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Microcontroller-controlled temperature difference controller for solar thermal systems
Operating manual
Solareg II BASIC DC
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Inhalt
1 Application area / device features 3
1.1 Application area 3
1.2 Device features 3
2 Safety instructions 3
3 Mounting the device 4
3.1 Opening the device 4
3.2 Wall mounting 4
3.3 Connections 5
3.4 Temperature sensor connection 5
4 Short descriptions and device operation 5
4.1 Display layout 5
4.2 Operating the device 6
5
Menu structure 6
5.1 "Info" menu 6
5.2 "Programming" menu 7
5.3 "Manual operation" menu 7
5.4 "Basic Setup" menu 7
6 System diagrams 8
Controller functions 9
7.1 General controller functions 9
7.2 Protective functions 9
7.2.1 Collector protection 9
7.2.2 Recooling (Holiday function) 9
7.2.3 System protection 10
7.3 Additional function 10
7.3.2 Operation without rechargeable battery: 10
7.3.3 Operation with rechargeable battery 10
Settings table for the switch-o threshold 11
8 System monitoring 12
8.1 Sensor monitoring 12
8.2 Flow monitoring 12
9 Troubleshooting 13
9.1 Faults with error messages 13
9.2 Faults without error messages 14
10 SOLAREG II Specications 15
11 Resistance table PT1000 15
12 Warranty conditions 16
13 Declaration of conformity 16
Explanation of the
graphic symbols
Attention!
Symbol indicates
possible dangers
and errors
List
Please note!
Information for
handling / special
features
Implementation /
procedure
Test /
check
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1 Application area / device features
1.1 Application area
The SOLAREG II BASIC DC controllers are high-performance microprocessor-controlled units for controlling the functions of solar thermal systems. They are suitable
for most types of south facing solar thermal systems.
The controller is only suitable for DC operation with a system voltage of 12V. All
connected pumps and valves must be designed accordingly. The controllers are
designed for use in dry rooms as well as residential, business and commercial applications. Prior to commissioning the device, make sure to verify that the intended
use complies with the applicable regulations.
1.2 Device features
The SOLAREG II generation of controllers is equipped with the following features:
Intuitive operating menu with graphic symbols and four operating buttons ◼
Adjustable values ◼
Integrated operating hours counter for storage tank charging ◼
Automatic 12V-battery detection ◼
Extensive functions for system monitoring that display symbols to indicate er- ◼
rors and faults
Storage of all values even during a prolonged mains power supply outage ◼
Various protective functions, such as system protection, collector protection, ◼
recooling and ow monitoring
Generous wiring space ◼
Available accessories:
Temperature sensor PT1000 ◼
Sensor connection box ◼
Immersion sleeves ◼
2 Safety instructions
Always completely disconnect the device from the operating voltage before ◼
performing installation or wiring work on the electrical equipment.
Never mix up the connections of the protective low voltage areas (sensor, ow
sensor) with the 12V connections. Otherwise, the device will be destroyed.
Solar power systems can reach high temperatures. Such temperatures pose a ◼
risk of burns! Exercise caution when installing the temperature sensors!
Mount the SOLAREG II controller in a position where it will not be subjected ◼
to excessive operating temperatures (> 50°C) by any external heat sources.For
safety reasons, the system may only remain in manual operation for testing
purposes. In this operating mode, the system does not monitor for maximum
temperatures and sensor functions. If there is any recognisable damage to the
controller, cables or the connected pumps and valves, the system must not be
started.
All installation and wiring
work must only be carried
out on the controller when the
device is disconnected from the
power supply.
The SOLAREG II must only be
connected and commissioned by
qualified personnel. In doing so,
the applicable safety regulations
must be observed.
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3 Mounting the device
3.1 Opening the device
The upper part of the housing is locked to the lower part using two latches. Pull the
side pieces (cover plates) of the upper part of the housing outwards (see picture) to
unlatch it and upwards until the cover plate is opened.
3.2 Wall mounting
The device is mounted on the marked points. A drilling template is provided with
the device. Insert the "Quick Info" card provided with the device into the pocket
provided on the back of the device. The "Quick Info" card provides the user with an
overview of the functions to facilitate rapid device operation.
The controller must only
be installed in dry and
non-explosive areas. Mounting
the controller on an inflammable
surface is prohibited
Prior to switching on or
commissioning the device:
make sure to close the cover until
both sides securely lock into
place!
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3.3 Connections
The following points must be followed for the 12V connections:
◼ We strongly recommend using a 12V lead gel rechargeable battery for this
device. Other rechargeable battery types can also be used, but only after taking
into account the end-of-charge voltage. A fuse that corresponds to the cable
cross-section must be installed in the battery cable.
The controllers are designed to operate using 12V DC. The pumps and valves to ◼
be connected must be designed for this voltage!
The earth connections (M) are electrically connected and are not switched! ◼
The switching output (A1) is electronic 12V DC N/O contact. A potential-free ◼
changeover contact is switched parallel to the output.
3.4 Temperature sensor connection
The SOLAREG II BASIC DC devices use PT1000 precision platinum temperature sensors. 2 sensors are required, the third sensor is optional.
Mounting / wiring the temperature sensors:
◼ Mount the sensors on the collector and the storage tank. Ensure proper heat
transfer and use heat-conducting paste if necessary.
Cross-sections for cable extensions (shielded): ◼
- up to 15m 2 x 0.5mm2,
- up to 50m 2 x 0.75mm2.
Connect the temperature sensors according to the system diagram. The polarity ◼
of both conductors for the temperature sensors is irrelevant.
◼ Sensor cables must be laid separately from 230V wires.
Sensor connection boxes equipped with surge protection should be used for ◼
collector sensors and cable extensions.
4 Short descriptions and device operation
4.1 Display layout
During actual operation, these symbols are only displayed for selection once
depending on the menu position.
Active menu in the menu levels ◂
Allocation of the current display ◂
Current measured values, times or control- ◂
ler states: herr 59.6C°.
Measuring point ◂
Controller state/messages ◂
Display symbols
All possible display symbols are
shown below.
ok?
hPa
start%stopdTmin max
F
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4.2 Operating the device
The SOLAREG II controller is convenient and easy to operate using four operating
buttons. Using the operating buttons, you can:
Access display values ◼
Perform device settings ◼
The graphic display symbols allow you to easily navigate through the operating
structure.
The operating buttons have the following functions:
Operating
buttons
Function Description
"Up"
„+“
Increase menu items ◼
Value change: increases the displayed
value by 1; when the button is held longer,
the value increases continuously
"Scroll left"
"Exit"
"Cancel"
Scroll left in the main menu ◼
Exit a menu ◼
Exit a menu item ◼
Cancel a value change without storing it ◼
"Access"
"Down"
"-"
Access a main menu, ◼
Decrease menu items
Value change: decreases the displayed ◼
value by 1; when the button is held longer,
the value decreases continuously
"Scroll right"
"Select"
"Conrm"
Scroll right in the main menu ◼
Select a menu item ◼
Conrm a value change and store it ◼
5
Menu structure
5.1 "Info" menu
The following measured and yield values are displayed in the Info menu:
Display
e.g.
Meaning
Can be
reset
75 °C
Displays current collector temperature
No
min
12 °C
Displays minimum collector temperature can
be reset to the current temperature
Ye s
max
105 °C
Displays maximum collector temperature can
be reset to the current temperature
Ye s
52 °C
Displays current storage tank temperature
No
min
40°C
Displays minimum storage tank temperature
can be reset to the current temperature
Ye s
max
67 °C
Displays maximum storage tank temperature
can be reset to the current temperature
Ye s
60 °C
Displays the current temperature - S3
No
1234 h
Operating hours for charging storage tank
Can be reset to 0 h
Ye s
The display illuminates
when any button is
pressed.
The number of displayed
values depends on the
activated additional functions.
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Display
e.g.
Meaning
Can be
reset
13,2
Measured voltage
U=solar module
UA=battery (only if connected)
No
5.2 "Programming" menu
The operating parameters are displayed and can be changed, if necessary, in the
Programming menu. The preset values generally ensure fault-free system operation.
Display
e.g.
Meaning
Value
range
Typical
setting
Current
setting
max
65 °C
Storage tank:
Maximum permissible temperature
15 –95°C 65°C
dT max
7K
Storage tank:
Switch-on dierence
3 –40K 7K
dT min
3K
Storage tank:
Switch-o dierence
2 –35K 3K
5.3 "Manual operation" menu
Automatic operation is switched o during manual operation. The outputs can be
manually switched on and o for servicing and testing purposes.
Once the menu has been exited or after 8 hours, automatic operation is reactivated.
Display
Meaning Value range
Manually switching on / o the switching
output A1 (pump 1)
0 = O
1 = On
5.4 "Basic Setup" menu
The hydraulic diagrams and additional functions are displayed in the Basic Setup
menu. Settings must only be changed by a specialised technician. Settings may
only be adjusted in the menu:
a) within one minute after the device has been switched on
or
b) after simultaneously pressing the buttons:
Display
Meaning Value range
Factory
setting
Current
setting
Line Value
0 0
Collector protection
function
0 = O
1 = On
0 = O
1 120 °C
Collector protection
function
110 –150°C 120°C
2 0
Recooling function
(only if the collector
protection is on)
0 = O
1 = On
0 = O
3 40°C Recooling temperature 30 –90°C 40°C
4 0
Switch-o threshold
See table p.11
0-9 2
Settings and changes in
this menu must only be
carried out by a specialised
technician. Incorrect settings can
damage or adversely affect the
function of the solar power system.
Settings and changes in
this menu must only be
carried out by a specialised
technician. Incorrect settings can
damage or adversely affect the
function of the solar power system.
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6 System diagrams
1 collector, 1 storage tank
S1
A1
S3
S2
Fuse
A4
+
M
A1 M0 B S1 S2 S3
12V connections
B Battery +
MO Module +
M Earth
A1 Solar circuit pump (switching output 1)
A4 Potential-free
Sensor connections
S1 Collector sensor
S2 Lower storage tank
S3 General temperature point
The ground or earth
terminal block is always
the front one
+
M
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Controller functions
7.1 General controller functions
The controller compares the temperatures of the various measuring points and optimally charges the storage tank. If the collector temperature exceeds the storage
tank temperature, the solar circuit pump is switched on. Monitoring and protection
functions ensure safe operation.
7.2 Protective functions
The controller is equipped with the following protective functions.
7.2.1 Collector protection
If the storage tank has reached the set maximum temperature and the collector
temperature exceeds the set collector protection temperature (line 1), the solar
circuit pump is switched on. The solar circuit pump is switched o once the collector temperature is 10K below the maximum value.
In this case, the storage tank is charged up to 95°C regardless of the set maximum
temperature.
7.2.2 Recooling (Holiday function)
The collector protection function is only eective if the storage tank temperature is
below the temperature limit (95°). Therefore, during the holiday period, for example, the storage tank is discharged at night to the set recooling temperature.
Make sure not to activate this function together with the backup heating!
"Basic Setup" menu
Display Meaning Value range Factory set-
ting
Line Value
0 0
Switches on or o the collector protection function
0 = O
1 = On
0 = O
1
120 °CTemperature at which the collector
protection function is activated
110 –150°C 120°C
2 0
Switches on or o the recooling
function (only if the collector protection is on)
0 = O
1 = On
0 = O
3 40°C
Temperature to which the storage
tank is recooled once the collector
protection function is activated
30 –90°C 40°C
Settings and changes in
this menu must only be
carried out by a specialised
technician. Incorrect settings can
damage or adversely affect the
function of the solar power system.
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7.2.3 System protection
If the collector temperature exceeds the collector protection temperature (see
7.2.2) by 10K, the solar circuit pump is switched o to protect the system components.
If the collector temperature drops below the collector protection temperature, the
solar circuit pump is switched on.The function is always activated.
7.3 Additional function
7.3.2 Operation without rechargeable battery:
If the module voltage is less than approx. 6V, the controller automatically switches
into energy-saving Low Power mode and the display is switched o.
The switch-o threshold for the outputs can be set between 8V and 9,8V in the
Main menu.The Basic Setup menu is no longer locked, since the device cannot
"actually" be switched o in Low Power mode.The module voltage is displayed.
7.3.3 Operation with rechargeable battery
If a battery is connected, the controller switches automatically in rechargeable
battery mode and the module charges the battery. The rechargeable battery is
protected against overcharging. This means that if the operating voltage exceeds
14.2 V, the module output is electronically reduced.
The rechargeable battery is also protected against deep discharging. If the re-
chargeable battery voltage falls below the programmed switch-o threshold for
more than 10 seconds (factory setting 10.4V), the outputs are switched o. The
battery is switched back on once it reaches a voltage of 12.4 V Low Power mode is
activated if:
the battery voltage drops below the switch-o threshold for more than 15 ◼
seconds
the battery voltage is below 11,5 V for 10 hours ◼
There is no RPM control.
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Settings table for the switch-o threshold
Values for rechargeable battery
operation
Values without rechargeable battery
Position
Switch-o voltage
in Volts
Position
Switch-o voltage
in Volts
0 10,0 0 8,0
1 10,2 1 8,2
2 10,4 2 8,4
3 10,6 3 8,6
4 10,8 4 8,8
5 11,0 5 9,0
6 11,2 6 9,2
7 11,4 7 9,4
8 11,6 8 9,6
9 11,8 9 9,8
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8 System monitoring
If an error occurs, the ashing symbol is generally displayed.
8.1 Sensor monitoring
The connected sensors and sensor cables are monitored for interruptions and
short-circuits. Errors are indicated by the symbol. You can nd the error source
by scrolling up or down the Info menu.
8.2 Flow monitoring
The controller is programmed to display a message if the ow is interrupted, e.g.
pump fault or if vapour is in the system. This message, however, does not switch o
the pump.
"Basic Setup" menu
Display Meaning
+
No circulation in the solar circuit
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9 Troubleshooting
System faults are distinguished into two general categories:
Faults that are automatically detected by the controller and therefore can be ◼
displayed using error messages
Faults that the controller cannot detect ◼
9.1 Faults with error messages
Error indication in
the display
Possible causes Measures
Flashing
Sensor cable is inter- ◼
rupted
Check cable
Defective sensor ◼
Check sensor resistance
and replace sensor if
necessary
Flashing
Short-circuit in the sensor ◼
cable
Check cable
Defective sensor ◼
Check sensor resistance
and replace sensor if necessary
Circulation error:
No ow
+
Flashing
Additional display
for energy yield
measurement:
Error in the pump con- ◼
nection
Check wiring
Defective pump ◼
Replace pump
Air in the system ◼
Deaerate the system
Defective ow meter ◼
Check whether the ow
meter impeller moves
freely when the system is
running (if visible)
Defective connection to ◼
the ow meter
Check cable
Sensor cable is inter- ◼
rupted
Check cable
Defective sensor ◼
Check sensor resistance
and replace sensor if
necessary
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9.2 Faults without error messages
Faults and malfunctions that cannot be displayed as well as possible causes and
their error source can be identied using the following table. If you cannot remedy
the fault using the description below, contact the supplier or installer.
Problem Possible causes Measures
Display does not
function
12V mains voltage not ◼
available
Switch on or connect
controller
Check the connection's
main fuse
Defective fuse inside the ◼
device
Check the fuse*,
replace with a new type
2A/T, if necessary.
Check the 12V compo- Check the 12V compo-Check the 12V compo-
nents for short-circuits
Defect device ◼
Contact the supplier
Outputs are not
switched on
Controller is in manual ◼
operation
Exit "Manual" operation.
Switch-on condition is not ◼
satised.
Wait until switch-on
condition is satised.
"Pump" symbol
rotates, but the
pump is not on
Connection to the pump ◼
interrupted.
Check the cable leading
to the pump
Pump is blocked. ◼
Free the pump
No voltage present at the ◼
switching output.
Contact the supplier.
Temperature
display strongly
uctuates at short
intervals
Sensor cables are installed ◼
near the 230V cables
Relocate sensor cables,
shield sensor cables
Long sensor cables ex- ◼
tended without shielding
Shield sensor cables
Defect device ◼
Contact the supplier
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10 SOLAREG II Specications
Housing
Material
100% recyclable ABS housing for wall mounting
Dimensions L x W x D in mm,
weight
175 x 134 x 56; approx. 360 g
Protection class IP20 according to DIN 40050
Electrical specications
Operating voltage DC 12 volts
Max. module voltage. DC 23 volts
Max. module current. 2A
Potential-free switching contact 12V DC / max. 2A
Radio interference level N according to VDE 0875
Max. cable cross-section
230V connections
2.5 mm² ne-wire/single wire
Temperature sensor /
measuring range
PT1000, 1 kΩ at 0°C
-30°C .. +250°C
Output - voltage
Power - switching output
12V DC
max. 1A
Power consumption (stand by) 0,3W
Fuse protection
Fine-wire fuse 5 x 20mm, 4A/T
(4 amperes, delayed-action fuse)
Miscellaneous
Operating temperature 0 – 50°C
Storage temperature -10 – +65°C
Humidity max. 60 %
11 Resistance table PT1000
The temperature sensors can be checked for proper function using the following
temperature resistance table and an ohmmeter:
Temperature
in °C
Resistance
in Ohm
Temperature
in °C
Resistance
in Ohm
-30 882 60 1232
-20 921 70 1271
-10 960 80 1309
0 1000 90 1347
10 1039 100 1385
20 1077 120 1461
30 1116 140 1535
40 1155 200 1758
50 1194
Subject to change in
accordance with technical
advances!
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12 Warranty conditions
The SOLAREG II controllers are carefully produced and tested on an automatic
testing station. If any failures occur, rst check if there are any operation / setting or
system errors. Furthermore, check the pump and temperature sensor connections.
PROZEDA GmbH provides a 2-year warranty starting at the date of purchase and
according to the following conditions.
a) The warranty comes into eect if the purchased good exhibits a material or
quality defect. If the defect is caused by improper handling, by exceeding the
permitted values stated in the specications, improper wiring, invalid technical
modications to the device performed by the buyer or by an another company
other than PROZEDA GmbH, the warranty shall be void.
b) The warranty requires a written notice that describes the defect in detail as well
as a copy of the customer invoice.
PROZEDA GmbH can choose to full the guarantee, at its own discretion, by one
of the following measures
- Repair (reconditioning) or
- Delivery of a fully functional replacement product
The device shall be repaired within 1 month after PROZEDA GmbH has received
it.
If the device is not repaired within the two repairs attempts, the buyer is entitled to delivery of a fully functional replacement product.
If a replacement product is delivered, a new warranty that corresponds to these
conditions shall come into eect.
c) Any further warranty (redhibitory action, reduction of price) is excluded.
Warranty claims may only be submitted by the customer and are non-transferable.
If a defect occurs during the warranty period, please contact the supplier / installer.
When returning the device for warranty service, please make sure to send a description of the error and, if possible, the system diagram along with the wiring diagram.
13 Declaration of conformity
We, Prozeda GmbH, declare under our sole responsibility that the SOLAREG type
1316 product complies with the following standards:
EMC Directive 89/336/EEC, amended by RL 92/31/EEC and RL 93/68/EEC
EN 50081-1:1992 / EN55022:1998 (Radiated Emission)
EN 50082-1: 1997 / EN 61000-4-2:1995/A1:1998 (ESD)
/ EN 61000-4-3:1996+A1:1998 (Radiated Immunity)
/ EN 61000-4-4:1995 (Burst)
/ EN 61000-4-5:1995 (Surge)
/ EN 61000-4-6:1996 (Conducted Immunity)
/ EN 61000-4-11:1994 (Voltage Drops)
Operation manual for Solareg II BASIC DC 1316BED049-20B-E, last revised 03/2008
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