Temperature differential controller 5 inputs, 1 output Installation and operating instructions EN 741.011 | Z02 | 12.
EN Contents 1 General safety instructions 2 Declaration of conformity with European standards (EC) 3 3 Proper usage 4 4 5 6 7 8 9 About these instructions 4 4.1 Contents 4 4.2 Target group 4 Installation 5 5.1 Opening/Closing the casing 5 5.2 Mounting the casing 6 5.3 Establishing the electrical connections 5.4 Terminal pin assignments 7 11 Commissioning the device for the first time 12 Structure 16 7.1 Casing 16 7.2 Display 16 Operation 19 8.
EN 15 Troubleshooting General faults 42 15.2 Error messages 43 15.3 Checking the Pt1000 temperature sensors 16 Technical data 1 44 45 16.1 Controller 45 16.2 Cable specifications 46 17 Exclusion of liability 46 18 Legal guarantee 46 19 Notes 47 General safety instructions • • • • • • • • • • 2 42 15.1 This document is part of the product. Use the device only after reading and understanding this document.
EN 3 Proper usage The temperature differential controller, subsequently referred to as the controller, is an independently installed electronic temperature controller for on-surface installation. Integration into a pump assembly is possible when the technical specifications of the controller are adhered to. The maintenance-free controller is exclusively intended for controlling solar and heating systems. 4 About these instructions 4.
EN 5 Installation Note The following section describes only the installation of the controller. Follow the instructions of each respective manufacturer when installing external components (collectors, pumps, storage tanks, valves etc.) 5.1 Opening/Closing the casing 5.1.1 Remove the front panel X Grasp the front panel by the grooves at the sides and pull forwards (Fig. 1). Fig. 1: 5.1.
EN 5.2 Mounting the casing √√ The mounting location must satisfy the prescribed conditions of use; see Section 16, p. 45. √√ The mounting surface is vertical and allows good access for installation. Danger Risk of death by electrocution! • Disconnect the controller from the power supply before opening the casing. • Make sure that the power supply cannot be unintentionally switched on when the casing is open. • Do not use the casing as a drilling template. 1. If necessary, remove the terminal cover 2.
EN 5.3 Establishing the electrical connections Danger Risk of death by electrocution! Make sure that the following conditions are satisfied when performing the work described in this section: • All cables leading to the controller must be disconnected from the power supply and it must be ensured that they cannot be unintentionally reconnected during installation. • Each connection terminal must only be connected to a single conductor.
EN 5.3.1 Position of the connection terminals L R1 1 N N 1 2 3 4 3 1 PWM 5 RS R1 4 1 1 3 1 RS 2 PE PE PE PE 5 1 5 1 6 7 8 1 Fig. 3: Terminal clamps in the lower part of the controller (terminal cover removed) Power connection terminal block: L 1x phase conductor (mains input) R1 1x output (TRIAC, for pump) N 2x neutral conductor (common neutral conductors for mains power input and output) Note Output R1 is protected by an electronic fuse.
EN 5.3.2 Preparing the cable openings The cables can be fed through openings in the rear wall of the casing or at the bottom of the casing. The openings are pre-punched and must be prepared as required before installation. Prepare the cable openings in the rear wall of the casing as follows: 1. Break out the cable openings (Fig. 3) using a suitable tool. 2. Deburr the edges. Prepare the cable openings at the bottom of the casing as follows: 1. Cut the required cable openings (Fig.
EN Remove the plastic links as follows: 1. Insert a screwdriver under the right plastic link between the casing and the spring clamp , (Fig. 5). 2. Carefully push the screwdriver to the left . Lever the spring clamp to the right until the plastic link is free. 3. Pull out the plastic link upwards by hand . 4. Remove the left plastic link accordingly. Fig. 5: 10 Removing the right plastic link 741.011 | 12.
EN 5.4 Terminal pin assignments For each solar system that can be selected at the controller, the external components (pumps, valves, temperature sensors) must be connected to particular terminals. The following table provides information on this: • Graphic and number of the solar system on the controller display. The graphic is only intended to provide an overview and is not a technical drawing.
EN 6 Commissioning the device for the first time Danger Risk of death by electrocution! Be sure to perform all the measures listed in Section 5 before starting the first commissioning. Notes • After commissioning the controller for the first time, it is configured in such a manner that it can be used in most applications without changes. • After completing the first commissioning, later recommissioning is not necessary.
EN Selecting a system 6. Press . System 1.1 is displayed, 1.1 flashes (Fig. left). 7. Press to select a different system. 8. Press SET. If System 0.1 was selected in step 7, then continue with step 18. Setting pump 1 (output R1) 9. Press . AC and flash (example in Fig. left). 10. Notice Standard pump: Select AC! High-efficiency pump: Select HE! Press to set the type of pump 1. 11. Press SET. 12. Notice Pay attention to the pump characteristics when selecting HE (high-efficiency pump).
EN Set the functions (necessary for System 0.1, or as required for other systems. The functions can also be set at a later date.) 19. Press SET to set the functions. F:01 (function number) flashes (example in Fig. left). or Press to skip the setting of the functions; Ok flashes. Continue with step 28. Finishing Initial commissioning 20. Press to select a different function; Function descriptions in Section 11.3. 21. Press SET. oFF is displayed. 22. Press SET. oFF flashes. 23. Press . on flashes.
EN Characteristics of high-efficiency pumps Display AA Ab C Pump type Characteristic curve High-efficiency pump with a PWM profile having a rising characteristic curve (Fig. 6) High-efficiency pump with a PWM profile having a falling characteristic curve (Fig. 6) Pressure-controlled high-efficiency pump 0% PWM: pump off 100% PWM: pump at maximum speed 0% PWM: pump at maximum speed 100% PWM: pump off – (no control cable; switched on/off via the supply voltage) Tab.
EN 7 Structure 7.1 Casing 1 No. Element Mode button (under front panel) , SET, ESC, operating buttons Display SET 2 3 1 ESC 4 1 5 1 6 1 Fig. 7: 1) Display 7.2.1 Overview ~~ ~ ~~ T of f on max min Terminal cover fastening screw 5.1 5.3.1 1) – Section 5.3.1 describes the terminals under the terminal cover. C T 4 T max 1 T max min T T V T K h 3 T Terminal cover 7.2 Front view of the controller 7.2 Fig. 8: Front panel see Section 8.1 9 8.
EN 7.2.2 Symbols used in the system graphics The following table describes the symbols used in the system graphics ( in Fig. 8). Symbol 7.2.3 Description Symbol Description Pipework Pump, switched on Collector (array) Pump, switched off Maximum collector temperature reached Temperature sensor Storage tank Back-up heating Swimming pool Solid fuel boiler Sufficient solar irradiation available for loading Domestic water outlet Settings menu The settings menu ( in Fig.
EN 7.2.5 Operational and setting values The display of the operational and setting values ( in Fig. 8) consists of the following elements: 1 2 3 of f on max min 18 4 T 6 5 C K h Symbol for time control of functions. This symbol is displayed when • a time restriction/control has been set, • the status of time restriction/control is displayed, • the time restriction blocks a temperature control (symbol flashes).
EN 8 Operation This section contains general information on operating the controller. 8.
EN 9.2 Off mode Functionality • • • • • The output is switched off (output/control output without power, relays open). Off and the software version are displayed alternately. See example in Fig. below: Software version St 1.3 Backlighting is red. Settings menu can be called up. The Off mode is preset when the device is delivered. Operation XX Press and hold the SET button for 2 seconds to call up the settings menu. 9.3 Manual mode Functionality • • • • • Backlighting is red, spanner symbol flashes.
EN 2 SET SET ESC SET SET 3 SET 9.4 Automatic mode Functionality Automatic is the normal mode of operation and the system is automatically controlled. The following actions are possible: • Display status (status display): Display the status of external components (temperatures, switching states, run times) • Display stored min./max. values (temperature sensors) or sum/difference values (operating hours1) of the pumps and valves). Summed values (symbol ∑): Operating hours since first commissioning.
EN Operation √√ The controller shows the status display. You can display the status of external components as follows: XX Press to display the status of other components ( , shown using system 1.1 as an example). You can display and reset the stored min./max./difference values as follows: 1. Press as required, in order to display other components ( , component flashes). 2. Press SET. The min./max./difference values are displayed alternately . 3.
EN 10 Settings menu 10.1 Overview The following graphic provides an overview of the structure of the settings menu. Time System SET SET Set time Functions 1) Parameters 1) SET Holiday - recooling – F01 SET Maximum temperature storage tank – P01 1 storage tank, 1 collector array – 1.1 Stagnation reduction – F02 Maximum temperature swimming pool – P02 1 swimming pool, 1 collector array – 1.
EN 10.3 Setting the time Note The time must be once more set to the correct values if power is removed for a longer period of time. After this, the same operating mode is displayed as was active previous to the removal of power. √√ 1. 2. 3. 4. 5. 10.4 flashes. Press SET. The hours display flashes. Press to change the hour. Press SET. The minute flashes. Press to change the minute. Press SET. The change is adopted. Setting the system Note The systems are described in Section 5.4, p. 11.
EN 11 Functions 11.1 Operation Displaying the functions The following information is visible when the functions are displayed: • Function number, e.g. F:08 (Fig. left) • Switching state: on: Function is activated off: Function is deactivated (Fig. left) Note If neither on nor off are displayed then the function cannot be used. Possible causes: • The set system does not allow the use of this function. • All outputs are used. You display the functions as follows: √√ Func flashes. 1. Press SET.
EN Setting the characteristics The functions have different numbers of characteristics. The characteristic values are always set via the same sequence of operating steps. You set the values of characteristics as follows: √√ The function has been activated as described previously. 1. Press to select a characteristic. 2. Press SET. The value of the characteristic is displayed, the associated components flash in the system graphics. 3. Press to change the value. 4. Press SET to adopt the change. 5.
EN Switch-off temperature difference of f K T If a function contains a differential thermostat then the switchoff temperature difference can be set. The affected sensor symbols blink while settings are being performed. SET T Func Switch-on temperature If a function contains a thermostat then the switch-on temperature can be set. The affected sensor symbol blinks while settings are being performed. Switch-off temperature If a function contains a thermostat then the switch-off temperature can be set.
EN End time of a time window When setting the end time of a time window, the following is displayed to the left of the end time (see Fig. left): • • Number of time window 1 ... 3, whose end time is to be set (in this case: 1) • off Note The start time always lies before the end time! When an attempt is made to set a start time that is later than the end time, the end time is automatically adjusted. 11.
EN 11.3.1 Holiday – recooling Attempts to reduce, or even to avoid, the system standstill (stagnation) times at high temperatures. To do this, at night the storage tank is discharged as far as possible to the set minimum temperature, if the storage tank temperature during the day was 10 K below the set maximum temperature. Stagnation occurs when not enough hot water is removed form the system during an absence (holiday).
EN Display Characteristic min. Activation on, oFF Factory setting oFF Time window start/end 0:00 23:59 8:00/19:00 Wait time 1 min 999 min 15 min 3s 999 s 5s Switch-on duration 11.3.4 max. Quick charge Uses a higher loading temperature to load the upper region of the storage tank more quickly in order to provide early prevention of back-up heating by the conventional heating system.
EN 11.3.5 Anti-freeze Attempts to prevent freezing of the collectors by pumping heat from the storage tank into the collectors: • Collector temperature below +5 °C: solar circuit pump is switched on. • Collector temperature above +7 °C: solar circuit pump is switched off. The frost protection function is only useful when the heat transfer fluid contains insufficient or no anti-freeze.
EN 11.3.7 Heat quantity of f h T SET T Func Calculates the acquired heat volume based on the following information: • Supply temperature • Return temperature • Flow rate volume determined via calculations based on the pump speed or by pulse water meter measurements (terminal 5). Note Calculation based on the pump speed cannot be performed when No System (System 0.1) has been selected. • Glycol proportion and accounting for the temperature-dependent thermophysical properties of the heat transfer fluid.
EN gCO2/kWhtherm 1 999 218 2) T SET T 1) 2) Func tyP 1: Calculation of the flow rate from the pump speed. To do this, the displayed flow rate values are entered at two measuring points (pump speed min. and max.). tyP 2: Determining the flow rate using a pulse water meter. The flow rate of the pulse water meter in litres/impulse is entered.
EN 11.3.9 Back-up heating of f T SET Func Display Performs temperature-dependent switching of output R1 for heating a storage tank using an oil or gas burner. The function can be time restricted. Temperature control: If the temperature in the storage tank falls below the Ton value, then the external heating is switched on until the Toff temperature is reached. Time restriction: The function is executed when the current time lies within one of 3 configurable time windows. Characteristic min.
EN Display Characteristic min. max. on, oFF Activation Pump type Pump characteristics (only HE) AC on, oFF 2) oFF – Minimum speed (only AC) 30 % 0% 100 % 25 % Minimum speed (only HE + Ab) 0% 100 % 75 % Minimum speed (only HE + AA) C AC, HE 1) 2) AA, Ab, C (see p. 15) Speed control Factory setting oFF 100 % 50 % Sensor input for storage tank temperature 1 ... 5 – Sensor input for solid fuel boiler temperature 1 ...
EN 11.3.11 Heating return increase on T SET T Func Display A heating return increase using a three-way valve switches on and off as follows: If the temperature difference between the tank and the heating return exceeds the value Tdiff on, then the three-way valve is switched on (heating return increase on), until the temperature difference drops below Tdiff off. The three-way valve must be connected to output R1. Characteristic on, oFF Factory setting oFF 1 ... 5 – 1 ... 5 – min.
EN 1) Notice Standard pump: Set AC! High-efficiency pump: Set HE! External consumer (e.g. 230 V relay): Set AC pump type! 11.3.13 Differential thermostat of f T T SET Func Switches output R1 on and off as follows – time restricted and depending on the set temperature difference between 2 selectable sensors: When the temperature difference exceeds Tdiff on, the output is switched on until the temperature difference drops below Tdiff off.
EN C Heat sink max. temperature Tsink max. 0 °C 95 °C 60 °C 23:59 23:59 23:59 00:00/00:00 00:00/00:00 00:00/00:00 max T SET Func Time restriction Time window 1 start/end Time window 2 start/end Time window 3 start/end 0:00 0:00 0:00 on, oFF oFF 1) Notice Standard pump: Set AC! High-efficiency pump: Set HE! 2) Notice External consumer (e.g. 230 V relay): Set AC pump type and set the speed control to oFF! 38 741.011 | 12.
EN 12 Parameters Note the following when setting parameters: • Observe the operating data of the solar components used. • The individual parameters are only displayed and can be changed when this is permitted by the type of solar system that has been set. Special case: System 0.1 has no parameters, no P is displayed. • In most applications the controller can be used without modifying any parameters. More information is provided in the Functionality column. The figures in this section show examples.
EN Display Parameters Storage tank loading strategy T SET Para T Para 1) 2) 3) 40 dIFF 1), AbS Factory setting 2) 2K 50 K 8K Control target of absolute temperature loading (AbS) 0 °C 95 °C 60 °C Pump characteristics (only HE) AC AC, HE AA, Ab, C (see p. 15) Speed control Minimum speed (only AC) 30 % Minimum speed (only HE + Ab) Minimum speed (only HE + AA) Tab. 3: max. Control target of differential temperature loading (dIFF) R1 pump type SET min.
EN 13 Dismantling and disposal Danger Risk of death by electrocution! • Disconnect the device from the power supply before opening the casing. • All work on an open device must be performed by professional personnel. 1. To dismantle the controller, follow the installation instructions in the reverse order; see Section 5. 2. Dispose of the device in accordance with the local regulations.
EN 15 Troubleshooting Danger Risk of death by electrocution! • Immediately disconnect the device from the mains supply when it can no longer be operated safely, e.g. in the case of visible damage. • Disconnect the device from the mains power before opening the case. • All work on an open device must be performed by professional personnel. Notes The controller is a quality product, conceived for years of continuous trouble-free operation.
EN Solar circuit pump not operating + switch-on condition is not fulfilled • The following functions are activated and are actively intervening in the control process: – Interval function – Holiday function – Anti-freeze function • Blockage protection for the pumps is being performed. Pump has been switched on in manual flashes mode (on). • • No fault Deactivate the relevant function, if necessary. • • No fault Switch to automatic mode if necessary.
EN The controller has detected faulty operation of the system. This is probably caused by swapped collector connections. A short-circuit exists at output R1, the pump connected to output R1 flashes. Possible causes: • The pump is faulty. • Wiring fault Output R1 is overloaded, the pump connected to output R1 flashes. Cause: The permissible values for R1 specified on the type plate have been permanently exceeded, the output has been switched off. Tab. 6: 15.3 Check the collector connections.
EN 16 Technical data 16.1 Controller Inputs/outputs Rated voltage (system voltage) 115 ... 230 V~, 50/60 Hz Own consumption ≤ 0.8 W, 2 Pt1000 temperature sensors connected Output R1 Quantity Type Switching current Voltage 1 TRIAC 1.1 (1.1) A each 115 ... 230 V~, 50/60 Hz Signal inputs/outputs Signal inputs 1 ... 5 Quantity 5 Type of signal inputs 1 ...
EN 16.2 Cable specifications Mains cable Mains cable type External diameter of mantle Conductor cross-section single strand (solid) fine strand (with core end sleeves) H05 VV-... (NYM…) 6.5 to 10 mm Diameter of the internal strain relief 6.5 to 10 mm ≤ 2.5 mm2 ≤ 1.5 mm2 Signal cable Sensor cable length ≤ 100 m, including extension Sensor extension cable design twisted-pair conductors for lengths > 10 m cross-section of each conductor 0.75 mm2 for lengths < 50 m 1.50 mm2 for lengths > 50 m Tab.
EN 19 Notes ............................................................................................................................................ ............................................................................................................................................ ............................................................................................................................................ ..........................................................................
EN 741011 48 741.011 | 12.
