Page 1. Universal controller for solar energy systems with one collector array and one storage reservoir COMMISSIONING MANUAL

Transcription

1 Page 1 Universal controller for solar energy systems with one collector array and one storage reservoir COMMISSIONING MANUAL

2 Page 2 Contents! Contents Note! Before beginning assembly or installation work, first read this commissioning manual and familiarise yourself with its content in full! The safety instructions and working instructions in the operating manual must also be observed! Take note of the s which you make, at the respective places provided for this purpose in this commissioning manual and in the operating manual! 1. Product description Features and functions Technical data Safety instructions Transport and storage Installing and connecting the controller Proceed as follows step by step Possible additional functions Relay connector assignment Sensor connector assignment Installing the controller Electrical connections Installing the collector sensor and storage reservoir sensor Dismantling and disposal Commissioning the controller Front view of the controller with buttons and display Structure of the start display The specialised mechanic level Structure of submenus and navigation Reset of the factory System layout (1 collector array, 1 storage reservoir, 1 pump) Pump blockage protection Setting the additional functions Additional function: low flow Additional function: collector monitoring / tube function Additional function: emergency collector switch-off Additional function: collector safety Additional function: storage reservoir safety Additional function: collector frost protection Additional function: thermostat, e.g. for activation of the circulation pump Additional function: temperature comparison System information menu Overview of all s Relay test submenu REL Faults and troubleshooting...18

3 Product description Page 3 1. Product description Your solar controller is a microprocessor-based controller, for control of solar energy systems with one collector array and one storage reservoir. The pump is controlled so as to optimise the heat energy obtained from the solar collector array, according to the solar irradiation and the temperatures which arise in the solar energy system. With the heat energy thus obtained, one storage reservoir can be loaded, e.g. a domestic water storage tank or a swimming pool Features and functions Large illuminated display (LCD) with universally understandable symbols All key system data at a glance Easy operation and programming Modern design in a compact housing for wall-mounting Predefined system layout Temperature difference control of a solar energy system with one collector array and one storage reservoir Low-flow concept for optimal stratified loading Frost protection function and protection from overheating for collectors and storage reservoirs Thermostat and temperature comparison System diagnostics

4 Page 4 Technical data 2. Technical data Supply voltage Power consumption Fuse Inputs 230 V AC 50 Hz 2.4 VA 1.6 AT, microfuse 5 mm x 20 mm 4 inputs: temperature sensor: Pt1000 (-20 C to +150 C) Outputs 2 electromechanical relays: each 1 A, 250 V AC (ε) Protection degree IP 20 as per DIN EN (VDE ) Mode of operation type 1 Y (as per DIN EN ) Insulation class 2 Ambient temperature 0 C to + 50 C Power reserve Installation Housing Dimensions Weight Conformity 3. Safety instructions DANGER > 10 years at + 20 C, with lithium battery wall-mounted plastic, PC / ABS 170 mm x 170 mm x 55 mm 0.65 kg The solar controller meets the requirements of the Electromagnetic Compatibility Directive (2004/108/EC), the Low Voltage Directive (2006/95/EC) and the harmonised standards DIN EN and DIN EN It bears the CE label. Danger of electrocution! The controller is to be assembled, electrically installed, commissioned, inspected and repaired by trained, competent and authorised persons (qualified electricians as per DIN VDE and BGV A3) only! Observe all applicable guidelines and regulations of the local electricity supplier! Before beginning installation or repair work on electrical equipment, always ensure complete disconnection from the mains and secure against reactivation! Do not work on live parts! The controller may only be installed and operated in: dry environments which are not potentially explosive closed rooms rooms with a temperature between 0 C and + 50 C

5 Transport and storage Page 5 4. Transport and storage Thoroughly check whether the packaging or the controller shows any sign of damage. Transport the controller in the original packaging only. If the controller falls, even from a low height, it may get damaged. Prevent impact and extreme temperatures (below 0 C or above + 50 C) during transport and storage. The controller may only be stored in its original packaging and in a dry environment. 5. Installing and connecting the controller 5.1. Proceed as follows step by step 1. Check whether you wish to use additional functions (see 5.2. Possible additional functions and 10. Setting the additional functions [the individual additional functions are explained here]). 2. Check whether the desired additional functions can be realised, i.e. whether there are free sensors and relays for the functions (see 5.3. Relay connector assignment and 5.4. Sensor connector assignment). 3. Install the controller at a suitable location and realise the electrical connections (see 5.6. Installing the controller and 5.7. Electrical connections). 4. Install the required sensors (see 5.8. Installing the collector sensor and storage reservoir sensor). 5. Connect the required sensors to the controller and assign the relays according to your requirements (see 5.3. Relay connector assignment and 5.4. Sensor connector assignment). 6. Switch on the controller by pressing and holding the esc button for at least 5 seconds. 7. Familiarise yourself with the controller s menu navigation (see 6.1. Front view of the controller with buttons and display and the detailed description in the operating manual). 8. Configure any additional functions (see 10. Setting the additional functions). 9. Record your s in the respective sections of this commissioning manual under Selection (10. Setting the additional functions).

6 Page 6 Installing and connecting the controller 5.2. Possible additional functions This table shows you the additional functions which can be used. One relay can be assigned individually. Funktion Low-Flow Collector monitoring / tube function Collector safety function Collector frost protection function Storage reservoir safety function * Thermostat function (circulation pump)* / ** Temperature comparison function* / ** * Free relay required Described in section ** For these functions, it is also possible to use a relay which is already assigned Relay connector assignment A solar pump must be connected to relay R1. The relay R2 is free and can be assigned individually.! Note! Safety extra-low voltage is not to be connected with the relays on the high-voltage side (R1 to R2) Sensor connector assignment The following table shows whether the selected additional functions can be realised: F1 F2 F3 F4 must be connected to the collector array is free and can be assigned individually can be connected to the upper part of the storage reservoir, otherwise it can be assigned individually must be connected to the lower part of the storage reservoir For the additional functions thermostat and temperature comparison the sensors can be configured freely and activated on the specialised mechanic level.

7 Installing and connecting the controller Page Installing the controller Upper fastening hole (for hanging) esc - + ok 130mm 140mm Terminal cover Lower fastening holes 1. Choose a suitable installation location. 2. Remove the collector s terminal cover. 3. Mark and drill (Ø 6 mm) the central upper fastening hole. Insert the provided rawlplug and a screw. 4. Hang the controller on the screw and align it. 5. Mark the lower fastening holes (140 mm between holes). Remove the controller once more. 6. Drill the two lower holes (Ø 6 mm). 7. Insert rawlplugs and hang up the controller once more. 8. Screw the controller firmly in place at the two fastening holes. Risk of injury! Do not use the controller as a drilling template! DANGER Connection diagram 5.7. Electrical connections Danger of electrocution! Every time the terminal cover is opened, the controller is to be disconnected from the power supply beforehand! Ensure that it cannot be reactivated! The type of current (alternating current) and the voltage must match the specifications in the connection diagram. Connect the controller as shown in the connection diagram. DANGER

8 Page 8 Installing and connecting the controller Electrical connections are to be realised with screw terminals (single wire / fine wire, max. 1.5 mm²). The mains supply s protective earth connector is to be connected to the 5-pole terminal block ( ). Protective earth connection of loads (pumps etc.) is to be realised at the 5-pole terminal block provided for this purpose. In so doing, it must be ensured that the mains supply s protective earth connector is also connected to this terminal block. Each terminal may only be connected to one connecting wire. Adequate strain relief must be ensured! Only use the Pt1000 temperature sensors approved for use with the controller. All cables which carry low voltage (e.g. sensor cables) are to be routed in such a way that they are kept separate from cables which carry mains voltage. The polarity of the sensor cables is arbitrary.! Note! Safety extra-low voltage is not to be connected with the relays on the high-voltage side (R1 to R2). After the electrical connection work, replace the terminal cover Installing the collector sensor and storage reservoir sensor! Note! Do not route sensor cables together with cables which carry more than 50 V (low voltage)! Shield sensor cables sufficiently. Thermally insulate sensors and piping. Installing the collector sensor: Insert the collector sensor into the provided opening on the collector array and fasten it in place (refer to the installation instructions from the collector manufacturer). Installing the storage reservoir sensor: Insert the storage reservoir sensor into the provided opening at the storage reservoir and fasten it in place (refer to the installation instructions from the storage reservoir manufacturer). Sensor cables can be extended to a maximum length of 100 m.! Note! As temperatures of up to + 90 C arise in the domestic water storage reservoir, a thermal hot water mixer must be installed (German Heating Installation Regulation HeizAnlV 8 para. 2)! In order to protect the storage reservoir from high temperatures, or to limit loading to the storage reservoir s maximum temperature, the collector safety function (KSF) can be set to no on the operating level E3-6 / Dismantling and disposal DANGER Danger of electrocution! Disconnect the controller from the power supply before dismantling! Ensure that it cannot be reactivated! To dismantle the controller, follow the installation instructions in reverse order. Disposal must comply with the German Electrical and Electronic Equipment Act (ElektroG), which governs the sale, return and environmentally sound disposal of electrical and electronic equipment.

9 Commissioning the controller Page 9 6. Commissioning the controller 6.1. Front view of the controller with buttons and display OK + : Apply current Open a submenu } : On the normal level: Select a submenu Within a menu: Scroll : For s: Change value esc : Return to previous menu Discard change and restore previous value Delete input Note! If OFF appears in the display, the controller has been switched off. Switch the controller back on by pressing and holding the esc button for at least 5 seconds. As soon as the start display appears, the controller has been reactivated. In order to switch off the controller, press and hold the esc button for another 5 seconds Structure of the start display! Please note that other symbols or values which are not pictured above can also appear in your controller s start display.

10 Page 10 The specialised mechanic level 7. The specialised mechanic level The specialised mechanic level contains the s which must be set during commissioning (possibly only once). To open the specialised mechanic level, press and hold the buttons + and simultaneously for five seconds while in the normal start display. To enter the various sublevels (E3-1 to E3-10), use the + or button. Press the OK button to view the sublevels s.! Note! Settings which deviate from the factory s are indicated by flashing underscore lines. These disappear if the value is set to the factory once more Structure of submenus and navigation Several functions can be set within each submenu. These functions are numbered sequentially and marked by the symbol N O. This numbering can be found in the tables regarding configuration of the system layout and additional functions (e.g.: E3-3 / 2): Example: E3-3 = number of the submenu N_ = number of the function = change value 65 C = set value TCS = function s identifier In the submenu, scroll through the individual values with the buttons + and. If you wish to change a value, press the button. The symbol appears in the display. Change the value with the buttons + and. Press the OK button to apply the new value. Pressing esc discards the new value; the original value then reappears in the display. In a submenu, only those values possible in the selected configuration are displayed. Relays and sensors can only be allocated if they have not already all been assigned. To leave a menu, press the esc button. OK

11 Reset of the factory Page Reset of the factory Open the specialised mechanic level (press and hold the buttons + and simultaneously for five seconds) and use the + or button to select the sublevel E3-1. Confirm your selection with OK. In the display RES appears. Press the button OK to reset the factory. When the symbol appears in the display, the adjustment or the shown value can be changed System layout (1 collector array, 1 storage reservoir, 1 pump) Description of the system layout: The solar controller compares the temperature from collector sensor F1 (TC) with the temperature from the storage reservoir sensor F4. If the measured temperature difference exceeds the switch-on temperature difference TDE the speed-controlled solar pump R1 is switched on and the storage reservoir is loaded. R1 F1 (F3) F4 The following s are possible in this system layout: Level Display Function Factory AE MAX Maximum loading temperature MAX for the storage reservoir. AE SPA Activation/deactivation of the storage reservoir Range 70 C 10 C to 90 C YES YES / no E3-1 / 1 RES Reset of the factory. no YES / no E3-1 / 13 SSP Upper storage reservoir sensor F3 present, see section 5.4. E3-2 / 1 TDE Switch-on temperature difference between F1 and F4 (not less than switch-off temperature difference + 1 K). E3-2 / 2 TDA Switch-off temperature difference between F1 and F4 (not greater than switch-on temperature difference - 1 K). YES YES / no 8 K 1 K to 20 K 4 K 1 K to 20 K Selection Additional functions: See the overviews in section 5.2. Possible additional functions, section 5.3. Relay connector assignment and section 5.4. Sensor connector assignment. For detailed descriptions of the individual additional functions, see section 10. Setting the additional functions.

12 Page 12 Pump blockage protection 9. Pump blockage protection If the pumps have been deactivated for a long time, there is a risk that they will block when reactivated, due to accumulated dirt or limescale. In order to prevent such blockages, the pumps are switched on for 10 seconds at a certain time each day. 10. Setting the additional functions! Note! Mark the additional functions which you have selected, as follows: Additional function: low flow In order to optimise the loading process, loading of the selected storage reservoir is only enabled once the collector temperature TCS (which is set here) is reached. When selecting this function, it is important to ensure that the loading pumps minimum speeds are set to values below 100%, i.e. that speed control is possible. Level Display Function Factory Range E3-3 / 1 LFF Activation of low-flow function. no YES / no E3-3 / 2 TCS Collector temperature which enables loading of the selected storage reservoir Additional function: collector monitoring / tube function 65 C 10 C to 90 C Selection The collector s temperature is monitored. If the measured temperature exceeds the value TCW (which is set here) and if the length of time defined by the PAUS has passed without the solar pump operating, the solar pump is switched on for the length of time defined by the PAN. Level Display Function Factory Range E3-3 / 4 CW Activation of the collector monitoring function. no YES / no E3-3 / 5 TCW Minimum collector temperature 35 C 10 C to 90 C during monitoring. E3-3 / 6 PAN Solar pump s runtime. 10 sec. 10 sec. to 60 sec. E3-3 / 7 PAUS Solar pump s idle time. 60 min. 10 min. to 60 min. Selection

13 Setting the additional functions Page Additional function: emergency collector switch-off If collector temperature exceeds the maximum value NOT (which is set here) for longer than 5 minutes, the solar pump is switched off and will not resume operation until the collector temperature has fallen below NOT - 10 K. Level Display Function Factory Range E3-6 / 1 NOT Emergency collector switch-off 110 C 90 C to 127 C Selection Additional function: collector safety If the collector temperature exceeds the maximum value TCM (which is set here), the storage reservoir shall be loaded until the emergency storage reservoir switch-off temperature is reached (fixed value: 90 C). Level Display Function Factory Range E3-6 / 2 KSF Activation of the collector safety YES YES / no function. E3-6 / 3 TCM Maximum temperature for 90 C 10 C to 127 C collector (above which the collector safety function is activated automatically) Additional function: storage reservoir safety Selection If the storage reservoir temperature (F3) exceeds the maximum storage reservoir loading temperature MAX (which is set on the user level) by 2 K, heat is dissipated out of the storage reservoirs (e.g. into the heating system). Level Display Function Factory Range E3-6 / 4 SSF Selection of relay for the storage 0 0 to 2 reservoir safety function. 0: no relay allocated (function is not enabled) 1 to 2: relay is allocated (function is enabled) Additional function: collector frost protection Selection If the collector temperature falls below the frost protection temperature of + 2 C, the solar pump is activated until the collector has been heated to + 5 C by the storage reservoir water. Level Display Function Factory E3-6 / 5 FSF Activation of the collector frost protection function. no Range YES / no Selection

14 Page 14 Setting the additional functions Additional function: thermostat, e.g. for activation of the circulation pump The sensor input and relay output are freely selectable. Additional function Level Display Function Factory Range E3-7 / 1 STH Selection of sensor for the 0 0 to 4 thermostat function. The number of any sensor which is still free is accentuated by flashing underscore lines. If the selected sensor is already assigned to another function, the corresponding number is displayed within brackets. 0: no sensor allocated (function is not enabled) 1 to 4: sensor is allocated (function is enabled) E3-7 / 2 RTH Allocation of relay for the thermostat 0 0 to 2 function. Any relay can be selected. If the selected relay is already assigned, the functions are combined in an OR relationship. E3-7 / 3 ETH Switch-on temperature for the 40 C 10 C to 127 C thermostat function. E3-7 / 4 ATH Switch-off temperature for the 45 C 10 C to 127 C thermostat function. Selection

15 Setting the additional functions Page Additional function: temperature comparison Sensor inputs and relay outputs can be freely selected for an additional temperature comparison function. Level Display Function Factory Range E3-8 / 1 VSA Selection of the first sensor 0 0 to 4 input. 0: no sensor allocated (function is not enabled) 1 to 4: sensor is allocated (function is enabled) The number of any sensor which is still free is accentuated by flashing underscore lines. If the selected sensor is already assigned to another function, the corresponding number is displayed within brackets. E3-8 / 2 VSB Selection of the second sensor 0 0 to 4 input (see above). E3-8 / 3 VR Selection of the relay output. 0 0 to 2 Any relay can be selected. If the selected relay is already assigned, the functions are combined in an OR relationship. E3-8 / 4 VDE Switch-on temperature difference 2 K 1 K to 20 K for the temperature com- parison function (cannot be set to less than VDA + 1 K). E3-8 / 5 VDA Switch-off temperature difference 1 K 1 K to 20 K for the temperature com- parison function (cannot be set to greater than VDE - 1 K). Selection

16 Page 16 System information menu 11. System information menu Here, you can read information about the solar controller and define system s. Level Display Function Factory E3-10 / 1 SOF Display of software version. E3-10 / 2 HAR Display of hardware version. E3-10 / 3 LP Display of circuit board version. E3-10 / 7 SER Setting for service operation / normal operation. no: normal operation (all temperature filter functions are switched on) YES: service operation (all temperature filter functions are switched off) no Range YES / no Selection

17 Overview of all s Page Overview of all s Level Display Function AE MAX Maximum loading temperature MAX for the storage reservoir. Factory Range 70 C 10 C to 90 C AE SPA Activation/deactivation of the storage reservoir YES YES / no E3-1 / 1 RES Reset of the factory. no YES / no E3-1 / 13 SSP Upper storage reservoir sensor F3 present. YES YES / no E3-2 / 1 TDE Switch-on temp. difference between F1 and F4. 8 K 1 K to 20 K E3-2 / 2 TDA Switch-off temp. difference between F1 and F4. 4 K 1 K to 20 K E3-3 / 1 LFF Activation of low-flow function. no YES / no E3-3 / 2 TCS Collector temperature which enables loading of the 65 C 10 C to 90 C selected storage reservoir. E3-3 / 4 CW Activation of the collector monitoring function. no YES / no E3-3 / 5 TCW Minimum collector temperature during monitoring. 35 C 10 C to 90 C E3-3 / 6 PAN Solar pump s runtime. 10 sec. 10 sec. to 60 sec. E3-3 / 7 PAUS Solar pump s idle time. 60 min. 10 min. to 60 min. E3-6 / 1 NOT Emergency collector switch-off 110 C 90 C to 127 C E3-6 / 2 KSF Activation of the collector safety function. YES YES / no E3-6 / 3 TCM Maximum temperature for collector. 90 C 10 C to 127 C E3-6 / 4 SSF Selection of relay for the storage reservoir safety 0 0 to 2 function. E3-6 / 5 FSF Activation of the collector frost protection function. no YES / no E3-7 / 1 STH Selection of sensor for the thermostat function. 0 0 to 4 E3-7 / 2 RTH Allocation of relay for the thermostat function. 0 0 to 2 E3-7 / 3 ETH Switch-on temperature for the thermostat function. 40 C 10 C to 127 C E3-7 / 4 ATH Switch-off temperature for the thermostat function. 45 C 10 C to 127 C E3-8 / 1 VSA Selection of the first sensor input. 0 0 to 4 E3-8 / 2 VSB Selection of the second sensor input. 0 0 to 4 E3-8 / 3 VR Selection of the relay output. 0 0 to 2 E3-8 / 4 VDE Switch-on temperature difference for the temperature comparison function. E3-8 / 5 VDA Switch-off temperature difference for the temperature comparison function. E3-10 / 1 SOF Display of software version. E3-10 / 2 HAR Display of hardware version. E3-10 / 3 LP Display of circuit board version. E3-10 / 7 SER Setting for service operation / normal operation. 2 K 1 K to 20 K 1 K 1 K to 20 K

18 Page 18 Relay test submenu REL 13. Relay test submenu REL To navigate to the submenu for manual adjustment of relays, press + or repeatedly until REL appears in the display. Call up the relay test sublevel by pressing the OK button. This causes all outputs (relays) to be switched off! The individual relays are selected by pressing + or. Here, the relay number (1 to 2), the switching state (OFF, On) are displayed. Switching the relays (numbers 1 to 2) on or off: Once the OK button has been pressed to select the relay, the symbol appears. The relay s switching state can now be changed by pressing the buttons + and. The relay s switching state thus set will then remain in effect until the relay test level is abandoned. 14. Faults and troubleshooting If your controller ever ceases to function properly, please check the following points: 1. Power supply: If anything appears in the display, there is no problem with the power supply. If nothing appears in the display, please check the mains voltage and the device fuse. 2. Sensors and sensor cables: If realistic temperatures are shown in the display (normal display and information level), there is no problem with the sensors or sensor cables. H C appears in the event of a sensor interrupt and L C in the event of a sensor short circuit. If the displayed temperatures are unrealistic, you can use an ohmmeter to check that the resistance values correspond to those in the following table: Pt1000 temperature sensor resistance table -20 C 922 ohms 20 C 1078 ohms 60 C 1232 ohms 100 C 1385 ohms -10 C 961 ohms 30 C 1117 ohms 70 C 1271 ohms 110 C 1423 ohms 0 C 1000 ohms 40 C 1155 ohms 80 C 1309 ohms 120 C 1461 ohms 10 C 1039 ohms 50 C 1194 ohms 90 C 1347 ohms 130 C 1498 ohms 3. Switching output: If the solar controller does not switch on the appropriate loading pump, please check the relay output by means of the relay test submenu. If it is not possible to remove the fault by means of the points mentioned above, the solar controller should be replaced. DANGER Danger of electrocution! The heating controller is to be assembled, electrically installed, commissioned, inspected and repaired by trained, competent and authorised persons (qualified electricians as per DIN VDE and BGV A3) only! Observe all applicable guidelines and regulations of the local electricity supplier! Before beginning installation or repair work on electrical equipment, always ensure complete disconnection from the mains and secure against reactivation! Do not work on live parts!

19 Notes: Page 19

20 Page 20 The descriptions, performance specifications and graphics in this manual are non-binding. Subject to technical alterations. This manual may not be duplicated, distributed, altered, passed on, translated into another language or used in any other way, without the express permission of the manufacturer. The content of this manual has been carefully checked. Nevertheless, the manufacturer cannot be held liable for any errors in this manual. Furthermore, if this commissioning manual or the operating manual is not adhered to, or is only partly adhered to, the manufacturer assumes no liability for any resulting damage. Art-Nr: /11