Operating instructions US
Contents
1. US Feeding the cable through the lower side of the case ZX WARNING Risk of electrical shock and fire due to cables coming loose gt Fasten the flexible cabling to the case using the strain relief clamps provided gt Cut the left and right plastic flaps using an appropriate tool e g knife and break them out of the case 4 4 2 Connecting the cables gt If a protective conductor is provided or required for the pump connect the productive conductor to the terminal clamps of the controller When connecting the protective conductor observe the following points Make sure that the grounding contact is also con nected to the controller s mains supply side Each terminal may only be connected to a single con necting wire max AWG 14 Fine core cables should use wire end sleeves ferrules gt Only use the original temperature sensors Pt1000 that are approved for use with the controller gt To avoid inductive effects observe the following points The polarity of the sensor contacts is not important Do not lay sensor cables close to 120 VAC or 240 VAC cables minimum separation of 3 94 inch If inductive effects are expected e g from heavy current cables overhead train cables transformer substations radi2. 9 9 2 Testing the temperature sensors 28 3 2 Case OVErViOW cee eee eee 10 10 Dismantling and disposal 30 4 Installation 11 11 Manufacturer s warranty 30 4 1 Overview of the device versions 11 12 Specifications 32 4 2 Opening closing the housing 12 43 Assembly nsii esiisa 13 4 4 Electrical connection eeeeeee 14 3 US 1 About this manual 1 1 Applicability This manual describes the installation commissioning func tion operation maintenance and dismantling of the tempe rature difference controller for solar thermal energy systems When installing the remaining components e g the solar collectors the pump assemblies and the storage unit be sure to observe the appropriate installation instructions provided by each manufacturer 1 2 Users Installation commissioning operation maintenance and dis mantling of the controller may only be performed by trained professional personnel The professional personnel must be familiar with this operation manual and follow the instruc tions contained herein The end user may only perform operating functions which are explained in the quick guide 1 3 Description of symbols 1 3 1 The structure of the warning notices A SIGNAL WORD Type source and consequences of the danger gt Measures for avoiding danger 4 717 025 06 26 Pictogram US 1 3 2 Danger levels in war
3. 8 Operating instructions Temperature Differential Controller 3 inputs 1 output These operating instructions are part of the product gt Read these operating instructions carefully before use gt Keep them over the entire lifetime of the product and gt pass them on to any future owner or user of this product US 717 025 Z02 06 26 Subject to change due to technical improvements US Quick guide for end users Safety WARNING Risk of death by electrocution gt Do not open the controller case gt Only clean the controller case using a dry cloth Installation commissioning maintenance and dismantling of the temperature difference controller may only be performed by trained professional personnel The operational tasks of the end user are limited to reading the temperature values and detecting faults All other opera tional tasks may only be performed by trained professional personnel Reading temperature values The temperature sensors measure the temperatures on the collector T1 in the lower section of the storage tank T2 and if connected in the upper section of the storage tank T3 The temperatures are shown on the display gt Select temperature sensor T1 T2 T3 using the and 7 operating buttons The selected temperature sensor and the current measured temperature are shown on the display Detecting faults gt Check the display regularly gt Incase of
4. faults isolate the cause see Chapter 9 2 717 025 06 26 US gt As soon as it becomes evident that safe operation is no longer possible e g visible damage remove the device from the mains supply immediately gt Have a trained technician remedy the fault Content Quick guide for end users 5 Display overview 17 SALTY ae pa E 6 Commissioning cccceeeeeeeeees 18 Reading temperature values 7 Description of the controller Detecting faults cccceeceeseesteeeeeteeees 2 FUNCTIONS i ecf2 ssc cites cscewrteeeceestts 19 1 About this manual 4 7 1 Automatic storage tank charging 19 1 1 Applicability ccc cvesee aassestesedecsceestevse 4 7 2 Automatic charging shutdown 19 TZ SCY Ske ek aac et esas ante E 4 7 3 Automatic pump blockage 20 1 3 Description of symbols 00000 4 7 4 Tube collector function 20 2 Safety cieee 6 7 5 Holiday function sesser 21 2 1 Proper Usage cccceseessssesesseseeseeeeeeees 6 7 6 Anti freeze FUNCTION 21 2 2 IMproper Usa geenien 6 8 Operations iicescineetitecccticereescsiess 22 2 3 Dangers during assembly and 8 1 Reading temperature values 22 COMMISSIONING ennari 6 8 2 Setting the controller ee 22 2 4 Exclusion of liability cceeee 7 D Faults soea dee 25 3 Description ecccceeeeeeeeeeeeeees 9 9 1 Fault CAUSES iccse 25 3 1 Controller in the solar circuit
5. the button for approx 2 seconds gt The current storage tank maximum temperature is displayed gt Symbol for the T2 temperature sensor and max flash gt To switch to the next setting press the or button gt To exit the menu settings press the button again until the menu display is no longer displayed 22 717 025 06 26 US 8 2 2 Setting the storage tank maximum temperature ZX CAUTION Risk of scalding by excessive domestic water temperature gt Set the storage tank maximum temperature to maximum 140 F gt Install a thermostatic mixer in the hot water pipe and set to maximum 140 F y The menu is open gt Press the button for approx 2 seconds until the sto rage tank maximum temperature flashes gt Change the storage tank maximum temperature using the or buttons gt To save the value press the button 8 2 3 Selecting the temperature unit vy The menu is open gt Press the button again until C F flashes gt Press the button for approx 2 seconds until the desired temperature unit C or F flashes 8 2 4 Activating the tube collector function NOTE Incorrectly setting the controller can compromise the effici ency of the solar energy system gt Only activate the tube collector function with vacuum tube collectors 717 025 06 26 23 US vy The menu is open gt Press the button again unti
6. 6 104 122 140 158 176 Resistance Q 1117 1155 1194 1232 1271 1309 Temperature F 194 212 230 248 266 284 Resistance Q 1347 1385 1423 1461 1498 1536 Temperature F 302 320 338 356 Resistance Q 1573 1611 1648 1685 717 025 06 26 29 US 10 Dismantling and disposal Z WARNING Risk of death by electrocution gt Remove the controller from the power supply before dis mantling the controller gt To dismantle the controller follow the assembly instruc tions in the reverse order gt Dispose of the controller in accordance with the regional regulations 11 Warranty Guarantee For this product the manufacturer assumes the following guarantee services to the specialist dealer The manufacturer will remove all manufacturing and mate rial faults that occur in the controllers and affect the correct functioning of the device during the guarantee period of 24 months Natural wear and tear does not constitute a malfunc tion No warranty or guarantee can be offered if the fault was caused by the end user or by third parties in an attributable manner after the purchase contract is made with the end user especially by unprofessional installation or commissio ning incorrect or negligent handling excessive loading use of improper equipment faulty construction work unsuitable construction location or improper operation or use Warranty or guarantee claims shall only be accepted if the specialist deale
7. all tick on the anti freeze symbol appears goes out 9 Faults The controller was conceived for years of continuous trouble free operation Nevertheless faults may occur In most cases the fault however does not lie with the controller but rather with the peripheral components The following description covers the most common problems encountered with the controller gt Only send in the controller if none of the following faults are present 9 1 Fault causes A WARNING Risk of death by electrocution gt Remove the controller from the power supply before ope ning the case 717 025 06 26 25 US Controller does not appear to function at all Secondary symptoms Possible cause remedy The controller display is No power supply present blank gt Have a specialist check the fuse and the supply cable The pump which is connected to the controller is not running although its switch on conditions have been ful filled sun symbol in display Secondary symptoms Possible cause remedy The pump symbol rotates The pump connecting cable in the display is not connected interrupted or the fuse in the controller is burned out gt If necessary have a specialist replace the fuse Only use Littelfuse 215 004 fuses Replacement fuse is located in the case e The pump symbol does Operating switch is set to not rotate manual e Display is lit with a red Set the operating sw
8. aulty or not correctly connected e The isolating valve in the solar circuit is still closed e Air is in the solar circuit Since a standard circulation pump cannot eliminate air bubbles inside the piping system the heat transfer medi um circuit comes to a standstill gt Have a specialist check the solar energy system to pre vent damage gt Once the fault has been remedied press any button to acknowledge the fault message 9 2 Testing the temperature sensors 9 2 1 Safety Only trained personnel may test the temperature sensors 9 2 2 Testing the resistance values ZX WARNING Risk of death by electrocution gt Remove the controller from the power supply before ope ning the case 28 717 025 06 26 US The temperature is recorded by resistance sensors These are PT1000 temperature sensors Depending on the temperature the resistance value also changes A potentially defective sen sor can be checked using an ohmmeter Measuring resistance values gt Disconnect the corresponding temperature sensor from the controller gt Measure the resistance value The typical resistance values depending on the temperature are listed in the following table Please observe that small deviations are acceptable Temperature sensor resistance values Temperature F 22 4 14 32 50 68 Resistance Q 882 922 961 1000 1039 1078 Temperature F 8
9. d the lower area of the storage tank T2 As soon as the temperature in the collector T1 is 16 diff F constant fixed value higher than the temperature in the storage tank T2 the following display appears e The sun symbol is displayed If no safety limits prohibit the pump from operating the pump is switched on The following display appears e The pump symbol rotates If the temperature difference falls below 8 diff F constant fixed value the pump is switched off The sun symbol is no longer shown in the display 7 2 Automatic charging shutdown If the lower area of the storage tank T2 reaches the set maxi mum storage tank temperature factory setting of 140 F charging is stopped A temperature of 6 diff F below the maximum storage tank temperature must first be reached before charging can be resumed 717 025 06 26 19 US The following displays appear e The pump symbol does not move e The sun symbol is displayed e The max indication flashes in the storage tank symbol 7 3 Automatic pump blockage During time periods of high solar irradiance the temperature T1 of the heat transfer fluid can exceed 266 F The heat trans fer fluid evaporates In this case the pump is blocked for pro tection purposes until the temperature drops below 261 F The following displays appear e The pump symbol does not move e The sun symbol is displayed e The vapor symbol flashes 7 4 Tube collector func
10. ersion B Prefabricated with mains connection cable and pump socket Input temperature sensor m Mains connection cable Pump socket Output not occupied 717 025 06 26 11 US 4 2 Opening closing the housing Z WARNING Risk of death by electrocution gt Remove the controller from the power supply before ope ning the case gt Make sure that the power supply cannot be unintentio nally switched on gt Do not damage the case gt Only switch the power supply back on after the case has been closed The top of the case is retained by two retaining pegs on the upper edge of the lower half of the case and fastened with a screw 4 2 1 Opening the case gt Loosen the screw and remove the upper case in an upwards direction 4 2 2 Closing the case gt Position the upper case at an angle to the lower case Insert the hinge grooves into the retaining pegs of the lower case gt Pivot the upper case down and feed the operating but tons through the matching holes gt Fasten the case tightly with the screw 12 717 025 06 26 Hinge grooves Upper case Lower case o ce 5 39 inch 6 02 inch 5 93 inch US 4 3 Assembly ZX WARNING Risk of electric shock and fire if assembled in a moist envi ronment gt Only assemble the controller in an area where the protec tion class is sufficient 4 3 1 Assembli
11. itch to background automatic operation e OFF flashes 26 717 025 06 26 US Short circuit symbol and warning display appear Secondary symptoms Possible cause remedy A e The pump symbol does Temperature sensor or its sup not rotate ply cable short circuited e Display background gt Have a specialist check the alternately flashes red supply cables of the tempe and yellow rature sensors and that they e Pump is short circuited are correctly connected to the controller NOTE In case of T3 short circuits the pump does not stop ZTT Interruption symbol and warning signal appear l Secondary symptoms Possible cause remedy A e The pump symbol does Temperature sensor T1 or T2 or not rotate its supply cable is interrupted e Display background Note No message appears for alternately flashes red T3 and yellow gt Have a specialist check the e Sun symbol goes out supply cables of the tempe rature sensors and that they are correctly connected to the controller NOTE If T3 is interrupted no message appears 717 025 06 26 27 US SYS flashes in the controller display cue Possible cause remedy jj SYS means there is a system error This means that despite the A pump running a temperature difference exceeding 160 diff F between the collector and the storage tank was recorded The following causes are possible e The pump is f
12. l the symbol for T1 flashes gt Press the button for approx 2 seconds until the sym bol for T1 switches from the upper to the lower position 8 2 5 Activating deactivating the holiday function NOTE Incorrectly setting the controller compromises the efficiency of the solar energy system gt Only activate the holiday function when you intend to be absent for an extended period gt Deactivate it again after having returned vy The menu is open gt Press the 4 button until the holiday symbol flashes gt Press the button for approx 2 seconds until the small tick on the holiday symbol appears goes out 8 2 6 Activating deactivating the anti freeze function CAUTION System can freeze despite the activated anti freeze function During a power outage the anti freeze function does not Operate During long term time periods of frost the system can freeze despite the anti freeze function gt If frost is expected for a long term period of time only operate the system with anti freeze 24 717 025 06 26 Rv US NOTE Incorrectly setting the controller can compromise the effici ency of the solar energy system gt Only activate the anti freeze function for solar energy sys tems that are not filled with anti freeze y The menu is open gt Press the button again until the anti freeze symbol flashes gt Press the button for approx 2 seconds until the sm
13. less liability is obligatory by law 717 025 06 26 31 US 12 Specifications Temperature Difference Controller Operating voltage 120 VAC 15 60 Hz optional 240 VAC 15 60 Hz Controller s own consumption lt 0 001 HP 3 inputs for tem perature recording Pt1000 1 output Switch relay Switching performance max 0 5 HP 120 VAC 1 HP 240 VAC Fuse Littelfuse 215 004 The output is protected against overloading and short circuiting Display Animated LCD display 2 colour back ground Protection class IP 20 DIN 40050 Permitted ambient 32 VP we 133 AF temperature Assembly Wall mounted Weight 19 54 oz 0 55 kg include cable Case Recyclable 3 piece plastic case Dimensions 6 3 W x 6 18 H x 1 85 D 160 mm x 157 mm x 47 mm LxBxH Temperature sensors 2x Pt1000 4 9 ft silicone cable with bushing Measuring range up to 356 F 0 9 ft twisted single conductor Flat surface sensors with compression cable lug Measuring range up to 221 F 32 717 025 06 26
14. message for evaporation of the collector fluid Displays message for sufficient heat supply 717 025 06 26 17 US 6 Commissioning 6 1 Testing the pump CAUTION Damage to pump caused by drawing in air gt Make sure that the solar circuit is filled with collector fluid The controller case is closed The solar energy system is filled Connect the mains supply To switch on the pump set the operating LR Man vyYA SN switch to the upper position gt The display is lit with a red background gt On appears in the display After approx 3 seconds on begins to flash gt To switch off the pump set the operating P switch to the lower position P gt The display is lit with a red background gt Off appears in the display After approx 3 seconds off begins to flash CAUTION The incorrect operating mode may cause the system to shut down or impair proper functioning gt After testing the pump set the operating switch to auto matic operation 18 717 025 06 26 lt Auto US gt To set the controller in automatic operation set the ope rating switch to the middle position gt The display is lit with a yellow background gt Aut is shown in the display for approx 3 seconds 7 Description of the controller func tions 7 1 Automatic storage tank charging The controller constantly compares the temperatures bet ween the collector T1 an
15. ng the controller ZX CAUTION Risk of injury and damage to the case when drilling gt Do not use the case as a drilling template Choose a suitable installation site Drill the upper fastening hole Screw in the screw Remove the upper case Hang the case in the recess Mark the position of the lower fastening holes 2 9 Remove the case again Drill the lower fastening holes Re hang the case in the recessO Screw the case firmly using the lower fastening holes and Mount the upper case vvvvvvvvvy v 717 025 06 26 13 US 4 4 Electrical connection WARNING Risk of death by electrocution gt Remove the controller from the power supply before ope ning the case gt Observe all guidelines and regulations of the local electri city supplier 4 4 1 Preparing the cable feed Depending on the type of installation the cables may enter the device through the rear of the case or the lower side of the case Feeding the cable through the rear of the case N WARNING Risk of electrical shock and fire due to cables coming loose gt Install an external strain relief for the cables gt Remove the plastic flaps from the rear side of the case using an appropriate tool 14 717 025 06 26
16. ning notices Danger level Probability of oc Consequences currence resulting from non compliance A DANGER Imminent threat of Death serious danger bodily injury A WARNING Possible threat of Death serious danger bodily injury A CAUTION Possible threat of Minor bodily injury danger CAUTION Possible threat of Property damage danger 1 3 3 Notes Note Notes on easier and safer working habits gt Measures for easier and safer working habits 1 3 4 Other symbols and markings Symbol Meaning v Condition for action gt Call to action gt Result of action List Emphasis on Emphasis on issue at hand issue at hand 717 025 06 26 5 US 2 Safety 2 1 Proper usage The temperature difference controller below called control ler may only be used for controlling solar thermal systems within the permissible ambient conditions see Chapter 12 2 2 Improper usage The controller must not be operated in the following envi ronments e Outdoors e In moist rooms e In rooms where highly flammable gas mixtures can occur 2 3 Dangers during assembly and commissioning The following dangers exist during assembly commissioning of the controller and during operation in case of assembly errors e Risk of death by electrocution e Risk of fire due to short circuit e Damage to any of the constructional fire safety measures present in the building due t
17. o and television devices amateur radio stations microwave devices etc then the sensor cables must be adequately shielded 717 025 06 26 15 US gt Sensor cables may be extended to a maximum length of ca 3937 inch When using extension cables select the following cable cross sections AWG 18 up to 1968 inch long AWG 15 up to 3937 inch long gt Connect the cables in accordance with the terminal plan see Chapter 4 4 3 or 4 4 4 4 4 3 Terminal plan 120 V version Sensor wiring Class 2 Look at the product label for the version 4 4 3 Terminal plan 240 V version Sensor wiring Class 2 Look at the product label for the version 16 717 025 06 26 US 5 Display overview ICICI r A a A max amp y Ge KY 11 QO OO CIOIGIONS Temperature sensor symbols Displays the temperature values and faults e g short circuit interruption see p 27 or SYS system error see p 28 Holiday function see p 21 Anti freeze function see p 21 Selecting the temperature unit C F Tube collector function see p 20 Setting the maximum storage tank temperature Solar circuit symbols Displays message Maximum storage tank temperature has been reached Warning display if faults occur e g short circuit interruption see p 27 or SYS system error see p 28 Displays
18. o incorrectly installed cables e Damage to the controller and connected devices due to improper ambient conditions inappropriate power sup ply and connecting prohibited devices Therefore all safety regulations apply when working on the mains supply Only electricians may perform work that requires opening the controller such as connecting or repla cing the fuse gt When laying cables ensure that no damage occurs to any 6 717 025 06 26 US of the constructional fire safety measures present in the building gt Make sure that the permissible ambient conditions at the installation site in particular the specified protection class are not exceeded see Chapter 12 gt Factory labels and markings may not be altered removed or rendered unreadable gt Before connecting the device make sure that the power supply matches the specifications on the type plate gt Make sure that all devices which are connected to the controller conform to the technical specifications of the controller gt Secure the device against unintentional start up gt All work on an open controller must be performed with the mains supply removed gt Protect the controller against overloading and short cir cuiting 717 025 06 26 7 US 2 4 Exclusion of liability The manufacturer cannot monitor the compliance to this manual as well as the conditions and methods during the installation operation usage and main
19. r and the storage tank the pump is switched on The pump extracts the heat transfer fluid from the lower cooler area of the storage tank and pumps it to the collector The heat transfer fluid in the collector is heated by the sun and flows back to the storage tank The heat transfer fluid heats the domestic water via a heat exchanger located in the storage tank 3 2 Case overview Display graphic display animated for operating and setting the system settings of the controller Operating switch The following modes of operation can be switched Operating buttons Manual qe 28 H Arrow up for commissioning for scrolling up through the and testing for function 3 menus Auto SS for normal operation Scape key Off Arrow down for scrolling down through the for switching off the menus system lt Manual lt Auto rr lt Off e na Connections Pump mains grid temperature sensor 10 717 025 06 26 US 4 Installation ZX WARNING Risk of electric shock caused by unintentional start up gt Make sure that the power supply cannot be unintentio nally switched on 4 1 Overview of the device versions The solar thermal controller is supplied in different versions 4 1 1 Version A Standard without connection cable Input temperature sensor r Output power connection Output pump Output not occupied 4 1 2 V
20. r is notified of the fault immediately after it is discove red The manufacturer must be notified of the fault via the 30 717 025 06 26 US specialist dealer A copy of the proof of purchase must be enclosed A precise description of the fault is required for processing The warranty guarantee expires 24 months after the purchase contract was made by the end user unless the manufacturer expressly agrees to extend the period in writing The dealer s guarantee based on the purchase contract with the end user is not affected by this warranty The manufac turer can choose to fulfill the warranty guarantee either by repair or replacement This does not include the costs incurred for exchange shipping or re installation Replacement of the product does not extend the warranty guarantee period the original date of purchase as shown on the proof of purchase remains valid If the product can neither be repaired or replaced or if this does not occur within a suitable period in spite of the specifi cation of an extension period in writing by the customer the reduction in value caused by the fault shall be replaced or if this is not sufficient taking the interests of the end customer into consideration the contract is cancelled Any further claims against the manufacturer based on this warranty guarantee obligation in particular claims for damages due to lost profit loss of use or indirect damages are excluded un
21. re difference between the collector and the storage tank is only 8 diff F the pump is switched off again 7 6 Anti freeze function If the anti freeze function is activated the controller switches the pump on as soon as the collector temperature falls below 41 F The heat transfer fluid is thus pumped through the collector and the system is prevented from freezing If the collector reaches a temperature of 45 F the pump is swit ched off again Despite the anti freeze function being activated the solar energy system can freeze under the following conditions In a power outage If frost is expected for a long term period of time Therefore solar energy systems which are exposed to frost for an extended period of time should only be operated with anti freeze 717 025 06 26 21 US 8 Operation CAUTION The incorrect operating mode may cause the system to shut down or impair proper functioning gt Make sure that the operating switch is set to automatic operation 8 1 Reading temperature values NOTE The temperature in the above storage tank is only displayed if the temperature sensor T3 not included is also connected gt Select temperature sensor T1 T2 T3 using the and buttons gt The selected temperature sensor and the current measured temperature appear in the display 8 2 Setting the controller 8 2 1 Menu operation gt To open the menu settings press
22. tenance of the system controller Improper installation of the system may result in damage to property and as a result to bodily injury Therefore we assume no responsibility and liability for loss damage or costs which result from or are in any way related to incorrect installation improper operation and incorrect usage and maintenance Similarly we assume no responsibility for patent right or other right infringements of third parties caused by usage of this system controller The manufacturer reserves the right to make changes to the product technical data or assembly and operating instruc tions without prior notice gt As soon as it becomes evident that safe operation is no longer possible e g visible damage remove the device from the mains supply immediately 8 717 025 06 26 US 3 Description 3 1 Controller in the solar circuit 3 1 1 The purpose of the controller The controller controls the solar thermal system 3 1 2 The structure of the solar circuit Temperature sensor 1 Temperature difference controller Collector Storage tank 717 025 06 26 US 3 1 3 The function of the solar circuit The controller constantly compares the temperatures between the collector T1 and the lower area of the storage tank T2 via temperature sensors Once the sun heats the collector and there is a temperature difference of 16 diff F constant fixed value between the collecto
23. tion Due to its construction the collector temperature T1 can only be inaccurately recorded with vacuum tube collectors in many cases there are no immersion sensors the sensor is outside the collector pipe In these cases the solar circuit must be briefly activated at regular intervals to transmit the actual heat from the collector pipe to the sensor T1 If the tube collector function is activated the controller automati cally switches the pump on every 30 minutes for 30 seconds The following displays appear e The tube collector funktion shows T1 in the lower position 20 717 025 06 26 US 7 5 Holiday function The holiday function is used to cool down a completely hea ted storage tank again via the collector The storage tank can heat up too much e g if no hot water is extracted from the storage tank over an extended period of time holiday and intense solar irradiance A completely heated storage tank subjects the solar energy system to a higher thermal load and the solar fluid can evaporate If the holiday function is activated the storage tank is cooled as follows If the temperature in the storage tank rises up to 20 diff F below the set storage tank maximum temperature the controller attempts to discharge the lower section of the storage tank to 95 F e g at night To do so the pump is automatically switched on once the collector is 16 diff F warmer than the storage tank If the temperatu
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