Caleffi 1522 User Manual

www.caleffi.com

OPTIMISER®digital regulator
for heating systems with solid fuel generator

18146.01EN

© Cop yr igh t 2 014 Ca lef fi

INSTALLATION AND COMMISSIONING MANUAL

CONTENTS

Function

Warnings

Technical data

Display and commands

General functions

1522 series

1

2

2

4

4

Function

®

The OPTIMISER
possible to combine a solid fuel generator with another type
of generator already present in the heating system.
The digital regulator automatically manages the two
generators, receiving the signal from the probes and
activating the pumps, the motorized diverter valves in the
system, according to the heating circuit needs.
Depending on the type and quantity of installed probes, the
regulator supports the following system solutions:

- heating;

- production of domestic hot water by means of storage or
instantaneous with plate heat exchanger;

- management of inertial water storage in parallel on the
heating circuit or alternatively management of an
independent solar system and direct inertial water
storage.

digital regulator code 152200 makes it

Available programs

Hydraulic diagrams of programs

5

7

1

WARNINGS

The following instructions must be read and understood before installing, commissioning and
maintaining the regulator.

The safety symbol is used in this manual to draw attention to the relative safety instructions. The
meaning of this symbol is as follows:

CAUTION!
YOUR SAFETY IS INVOLVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN INJURY.

- The digital regulator must be installed by a licensed installer in accordance with national regulations and/or

relevant local requirements.

- If the digital regulator is not installed, commissioned and maintained correctly in accordance with the instructions

in this manual, then it might not work properly and may endanger the user.

CAUTION: Risk of electric shock. The rear panel is live. Cut off the electric supply
before carrying out any work. Failure to follow these instructions may result in
personal injury or damage to property.

LEAVE THIS MANUAL AS A REFERENCE GUIDE FOR THE USER

Technical data

Regulator

Electric supply: 230 V (ac) ±10%; 50-60 Hz
Power consumption: 5,5 VA
Output signals: 10 relay contacts for heating
Contact rating: 250 V (ac), 8 (2) A (max 9 A in total)
Protection class: II
Protection class: IP 40
Clock data retention with no electric supply: 24 h
EEPROM data retention with no electric supply: permanent

Ambient conditions

Ambient temperature:
Operation: 0–55°C EN 60721-3-3 Cl. 3K3, max. humidity 85%
Transportation:-10–70°C EN 60721-3-2 Cl. 2K2, max. humidity 95%
Storage: -5–50°C EN 60721-3-1 Cl. 1K2, max. humidity 95%

When the solid fuel generator is equipped with an anti-condensation valve, it is good practice to set the minimum
working temperature of the solid fuel generator (TSG, settable in the regulator menu) to a value at least 2°C higher than
the anti-condensation valve setting.

Temperature probe* for solid fuel generator flow, domestic
water storage, domestic heat exchanger, inertial water storage
in parallel on the heating system, solar water storage.

NTC type
Working range: -20–100°C
Two-wire cable

Temperature probe* for solar collector

Pt1000 type
Cable length: 3 m
Cable SIHF,
Cross section: 2 x 0,5 mm
Max working temperature: 180°C

*The use of the probes is specified in the “Available programs”
heading on page 5.

2

- Anti-condensation valve setting: °C

- Minimum working temperature of the
solid fuel generator (TSG, working temperature range: 20–85°C): °C (factory setting: 55°C).

It is good practice to compile the two blank fields to facilitate any system checks to be performed.

2

NTC probes* resistance table: for solid fuel generator flow, domestic water storage, domestic heat exchanger, inertial water

100 23 1/2”

ø 6,4

A

C

B

650 3

L (m)

B

A

AB

628 2

L (m)

B

A

AB

1,530

55 9 11

L (m)

B

A

C

D

D

43 17 1/4”

ø 6,4

C

B

A

storage in parallel on the heating system, solar water storage.

°C

-20

-18

-16

-14

-12

-10

-8

-6

-4

Pt1000 probe* resistance table: for solar collector.

Ω

14616
13211
11958
10839

9838
8941
8132
7405
6752

°C

-2
±0
+2
+4
+6
+8

+10
+12
+14

Ω

6164
5634
5155
4721
4329
3974
3652
3360
3094

°C
+16
+18
+20
+22
+24
+26
+28
+30
+32

Ω

2852
2632
2431
2247
2079
1925
1785
1657
1539

°C
+34
+36
+38
+40
+42
+44
+46
+48
+50

Ω

1430
1331
1239
1154
1076
1004

938
876
819

°C
+52
+54
+56
+58
+60
+62
+64
+66
+68

Ω

767
718
673
631
592
556
522
491
462

°C
+70
+72
+74
+76
+78
+80
+82
+84
+86

Ω

434
409
386
364
343
324
306
290
274

°C
+88
+90
+92
+94
+96
+98

+100

Ω

260
246
233
221
210
199
189

°C

-10 961 65 1252

-5 980 70 1271
0 1000 75 1290
5 1019 80 1309

10 1039 85 1328
15 1058 90 1347
20 1078 95 1366
25 1097 100 1385
30 1117 105 1404
35 1136 110 1423
40 1155 115 1442
45 1175 120 1461
50 1194 140 1536
55 1213 160 1611
60 1232 170

CAUTION

Install Pt1000 probe, with red silicone sheath cable (Tmax 180°C), on the solar collector.

Dimensions

NTC probe and contact probe
holder code 150009

Ω

°C

Immersion pocket
code 150029

Ω

NTC probe
code 150006

Pt1000 probe
code 257006

Probe connection

The cable connecting probes to the regulator must be
installed in a dedicated raceway. If the connection
cable shares the raceway with other power cables, an
earthed shielded cable must be used.
Any alteration to the wiring of the regulator could
result in electrical disturbance.
After performing work on the wiring, the regulator
must be reset by cutting off the electric supply for a
few seconds. Cable length can be increased to 100 m
using a 1 mm

2

cross section cable.

Immersion pocket
code 257004

Relay box
code F29525

Probe Type Supply Standard application Optional application

S1* NTC series

S2* NTC optional - probe code 150006 + pocket code 257004

S3* NTC optional - probe code 150006 + pocket code 150029

S4* NTC series

S5* NTC series

Sol2* NTC optional - probe code 150006 + pocket code 257004

Sol1* Pt1000 optional -

*The use of the probes is specified in the “Available programs” heading on page 5.

See instruction sheet,
code 28134

probe + contact probe holder:

code 150009

immersion pocket code 150029

probe code 150006 +

pocket code 257004

probe + contact probe holder:

code 150009

3

immersion type: probe code 257006 +

pocket code 257004

-

-

5

-

+

Optimiser



1

2

3

4

Display and commands

-

+

-

- -

General functions

Display

The regulator is equipped with a display to read and program the
control parameters, such as cut-in temperatures, function
activation delay times, thermal disinfection programs, solar system
control, etc. All the system’s functional parameters can be
configured to match individual requirements by means of the
“Select” knob and the three function keys.

Block protection function “Block Protect.”

When it is powered on, the regulator performs an initial check,
activating the valves and pumps to which it is connected. The
message “Block Protect.” appears on the display.

Pump and diverter valve anti-clog function

To prevent clogging of the pumps and diverter valves due to
prolonged stoppages, the regulator activates them for 60 seconds
after each period of 24 consecutive hours of disuse.

Control description

1- Operating status indicator LED.
2- Mini DIN connector on front of panel for PC connection.
3- Menu display.
4- Select knob: selection of functions menu and parameter editing.
5- Function keys

Display

The display (3) shows the text with the main operating information.
In the absence of control signals, after four minutes the display
reverts to the initial page.

Select knob and function keys

Select knob (4): can be rotated or pressed

Turn the Select knob clockwise or

anticlockwise to select the options of the
function menu or to modify the values of the
various user-settable parameters.

Press the Select knob to open the submenu
relative to the selected option.

Function keys (5): can be pressed

Esc: change the display of the selected menu

point and return to the previous menu level

Frost protection

When the solid fuel generator flow temperature reaches a minimum
user-settable value, the regulator activates the primary side pump
to prevent the circuit from freezing.

Anti-legionella function (programs 5 and 8 only)

The regulator keeps the domestic water storage at the minimum set
temperature and raises the temperature in order to perform thermal
disinfection in accordance with customizable times.

Instantaneous domestic hot water production (programs 6 and
9 only)

The regulator manages the instantaneous domestic hot water
production by means of a second heat exchanger and, if
necessary, it sends the water to the boiler for thermal integration by
means of the (optional) SOLARINCAL kit (code 265359).

Overtemperature safety function

The regulator is equipped with a solid fuel generator
overtemperature monitoring function.
When the user-settable emergency temperature is reached on the
solid fuel generator, the regulator generates an alarm signal and
starts the pumps to dissipate the excess heat to the system or to an
emergency user service. This latter function can be activated by
means of a specific menu item. In this case, it is necessary to install
a diverter valve, driven by the regulator, to transfer the flow to the
emergency user service.

Probe control
Solid fuel generator flow temperature sensor error

When the working temperature range detected is below 0°C or
above 110°C, the following status is activated automatically: pumps
OFF, while the display shows the message “probe error” and the
LED flashes green and red alternately.

Info: displays brief information on the current
menu point

Set: executes the change, confirming the
selected parameter value

LED

The LED (1) gives status information by means of a multicoloured
diode:

- flashing green: regulator initialisation

- steady green: regulator operating

- flashing green/red: regulator operating with probe error or alarm

- flashing red: regulator checking loop

- steady red: regulator error.

To set parameters use the document

“MENU LIST” code 28180 supplied in the pack

4