Installation and operating instructions EN
Contents
1. SOLARTHERMIE SOLAR THERMAL SOLAR TERMICA SOLAIRE THERMIQUE SOLARE TERMICO Installation and operating instructions Temperature differential controller 2 inputs 1 output These operating instructions are part of the product P Read these operating instructions carefully before use P gt Keep them over the entire lifetime of the product P and pass them on to any future owner or user of this product Table of Contents 1 About this manual 000 3 6 Commissioning 2 cceeee 18 1 1 Applicability 0 cc cc cceeseceeeeeees 3 7 Description of the controller PAU is ease E dts ate eee 3 FUNCTIONS eeceeeteeeeeeteeee tenes 19 1 3 Description of symbols 0 4 7 1 Switch on switch off 2 Safety 5 temperature difference 19 2 1 Proper usage 5 7 2 Maximum storage tank 2 2 Improper usage 5 temperature eee 19 2 3 Dangers during assembly and 7 3 Maximum collector temperature 20 COMMISSIONING ossessi 6 7 4 Tube collector function F1 20 2 4 Detecting faults eeeeeeeeeee 7 7 5 Anti freeze function F2 21 2 5 Exclusion of liability 0 ee 7 8 Operation ee eeeeeeeeeeeeeeeees 22 3 Description cceseceeeeereeeeeeees 9 8 1 Reading the temperature values 22 3 1 Controller in the solar circuit 9 8 2 Setting the controller 23 3 2 Case overview 9 Maintenance 29 4 Installation o ae 9 1 Fault caus2. rial faults that occur in the product during the legal guarantee period and affect the correct functioning of the product Natural wear and tear does not constitute a malfunction Legal guarantee does not apply 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 notification of the fault is provided immediately after it is discovered Legal guarantee claims are to be directed to the seller The seller must be informed before legal guarantee claims are processed For processing a legal guaran tee 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 not sufficient taking the interests of the end customer into consideration the contract is cancelled Any further claims against the seller based on this legal guarantee obligation in particular claims for damages due to lost profit loss
3. its supply cable is l interrupted 27 gt gt Have professional personnel check the supply a cables of the temperature sensors and that they E crreor are correctly connected to the controller T1 temperature sensor with interruption symbol and warning sign example 719 450 07 49 31 SYS and the warning symbol flash in the control ler display Possible cause remedy SYS means there is a system error This means that gt despite the pump running a temperature differ 5 45 ence exceeding 80 K between the collector and the storage tank was recorded The following causes are possible E Cor The pump is faulty or not correctly connected e The isolating valve in the solar circuit is closed SYS display roa ee and warning sign example e 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 gt 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 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 Z DANGER Risk of death by electrocution gt Remove the controller from the power supply before opening the case The temp
4. of use or indirect damages are excluded unless liability is obligatory by German law 12 Technical data Temperature differential controller Operating voltage 230 V 15 50 Hz optional 115 V 15 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 230 C Fuse 4 AMT 250 V or T4AH 250 V Littelfuse 215004 37 38 39 719450
5. 3 or a buttons gt To save the setting press the button EN 8 2 8 Selecting the temperature format F3 y The F3 menu is open gt gt Press the button for approx 2 seconds until either C or F flashes gt Toggle between C and F using the or 4 buttons gt To save the setting press the button cr 8 2 9 Reset The reset function causes the controller to revert to its factory settings these are as follows 60 8 4 OFF OFF SG y The RESET menu is open gt Press the button for approx 5 seconds until I RESET flashes The controller reverts to its factory settings WwW X t am I ro ar a 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 gt Only send in the controller with a precise fault description if none of the following faults are present 9 1 Fault causes pes WARNING Risk of death by electrocution gt Remove the controller from the power supply before opening the case Controller does not appear to function at all Secondary symptoms Possible cause remedy e The controller No power su
6. ambiguities regarding the operation and alteration of parameters or functions consult profes sional personnel 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 PEC am Likelihood of occurrence Consequences 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 Notes on easier and safer working habits gt Measures for easier and safer working habits 1 3 4 Other symbols and markings Symbol ACETA v Condition for action gt 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 differential 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 e outdoors e in damp rooms e in rooms where highly flammable gas mixtures can occur e in rooms in which the operati
7. ank T2 and if no safety limits prohibit the pump from operating the pump is switched on The following display appears e 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 719 450 07 49 19 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 e 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 e 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 inaccurately recorded with vacuum tube coll
8. 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 gt 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 gt Connect the cables in accordance with the terminal plan 4 3 3 Terminal plan NOTE For any handling of the connecting terminal only adequate tools must be used Any inadequate tool or mechanical over pressure will damage the terminal 5 Display overview Symbol for pump operation Symbol for anti frost function see chapter 7 5 maximum collector temperature see chapter 7 2 and 7 3 Display for temperature sensor temperature readings and fault symbols see chapter 9 1 interruption or SYS system fault 3 Symbol max for maximum storage tank temperature and see chapter 9 1 Temperature format C F see chapter 8 2 8 6 Commissioning 6 1 Testing the pump CAUTION Damage to pump caused by dry ope
9. e 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 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 a WARNING Risk of death by electrocution gt Remove the 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 and 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 d
10. ectors 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 07 49 Pi 56 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 T1 falls below 5 C The heat transfer fluid is thus pumped through the collector and tries to pre vent refreezing If the collector reaches a temperature 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 It is recommended to generally use the heat carrier fluid with antifreeze for Solar Plants Standard antifreeze liquid for solar energy systems also contain an additional corrosion inhibitor 4 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 fu
11. erature 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 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 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 _ eS Risk of death by electrocution gt 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 Guarantee In accordance with German statutory regulations there is a 2 year legal guarantee on this product for the customer The seller will remove all manufacturing and mate
12. es 29 4 1 Opening closing the case 11 9 2 Testing the temperature sensors 33 4 2 Assembly 12 10 Dismantling and disposal 34 4 3 Electrical connection 006 13 11 Legal Guarantee 05 35 5 Display overview ssn 17 12 Technical data 37 2 1 About this manual 1 1 Applicability This manual describes the installation commissioning operation maintenance and dismantling of the temper ature differential controller for solar thermal energy sys tems When installing the remaining components e g solar collectors pump assemblies storage tank pumps and switching valves be sure to observe the appropriate installation instructions provided by each manufacturer 1 2 Users Installation commissioning maintenance and disman tling of the controller may only be performed by trained professional personnel Before commissioning the con troller 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 installa tion and instruction manual The 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
13. f the controller gt Secure the device against unintentional commission ing gt All work on an open controller must be performed with the mains supply disconnected gt Protect the controller against overloading and short circuiting 2 4 Detecting faults gt Check the display regularly gt Incase of faults isolate the cause see chapter 9 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 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 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 assembly and operat ing instructions without prior notice 3 Description 3 1 Contro
14. ller 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 3 collector sensor Temperature differential controller Storage tank Y Collector Solar circuit gt Pump Temperature sensor 2 lower area of storage tank EN 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 selected On for commissioning and testing for function Automatic for automatic operation Off to switch off the pumps ES lt Automatic Display Display for controller operation and system settings Z Operating buttons erating butto
15. nctioning gt 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 and buttons T1 2 T2 gt The selected temperature sensor and the current gt oC co measured temperature appear in the display Co 1 oo Temperature sensor T1 display with temperature reading from collector and active pump eg 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 C A m f c g is displayed gt To switch to the next setting press the 2 button gt To exit the settings menu press the 4 button again until the temperature sensor and tempera ture reading are shown again 8 2 2 Overview of menu settings l 6a Temperature reading T1 or T2 ala G hold down for 2 seconds A y p 58 P1 storage tank maximum ou temperature lt 2 p 2 8 P2 switch on temperature difference lt 2 p 3 4 P3 switch off temperature i difference lt F1 tube collect
16. ns Arrow up SET button Arrow down lt On A fal H Connections lt off 10 719 450 07 49 grid pump temperature sensors _ N Operating buttons Upper case Lower case EN 4 Installation 4 1 Opening closing the case Z DANGER Risk of death by electrocution gt 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 gt Only switch the power supply back on after the case has been closed The top of the case will be fixed with two clips and one screw on the lower case 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 clips in the pocket 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 07 49 11 4 2 Assembly ZA WARNING Risk of electric shock and fire if assembled in a damp environment gt Only assemble the controller in an area where the degree of protection is sufficient 4 2 1 Assembling the controller 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 sit
17. on 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 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 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 con nection work gt 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 gt Be sure to comply with the specified degree of protection 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 specifica tions o
18. or function F toFF F2 anti freeze function FeoFF F3 temperature format C F FJ C j v reser Reset 24 719 450 07 49 Ba A Pe cm ce co a a 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 y 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 buttons gt To save the value press the J button 8 2 4 Setting the switch on temperature dif ference P2 v The P2 menu is open gt Press the 4 button for approx 2 seconds until the switch on temperature difference flashes gt Change the switch on temperature difference using the or 4 buttons gt To save the value press the J button 719 450 07 49 25 y The P3 menu is open gt D I uf gt Press the button for approx 2 seconds until the a 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 5 Setting the switch off temperature dif ference P3 8 2 6 Activating the tube collector function F1 NOTE Inc
19. orrectly 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 vy The F1 menu is open gt gt Press the button for approx 2 seconds until either oFF or on flashes gt Toggle between oFF and on using the or 2 buttons gt To save the setting press the 4 button 26 719 450 07 49 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 gt Only activate the anti freeze function for solar energy systems that are not filled with anti freeze y 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 2
20. pply is present display is blank gt 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 e The pump symbol is shown in the display Possible cause remedy The pump connecting cable is not connected inter rupted or the fuse in the controller is burned out gt If necessary have profes sional personnel replace the fuse The pump symbol is not shown in the display e Off is displayed in alternation with the temperature reading Operating switch is set to Off gt Set the operating switch to automatic operation 30 719 450 07 49 i Pump symbol display example gt 4 5 G l l _ Z ori T1 temperature sensor with temperature reading and off display example EN Short circuit symbol and warning display appear Possible cause remedy Temperature sensor T1 or T2 or its supply cable is t ZIZ short circuited a gt Have professional personnel check the supply c cables of the temperature sensors and that they error are correctly connected to the controller i T1 temperature sensor with short circuit symbol and ing si l 5 warning Eion Cameo Interruption symbol and warning signal appear Possible cause remedy 4 Temperature sensor T1 or T2 or
21. ration gt 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 gt on appears in the display After approx 3 sec onds on flashes in alternation with the display m 5 YSS NS gt To switch off the pump set the operating switch to gt e the lower position OFF o fF gt OFF appears in the display After approx 3 sec onds oFF flashes in alternation with the display m 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 07 49 a l Mucg lt fa lt Automatic lt EN gt To set the controller in automatic operation move the operating switch to the middle position gt Auto is shown in the display for approx 3 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 K higher than the temperature in the storage t
22. ue 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 If a 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 07 49 oe A gt H pon T maim Ho aee er E 5 C Kd EDCED d DdsD0 En E E Ei Diagram 1 Cable feed from the rear E Hp Eb Ep ED gt HI perma i c eD Diagram 2 Cable feed from below 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 without sleeves stranded wires are to be twisted 1 twist per 20 mm gt Only use the original temperature sensors Pt1000 that
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