CONTENTS · EN 2R-1120 6 01.04.98 (EN\2R\EN2R1120.DOC) Basic setting After start-up, the controller works initially with a basic setting made in the factory. The slope of this characteristics

$Page 1: CONTENTS · EN 2R-1120 6 01.04.98 (EN\2R\EN2R1120.DOC) Basic setting After start-up, the controller works initially with a basic setting made in the factory. The slope of this characteristics$
MCR 200 - SERVICE INSTRUCTIONS

(EN\2R\EN2R1120.DOC) 01.04.98 1 EN 2R-1120

CONTENTSHEATING CONTROL

HEAT CONSUMERS.................................................................................................................. ......................................... 3Time program ........................................................................................................... 3Outside temperature controlled cut-off ..................................................................... 3Room temperature controlled cut-off ........................................................................ 4Optimization.............................................................................................................. 4

HEATING CIRCUIT CONTROL.......................................................................................................... ................................. 5Outside temperature controlled flow temperature control......................................... 5

Heating characteristic .......................................................................................... 5Automatic adaptation of the heating characteristic .............................................. 7

Room temperature control...................................................................................... 13Limitation of the heating up speed ..................................................................... 14Maximum limitation of the room temperature..................................................... 14Minimum limitation of the room temperature...................................................... 14Overtime compensation with TF 26 ................................................................... 14Overtime compensation via room sensor input.................................................. 15

Statistics ................................................................................................................. 15Determining the number of degree days............................................................ 15Counter for operating hours ............................................................................... 15

External temperature demand ................................................................................ 16Overlapping mixing circuit functions, sensors, device connections ................... 17Passing on the outside temperature sensor value through the C bus ............... 17Signal: Hot water priority switching and system overheating,

corrosion protection .............................................................................. 17Janitor function, heating limits ................................................................................ 18Flow temperature control........................................................................................ 19

Setpoint ramp (flow temperature)....................................................................... 19Limitations, special functions.................................................................................. 20

Limitation of the heating flow temperature - minimum and maximum................ 20Pump logic ......................................................................................................... 20Boiler excess...................................................................................................... 20Screed drying heating function according to DIN 4725/T4................................. 20

Protective functions ................................................................................................ 21Frost protection .................................................................................................. 21Pump actuation .................................................................................................. 21Mixing valve and pump forced operation ........................................................... 21

Domestic hot water control ..................................................................................... 22Standard control................................................................................................. 22Domestic hot water priority settings ................................................................... 22Domestic hot water charging pump.................................................................... 22Pump forced operation....................................................................................... 23

BOILER / BOILER SEQUENCE CONTROL ................................................................................................... .................. 24Setpoint setting....................................................................................................... 24

1. Flow temperature demand from other MCR 200 controllersthrough 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) ........................................................... 275. Flow demand by EXCEL 5000 system.......................................................... 276. Flow demand by an internal heating circuit program HKZ ............................ 27

Setpoint formation .................................................................................................. 28Excess................................................................................................................ 28Limitations.......................................................................................................... 28Minimum limitation / Boiler corrosion protection ................................................ 28Maximum limitation / Boiler overheating (for single boiler)................................. 28Boiler overheating for boiler sequence (MCR 200-71 only ................................ 28

Return temperature limitation control ..................................................................... 29Minimum switch-on time of the burner (Code 706 / 806) ................................... 29Minimum switch-off time of the burner (Code 707 / 807) ................................... 29


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Total shutdown of the boiler (Code 703 / 802) ................................................... 29Boiler sequence exchange (only MCR 200-71).................................................. 29Leading boiler .................................................................................................... 30Parallel / sequential boiler sequence ................................................................. 30Outside temperature blockage of the 2nd boiler ................................................ 30

Strategy function (only MCR 200-71) ..................................................................... 31Heating up time (Code 921)............................................................................... 31Gradient waiting time (Code 708 / 808) ............................................................. 31Overheating of strategy temperature ................................................................. 31Control range strategy (Code 914)..................................................................... 32

PID method (only MCR 200-71) ............................................................................. 34Starting circuit for modulating burner (MCR 200-71/22) ......................................... 34Boiler control for single-boiler systems:.................................................................. 35

Boiler sensor / Sensor detection: ....................................................................... 35Outside sensor:.................................................................................................. 35Pump run-on time (only MCR 200-71) ............................................................... 35Using a heating controller as boiler return temperature controller ..................... 35

Alarms / Faults........................................................................................................ 36Burner fault ........................................................................................................ 36Boiler pump fault ................................................................................................ 36

Status displays in the.............................................................................................. 36operating sequence................................................................................................ 36

WE (total heat generator / strategy) only for MCR 200-71................................. 36WE1 / WE2 ........................................................................................................ 36

DISTRICT HEATING CONTROLLER...................................................................................................... .......................... 37Return temperature limitation ................................................................................. 37Return interval flushing........................................................................................... 38100 % function........................................................................................................ 38Control parameters for district heating valve .......................................................... 39Unmixed domestic hot water storage tank control.................................................. 39

Manuelle Warmwasserladung............................................................................ 39Switch on conditions for the secondary loading pump....................................... 39Sollwertbegrenzung Warmwasserladung........................................................... 39Protection against calcification........................................................................... 40Boiler or flow temperature requirement of the hot water control ....................... 40Minimum valve lift for incidental amount suppression........................................ 40

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

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

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

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

COMMUNICATION

CONTROLLER TO CONTROLLER SIGNALS .................................................................................................. ................ 45MCR 200 Fax � Controller ...................................................................................... 46MCR 200 Voice � Controller ................................................................................... 47MCR 200 � EXCEL................................................................................................. 47

C-Bus ................................................................................................................. 47Outside temperature indications............................................................................. 48

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

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


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HEATING CONTROL

Heat consumers

Time programDifferent 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 everymixing circuit for the switching points of which an individual setpoint can be set.

Example: A room temperature of 21 °C should be guaranteed in the senior citizensgymnastics hour in a multipurpose building (heating operation). In school sportsevents 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 °C10:00 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 valveclosed for this purpose. If the heating is switched off, only frost protection functionswhich prevent the heating system freezing are active.

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

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

09:00 Setpoint 21 °C Opt: yes optimized heating up,so that 21°C are reachedby 9.00 am

10:00 Setpoint 18 °C Opt: no only reducing the roomsetpoint to 18 °C

12:00 Setpoint 15 °C Opt: yes early cut-off

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

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

Outside temperature controlled cut-offThe outside temperature controlled cut-off function is activated if no room tempera-ture sensor is present and "Opt: yes " is selected.

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 controlledso that the heating system does not freeze.


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Room temperature controlled cut-offThe room temperature controlled cut-off function is activated automatically if aroom temperature sensor is connected to the corresponding heating circuit and"Opt:yes" is selected. (The Code No. 133, 233, 333, 433 must also stand at 1).

If the time program switches the heating off, the control is switched over to roomtemperature control. In this way the heating is switched off in the night until thetemperature has dropped to the corresponding setpoint. To avoid the room coolingdown 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.

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

CODE - 133 - 233 - 333 - 433Room temperature sensor for optimization= 1 → Optimization with room temperature sensor= 0 → Optimization without room temperature sensor


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Heating circuit controlThe heating circuits serve for temperature control with a mixing valve. The followingcontrols can be implemented by setting code values:

CODE 117 - 217 - 317 - 417

Type of control= 2 → Outside temperature controlled flow temperature control= 1 → Room temperature control= 3 → Constant flow temperature control,

internal 0...10 V signal= 4 → External requirement with switching contact, outside

temperature controlled= 5 → External requirement with switching contact, independent of

outside temperature

Outside temperature controlledflow temperature control

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

In addition, the maximum room temperature can be limited by connecting a roomtemperature sensor. This adjustable limiting function ensures that heating energy isnot consumed unnecessarily.

Heating characteristicThe outside temperature controlled flow temperature controller requires a heatingcharacteristic according to which it can provide the correct flow temperature for themixing circuit concerned corresponding to the outside temperature.The heating characteristic shows the relationship between the outside temperatureand the associated flow temperature.

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


EN 2R-1120 6 01.04.98 (EN\2R\EN2R1120.DOC)

Basic settingAfter 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

Setting recommendationBoth 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 externalremote control.

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

Fig.Heating characteristicCurvaturefor floor heating approx. 1.1DIN radiators or plate heaters approx. 1.3Convectors 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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The basic setting does not have to be changed for all other types of system inwhich higher flow temperatures are permitted. The controller corrects the heatingcharacteristic by the adaptation automatically.

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

CODE 102 - 202 - 302 - 402

Maximum limitation [°C]

Automatic adaptation of the heating characteristicThe ability of the controller to adapt the default heating characteristic (heatingcurve) 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 loopconcerned 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 3rdday. If the basic setting (1.6) is too high, it can be that too high flow temperaturesoccur 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 roomsensor 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 startingthe 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 ofthe heating characteristic can be changed.

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

Note The curvature can be changed only manually through the operatingunit 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 thetype of the radiators. The larger the numerical value, the more is the heating char-acteristic curved.

CODE 131 - 231 - 331 - 431

Allow / prevent adaptation= 0 → Adaptation not allowed= 1 → Adaptation allowed= 2 → New start of the adaptation


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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 timewith the outside temperature.The heating time at 0 °C outside temperature (Fig. on the left) can be set in theCode 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 constantsand dead times are not relevant for this heating up optimization. If the target time isreached (as in the example diagram 8.00 am), then the controller switches back tonormal 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 onthe 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 ofthe room temperature. The maximum early cut-off is 2 hours. The switching pointmust always be set at the latest possible cut-off.

The limiting value of the outside temperature, ta min can be used for the early cut-offin the Code Table (CODE No. 138, 238, 338, 438).

This means that the controller cuts off the heating earlier between this limiting valueand 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 valveclosed). 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 currentnight setpoint from the time program (supporting mode) only if the temperaturedrops below the frost protection limit (CODE No. 109, 209, 309, 409).

CODE 109 - 209 - 309 - 409

Frost protection limit [°C]


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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 heatingup 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 heatdemand the controller can only shift the heating up time towards earlier times. Thistransition 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 availableare determined for heating up. The heating up process starts at the calculated timewith 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 valveclosed). 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 theroom 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 minutesas room temperature controller. It then switches back to outside temperature con-trol.

CODE 101 - 201 - 301 - 401

Minimum limitation [°C]


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Cut-off with room sensor

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

• If the room temperature tR is equal to the setpoint tRS, then the early cut-offapplies as in the case without room sensor.

• If the room temperature tR is greater than the setpoint tRS (solar radiation, per-sonal heat, then the set characteristic becomes steeper, i.e. the heatingswitches off earlier (max. 2 hours).

NOTE: If the room temperature tR is smaller than the setpoint tRS, then the setcharacteristic becomes flatter. The heating remains switched on lon-ger, as a maximum up to the programmed cut-off point.

In the code Table, the limiting value of the outer temperature ta min can be set via theearly cut-off (CODE No. 138, 238, 338, 438).This means that at this limiting value, the controller cuts off the heating earlier. Ifthe 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]

Identification of time constant and dead time

The program identifies the necessary time constants and dead times for heating upoptimization 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]

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 eachheating 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. Beforethe 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 theold and new value.


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Depending upon the cut-off time of the heating system, the controller uses in eachcase 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 →→ disabled= 1 →→ enabled= 2 →→ New start

• A room sensor is connected.

• The temperature difference between room temperature on switching on theheating and room temperature setpoint at the target time is greater than 2 K.

• The outside temperature is less than 10 °C.

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

Solar compensationThe solar radiation influences the value of the damped outside temperature throughthe SAF20. A radiation power of 500 W/m

2has 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 heatingcircuits (CODE No. 116, 216, 316, 416).

CODE 116 - 216 - 316 - 416

Solar compensation= 0 → off= -1 → on


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Wind compensationThe 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 isreduced by max. 20 K.The influence of the wind compensation can be set between 0 and +1 for all threeheating circuits (CODE No. 116, 216, 316, 416).

CODE 116 - 216 - 316 - 416

Wind compensation= 0 → off= +1 → on

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

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

CODE 113 - 213 - 313 - 413

Building parameter T [h]

Typical values:very light construction approx. 0.5 hlight construction approx. 2 hmedium heavy construction approx. 5 hheavy construction approx. 10 h


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Room temperature controlIf 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 roomtemperature and the room temperature set point the flow temperature which themixing valve must set. If room temperature control is wanted, no thermostatic valvemay 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 themain controller is the room temperature controller and the auxiliary controller is theflow 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 theroom temperature changes.

A change of the room temperature by 1 K results (at P band Xp = 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 / XP x 100 K = ∆tflow

The working point of the room temperature controller is determined by the heatingcharacteristic (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 thesame amount as it reaches due to the P component. The control circuit works aspure P controller with integral action times < 15 s.

In most cases, the P controller is sufficient for the room temperature control, sincethe 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 boilerduring the morning heating up, the P controller is set as basic setting for the roomcontrol.

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

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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Limitation of the heating up speedThe user can reduce the heating up speed for special applications. By setting aroom temperature setpoint ramp (CODE No. 106, 206, 306,406) it is possible to letthe 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!

Maximum limitation of the room temperatureWith connected room sensor and if an adjustable room temperature limitation isexceeded, the flow temperature setpoint is lowered.Example:Room temperature setpoint 20 °C, maximum limitation of the room temperature to22 °C. It results from this that starting from a room temperature of 22 °C, the flowtemperature of the heating circuit constantly starts to decrease. The maximumpermissible 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 theroom temperature - room limitation setpoint).

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]

Minimum limitation of the room temperatureIf 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 setpointis set to 0 °C.

CODE 104 - 204 - 304 - 404

Minimum limitation of the room temperature [°C]

Overtime compensation with TF 26The 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 onthe 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 roomtemperature (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 → Night setpoint for TW intervention

CODE 104 - 204 - 304 - 404 → Minimum room temperature

CODE 105 - 205 - 305 - 405 → Maximum room temperature


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Overtime compensation via room sensor inputIn order to start the overtime function, the room sensor input of the control circuithas 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 isactivated.

Statistics

Determining the number of degree daysThe number of degree days is required for determining the energy consumption ofan 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 productof the heating days of a heating period and the temperature difference between thefixed 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.

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 VDI2067 BL 1).

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

CODE 1650

degree day calculation: basic temperature [°C]

Counter for operating hoursOne counter each is available in the MCR200 for recording the operating hours ofthe individual control circuits. The counter registers all times in which the pumps orburners are in operation.


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

1. by a temperature selector2. by a 0...10 V signal3. 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 = 1 or 2)The room setpoint setting of the time program can be overwritten by a temperatureselector (TF 26).The TF 26 has a selector switch with the following functions:auto automatic operation according to time programDay constant day setpoint (overtime)Night constant night setpointThe setpoints for "Day" and "Night" can be set in the Code Table. The setpoint ofthe time program and the overtime setpoint can be changed in 1 °C steps with thesetting knob of the TF 26.The TF 26 can be used only for room controlled and outside temperature controlledcontrol.

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 thispurpose 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 convertedto 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, 407as outside temperature controlled controller

Open contact The controller works without switching program with thesetpoint from Code 108 , 208, 308, 408as 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 programwith the setpoint from Code No. 102

Open contact The controller works without switching programwith the setpoint from Code 101


(EN\2R\EN2R1120.DOC) 01.04.98 17 EN 2R-1120

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

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

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

CODE 107 - 207 - 307 - 407 → Overtime setpoint TW

CODE 108 - 208 - 308 - 408 → Night setpoint for TW intervention [°C]

Overlapping mixing circuit functions,sensors, device connections

In an extensive system with several control groups, different sensors can be usedjointly. 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 aplug-in module GV1, for longer distances (> 2 m) also with GV2 and be connectedwith one another through a cable.

Passing on the outside temperature sensor valuethrough the C bus

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 temperaturesensor 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 mustbe changed. The highest of all values in each case is transmitted through the de-vice connection (GV1/GV2).

CODE 115 - 215- 315 - 415

Number of the valid outside temperature sensor= 0 → local= 1 → bus= 2 → automatic

Signal: Hot water priority switchingand system overheating, corrosion protection

Signals can be branched in an extensive system with several control groups. Thismeans 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 waterpriority, the influence (CODE No. 114, 214, 314, 414) of the hot water priority canbe changed continuously.

CODE 114 - 214- 314 - 414

Hot water priority= 0 → off= 1 → on> 2 → intensified

The priority signal is also used simultaneously as overheating signal and boilercorrosion protection signal.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 minimumtemperature), the allowed heating circuits close (see also Maximum limitation /Boiler corrosion protecting).


EN 2R-1120 18 01.04.98 (EN\2R\EN2R1120.DOC)

Janitor function, heating limitsBecause 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 outsidetemperature delayed by the storage masses of the building. Under this we under-stand averaging the outside temperature or assessment of the time constant of thebuilding.

For instance, the limiting value of the delayed outside temperature prevents theheating 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 theoutside temperatures. Heating energy is no longer required at the latest at thistime. However, external heat is always available in a residential building: direct ordiffuse 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 alreadyat 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 theheating switches off (e.g. point A).

• If the momentary outside temperature (ta - CODE No. 110, 210, 310, 410) andthe delayed outside temperature (tam - CODE No. 111, 211, 311, 411) drops be-low its relevant set value, then the heating is switched on (e.g. point B).

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: At around 10.30 am, the momentary outside temperature ta exceeds theset value and the heating is switched off (point A). At around 2.45 am, the delayedoutside temperature drops below the set value, the momentary outside temperaturehas already been below the set value since 6.45 pm, the heating is switched on(point B).


(EN\2R\EN2R1120.DOC) 01.04.98 19 EN 2R-1120

Flow temperature controlThe controller computes the setpoint for the flow temperature control from severalvariables. Flow setpoints of heating characteristic, optimization, room temperaturecontrol, room temperature limitation, 0...10 V input or contact requirement areavailable for selection. The controller decides which of the flow setpoints is valid.The current flow setpoint for each heating circuit is stated in the systemstatus menu (index key and 2).

The sensitivity of the flow temperature controller is set with the proportional bandand 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 theservomotor 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 theset 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 controlsystem occur. If the deviation is significantly smaller, the control response of thecontrol system becomes more inert.

CODE 118 - 218 - 318 - 418

Proportional band of the flow temperature controller [%/K]

CODE 121 - 221 - 321 - 421

Motor running time [sec]

The integral action time (CODE No. 119, 219, 319, 419) states the time after whichwith unchanging system deviation the controller increases the manipulated valueby 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 worksas 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]

Setpoint ramp (flow temperature)Limiting the heating up speedThe user can reduce the heating up speed for special applications and to reducecrackling 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]


EN 2R-1120 20 01.04.98 (EN\2R\EN2R1120.DOC)

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 exceedcertain limits. For example, the maximum limitation of the heating flow temperatureis very expedient in floor heating systems. An additional temperature sensor is notrequired, since the limiting temperature is acquired with the existing flow tempera-ture sensor. If minimum limitation is set, then it is constantly effective. Only theheating limits determined by the controller can put the minimum limitation out offorce.

Note: The limitation does not replace safety measures, such as the limitingthermostat of a floor heating system.

CODE 101 - 201 - 301 - 401

Heating flow temperature minimum limitation [°C]

CODE 102 - 202 - 302 - 402

Heating flow temperature maximum limitation [°C]

Pump logicTo prevent the heating pump running unnecessarily, the controller decides whetherheat 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 (CODENo. 128, 228, 328, 428) to utilize the residual heat from the hydraulic network.

CODE 128 - 228 - 328 - 428

Pump cut-off delay [min]

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

Screed drying heating functionaccording to DIN4725/T4

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 inthe 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 (CODENo. 102, 202, 302, 402).

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


(EN\2R\EN2R1120.DOC) 01.04.98 21 EN 2R-1120

Protective functionsImportant note:

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

Frost protectionTo avoid the heating circuit freezing at unfavourable places of the piping system,the frost protection function bypasses the demand driven pump actuation.

Pump actuationIf the outside temperature drops below a value to be set (frost limit), the circulatingpump 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 theminimum room temperature setpoint (CODE 104, 204, 304, 404), the flow tempera-ture is regulated to the setpoint from the time program according to the heatingcharacteristic. The flow temperature control is switched off again after two hoursuntil the flow temperature drops below one of the limiting values again.

Mixing valve and pump forced operationTo avoid the mixing valve seizing (e.g. during the summer), the mixing valve isopened once daily and closed again in heating breaks. To avoid the heating circuitpump 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).

CODE 126 - 226 - 326 - 426

Pump protection interval [h]

CODE 127 - 227 - 327 - 427

Running time of the pump protective function [sec]


EN 2R-1120 22 01.04.98 (EN\2R\EN2R1120.DOC)

Domestic hot water control

Standard controlIf a standard hot water storage tank (hot water storage tank with integrated heatexchanger) is installed in the heating system, the charging pump is switched on assoon 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 value15 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]

Domestic hot water priority settingsIt 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, themixers are closed continuously. If the hot water temperature rises, the mixersopen 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 theset hot water temperature is not reached within this time, the system switchesover to absolute hot water priority.

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 watercharging.

Example: The duration of the hot water priority can be set in CODE 501, 601. "0"means no priority, "40 min." means 40 minutes priority. Thus the priority circuitstarts 20 minutes after start of hot water charging.

CODE 501 - 601

Hot water priority [min]

Domestic hot water charging pump

Switch-on conditionsPrerequisites for switching on the hot water charging pumps are:

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

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

CODE 506 - 606

Boiler temperature influence= 0 → off= 1 → on

Cut-off conditionThe hot water temperature must be greater than or equal to the water temperatureplus a switching difference (CODE No. 503, 603).

CODE 503 - 603

Switching difference [°C]

Charging pump run-on


(EN\2R\EN2R1120.DOC) 01.04.98 23 EN 2R-1120

This function enables the boiler residual heat to be utilized in hot water charging insummer operation and in the transitional period. The charging pump runs on untilthe 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 haselapsed, the pump will stop even the temperature in the tank is still rising.

Boiler setpoint for hot water chargingThe boiler temperature setpoint required for hot water charging is calculated fromthe hot water setpoint plus a boiler temperature excess (CODE No. 504, 604) plusthe switching difference (CODE No. 503, 603).

CODE 503 - 603

Switching hysteresis [°C]

CODE 504 - 604

Hot water charging temperature excess [°C]

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

Hot water heating with separatelyheated hot water storage tank(special application)

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 orwith an electrical heating element. In the case of hot water charging, the gas burneris 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 temperaturesetpoint is influenced or not during hot water charging.

CODE 505 - 605

Boiler requirement= 0 → off= 1 → on

Pump forced operationTo 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]


EN 2R-1120 24 01.04.98 (EN\2R\EN2R1120.DOC)

Boiler / Boiler sequence control

Setpoint settingThe 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 isprocessed.

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

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

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

An analog voltage signal which is connected through the input EX1 to theMCR 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 inputE.g. all MCR 32 / 33 or other controllers installed in the field can pass on their heatdemand 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 boilercontroller, it is important to activate its output through Code 922. Withactivated input and open contact, the demand is automatically approx.80 °C. There is no demand with closed contact. This function can beused, for instance, for an external hot water heater.


(EN\2R\EN2R1120.DOC) 01.04.98 25 EN 2R-1120

3. Flow temperature demand by floatingnormally 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, isset by Code 907.

From this results a "Working band" outside the set heating characteristic, which isalso 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-yearprogram) or via the code table Code 901. The setpoint applies for the common flowtemperature 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).


EN 2R-1120 26 01.04.98 (EN\2R\EN2R1120.DOC)

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 Setting904 20 °C905 1.6 (maximum selection)906 1.3907 20 °C (without hot water charging)908 1

Note: We recommend a separate connection through the input EX 1 for thehot water charging of the external controllers to improve the dynamicresponse


(EN\2R\EN2R1120.DOC) 01.04.98 27 EN 2R-1120

4. Minimum demand (only MCR 200-71)A minimum demand can be determined through the MCR 200-71 time programWEZ (day/year program). The setpoint applies for the common flow temperature inthe hydraulic crossover. These setpoints are always fixed flow setpoints and notoutside temperature dependent.

5. Flow demand byEXCEL 5000 system.

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 flowsetpoint.For this purpose there is a user adress defined as VA_EXCEL________XX, where-by XX is the controller number.

6. Flow demand by aninternal heating circuit program HKZ

An outside temperature controlled demand can be determined through the MCR200-71 time program HKZ.

This internal heating circuit program also works with an independent year timer andserves 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 noinputs 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 outsidetemperature and number of degree days calculation are not integrated.


EN 2R-1120 28 01.04.98 (EN\2R\EN2R1120.DOC)

Setpoint formationExcess

The setpoint of the boiler or of the boiler sequence results from the maximum heatdemand of the consumers and an adjustable excess.For the single boiler controllers this is Code 709 and for the boiler sequence Code903.The excess takes account of piping losses.

LimitationsIn 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.

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

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

Maximum limitation / Boiler overheating(for single boiler)

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

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

Boiler overheating for boiler sequence(MCR 200-71 only

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


(EN\2R\EN2R1120.DOC) 01.04.98 29 EN 2R-1120

Return temperature limitation control

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 outputcan 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 corrosionprotection" function.

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

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

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

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

Total shutdown of the boiler(Code 703 / 802)

If the boiler is suitable for low or extra low temperature operation, it can also shutdown heat generation completely to save energy outside the times of use. Thismust be notified to the controller at start-up through the parameter. If because ofthe 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 onbecause 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 ahigh setting results in the consumers not receiving heat until the boiler minimumtemperature is reached.

Boiler sequence exchange(only MCR 200-71)

Code 909 determines the conditions for the boiler sequence exchange:

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

1 = according to operating hoursIf 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 previousfollowing boiler becomes the base load boiler.

2 = according to outside temperatureIf 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 followingboiler. The sequence of the requirement is the other way round below this outsidetemperature limit.

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


EN 2R-1120 30 01.04.98 (EN\2R\EN2R1120.DOC)

Leading boilerIn systems without hydraulic crossover, it is necessary that system water cancirculate 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 boileris always connected hydraulically with the heating circuit distributor, so that systemwater can flow through it.In the case of boilers which are shut off with butterfly valves, the butterfly valve isopen. 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 returntemperature control for the leading boiler is not in operation.

NOTE: We therefore urgently recommend installing a hydraulic crossover foreach boiler sequence circuit, since without hydraulic crossover, relia-ble control of the return temperature and all flow temperatures is notpossible in all operating conditions.

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

Boiler 1, stage aBoiler 2, stage aBoiler 1, stage bBoiler 2, stage b

NOTE: Manual sequence exchange: If the second boiler must always startfirst 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 alwayssimulated (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 toenergy for condensing boilers.

Outside temperature blockage of the 2nd boilerIf the 72-hour mean value of the outside temperature exceeds the temperature setin 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).


(EN\2R\EN2R1120.DOC) 01.04.98 31 EN 2R-1120

Strategy function(only MCR 200-71)

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

Heating up time (Code 921)As long as the system deviation is larger than set via Code 914, and increases, thetarget 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 deviationstarts to become smaller.

Gradient waiting time (Code 708 / 808)To acquire an accurate temperature gradient with the heat generation running, thegradient waiting time must first have ended, to balance out the effect of all storageprocesses.

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 temperatureIf the strategy temperature exceeds the value of Code 902 the overheating functionis 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.


EN 2R-1120 32 01.04.98 (EN\2R\EN2R1120.DOC)

Control range strategy (Code 914)This setting above and below the setpoint to be reached is used to define the cut-inand 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.


(EN\2R\EN2R1120.DOC) 01.04.98 33 EN 2R-1120

What happens in the strategy control range?

1. Actual value < setpointIf there is a system deviation within the strategy, then the next stage can beswitched on. If this system deviation is present for longer than the heating uptime 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 nothinghappens.

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

4. If the actual value > setpoint + Code 914 (control range) the las boiler swithedon will cut out.

5. The modulating stage controls with the PID settings.


EN 2R-1120 34 01.04.98 (EN\2R\EN2R1120.DOC)

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 thesteady 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 Code713, 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 hasbeen 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 themodulating output is 100 % and all delay times have elapsed a decision can bemade (depending on the PID signal) if a further stage will be switched on.


(EN\2R\EN2R1120.DOC) 01.04.98 35 EN 2R-1120

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 outputwith 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 donot arise, the final sensor configuration should be confirmed through the operatingsequence.

Outside sensor:If no outside sensor is connected, and if there is no outside sensor information onthe 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.

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

The condition for the pump run-on time can be set individually for each boiler of theboiler 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 / 822with the maximum run-on time.

Using a heating controller asboiler return temperature controller

A heating controller can, if the flow temperature demand ist switched of with Code156 / 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 °CCode 117 to 5Code 110 and 111 adjusted to highest values, so that janitor function is out of order.


EN 2R-1120 36 01.04.98 (EN\2R\EN2R1120.DOC)

Alarms / Faults

Burner faultIf the temperature gradient (boiler sensor) is not positive once within 60 minutesafter 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 areused. This delay time is not adjustable.The fault will be reported if the inputs are closed. At the same time the outdoortemperature disable function of the second boiler will be cancelled so that the sec-ond boiler can cut in if necessary.

Boiler pump faultIf the temperature difference between flow and return is > 30 K for more than 15minutes, 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.

Status displays in theoperating sequence

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 outputrelays.

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

First line:WE Total heat generatorOff Operating mode switch to "0" or "Holiday"Parallel Code 910 to 0Sequence Code 910 to 1Second line:FK: 0/1/2 Leading boilerW Setpoint for common flow sensorThird line:A : Int. Internal requirement of the time programA : Bus. External requirement through busA : ext. External requirement through EX2A : 0 - 10 V External requirement EX1X Actual temperature at the common flow sensor

WE1 / WE2

First line:WE... WE1 or WE2: Number of the heat generatorMini.T Minimum limitation for boiler active

if there is no demand and the boiler temperature < tk minand total shut down is not permitted.As soon as there is a demand the line will show "normal".

Totaloff Total cut-off of the heat generatorif there is no demand and the boiler temperature < tk minand total shut down is permittedAs soon as there is a demand the line will show "normal".

off if the burner is cut offNormal if operating mode normalOverheat if boiler temperature > Code 702Second line:P : Pumpx : Boiler temperature actual valueThird line:ST: St1 or St2: Burner stage 1 or 2mod: ... % Component of the modulating stage

WE: OffFK:0 w: 50°CA :Int. x: 52°C MORE

WE1: Mini.TP :On x : 75°CST:St2 mod:100%BACK MORE


(EN\2R\EN2R1120.DOC) 01.04.98 37 EN 2R-1120

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 setseparately 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 pointdetermines from which outside temperature the shift starts.

Examples:


EN 2R-1120 38 01.04.98 (EN\2R\EN2R1120.DOC)

Return interval flushingSo that the return temperature can be measured with sufficient accuracy even withthe distant heating valve closed, the distant heating valve is opened briefly every10 minutes. This guarantees that the limitation sensor in the distant heating returnis sufficiently flushed.

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

100 % functionIn 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.


(EN\2R\EN2R1120.DOC) 01.04.98 39 EN 2R-1120

Control parameters for district heating valveFor the district heating valve control there are three different parameters(proportional band):

1. for only one heating circuit Code 728 default = 1002. for two and more heating circuits Code 751 default = 203. 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 anunmixed 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 externalheat exchanger.

• The heated water flows from above into the unmixed domestic hot water storagetank.

• At the same time cold water flows from the bottom of the unmixed domestic hotwater storage tank to the heat exchanger. In this way the return temperature ofthe 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 lyingbelow the setpoint, the charging process is started.

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

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

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 thisswitch on condition by changing Code 506 to 0.

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

Sollwertbegrenzung Warmwasserladung


EN 2R-1120 40 01.04.98 (EN\2R\EN2R1120.DOC)

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

This is measured at the sensor VF3. This maximum limitation is always activein hot water charging.

Boiler or flow temperature requirementof the hot water control

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

Minimum valve lift forincidental amount suppression

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

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

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


(EN\2R\EN2R1120.DOC) 01.04.98 41 EN 2R-1120

Heat meter connectionThe MCR 200 can process the volume and heat quantity signal of the heat meterfor power and volume limitation.

• With the aid of the primary flow and return sensor, the MCR 200 converts thevolume 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.

Electrical connection


EN 2R-1120 42 01.04.98 (EN\2R\EN2R1120.DOC)

Computing the heat powerand 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 volumeflow under Code 749. The distant heating valve will be closed continously if thesevalues are exceeded.


(EN\2R\EN2R1120.DOC) 01.04.98 43 EN 2R-1120

AIR CONDITION CONTROL


EN 2R-1120 44 01.04.98 (EN\2R\EN2R1120.DOC)

HARDWARE


(EN\2R\EN2R1120.DOC) 01.04.98 45 EN 2R-1120

COMMUNICATION

Controller to controller signalsIn order to exchange data between the MCR 200 controllers there must be installeda 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 bythe heat generators for the control of boilers and/or heat exchangers.

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

3. Collective alarm signalWherever there is an alarm in the system (connected by the bus) this signalwell be activated an can be utilized in every controller as a 5 V signal.

4. Outside temperatureFor 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 sensorcan be connected to any MCR 200 controller.If a different outside temperature is needed for a special purpose (north/southvalues) then may controllers have inputs for an individual outside temperaturesensor. This value must then be defined for every consumer of the correspon-ding controller.

5. Solar / Wind sensorThe information of solar and wind influence is available for every controller onthe bus. There can be only one wind or one solar sensor.

6. Especially for district heating controllers this combined signal was created. Itserves the following purpose:� to inform every heat consumer, that the heat generator is a district heatingheat generator� to tell every district heating heat generator how many heat consumers areactive 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 flowtemperature demand)� to find the heat consumer with the highest flow temperature demand in orderto open this control valve 100 %.


EN 2R-1120 46 01.04.98 (EN\2R\EN2R1120.DOC)

MCR 200 Fax – ControllerIn order to show the values of datapoints on an alarm fax, these datapoints musthave 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 withheat 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 temperatureon the bus


(EN\2R\EN2R1120.DOC) 01.04.98 47 EN 2R-1120

MCR 200 Voice – ControllerIn 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

MCR 200 – EXCEL

C-BusIn order to transmit a flow temperature demand from MCR 200 to an EXCEL heatgenerator the following steps are necessary:

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

LCGesAnf--------XX (XX = Controller-Nr.)___________________

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.


EN 2R-1120 48 01.04.98 (EN\2R\EN2R1120.DOC)

Outside temperature indications

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

Code 1604 input from bus without local sensor information (without delay)

Code 1614 value of local sensor (without delay)

Code 1639 as Code 1640 but without delay

Code 1640 OT sensor information as set under Code 1017sensor with 1 h delay time (for vent. controller)

Code 112 OT sensor information with 72 h delay

Code 146 OT sensor information with the delay of thebuilding time constant (Code 113)


(EN\2R\EN2R1120.DOC) 01.04.98 49 EN 2R-1120

INSTALLATION CHECKLIST


EN 2R-1120 50 01.04.98 (EN\2R\EN2R1120.DOC)

CODE TABLES

Code 904

Slope / curvature(Code 905 / 906)

t [°C]a

CB

-23

42

-E

t[°C]

HC

tKmax

tKmin

20 10 0 -10 -20

Maximum shift(Code 907)

t = Starting temperature of the heating characteristicsHC

CB

-23

48

-E

Code 914 Control rangeSetpoint

Time

Code 704 / 804Gradient waiting time

Time 1, step a Time 1, step aTime 1, step b

Time 1, step a

Target point

Temperaturegradient

Setpointstep

CB

-235

2d-Et RequirementVL

tHC

Contac t open

Boil er off

Contac t openContac t cl ose d

Boil er on

Slope Code 908

I II III IV V VI

Waitingtime

Waitingtime

Boil er off

Return temperature limitation

Code 737154 / 254

Code 734151 / 251

Outside temperature

Slope

Characteristic of the moving returntemperature limitation

Code 735152 / 252

Code 736153/253

CB

-23

83

-E

t[°C]

V

Code 902

Code 901

0,30 10

CB

-23

40

-E

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

2h

6:00 8:00

CB-2079-E

Room temperature

possible early cut-off

with intervention of the frost protection

Day setpoint

Excess

Time

Outside temperature

Setting valuein code table

Fast

heat

ing

uptim

e

0°C CB

-20

77

-E

t = ta RS

CB

RS

AT

E

+10

-10

+5

-50 -20°+20° -15°+10° -10°+5° -5°0°

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

2,0

1,8

1,6

1,4

1,2

1,0

0,8

0,6

0,4

110°

100°

90°

80°

70°

60°

50°

40°

30°

20°

Outside temperature in °CRoom setpoint

Slo

pe

Flo

wte

mpe

ratu

rein

°C

t = ta RSta min

k*(t t )R RS

k*(t t )RS R

Outside temperature

Early cut-off at ...h

2

Roomtemp. < room setpoint

Roomtemp. > room setpointRoomtemp. = room setpoint

CB

-20

84

-E

SERVICE INSTRUCTIONS

SI

Microprozessor Controller MCR 200

EN 2R-1120 GE51 PRERELEASE 0797

Documents

CONTENTS · EN 2R-1120 6 01.04.98 (EN\2R\EN2R1120.DOC) Basic setting After start-up, the controller works initially with a basic setting made in the factory. The slope of this characteristics