / 823: Temperature difference run-on time.

The temperature difference between the boiler flow or return. If the temperature difference is smaller than the set value, the pump stops.

If no return sensor is connected, then the pump runs according to Code 722 / 822 with the maximum run-on time.

A heating controller can, if the flow temperature demand ist switched of with Code 156 / 256 / 356 / 456, be used as an independant return temperature controller.

The following codes must be set according by

Code 101 for return temperature set point e.g. 50 °C Code 117 to 5 Code 110 and 111 adjusted to highest values, so that janitor function is out of order.

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MCR 200 - SERVICE INSTRUCTIONS

Alarms / Faults

Burner fault

Boiler pump fault

Status displays in the operating sequence

WE (total heat generator / strategy) Only for MCR 200-71

If the temperature gradient (boiler sensor) is not positive once within 60 minutes after the burner relay pulling in, then a burner fault is reported. The waiting time is adjustable in Code 721 / 821. A value of 10,001 deactivates the alarm.

Only for MCR 200-71:

Within 10 seconds a burner fault will be reported, if the inputs SK 1 and SK 2 are used. This delay time is not adjustable. The fault will be reported if the inputs are closed. At the same time the outdoor temperature disable function of the second boiler will be cancelled so that the sec- ond boiler can cut in if necessary.

If the temperature difference between flow and return is > 30 K for more than 15 minutes, then a boiler pump fault is reported. The temperature difference can be set with Code 724 / 824. A value of 100 K deac- tivates the alarm.

The status display explains the load conditions of the heat generator(s) and indi- cates the actual and setpoint values as well as the current statuses of the output relays.

WE1 / WE2

WE: Off FK:0 w: 50°C A :Int. x: 52°C MORE

WE1: Mini.T P :On x : 75°C ST:St2 mod:100% BACK MORE

First line:

WE Total heat generator Off Operating mode switch to "0" or "Holiday" Parallel Code 910 to 0 Sequence Code 910 to 1

Second line:

FK: 0/1/2 Leading boiler W Setpoint for common flow sensor

Third line:

A : Int. Internal requirement of the time program A : Bus. External requirement through bus A : ext. External requirement through EX2 A:0-10V External requirement EX1 X Actual temperature at the common flow sensor

First line:

WE... WE1 or WE2: Number of the heat generator Mini.T Minimum limitation for boiler active

if there isnodemand and the boiler temperature<t and total shut down is As soon as there is a demand the line will show "normal".

Totaloff Total cut-off of the heat generator

if there isnodemand and the boiler temperature<t and total shut down is permitted

As soon as there is a demand the line will show "normal". off if the burner is cut off Normal if operating mode normal Overheat if boiler temperature>Code 702

Second line:

P : Pump x : Boiler temperature actual value

Third line:

ST: St1 or St2: Burner stage 1 or 2 mod: ... % Component of the modulating stage

not

permitted.

k min

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MCR 200 - SERVICE INSTRUCTIONS

District heating controller

Return temperature limitation

All MCR 200 heating and district heating controllers offer the possibility of continu- ous return temperature limitation. The return temperature limitation can be set separately both for the individual mixing circuits and the total system.

Code 735 specifies the lower value of the return temperature limit

Code 736 specifies the upper value of the return temperature limit

Code 737 is the onset point of the outside temperature. The onset point

determines from which outside temperature the shift starts.

Examples:

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MCR 200 - SERVICE INSTRUCTIONS

Return interval flushing

So that the return temperature can be measured with sufficient accuracy even with the distant heating valve closed, the distant heating valve is opened briefly every 10 minutes. This guarantees that the limitation sensor in the distant heating return is sufficiently flushed.

This function is active only if the distant heating valve has been closed in the distant heating return by reaching the maximum limitation.

100 % function

In order to achieve stable control conditions for one or more heating circuits we ha- ve the 100 % function. This function takes care that the heat consumer with the highest flow set point ope- nes the valve 100 % and is controlled by the heat exchanger valve directly. 'This function can be diabled with Code 763 if temperatures due to minimum limita- tions must not enter this heating circuit.

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MCR 200 - SERVICE INSTRUCTIONS

Control parameters for district heating valve

For the district heating valve control there are three different parameters (proportional band):

1. for only one heating circuit Code 728 default = 100

2. for two and more heating circuits Code 751 default = 20

3. for unmixed DHW control Code 752 default = 10

In order to achieve a stable condition it may be necessary to adjust these parame- ters to the heating system.

Unmixed domestic hot water storage tank control

The MCR 200-52 and MCR 200-53 offer the possibility of hot water heating with an unmixed domestic hot water storage tank. The water is not heated by a heat ex- changer fitted in the unmixed domestic hot water storage tank but by an external heat exchanger.

•

The heated water flows from above into the unmixed domestic hot water storage tank.

•

At the same time cold water flows from the bottom of the unmixed domestic hot water storage tank to the heat exchanger. In this way the return temperature of the heating medium is relatively low during the entire heating time, also in after- heating processes.

•

As soon as the sensor WW1 located at the top measures a temperature lying below the setpoint, the charging process is started.

•

Hot water charging is ended when the sensor WW2 located at the bottom of the unmixed domestic hot water storage tank has reached the hot water setpoint.

A setpoint increased by Code 504 applies at the sensor VF3 for the charging process.

Manuelle Warmwasserladung

Switch on conditions for the secondary loading pump

If Code 506 is set to 1, the controller will wait with the loading process until the flow temperature is>regular loading temperature.

In case the flow sensor is not in flowing water then it is necessary to change this switch on condition by changing Code 506 to 0.

Ideal is a correct mounting of the sensor, as shown in picture left.

Sollwertbegrenzung Warmwasserladung

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MCR 200 - SERVICE INSTRUCTIONS

Protection against calcification

To protect from calcification the external heat exchanger, which is required in un- mixed domestic hot water storage tank charging, a maximum inlet temperature in the hot water heat exchanger can be determined especially for unmixed domestic hot water storage tank charging.

Boiler or flow temperature requirement of the hot water control

Minimum valve lift for incidental amount suppression

This is measured at the sensor VF3.

This maximum limitation is always active

in hot water charging.

The hot water control determines its own setpoint for the heat requirement. This setpoint is passed onto the heat generators (boiler, heat exchanger).

The heat quantity metering necessary in district heat transfer stations represents a technical problem in the range of strongly reduced flow quantities.

Whereas in the normal working range the measurement is sufficiently accurate for heating cost calculation, in light load operation, therefore if the valve is opened only a little, clearly noticeable faulty messages can occur.

The "Minimum valve lift" function ensures that there is constant control only in the range of the flow volume which can be reliably measured, in that the MCR 200-52 changes from constant to two-point control below adjustable limiting values for the valve lift. The heat quantity can be recorded exactly with this function even in light load operation.

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MCR 200 - SERVICE INSTRUCTIONS

Heat meter connection

Electrical connection

The MCR 200 can process the volume and heat quantity signal of the heat meter for power and volume limitation.

•

With the aid of the primary flow and return sensor, the MCR 200 converts the volume flow signal into the actual power and vice versa.

•

The MCR 200 can limit both the volume flow and the delivered power, indepen- dent of the signal which it receives from the heat quantity meter.

The corresponding settings are made in Code 743...750.

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MCR 200 - SERVICE INSTRUCTIONS

Computing the heat power and the volume flow

The MCR 200 code tables must be adjusted to the heat meter. In the ideal case it is calibrated so that a signal is transmitted about every second.

Example:

The maximum power hint is entered under Code 748 and the maximum volume flow under Code 749. The distant heating valve will be closed continously if these values are exceeded.

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MCR 200 - SERVICE INSTRUCTIONS

AIR CONDITION CONTROL

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MCR 200 - SERVICE INSTRUCTIONS

HARDWARE

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MCR 200 - SERVICE INSTRUCTIONS

COMMUNICATION

Controller to controller signals

In order to exchange data between the MCR 200 controllers there must be installed a serial bus connection. Through this bus there is a continuous exchange of, at the moment, 6 values:

1. The max. flow set point of all MCR 200 controllers in the system.

This value will be received by all connecxted MCR 200 controllers an is used by the heat generators for the control of boilers and/or heat exchangers.

2. The priority signal

This signal serves the purpose to override the heat consumer output signals an can have three different causes:  The DHW priority: when loading DHW there is an adjustable signal for each heat consumer, which will individually close the control valves.  Boiler corrosion protection: if there are boiler temperatures lower than the minimum limit then this function takes care that the consumer control valves will close, to take care that the boiler will reach ist minimum temperature as fast as possible. Boiler overheating  if there are boiler temperatures higher than the max. limitation this function will take care that the consumer valves will open and so reduce the excess temperature as quick as possible.

3. Collective alarm signal

Wherever there is an alarm in the system (connected by the bus) this signal well be activated an can be utilized in every controller asa5Vsignal.

4. Outside temperature

For a MCR 200 system only ohne outside temperature sensor is necessary, be- cause this value is transmitted to every other controller on the bus. This sensor can be connected to any MCR 200 controller. If a different outside temperature is needed for a special purpose (north/south values) then may controllers have inputs for an individual outside temperature sensor. This value must then be defined for every consumer of the correspon- ding controller.

5. Solar / Wind sensor

The information of solar and wind influence is available for every controller on the bus. There can be only one wind or one solar sensor.

6. Especially for district heating controllers this combined signal was created. It

serves the following purpose:  to inform every heat consumer, that the heat generator is a district heating heat generator  to tell every district heating heat generator how many heat consumers are active at the moment  to tell every heat consumer, that an unmixed DHW storage tank of MCR 200- 53 is beeing loaded (this function will disable the max. selection of the flow temperature demand)  to find the heat consumer with the highest flow temperature demand in order to open this control valve 100 %.

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MCR 200 - SERVICE INSTRUCTIONS

MCR 200 Fax – Controller

In order to show the values of datapoints on an alarm fax, these datapoints must have the attribute "Fax". This attribute is currently added to the following user adresses:

1. All sensor inputs except LQR, all TW remote setpoint selectors and all SM ge-

neral alarm inputs

2. All digital, floating an analogue outputs

3. All set points

4. Datapoint for VD_MK1_STATUS Status of controller

5. Datapoint for VD_DHW_STATUS DHW status (Code 509)

6. Heat energy if heat meter with

heat energy signal is connected

7. Datapoint for heat power Code 746

8. Datapoint for volume flow Code 747

9. Status vent. controller Code 1001 Code 1001

10. Aux output 0...100 %

11. Operating mode switch (MODE_SWITCH_POS)

12. real set point for vent. controller

13. Vent. stage

14. Set point from switching program

15. VA_Excel

16. Sensor input ?? quality control in ppm or %

17. Datapoint for max. outside temperature

on the bus

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MCR 200 - SERVICE INSTRUCTIONS

MCR 200 Voice – Controller

MCR 200 – EXCEL

C-Bus

In order to transmit values of datapoints by means of a "spoken word", these corre- sponding datapoints must have the attribute "Voice".

This is, by the moment, utilized with the following datapoints:

1. Outside temperature on the bus

2. Room temperature for heating an ventilation controllers

3. Status of remote set point selector TF 26

4. Status of remote set point selector T 4712D

In order to transmit a flow temperature demand from MCR 200 to an EXCEL heat generator the following steps are necessary:

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If without exception all heat consumers shall pass a flow temperature demand to the Excel heat generator, then the common signal from the bus may be used as datapoint for Excel

LCGesAnf--------XX

___________________

18 characters

Please take care that the controller numbers are manually set for mixed systems, to prevent that they will change in case of a power cut.

47 EN 2R-1120

(XX = Controller-Nr.)

Page 48

MCR 200 - SERVICE INSTRUCTIONS

Outside temperature indications

OT display

Code 1604

Code 1614

Code 1639

Code 1640

Code 112

Code 146

either local sensor or if not mounted, bus value of outside temperature (without delay)

input from bus without local sensor information (without delay)

value of local sensor (without delay)

as Code 1640 but without delay

OT sensor information as set under Code 1017 sensor with 1 h delay time (for vent. controller)

OT sensor information with 72 h delay

OT sensor information with the delay of the building time constant (Code 113)

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INSTALLATION CHECKLIST

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MCR 200 - SERVICE INSTRUCTIONS

CODE TABLES

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Microprozessor Controller MCR 200

SERVICE INSTRUCTIONS

110°

100°

90°

80°

70°

Flow temperature in °C

60°

50°

40°

30°

+10

20°

+20°

Room setpoint

-5

Outside temperature in °C

-10

Fast

heating up time

Setting value in code table

0°C

t=t

Outside temperature

Room temperature

possible early cut-off

Daysetpoint

Excess

6:00 8:00

with intervention of the frost protection

CB-2079-E

4,5 3,5 3,0 2,5

-15°+10° -10°+5° -5°0°

[°C]

Code 902

Code 901

Returntemperature limitation

Characteristic of the moving return temperature limitation

Code 735 152 / 252

Code 736

CB-2077-E

153/253

Early cut-off at ...h

Roomtemp.> room setpoint

Time

amin

Slope

2,0 1,8 1,6

1,4 1,2

1,0 0,8 0,6 0,4

-20°

0,3010

0...0,3 V: no requirement!

Slope

Code 734 151 / 251

Code 737 154 / 254

Roomtemp.= room setpoint

Outside temperature

Roomtemp.< room setpoint

k*(t t )

RRS

k*(t t )

RS R

t= t

Outside temperature

CB-2084-E

t Requirement

Slope Code 908

Boil er off

Waiting

time

Boil er on

Contac t open

I II III IV V VI

Setpoint

CB-2340-E

Setpoint step

Code 914 Control range

Time 1, step b Time 1, step a Time 1, step a Code 704 / 804

Gradient waiting time

[°C]

Kmax

CB-2383-E

Slope /curvature (Code 905 / 906)

Kmin

Code 904

20 10 0 -10 -20

t = Starting temperature of the heating characteristics

Waiting

time

Contac t openContac t cl ose d

Temperature gradient

Time 1, step a

Maximum shift (Code 907)

Boil er off

Target point

t [°C]

CB-2352d-E

Time

CB-2348-E

CB-2342-E

CBRSATE

EN 2R-1120 GE51 PRERELEASE 0797

Honeywell MCR 200 SERVICE INSTRUCTIONS

Specifications and Main Features

Frequently Asked Questions

User Manual