Operating instructions Operating instructions
Contents
1. 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 ASO 160 120 180 Resistance Q 1573 1611 1648 1685 10 Dismantling and disposal 2 A DANGER Risk of death by electrocution Remove the controller from the power supply before dismantling it To dismantle the controller follow the assembly instructions in the reverse order gt Dispose of the controller in accordance with the regional regulations In accordance with German statutory regulations there is a 2 year legal guarantee on this product for the customer 11 Legal guarantee The seller will remove all manufacturing and material faults that occur in the product during the guaran tee period and affect the correct functioning of the product Natural wear and tear does not constitute a malfunction No legal guarantee can be offered if the fault can be attributed to third parties 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 Legal guarantee claims shall only be accepted if notificati2. 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 NOTE The connecting terminal may only be actuated with an appropriate tool An unsuitable tool or too much mechanical pressure can damage or even destroy the connecting terminal 5 Display overview Temperature sensor symbols Display for temperature values and fault symbols e g short circuit interruption see page 30 or SYS system error see page 39 Holiday function see pages 22 23 Anti freeze function see page 23 Setting the temperature unit C oF tube collector function Setting the maximum storage tank temperature O 9 Solar circuit symbols Displays message Maximum storage tank temperature has been reached Warning display if faults occur e g short circuit interruption see page 30 or SYS system error see page 31 Displays message for evapora tion of the collector fluid Displays message for Sufficient heat supply 6 Commissioning 4 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 casing is closed All connections are properly made The solar energy system is fille
3. button for approx 2 seconds until the symbol for T1 switches from the upper to the lower position Tt 8 2 5 Activating deactivating the holiday func tion NOTE Incorrectly setting the controller can compromise the efficiency of the solar energy system Only activate the holiday function if you intend to be absent for an extended period Deactivate it again upon your return EN lt The menu is open gt Press the SZ button until the holiday symbol Ny 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 The solar energy system can freeze despite the acti vated anti freeze function During a power outage the anti freeze function does not operate During long term periods of frost the system can freeze despite the anti freeze function gt If frost is expected for a long period of time only operate the system with anti freeze 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 y The menu is open gt Press the 7 button until the anti freeze symbol flashes gt Press the Wi button for approx 2 seconds until the small tick on the anti freeze symbol appears goes out 9 Maint
4. Set the operating switch to automatic operation e The pump sym bol does not rotate e The display is backlit in yellow e Evaporation symbol or max are flashing No fault The system has stopped because maximum collector temperature or maximum storage tank tem perature have been reached 30 EN O 73 gt Short circuit symbol and warning display appear Secondary symptoms Possible cause remedy A e The pump symbol Temperature sensor or its sup does not rotate ply cable short circuited e Display background Have professional per alternately flashes sonnel check the supply red and yellow cables of the tempera ture sensors and that they are correctly con nected to the controller NOTE In case of a T3 short circuit the pump does not stop Interruption symbol and warning signal appear Secondary symptoms Possible cause remedy e The pump symbol Temperature sensor T1 or T2 does not rotate or its supply cable is inter e Display back rupted ground alternately Have professional person flashes red and nel check the supply yellow cables of the temperature sensors and that they are correctly connected to the controller NOTE If T3 is interrupted no message appears SYS flashes in the controller display Possible cause remedy SYS means there is a system error This means that despite the pump running a temperature d
5. 3 piece plastic casing 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 709 752 07 50 37 709752
6. Consequences occurrence resulting from non compliance A Imminent threat Death serious bodily DANGER of danger injury A Possible threat of Death serious bodily WARNING danger injury A Possible threat of Minor bodily injury CAUTION y anger CAUTION Possible threat of Property damage danger 1 3 3 Notes NOTE Note on easier and safer working habits gt Measures for easier and safer working habits 4 709 752 07 50 1 3 4 Other symbols and markings Symbol ACETATA A Precondition for action p Call to action D Result of action List Emphasis on is Emphasis on issue at hand sue at hand 2 Safety 2 1 Proper usage The temperature differential controller called control ler in the following 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 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 2 3 Dangers during installation and commis sioning The following dangers exist during installation com missioning of the controller and during operation in case of installation errors e Risk of death by electrocution e Risk of fire due to short cir
7. Risk of death by electrocution Remove the controller from the power supply before opening the casing 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 casing or the lower side of the casing Uk BOR EABEEA 1 KDEa TED Diagram 1 Cable feed from the rear i Diagram 2 Cable feed from below EN Feeding the cable through the rear of the cas ing diagram 1 AN WARNING Risk of electrical shock and fire due to cables com ing loose Install an external strain relief for the cables Remove the plastic flaps from the rear side of the casing using an appropriate tool Feedin
8. constant fixed value the pump is switched off The sun symbol is no longer shown on the display 7 2 Maximum storage tank temperature e If the lower area of the storage tank T2 reaches the set maximum storage tank temperature factory setting 60 C charging is stopped A tem perature of 3 K below the maximum storage tank temperature must first be reached before charging can be resumed The following displays appear The pump symbol does not move e The sun symbol is displayed e The max indication flashes in the storage tank symbol 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 stopped for protection purposes until the temperature drops below 127 C The following displays appear e The pump symbol does not move e The sun symbol is displayed e The vapour symbol flashes 7 4 Tube collector function For reasons of construction the collector temperature T1 can only be imprecisely recorded with vacuum tube collectors in many cases there are no immersion sensors the sensor is outside the collector pipe In EN 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 col lector function is activated the controller automati cally switches the p
9. SOLARTHERMIE SOLAR THERMAL SOLAR TERMICO SOLAIRE THERMIQUE UP iei ns sleell Temperature differential controller 3 inputs 1 output These operating instructions are part of the product P Read these operating instructions carefully before use P keep them over the entire lifetime of the product P and pass them on to any future owner or user of this product Contents Improper usage Dangers during installation and commissioning Detecting faults Exclusion of liability Controller in the solar circuit Casing overview Opening closing the casing Electrical connection Display overview Commissioning 19 Description of controller FUNCTIONS nann 20 Automatic storage tank charging 20 Maximum storage tank temperature e sees see iii 21 Maximum collector temperature 21 Tube collector function 21 Holiday function 22 Anti freeze function 23 Operation sssrinin 24 Reading temperature values 24 Setting the controller 24 Maintenance 29 Fault causes e seine 29 Testing the temperature sensors 33 Dismantling and disposal 35 Legal guarantee Technical data 1 About this manual 1 1 Applicability This manual describes the installation com
10. ause 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 with this manual or 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 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 incorrect execution of installation work 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 controller The manufacturer reserves the right to make changes to the product technical data or installation and oper ating instructions without prior notice 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 collector sensor p Temperature differential controller Temperature sensor 3 upper area of storage tank Storage tank Temperature sensor 2 lower area of storage ta
11. cuit e Damage to any of the constructional fire safety measures present in the building due to incorrectly installed cables e 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 electrical connection work When laying cables ensure that no damage occurs to any of the constructional fire safety measures present in the building gt Make sure that the permissible ambient condi tions at the installation site are not exceeded see chapter 12 Be sure to comply with the specified protection degree 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 Make sure that all devices which are connected to the controller conform to the technical data of the controller Secure the device against unintentional start up 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 gt gt gt gt Check the display regularly In case of faults isolate the c
12. d Connect the mains supply To switch on the pump set the operating switch to the upper position on gt The display is backlit in red gt onappears in the display After approx 3 sec onds on flashes in alternation with the display To switch off the pump set the operating switch to the lower position OFF gt The display is backlit in red gt oFFappears in the display After approx 3 seconds oFF flashes in alternation with the display 709 752 07 50 19 m CAUTION The incorrect operating mode may cause the sys tem to shut down or impair proper functioning After testing the pump always set the operating switch to automatic operation To set the controller to automatic operation move the operating switch to the middle position Auto Aut is shown on the display for approx 3 seconds 7 Description of controller functions 7 1 Automatic storage tank charging 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 constant fixed value higher than the temperature in the storage tank T2 the following display appears e The sun symbol is displayed F If no safety limits prohibit the pump from operat ing the pump is switched on The following display appears e The pump symbol rotates If the temperature difference falls below 4 K
13. enance 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 ao AN WARNING Risk of death by electrocution Remove the controller from the power supply before opening the casing Controller does not appear to function at all Secondary symptoms Possible cause remedy The controller dis No power supply present play is blank Have professional person nel 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 fulfilled Secondary symp toms The pump symbol rotates in the dis play Possible cause remedy The pump connecting cable is not connected interrupted or the fuse in the controller is burned out gt If necessary have professional personnel replace the fuse Replacement fuse is located in the casing e The pump sym bol does not rotate e The display is backlit in red e OFF flashes Operating switch is set to man ual
14. g the cable through the lower side of the casing diagram 2 AN WARNING Risk of electrical shock and fire due to cables com ing loose Fasten the flexible cabling to the casing using the strain relief clamps provided Cut the left and right plastic flaps 6 using an appro priate tool and break them out of the casing 4 3 2 Connecting the cables gt Ifa protective conductor is provided or required for the pump connect it to the controller termi nals When connecting the protective conductor observe the following points 709 752 07 50 15 Make sure that the grounding contact is also 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 with out 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 impor tant 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 trans former 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
15. ifference exceeding 80 K between the collector and the stor age tank was recorded The following causes are possible e The pump is faulty 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 medium circuit comes to a standstill Have professional personnel check the solar energy system to prevent damage Once the fault has been remedied press any but ton to acknowledge the fault message 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 e AN DANGER Risk of death by electrocution Remove the controller from the power supply before opening the casing 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 relevant 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 note that small devia tions are permissible Temperature sensor resistance values
16. is switched off again CAUTION The solar energy system can freeze despite the acti vated 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 It is recommended to generally use heat transfer fluid with anti freeze for solar energy systems Standard anti freeze heat transfer fluids for solar energy systems also contain an additional corrosion inhibitor 3 The following display appears e The anti freeze symbol is displayed 8 Operation CAUTION The incorrect operating mode may cause the sys tem 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 dis played if the temperature sensor T3 not included in delivery is also connected gt Use the buttons 3 and SI to select temperature sensor T1 T2 T3 gt The selected temperature sensor and the current temperature reading appear in the display 8 2 Setting the controller 8 2 1 Menu operation gt To open the Settings menu press 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
17. missioning operation maintenance and dismantling of the tem perature differential controller for solar thermal energy systems When installing the remaining components e g solar collectors pump assemblies storage units pumps and switching valves be sure to observe the appropriate installation instructions provided by each manufacturer 1 2 Users Installation commissioning maintenance and dis mantling 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 instruc tions within these installation and operating instruc tions The professional personnel must be familiar with these operating instructions 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 EN and alteration of parameters or functions consult pro fessional personnel 1 3 Description of symbols 1 3 1 The structure of the warning notices Z SIGNAL WORD Type source and consequences of the danger gt Measures for avoiding danger 1 3 2 Danger levels in warning notices Danger level Likelihoodof
18. nk The controller constantly compares the temperatures between the collector T1 and the lower area of the storage tank T2 Once the sun heats the collector and there is a temperature difference of 8 K between the collector 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 3 1 3 The function of the solar circuit The heat transfer fluid heats the domestic water via a heat exchanger located in the storage tank Operating switch The following modes of operation can be selected On for commissioning and testing for function Automatic for automatic operation Off to switch off the pumps On Automatic Off 3 2 Casing overview Display and system settings graphic display animated for controller operation Operating buttons Arrow up SET button Arrow down Connections Pump mains grid temperature sensor 11 4 Installation 4 1 Opening closing the casing AN DANGER gt s Risk of death by electrocution Remove the controller from the power supply before opening the casing Make sure that the power supply cannot be unin tentionally switched on eee Operating b
19. on of the fault is provided immediately after it is discovered Guarantee claims are to be directed to the seller The seller must be informed before guarantee claims are processed For processing a guarantee claim an exact fault description and the invoice delivery note must be provided The seller can choose to fulfil the legal guarantee either by repair or replacement If the product can neither be repaired nor replaced or if this does not occur within a suitable period in spite of the specification of an exten sion period in writing by the customer the reduction in value caused by the fault shall be replaced or if this is 12 Technical data EN not sufficient taking the interests of the end customer into consideration the contract is cancelled Any further claims against the seller based on this guarantee obligation in particular claims for damages due to lost profit loss of use or indirect damages are excluded unless liability is obligatory by law Temperature differential controller Operational voltage 230 V 15 90 50 Hz optional 115 V 15 60 Hz Controller s own consumption lt 1W Inputs 3 temperature recording Pt1000 Output 1 switched output switching performance max 800 W 230 V Display Animated LCD display 2 colour background Protection degree IP 20 DIN 40050 Permitted ambient temperature 0 to 45 C Mounting wall mounted Weight 250g Casing recyclable
20. to the next setting press the SI or O button EN gt To exit the Settings menu press the SZ button again until the menu is no longer displayed 8 2 2 Setting the storage tank maximum tem perature AN CAUTION Risk of scalding by excessive domestic water tem perature Set the storage tank max temperature no higher than 60 C gt Install a thermostatic mixer in the hot water pipe and set to max 60 C The menu is open gt Press the Si button for approx 2 seconds until the storage tank maximum temperature flashes Change the storage tank maximum temperature using the SZ or AY buttons gt To save the value press the button 8 2 3 Selecting the temperature unit vy The menu is open gt Press the 7 button again until C F flashes gt Press the Wi button for approx 2 seconds until the desired temperature unit C or F flashes 709 752 07 50 25 EN 8 2 4 Activating the tube collector function NOTE Incorrectly setting the controller 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 The menu is open gt Press the 7 button again until the symbol for T1 flashes gt Press the
21. ump on every 30 minutes for 30 seconds The following display appears e The lower temperature sensor T1 is shown 7 5 Holiday function The holiday function is used to cool down a completely heated storage tank again via the collector The stor age 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 of 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 to 10 K below the set storage tank maximum temperature the controller attempts to discharge the lower section of the storage tank to 35 C e g at night To do so the pump is automatically switched on once the collector is 8 K colder than the storage tank Once the temperature difference between the collector and the storage tank is only 4 K the pump is switched off again EN The following display appears e The holiday symbol is displayed 7 6 Anti freeze function If the anti freeze function is activated the controller switches the pump on as soon as the collector tem perature T1 falls below 5 C The heat transfer fluid is then pumped through the collector in an attempt to prevented the system from freezing If the collector reaches a temperature of 7 C the pump
22. uttons Upper casing Do not damage the casing Only switch the power supply back on after the cas ing has been closed The upper casing is connected to the lower casing by two latches and fastened with a screw 4 1 1 Opening the casing Loosen the screw and remove the upper casing in an upwards direction 4 1 2 Closing the casing Place the upper casing over the lower casing at an angle Insert the latches into the recesses of the lower casing gt Pivot the upper casing down and feed the operat ing buttons through the matching holes gt Fasten the casing tightly with the screw Lower casing 4 22 Mounting AN WARNING Risk of electrical shock and fire if mounted in a damp environment Only assemble the controller in an area where the degree of protection is sufficient 4 2 1 Mounting the controller A CAUTION Risk of injury and damage to the casing when drill ing Do not use the casing as a drilling template Choose a suitable installation site Drill the upper fastening hole Screw in the screw Remove the upper casing Hang the casing in recess Mark the position of the lower fastening holes Remove the casing again Drill the lower fastening holes Hang the casing in recess Screw the casing firmly using the lower fastening holes and 9 gt Mount the upper casing vvvvvvvvvyv iii 4 3 Electrical connection AN WARNING ae
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