Installation and operating instructions EN
Contents
1. Removethe controller from the power supply before opening the case The temperature is recorded by resistance sensors These are Pt1000 temperature sensors Depending on the temperature the resistance value also changes A potentially defective sensor can be checked using an ohmmeter Measuring resistance values gt Disconnect the corresponding temperature sensor from the controller Measure the resistance value The typical resistance values depending on the temperature are listed in the following table Please note that small devia tions are permissible Temperature sensor resistance values Temperature C 30 20 10 0 10 20 Resistance Q 882 922 961 1000 1039 1078 Temperature C 30 40 50 60 70 80 Resistance Q 1117 1155 1194 1232 1271 1309 Temperature C 90 100 110 120 130 140 Resistance Q 1347 1385 1423 1461 1498 1536 Temperature C 150 160 170 180 Resistance Q 1573 1611 1648 1685 10 Dismantling and disposal N DANGER be 8 Risk of death by electrocution Remove the controller from the power supply before dismantling the controller gt To dismantle the controller follow the assembly instructions in the reverse order gt Dispose of the controller in accordance with the regional regulations 11 Legal warranty The manufacturer assumes the following warranty2. Installation and operating instructions Temperature differential controller 2 inputs 1 output 719450 ah 719 450 Z01 06 33 Subject to change due to technical improvements LL Table of Contents 1 1 1 1 2 1 3 2 2 1 2 2 2 3 2 4 2 5 3 3 1 3 2 A 4 1 4 2 4 3 5 About this manual 3 Applicability sse 3 SONS 3 Description of symbols 4 Safety ees 5 Proper usage esses 5 Improper usage 5 Dangers during assembly and commissioning eeeee 6 Detecting faults 7 Exclusion of liability 7 Description 9 Controller in the solar circuit 9 Case overview Installation Opening closing the case 11 Assembly eese 12 Electrical connection 13 Display overview 17 6 Commissioning 18 7 Description of the controller functions eeseussss 19 7 1 Switch on switch off temperature difference 19 7 2 Maximum storage tank temperature eee 19 7 3 Maximum collector temperature 20 7 4 Tube collector function F1 20 7 5 Anti freeze function F2 21 8 Operation 22 8
3. K higher than the temperature in the storage tank T2 and if no safety limits prohibit the pump from operating the pump is switched on 4 The following display appears The pump symbol is displayed If the temperature difference falls below 4 K adjust able in setup gt P3 K the pump is switched off The pump symbol is no longer shown in the display 7 2 Maximum storage tank temperature The maximum storage temperature function is to pre vent the hot water tank from overheating If the lower area of the storage tank T2 reaches the set maximum EN storage tank temperature factory setting of 60 C gt P1 charging is stopped A temperature of 3 K below the maximum storage tank temperature must first be reached before charging can be resumed The following display appears The display flashes max Note The display only shows max when temperature sensor T2 is also selected 7 3 Maximum collector temperature During periods of high solar irradiance the tempera ture T1 of the heat transfer fluid can exceed 130 C The heat transfer fluid evaporates In this case the pump is blocked for protection purposes until the temperature drops below 127 C The following display appears The display flashes max Note The display only shows max when temperature sensor T1 is also selected 7 4 Tube collector function F1 Due to its construction the collector temperature T1 can only be inaccura
4. damp environment Only assemble the controller in an area where the degree of protection is sufficient 4 2 1 Assembling the controller N CAUTION Risk of injury and damage to the case when drill ing 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 9 8 Remove the case again Drill the lower fastening holes Hang the case up again in the recess Screw the case firmly using the lower fastening holes and Mount the upper case vvvvvvvvvy v 4 3 Electrical connection c WARNING Risk of death by electrocution Removethe controller from the power supply before opening the case gt Observe all guidelines and regulations of the local electricity supplier NOTE The device is to be connected to the grid by means of a plug with grounding contact or in the case of a fixed electrical installation via a disconnection device for complete disconnection in accordance with the installation guidelines 4 3 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 EN Feeding the cable through the rear of the case diagram 1 ZA WARNING Risk of electrical shock an
5. obligations The manufacturer will rectify all manufacturing and material faults that occur in the controller and affect the correct functioning of the device during the war ranty period Natural wear and tear does not constitute a malfunction No warranty claims can be accepted if a fault occurring after the purchase contract is made with the end user can be attributed to the end user or to third parties especially in case of unprofessional installation or commissioning incorrect or negligent handling improper transport excessive loading use of improper equipment faulty construction work unsuit able construction location or improper operation or use Warranty claims shall only be accepted if the spe cialist dealer is notified of the fault immediately after it is discovered The manufacturer must be notified of the fault via the specialist dealer A copy of the proof of purchase must be enclosed A precise description of the fault is required for processing The warranty expires 24 months after the purchase con tract was made by the end user unless the manufac turer expressly agrees to extend the period in writing The dealer s warranty based on the purchase contract with the end user is not affected by this warranty obligation The manufacturer can choose to fulfill the warranty either by repair or replacement This does not include the costs incurred for exchange shipping or re installation If the product can neither be
6. tube collector function F lofF 1 F2 anti freeze function FeoFF F3 temperature format C F F3 OC P 4 FPSPL Reset A 24 719 450 06 33 EN 8 2 3 Setting the storage tank maximum tem perature P1 A DANGER Risk of scalding due to storage tank temperature of over 60 C gt Install a thermostatic mixer in the hot water pipe and set to a maximum 60 C V The P1 menu is open gt Press the button for approx 2 seconds until the storage tank maximum temperature flashes gt Change the storage tank maximum temperature using the or 4 buttons gt To save the value press the button 8 2 4 Setting the switch on temperature dif ference P2 V The P2 menu is open gt Press the 3j button for approx 2 seconds until the switch on temperature difference flashes gt Change the switch on temperature difference using the 3 or 4 buttons gt To save the value press the button 719 450 06 33 25 8 2 5 Setting the switch off temperature dif ference P3 V The P3 menu is open gt J gt Press the button for approx 2 seconds until the Lj switch off temperature difference flashes gt Change the switch off temperature difference using the or buttons gt To save the value press the button 8 2 6 Activating the tube collector function F1 NOTE Incorrectly setting the con
7. comply with the specified degree of protection gt Factory labels and markings may not be altered removed or rendered unreadable Before connecting the device make sure that the power supply matches the specifications on the type plate Make sure that all devices which are connected to the controller conform to the technical specifica tions of the controller Secure the device against unintentional commission ing All work on an open controller must be performed with the mains supply disconnected Protect the controller against overloading and short circuiting 2 4 Detecting faults Check the display regularly In case of faults isolate the cause see chapter 9 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 Have professional personnel remedy the fault 2 5 Exclusion of liability The manufacturer cannot monitor the compliance to this manual as well as the conditions and methods dur ing the installation operation usage and maintenance of the controller Improper installation of the system may result in damage to property and as a result in 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 opera tion incorrect execution of installation work and incor rect usage and m
8. repaired or replaced or if this does not occur within a suitable period in spite of the specification 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 obligation in particular claims for dam ages due to lost profit loss of use or indirect damages are excluded unless liability is obligatory by law 12 Technical data Temperature differential controller Operating voltage 230 V 15 96 50 Hz optional 115 V 15 96 60 Hz Own consumption lt 1W Inputs 2 temperature recording Pt1000 Output 1 1 x relay switched output switching performance max 800 W 230 V Switch on temperature difference 4 20 K factory setting 8 K Switch off temperature difference 2 18 K factory setting 4 K Display LCD display 48 segments Degree of protection IP 20 DIN 40050 Permitted ambient temperature 0 to 45 C Installation wall mounted Weight 250g Case recyclable 3 piece plastic case Dimensions L x W x H mm 137 x 134 x 38 Temperature sensors 2 x Pt1000 1 5 m silicone cable measuring range up to 180 C Fuse 4AMT 250V 37 38 39 719450
9. sys tem to shut down or impair proper functioning Make sure that the operating switch is set to automatic operation On the display you can see the temperature readings of the individual temperature sensors The controller settings may be set in the settings menu 8 1 Reading the temperature values gt Select the temperature sensor using the F3 and buttons 1 T1 2 T2 The selected temperature sensor and the current gt mere measured temperature appear in the display e H e H Temperature sensor T1 display with temperature reading from collector and active pump C ee J34 Temperature sensor T2 display with temperature reading from lower area of storage tank and active pump EN 8 2 Setting the controller 8 2 1 Using the settings menu gt To open the settings menu press the button for approx 2 seconds 4 gt Setting P1 storage tank maximum temperature P BD is displayed I piayea gt To switch to the next setting press the amp 4 button gt To exit the settings menu press the amp 4 button again until the temperature sensor and tempera ture reading are shown again 8 2 2 Overview of menu settings l 58 Temperature reading T1 or T2 ala hold down for 2 seconds p n 50 P1 storage tank maximum r temperature 8 P2 switch on temperature difference 4 P3 switch off temperature difference F1
10. 1 Reading the temperature values 22 8 2 Setting the controller 23 9 M Maintenance 29 9 1 Fault causes 29 9 2 Testing the temperature sensors 33 10 Dismantling and disposal 34 11 Legal warranty 35 12 Technical data 37 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 gt and pass them on to any future owner or user of this product 2 1 About this manual 1 4 Applicability This manual describes the installation commissioning function operation maintenance and dismantling of the temperature differential controller for solar thermal energy systems When installing the remaining compo nents 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 dismantling of the controller may only be performed by trained professional personnel Before commissioning the controller must be professionally assembled and installed by professional personnel in accordance with the applicable regional and transregional regulations as well as the safety instructions and general instructions within this installation and instruction manual The
11. 28 EN 6 Commissioning 6 1 Testing the pump CAUTION Damage to pump caused by dry operation Make sure that the solar circuit is filled with heat transfer fluid The controller case is closed All connections are properly made The solar energy system is filled Connect the mains supply To switch on the pump set the operating switch to gt the upper position on Cc on Onappears in the display After approx 3 sec RIOT onds on flashes in alternation with the display B lt SSS gt To switch off the pump set the operating switch to gt the lower position off Pr rr gt offappears in the display After approx 3 sec onds off flashes in alternation with the display al CAUTION The incorrect operating mode may cause the sys tem to shut down or impair proper functioning gt After testing the pump always set the operating switch to automatic operation 18 719 450 06 33 gt To set the controller in automatic operation move H f t ur the operating switch to the middle position Auto is shown in the display for approx 3 ial Auto seconds 7 Description of the controller functions 7 1 Switch on switch off temperature difference The controller constantly compares the temperatures between the collector T1 and the lower area of the storage tank T2 As soon as the temperature in the collector T1 is 8 K adjustable in setup gt P2
12. aintenance Similarly we assume no responsibility for patent right or other right infringements of third parties caused by usage of this controller The manufacturer reserves the right to make changes to the product technical data or assembly and operat ing instructions without prior notice j 7 NL 3 Description 3 1 Controller in the solar circuit 3 1 1 The purpose of the controller The controller controls the pump in a solar thermal system 3 1 2 The structure of the solar circuit Temperature sensor 1 collector sensor E Temperature difference controller aba Storage tank Y Temperature sensor 2 lower area of storage tank 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 dif ference of 8 K adjustable parameter between the col lector 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 Operating switch The following modes of operation can be sele
13. ause remedy The controller No power supply is present display is blank Have professional person nel check the fuse and the supply cable EN The pump which is connected to the controller is not running although its switch on conditions have been fulfilled Secondary symptoms Possible cause remedy The pump symbol is shown in the display The pump connecting cable is not connected interrupt ed or the fuse in the pump is burned out gt If necessary have profes sional personnel replace the fuse The pump symbol is not shown in the display Offis displayed in alternation with the temperature reading Operating switch is set to Off gt Set the operating switch to automatic operation 30 719 450 06 33 Pump symbol display example gt mpm 4 cc 56 Z E ar T1 temperature sensor with temperature reading and oFF display example i 2352 a error T1 temperature sensor with short circuit symbol and warning sign example n a E t gt E tc ror T1 temperature sensor with interruption symbol and warning sign example A A EN Short circuit symbol and warning display appear Possible cause remedy Temperature sensor T1 or T2 or its supply cable is short circuited Have professional personnel check the supply cables of the temperature sensors and that they are corr
14. cted On for commissioning and testing for function Auto for normal operation Off to switch off the pumps On lt Auto lt Off ee 10 719 450 06 33 Display Display for controller operation and system settings Operating buttons Arrow up SET button Arrow down Connections grid pump temperature sensors I N Hinge grooves Operating buttons Upper case Lower case EN 4 Installation 4 1 Opening closing the case N DANGER Risk of death by electrocution Remove the controller from the power supply before opening the case gt Make sure that the power supply cannot be uninten tionally switched on gt Do not damage the case Only switch the power supply back on after the case has been closed The top of the case is held in place by two retaining pegs on the upper edge of the bottom half of the case and fastened with a screw 4 1 1 Opening the case gt Loosen the screw and remove the upper case in an upwards direction 4 1 2 Closing the case gt Place the upper case over the lower case at an angle Insert the hinge grooves into the retaining pegs of the lower case gt Pivot the upper case down and feed the operating buttons through the matching holes gt Fasten the case tightly with the screw 719 450 06 33 11 4 2 Assembly ZA WARNING Risk of electric shock and fire if assembled in a
15. d fire due to cables com ing 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 Feeding the cable through the lower side of the case diagram 2 ZA WARNING Risk of electrical shock and fire due to cables com ing 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 appro priate tool and break them out of the case 4 3 2 Connecting the cables gt Ifa protective conductor is provided or required for the pump connect the protective conductor to the terminal clamps of the controller When connecting the protective conductor observe the following points 14 719 450 06 33 b PP pamona pman LO BEIBBRE BEER ame C 5 D EDE E ES Diagram 1 Cable feed from the rear v H Hp E B Hh Br Hr HJ H5 Hh E D SESIDIGIESID I GESDIGESD e Diagram 2 Cable feed from below Make sure that the grounding contact is a
16. ectly connected to the controller Interruption symbol and warning signal appear Possible cause remedy Temperature sensor T1 or T2 or its supply cable is interrupted Have professional personnel check the supply cables of the temperature sensors and that they are correctly connected to the controller 719 450 06 33 31 EN SYS and the warning symbol flash in the control ler display Possible cause remedy SYS means there is a system error This means that despite the pump running a temperature differ ence exceeding 80 K between the collector and the storage tank was recorded The following causes are possible The pump is faulty or not correctly connected The isolating valve in the solar circuit is closed There is air in the solar circuit Since a standard circulation pump cannot elimi nate air bubbles inside the piping system the heat transfer medium circuit comes to a standstill Have professional personnel check the solar energy system to prevent damage gt Once the fault has been remedied press any but ton to acknowledge the fault message 32 719 450 06 33 L Lc Ln tc ror SYS display and warning sign example 9 2 Testing the temperature sensors 9 2 1 Safety Only professional personnel may test the temperature sensors 9 2 2 Testing the resistance values mt Z DANGER Risk of death by electrocution
17. ial controller below called controller may only be used for controlling solar ther mal systems within the permissible ambient conditions see chapter 12 2 2 Improper usage The controller must not be operated in the following environments outdoors in damp rooms in rooms where highly flammable gas mixtures can occur in rooms in which the operation of electrical and electronic components may cause dangers to arise The following dangers exist during assembly commis sioning of the controller and during operation in case of assembly errors 2 3 Dangers during assembly and commis sioning Risk of death by electrocution Risk of fire due to short circuit Damage to any of the constructional fire safety measures present in the building due to incorrectly installed cables Damage to the controller and connected devices due to improper ambient conditions inappropriate power supply and connecting prohibited devices or faulty devices and incorrect assembly or installation Therefore all safety regulations apply when working on the mains supply Only electricians may perform work that requires opening the controller such as con nection work When laying cables ensure that no damage occurs to any of the constructional fire safety measures present in the building Make sure that the permissible ambient condi tions at the installation site are not exceeded see chapter 12 Besure to
18. lso connected to the controller s mains supply side Each terminal may only be connected to a single connecting wire max 2 5 mm The terminals are suitable for connection without sleeves stranded wires are to be twisted 1 twist per 20 mm Only use the original temperature sensors Pt1000 that are approved for use with the controller gt Observe the following points The polarity of the sensor contacts is not important Do not lay sensor cables close to 230 volt or 400 volt cables minimum separation 100 mm If inductive effects are expected e g from heavy current cables overhead train cables transformer substations radio and television devices amateur radio stations microwave devices etc then the sensor cables must be adequately shielded Sensor cables may be extended to a maximum length of 100 m When using extension cables select the following cable cross sections 0 75 mm up to 50 m long 1 5 mm up to 100 m long Connect the cables in accordance with the terminal plan 4 3 3 Terminal plan 5 Display overview 4 Symbol for pump operation Symbol for anti frost function see p 21 maximum collector temperature see p 19 20 Display for temperature sensor temperature readings and fault symbols see p 31 interruption or SYS system fault see 3 Symbol max for maximum storage tank temperature and p 31 32 Temperature format C F see p
19. ons gt To save the setting press the button EN 8 2 8 Selecting the temperature format F3 V The F3 menu is open gt CI oO gt Press the button for approx 2 seconds until FI L either C or F flashes gt Toggle between C and F using the X or 4 buttons gt To save the setting press the button 8 2 9 Reset The reset function causes the controller to revert to its factory settings these are as follows P1 P2 P3 F1 F2 F3 60 8 4 off off C V The RESET menu is open gt l COCOL gt Press the amp button for approx 5 seconds until C Jcc RESET flashes The controller reverts to its factory settings 28 9 Maintenance The controller was conceived for years of continuous trouble free operation Nevertheless faults may occur Maintenance may only be performed by professional personnel In most cases however the fault does not lie with the controller but rather with the peripheral components The following description covers the most common problems encountered with the controller Only send in the controller with a precise fault description if none of the following faults are present 9 1 Fault causes N WARNING Risk of death by electrocution Removethe controller from the power supply before opening the case Controller does not appear to function at all Secondary symptoms Possible c
20. professional personnel must be familiar with this operation manual The controller is maintenance free Use the controller only after first thoroughly reading and understanding this instruction manual and the safety instructions Adhere to all safety instructions In the event of any ambiguities regarding the operation and alteration of parameters or functions consult profes sional personnel BEEN i 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 1 3 2 Danger levels in warning notices Danger level Likelihood of Consequences occurrence resulting from non compliance Imminent Death serious A DANGER threat of danger bodily injury Possible Death serious A WARNING threat of danger bodily injury Possible Minor A CAUTION threat of danger bodily injury CAUTION Possible Property damage threat of danger 1 3 3 Notes Note Pictogram with corres ponding warning sym Notes on easier and safer working habits bol gt Measures for easier and safer working habits a 7550055 MEI 1 3 4 Other symbols and markings Symbol Meaning V Condition for action Call to action gt Result of action List Emphasis on Emphasis on issue at hand issue at hand 2 Safety 2 1 Proper usage The temperature different
21. tely recorded with vacuum tube collectors in some cases there are no immersion sen sors the sensor is outside the collector pipe In these cases the solar circuit must be briefly activated at reg ular intervals to transmit the actual heat from the col lector pipe to the sensor T1 If the tube collector func 20 719 450 06 33 tion is activated the controller automatically switches the pump on every 30 minutes for 30 seconds 7 5 Anti freeze function F2 If the anti freeze function is activated the controller switches the pump on as soon as the collector tem perature falls below 5 C The heat transfer fluid is thus pumped through the collector and the system is prevented from freezing If the collector reaches a tem perature of 7 C the pump is switched off again CAUTION System can freeze despite the activated anti freeze function During a power outage the anti freeze function does not operate During long term periods of frost due to restricted water tank heat storage If collectors are mounted in locations exposed to wind gt If frost is expected for a long term period of time only operate the system with heat transfer fluid Standard heat transfer fluids for solar energy systems also contain an additional corrosion inhibitor 4 The following display appears Theanti freeze symbol is displayed 8 Operation CAUTION The incorrect operating mode may cause the
22. troller can compromise the efficiency of the solar energy system Therefore only activate the tube collector function if the construction of the collector does not allow its temperature to be recorded immediately and or accurately in some cases there are no immersion sensors the sensor is outside the collector pipe V The F1 menu is open gt crec gt Press the button for approx 2 seconds until F DUCIT either oFF or on flashes gt Toggle between oFF and on using the 3 or 4 buttons gt To save the setting press the button ru C 8 2 7 Activating the anti freeze function F2 CAUTION System can freeze despite the activated anti freeze function During a power outage the anti freeze function does not operate During long term periods of frost due to restricted water tank heat storage If collectors are mounted in locations exposed to wind gt If frost is expected for a long term period of time only operate the system with heat transfer fluid For further information see chapter 7 5 NOTE Incorrectly setting the controller can compromise the efficiency of the solar energy system Only activate the anti freeze function for solar energy systems that are not filled with anti freeze V The F2 menu is open gt Press the button for approx 2 seconds until either oFF or on flashes gt Toggle between oFF and on using the or 4 butt
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