Microcontroller-controlled temperature difference controller for solar thermal systems
Operating manual
Solareg PICO 200
2
Table of content
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 4
3.4 Temperature sensor connection 4
4
Settings 5
4.1 Maximum storage tank temperature setting TSPmax 5
4.2 Temperature dierence setting dT 5
5 System diagram 6
6 Controller functions 7
6.1 General controller functions 7
6.2 Protective functions 7
6.2.1 Anti-freeze protection (Jumper=on) 7
6.2.2 System protection 7
6.2.3 Pump blocking protection 7
7 System monitoring 7
7.1 Sensor monitoring 7
7.2 Flow monitoring 7
8 Troubleshooting 8
8.1 Faults with error messages 8
8.2 Faults without error messages 9
9 SOLAREG PICO 200 Specications 10
10 Resistance table PT1000 10
11 Warranty conditions 11
12 Declaration of conformity 11
Explanation of the
graphic symbols
Attention!
Symbol indicates
possible dangers
and errors
Attention 230V~
voltage!
Symbol indicates
risks posed by
lethally high voltages.
List
Please note!
Information for
handling / special
features
Implementation /
procedure
Test /
check
3
1 Application area / device features
1.1 Application area
The SOLAREG PICO 200 controllers are high-performance microprocessor-controlled units for controlling the functions of solar thermal systems. The SOLAREG PICO
200 controls solar power systems equipped with one collector and one storage
tank.
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 PICO 200 controller is equipped with the following features:
No manual operation needed ◼
Adjustable values ◼
Extensive functions for system monitoring to indicate errors and faults with LED ◼
indicators.
Various protective functions, such as system protection, collector protection, ◼
anti-freeze and ow monitoring
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 (sensors) with
the 230V connections. Otherwise, the device will be destroyed. The device and
the connected sensors may carry deadly voltages.
Solar power systems can reach high temperatures. Such temperatures pose a ◼
risk of burns! Exercise caution when installing the temperature sensors!
Mount the SOLAREG controller in a position where it will not be subjected to ex- ◼
cessive 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 must only be
connected and commissioned by
qualified personnel. In doing so,
the applicable safety regulations
must be observed.
4
3 Mounting the device
3.1 Opening the device
Prior to opening the device, make sure to disconnect the mains voltage and ensure
that it cannot be switched back on again.
3.2 Wall mounting
Secure the controller on the wall. Tighten all screws only as tight as necessary to
prevent damage to the lower part of the housing.
3.3 Connections
The following points must be followed for the 230V connections:
◼ In case of a xed mains connection, there must be a switch installed outside
the controller that can disconnect the device from the mains power supply. This
switch is not required if the mains supply is connected using a cable and an
earthed mains plug.
The controllers are designed to operate using a 230V/50Hz. The pumps and ◼
valves to be connected must be designed for this voltage!
All protective conductors must be connected to terminals marked with PE. ◼
The neutral conductor terminals (N) are electrically connected and are not ◼
switched!
The switching output (A1) is electronic 230V~ N/O contact. If potential-free ◼
contacts are required, the appropriate corresponding accessories are available.
3.4 Temperature sensor connection
The SOLAREG PICO 200 devices use PT1000 precision platinum temperature sensors.
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.
The shield is connected to the earth (PE)
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.
The controller must only
be installed in dry and
non-explosive areas. Mounting
the controller on an inflammable
surface is prohibited
5
4
Settings
4.1 Maximum storage tank temperature setting TSPmax
Using this setting, you dene the maximum temperature the storage tank is allowed to reach. Using the TSPmax setting button, the value is set so that the arrow
points at the desired temperature. The value can be set between 25°C and 95°C.
The factory setting is preset to 60°C.
4.2 Temperature dierence setting dT
Using this setting, you dene the switch-on or switch-o dierence.
If the collector temperature TKoll is greater than storage tank temperature TSp + dT,
the pump is switched on.
If the collector temperature falls below the value of the storage tank temperature +
dTmin, the pump is switched o. (dTmin corresponds to trimmer setting dT/2).
The factory setting is preset to 10K.
The adjusting knobs are
inside the case and can be
operated with a small screwdriver.
All installation and wiring
work must only be carried out on
the controller when the device is
disconnected from the power
supply..
Please consult the
guideline of the storage manufacturer!
6
5 System diagram
1 collector, 1 storage tank
230V connections
L Mains phase
N Neutral conductor - mains and outputs
A1 Solar circuit pump (switching output 1)
Sensor connections
S1 Collector sensor
S2 Lower storage tank
Jumperposition:
on=anti-freeze on
off=anti-freeze off.
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6 Controller functions
6.1 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.
6.2 Protective functions
The controller is equipped with the following protective functions.
6.2.1 Anti-freeze protection (Jumper=on)
This function must be activated if the water or glycol mixture can freeze. If the temperature of the collector sensor drops below 5°C, the solar circuit pump is activated
and heats the solar circuit using the heat exchanger in the storage tank.
6.2.2 System protection
If the collector temperature exceeds 135°C, the solar circuit pump is switched o to
protect the system components.
If the collector temperature drops below this temperature, the solar circuit pump is
switched on. The function is always activated.
6.2.3 Pump blocking protection
If the solar power system is out of commission for an extended period of time due
to poor weather, for example, the solar circuit pump may “seize”. To prevent this, the
controller switches the pump on for 30 seconds after 10 days.
7 System monitoring
7.1 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.
7.2 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.
LED Meaning
LED green is on Power on ◼
LED green ashes Pump is ON ◼
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8 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 ◼
8.1 Faults with error messages
LED Meaning Measures
LED red ashes:
1 x
Collector sensor cable is inter- ◼
rupted
Check wiring / replace
it
Check sensor resistance
and replace sensor if
necessary
LED red ashes
2 x
Short-circuit in the collector ◼
sensor cable
LED red ashes:
3 x
Storage sensor cable is inter- ◼
rupted
LED red ashes:
4 x
Short-circuit in the storage ◼
sensor cable
LED red is on no ow ◼
Error in the pump connection ◼
Pump defective ◼
Air in the system ◼
Check cable
Replace pump
Deaerate the system
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8.2 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
LED green is o 230V 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 230V compo- Check the 230V compo-Check the 230V compo-
nents for short-circuits
Defect device ◼
Contact the supplier
Output is not
switched on
Switch-on condition is not ◼
fullled.
Wait until switch-on
condition is satised.
LED green is ashing, 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.
Faults that affect the
230V/A mains power
supply must only be remedied by
a specialist!
10
9 SOLAREG Specications
Housing
Material
100% recyclable ABS housing for wall mounting
Dimensions W x H x D in mm,
weight
95 x 75 x 50;
approx. 130 g
Protection class
IP20 according to DIN 40050, IEC 529, VDE
0470, EN 60529
Electrical specications
Operating voltage AC 230 Volts, 50Hz, -10 – +15%
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
Rated impulse voltage
4 kV according to EN 60730/DIN, VDE 0631, IEC
60664/IEC
Output Voltage
Power - switching output
230V~
1A / approx. 230VAfor cos φ = 0,7-1,0
Fuse protection
Fine-wire fuse 5 x 20mm, 2A/T
(2 amperes, delayed-action fuse)
Miscellaneous
Operating temperature 0 – 50°C
Storage temperature -10 – +65°C
Humidity max. 60 %
10 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!
11
11 Warranty conditions
The SOLAREG 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.
12 Declaration of conformity
We, Prozeda GmbH, declare under our sole responsibility that the SOLAREG type
1328 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)
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Operating manual for SOLAREG PICO 200 1328BED006-10B-E, 05/2008
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