Temperature differential controller 5 inputs, 2 outputs Installation and operating instructions EN 742.886 | Z02 | 12.
EN Content General safety instructions.....................................3 EC declaration of conformity.................................3 1 2 Proper usage ..........................................................4 About this manual..................................................4 2.1 2.2 3 Installation .............................................................5 3.1 3.2 3.3 3.4 4 5 Construction.........................................................17 Changing the mode of operation...........
EN 14 Technical data.......................................................50 14.1 14.2 Controller................................................................ 50 Cable specifications................................................. 51 Exclusion of liability..............................................51 Legal guarantee....................................................51 General safety instructions • • • • • • • • • • • This document is part of the product.
EN 1 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. 2 About this manual 2.
EN 3 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.) 3.1 Opening / Closing the casing 3.1.1 Removing the front panel X Grasp the front panel by the grooves at the sides and pull forwards (Fig. 1). Fig. 1: 3.1.
EN 3.2 Mounting the casing √√ The mounting location must satisfy the prescribed conditions of use; more information on this is provided in Section 14, p. 50. √√ 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.
EN 3.3 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 3.3.1 Position of the connection terminals 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, R2 X Lconst. N 2x output (TRIAC, for pumps or valves) not used 2x phase conductor (outputs, permanent voltage) 4x neutral conductor (common neutral conductors for mains power input and outputs) Note Outputs R1 and R2 are protected by an electronic fuse.
EN 3.3.2 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 flat-blade screwdriver under the right plastic link between the casing and the spring clamp , (Fig. 5). 2. Carefully push the flat-blade 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: 3.
EN Display Legend 1 storage tank with heating return increase, 1 collector array T1: Collector array sensor T1 T2: Lower storage tank sensor T3: Upper storage tank sensor T3 T4: Sensor heating return increase R1: Solar circuit pump T4 T2 R1 R2: Heating return switching valve 3) R2 Terminal layout 1, 2, 3, 4, R1, N, PE (PWM R1, R2, N, PE 1 storage tank with external heat exchanger, 1 collector array T1: Collector array sensor T1 T2: Lower storage tank sensor T3: External heat exchanger sensor R1: Stora
EN Display Legend 1 swimming pool, 1 collector array T1: Collector array sensor T1 T2: Swimming pool sensor R2: Solar circuit pump Terminal layout 1, 2, R2, N, PE (PWM R2, T2 R2 1 swimming pool with external heat exchanger, 1 collector array T1: Collector array sensor T1 T2: Swimming pool sensor T3: External heat exchanger sensor R1: Solar circuit pump T3 R2: Swimming pool loading circuit pump R1 T2 R2 1 storage tank, 1 swimming pool, 1 collector array (pump-controlled) T1: Collector array sensor
EN 4 Commissioning the device for the first time Danger Risk of death by electrocution! Be sure to perform all the measures listed in Section 3 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 another system. 8. Press SET. If System 0.1 was selected in step 7, proceed with step 20. Setting pump 1 (output R1) 9. Press . AC and left). (pump 1) flash (example in fig. 10. Notice Standard pump: Select AC! High-efficiency pump: Select HE! Press to select the type for pump 1. 11. Press SET. 12. Notice When selecting HE (high-efficiency pump) pay attention to the pump characteristics.
EN Make the settings for pump 2 (output R2; only if a system with 2 pumps was selected in step 7, otherwise continue with step 20). 18. Press . AC and (pump 2) flash (example in fig. left). 19. Perform steps 10 to 17 accordingly for pump 2. 20. Press . F: is displayed. Set the functions (Necessary for System 0.1, or as required for other systems. The functions can also be set at a later date.) 21. Press SET to set the functions. F:01 (function number) flashes (example in Fig. left).
EN 32. Notice Danger of pump damage if run dry. Only switch the system to manual or automatic mode when the system is filled. Press and hold the mode button (arrow in Fig. left) for 2 seconds to change the mode of operation; more information on this is provided in Section 7, p. 20. 33. Mount the front panel. The controller is now ready for operation. Characteristics of high-efficiency pumps Display Pump type AA High-efficiency pump with a PWM profile for a rising characteristic curve (Fig.
EN 5 Construction 5.1 Casing 1 SET 3 1 2 ESC 4 1 5 1 1) 6 1 Fig. 7: No. Element Mode button (under front panel) Operating buttons: , SET, ESC, Display Front panel Terminal cover Terminal cover fastening screw See section 6.1 7 6.1 5.2 3.1 3.3.11) – Section 3.3.1 describes the terminals under the terminal cover. Front view of the controller 5.2 Display 5.2.1 Overview 4 3 1 2 Fig.
EN 5.2.2 System graphical symbols The following table describes the symbols used in the system graphics ( in Fig. 8).
EN 5.2.5 Operational and setting values The display of the operational and setting values ( in Fig. 8) consists of the following elements: 1 2 742.886| 12.31 3 4 5 6 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 6 Operation This section contains general information on operating the controller. 6.
EN 7.2 Off mode Functionality • • • • • All outputs are switched off (outputs/control outputs 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 ( 7.3 ).
EN 2 SET SET SET SET ESC SET 7.4 3 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 Time System SET Set time Functions 1) SET SET No system – 0.1 Circulation – F01 1 storage tank, 1 collector array – 1.1 Back-up heating – F02 1 storage tank with heating return increase, 1 collector array – 1.2 Solid fuel boiler – F03 1 storage tank with external heat exchanger, 1 collector array – 1.3 Quick charge – F04 1 storage tank with zone loading, 1 collector array – 1.4 Heat quantity – F05 1 storage tank, 2 collector arrays – 1.
EN Parameters 1) SET Maximum temperature storage tank 1 – P01 Priority Factory setting SET Storage tank 1 before storage tank 2 Maximum temperature storage tank 2 – P02 Storage tank 2 before storage tank 1 Maximum temperature swimming pool – P03 Only storage tank 1 Switch-on temperature difference solar circuit 1 – P04 Only storage tank 2 SET for 5 seconds Reset to factory settings Switch-off temperature difference solar circuit 1 – P05 Switch-on temperature difference solar circuit 2 – P06 Switc
EN 8.2 Calling up the settings menu and selecting a menu entry √√ Automatic or Off mode is selected. 1. Press and hold SET for two seconds. The settings menu is displayed, menu entry flashes. 2. Press to select a different menu entry. 3. Change the settings as described in the following sections. 8.3 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.
EN 8.7 Setting the priority Functionality The priority determines the sequence in which the storage tanks are loaded (only for systems with more than 1 storage tank). If the higher priority storage tank (first-priority storage tank) cannot be loaded because the collector temperature is too low then the lower priority storage tank (second-priority storage tank) is loaded 1). The following values can be selected: -1-: Only storage tank 1 is loaded. -2-: Only storage tank 2 is loaded.
EN 9 Functions 9.1 Operation Displaying the functions The following information is visible when the functions are displayed: • Function number, e.g. F:01 (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-on temperature difference If a function contains a differential thermostat then the switchon temperature difference can be set. The relevant sensor symbols flash. Switch-off temperature difference If a function contains a differential thermostat then the switchoff temperature difference can be set. The relevant sensor symbols flash. Switch-on temperature If a function contains a thermostat then the switch-on temperature can be set. The relevant sensor symbol flashes.
EN Starting time of a time window When setting the start time of a time window, the following is displayed to the left of the start time (see Fig. left): • • Number of time window 1 ... 3, whose start time is to be set (in this case: 1) • on 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 ...
EN 9.3.1 Circulation Switches a circulation pump on and off on a temperature and/or time controlled basis. Temperature control: If the temperature in the circulation return falls below the Ton value, then the circulation pump is switched on until the Toff temperature is reached. Time control: The circulation pump is switched on when the current time lies within one of 3 configurable time windows.
EN 9.3.2 Back-up heating Performs temperature-dependent switching of an output 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. Display Characteristic min.
EN Display Characteristic min. max. on, oFF Activation Output (pump) Pump type (R1, R2 only) Pump characteristic (HE only) Speed control (R1, R2 only) Factory setting oFF free output R1/R2/RS – AC AA, Ab, C (see page p. 16) – oFF AC, HE 1) 2) on, oFF 2) Minimum speed (AC only) 30% 100% 50% Minimum speed (HE + AA only) 0% 100% 25% 0% 100% 75% Minimum speed (HE + Ab only) Sensor input for storage tank temperature 1 ... 5 – Sensor input for solid fuel boiler temperature 1 ...
EN 9.3.4 Quick charging Uses a higher loading temperature to load the the upper region of the storage tank more quickly in order to provide early prevention of backup heating by the conventional heating system. To do this, the loading strategy of the first-priority storage tank is changed from differential loading to absolute temperature loading as soon as the temperature in the upper tank region drops below Ton*).
EN Type 1: Flow rate value at max. speed Fmax. (pump 1). When the Fig. at the left is displayed (value flashes) then enter the value read from the flow rate display. Fmin. 99.9 l/min 0.0 l/min Type 1: Flow rate value at min. speed Fmin. (pump 1). When the Fig. at the left is displayed (value flashes) then enter the value read from the flow rate display. 0.0 l/min Fmax. 0.0 l/min Type 1: Flow rate value at max. speed Fmax. (pump 2) 2) Fmin. 99.9 l/min 0.0 l/min Type 1: Flow rate value at min.
EN 9.3.6 Thermostat Switches an output on and off, depending on the temperature range of any desired sensor. The function can be time restricted and is set for heating or cooling as follows: Heating: The Ton value is set lower than Toff. When the sensor temperature drops below Ton, the output is switched on until the temperature exceeds Toff. Cooling: The Ton value is set higher than Toff. When the sensor temperature exceeds Ton, the output is switched on until the temperature drops below Toff.
EN Display Characteristic min. on, oFF Activation Output Pump type (R1, R2 only) Pump characteristic (HE only) Speed control (R1, R2 only) max. Factory setting oFF free output R1/R2/RS – AC AA, Ab, C (see page p. 16) – oFF AC, HE 1) 2) on, oFF 2) Minimum speed (AC only) 30% 100% 50% Minimum speed (HE + AA only) 0% 100% 25% 0% 100% 75% Minimum speed (HE + Ab only) Heat source sensor input 1 ... 5 Heat sink sensor input 1 ...
EN 9.3.8 Interval Periodically switches the solar circuit pump on and off in order to measure the actual collector temperature. The delay between 2 switch-on operations and the switch-on duration can be set. Applications: • Collector types where the mechanical construction prevents the temperature from being measured at a suitable place • Unsuitable position of the temperature sensor on the collector The function can be time restricted to prevent unnecessary periodic operation at night.
EN 9.3.10 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 – or the second-priority storage tank if 2 storage tanks are present – 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 9.3.12 Frost protection Attempts to prevent freezing of the collectors by pumping heat from the first-priority storage tank into the collectors: • The collector temperature is below +5 °C: Solar circuit pump is switched on. • The collector temperature is 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 9.3.14 Alarm output Activates the set output in the case of the following faults: • Sensor fault due to short-circuit or interruption • Clock loses the current time due to an extended power outage. • Volume flow fault: Er: 1 1) • The electronic overload switch or fuse has triggered: Er: 3 ... Er: 6 1) Display Characteristic Activation Output Control 1) 2) 42 min. max. on, oFF free output R1/R2/Rs norm, InV 2) Factory setting oFF – norm More information is provided in Section 13.2, p. 48.
EN 10 Parameters Display 742.886| 12.31 Factory setting 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.
Display Parameter min. Factory setting EN Functionality Maximum collector temperature TP11 + 20 K 180 °C 130 °C When the maximum collector temperature is exceeded, no more loading occurs until the temperature drops to 3 K below the set value. Minimum collector temperature 0 °C TP10 – 20 K 0 °C Load only starts when the minimum collector temperature is exceeded.
Display Parameter Pump type R1 Pump characteristic (HE only) Speed control (R1, R2 only) 742.886| 12.31 oFF Minimum speed (HE + AA only) 0% 100% 25% 0% 100% 75% AC, HE AC AA, Ab, C (see p. 16) – on, oFF oFF Minimum speed (AC only) 30% 100% 50% Minimum speed (HE + AA only) 0% 100% 25% 0% 100% 75% Minimum speed (HE + Ab only) 4) on, oFF 50% Speed control (R1, R2 only) 3) – 100% Pump characteristic (HE only) 2) AC, HE AC AA, Ab, C (see p. 16) 30% Pump type R2 Tab.
EN 11 Deinstallation 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 3, p. 5. 2. Dispose of the device in accordance with the local regulations.
EN 13.1 General faults Display Possible cause Remedy Controller not functioning at all Display empty/ dark Controller power supply is interrupted. • • Check the controller power cable. Check the fuse for the power supply. Controller constantly displays 12:00 12 flashes Controller power supply was interrupted for longer than 15 minutes. Set the time. Solar circuit pump not operating + switch-on condition is fulfilled Pump power supply is interrupted. Check the pump power cable.
EN Solar circuit pump is operating + switch-on condition is fulfilled but no heat transport in the solar circuit (no heat transfer fluid circulation) Air is in the solar circuit. The isolating valve is closed. Limescale or contamination in solar circuit Check the solar circuit for air. Check the isolating valve. Clean the solar circuit (flush). Solar circuit pump shows cycle behaviour Temperature difference too small Collector sensor incorrectly positioned Tab. 5: 13.
EN Tab. 6: 13.3 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. A short-circuit exists at output R2, the pump connected to output R2 flashes. Possible causes: • The pump is faulty. • Wiring fault Check the electrical data of the pump, replace pump if necessary. R1 is automatically switched on again.
EN 14 Technical data 14.1 Controller Inputs/outputs Rated voltage (system voltage) 115 ... 230 V~, 50/60 Hz Own consumption ≤ 0.8 W, two Pt1000 temperature sensors connected Outputs R1, R2 Quantity Type Switching current Voltage 2 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 14.2 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 mm to 10 mm ≤ 2.5 mm2 ≤ 1.5 mm2 Diameter of the internal strain relief 6.5 mm to 10 mm 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 742886 52 742.886| 12.
