Steca TR A502 TT Installation And Operating Instructions Manual
Temperature differential controller
5 inputs, 2 outputs
742.114 | Z03 | 14.50 | Subject to change due to technical improvements!
EN
Installation and operating instructions
2
742.114 | 14.50
EN
1 General safety instructions ....................................................................3
2 Proper usage .........................................................................................4
3 About these instructions .......................................................................4
3.1 Contents ........................................................................................................ 4
3.2 Target audience ............................................................................................. 4
3.3 Danger levels in warning notices
Évaluation du niveau de risque dans les avertissements....................................4
4 Installation .............................................................................................5
4.1 Opening / Closing the casing ......................................................................... 5
4.2 Mounting the casing .....................................................................................6
4.3 Establishing the electrical connections...........................................................7
4.4 Terminal pin assignments ............................................................................. 10
5 Commissioning the device for the first time .......................................13
6 Structure ..............................................................................................17
6.1 Casing ..........................................................................................................17
6.2 Display ......................................................................................................... 17
7 Operation .............................................................................................20
7.1 Operating buttons ....................................................................................... 20
7.2 Display when operating ............................................................................... 20
8 Modes of operation .............................................................................20
8.1 Changing the mode of operation ................................................................20
8.2 "Off" mode ...................................................................................................21
8.3 “Manual” mode ........................................................................................... 21
8.4 "Automatic" mode ........................................................................................22
9 Settings menu ......................................................................................23
9.1 Overview ......................................................................................................23
9.2 Calling up the settings menu and selecting a menu entry ..............................26
9.3 Setting the time ........................................................................................... 26
9.4 Setting the system ....................................................................................... 26
9.5 Setting the functions .................................................................................. 26
9.6 Setting the parameters ............................................................................... 26
9.7 Setting the priority ......................................................................................27
9.8 Resetting to factory defaults ........................................................................27
10 Functions ..............................................................................................28
10.1 Operation ....................................................................................................28
10.2 Characteristics .............................................................................................29
10.3 Functional description .................................................................................31
11 Parameters ...........................................................................................45
12 Dismantling and disposal ....................................................................48
13 Info messages ......................................................................................48
Contents
3
742.114 | 14.50
EN
1 General safety instructions
• This document is part of the product.
• Install and use the device only after reading and understanding this document.
• Keep this document in a safe place for the entire service life of the device. Pass the
document on to subsequent owners and operators of the device.
• Adhere to all safety instructions. Consult (further) professional personnel in the
event of any ambiguities.
• The measures described in this document may only be performed by qualified
technical professionals. Exception: End-customers may operate the device when they
have previously been trained by a technical professional.
• The solar energy system can be damaged by improper operation of the device.
• The device must not be connected to the mains power supply when:
– the casing is open or damaged.
– cables are damaged.
• Factory labels and markings must never be altered, removed or rendered unreadable.
• The prescribed conditions of use must be adhered to; more information is provided
in 15, p. 53.
• This device is not intended for:
– children.
– persons with physical, sensory or mental impairment.
– persons without sufficient experience or knowledge, unless they are instructed
in the use of the device, and initially supervised, by a person responsible for their
safety.
This product is CSA certified and complies with the requirements of the applicable UL
and CSA standards in terms of design and operating behaviour. Please contact your
dealer should you require further information on this.
14 Troubleshooting ...................................................................................49
14.1 General faults ..............................................................................................49
14.2 Error messages ............................................................................................50
14.3 Checking the Pt1000 temperature sensor ....................................................52
15 Technical data ......................................................................................53
15.1 Controller ....................................................................................................53
15.2 Cable specifications .....................................................................................54
16 Exclusion of liability .............................................................................54
17 Legal guarantee ...................................................................................54
18 Notes ...................................................................................................55
4
742.114 | 14.50
EN
2 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 energy and
heating systems.
3 About these instructions
3.1 Contents
This manual contains all information required by a technical professional for setting up
and operating the temperature differential controller.
3.2 Target audience
The target audience of this manual are technical professionals who:
• have the knowledge of terminology and the skills necessary for setting up and operating solar energy systems.
• have the necessary training, knowledge and experience, and knowledge of the applicable regulations in order to evaluate and recognise the dangers inherent in the
following work:
– Installation of electrical equipment
– Production and connection of data communication cables
– Production and connection of mains grid power supply cables
3.3 Danger levels in warning notices
Évaluation du niveau de risque dans les avertissements
Danger level
Niveau de risque
Likelihood of occurrence
Éventualité de l’intervention
Consequences resulting from non-compliance
Conséquences en cas de non-respect
Danger
Danger
Imminent threat of danger
Danger imminent
Death, serious bodily injury
Mort, lésions corporelles graves
Warning
Avertissement
Possible threat of danger
Danger éventuel
Death, serious bodily injury
Mort, lésions corporelles graves
Caution
Attention
Possible threat of danger
Danger éventuel
Minor bodily injury
Lésions corporelles simples
Notice
Avis
Possible threat of danger
Danger éventuel
Property damage
Dommages matériels
5
742.114 | 14.50
EN
4 Installation
The following section describes only the installation of the
4.1 Opening / Closing the casing
4.1.1 Removing the front panel
by the grooves at the sides
and pull forwards
(Fig.
4.1.2 Mounting the front panel
and then press it onto the casing until it latches
4.1.3 Removing the terminal cover
(Fig. 1).
4.1.4 Mount the terminal cover.
Tighten the screw
to a torque of 0.5
6
742.114 | 14.50
EN
4.2 Mounting the casing
√ The mounting location must satisfy the prescribed conditions of use; more informa-
tion on this is provided in section 15, p. 53.
√ 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. If necessary, remove the terminal cover.
2. Screw in the screw for the upper mounting hole (Fig. 2) until the screw head has
a clearance of 5 ... 7 mm (0.20 ... 0.28 inch) from the mounting surface.
3. Hang the controller on the screw by the upper mounting hole and align it vertically.
4. Mark the position of the lower mounting hole through the casing.
5. Remove the controller and prepare the mounting hole for the lower screw.
6. Hang the controller by the upper mounting hole and then fasten the screw in the
lower mounting hole .
7. Mount the terminal cover.
ø5 (0.20 inch)
ø5 (0.20 inch)
8.5 (0.33 inch)
140 (5.51 inch)
105 (4.13 inch)
156 (6.14 inch)
Fig. 2: Rear side of the controller with the upper and lower mounting holes.
7
742.114 | 14.50
EN
4.3 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 terminal must only be connected to a single conductor.
• The protective earth conductors (PE) from the mains cable and pump and valve
cables must be connected to the protective earth conductor terminal block.
• All cables must be laid so that persons cannot stand on them or trip over them.
• The cables must satisfy the requirements listed in Section 15, p. 53.
• The local power supply must match the specifications on the type plate of the con-
troller.
• The power supply cable is to be connected to the mains power as follows:
– using a plug connected to a wall mains socket or
– via an isolating mechanism allowing complete isolation in the case of permanent
wiring.
• The power supply cable must be laid in conformance to all applicable legal guide-
lines and regulations of the local electricity supplier.
Notice
Danger of damage and malfunction.
• Connect only components that do not overload the controller inputs and outputs;
more information is provided on the type plate and in Section 15, p. 53.
• For outputs R1 and R2, the following applies:
– Speed control must be deactivated when an external relay is connected.
– The correct pump type must be set (standard/high-efficiency pump).
More information on this is provided in Sections 5, p. 13 and 11, p. 45 (P18, P19).
Notes
• Any connection polarity may be used for the 1 – 5 and RS signal inputs and outputs.
• Only type Pt1000 temperature sensors may be used.
• Lay the sensor cables at least 100 mm (4 inch) away from any power supply cables.
• Use shielded sensor cables when inductive sources are present, e.g. high-voltage
lines, radio transmitters, microwave devices.
8
742.114 | 14.50
EN
4.3.1 Position of the terminals
11
2
13
14
6
7
18
L R1
L
const.
X
NN
PE PEPEPE
N
R1 R2
R
S54321
N
R2
L
const.
11
13
R
S
0-10
15
Fig. 3: Terminals in the lower part of the controller (terminal cover removed)
Power connection terminal block:
L
1x phase conductor (mains input)
R1, R2 2x output (TRIAC, for pumps or valves)
X
not used
L
const.
2x phase conductor (outputs, permanent voltage)
N
4x neutral conductor (common neutral conductors for mains power
input and outputs)
Note
Outputs R1 and R2 are protected by an electronic fuse.
Protective conductor terminal block:
PE
4x protective earth (common protective earth for power connection
terminal block)
Signals terminal block:
1 – 4 4x sensor input (Pt1000 temperature sensor)
5
1x sensor input (Pt1000 temperature sensor or pulse water meter input)
R
S
1x signal output (potential-free relay contact for safety extra-low voltage)
0–10 R1
0–10 R2
2x control output (for 0–10 V-controlled high-efficiency pumps)
7x mass connection (common mass for sensor inputs and control outputs)
Pin strip, for internal use only.
Cable openings on the rear side of the casing
Upper strain relief clamps (2 identical plastic links, each with 2 strain relief clamps,
supplied in the scope of delivery)
Lower strain relief clamps
Cable openings at the bottom of the casing
9
742.114 | 14.50
EN
4.3.2 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. 3) at the left and right using a suitable knife
and break them out.
2. Deburr the edges.
4.3.3 Connecting the cables
√ All cables are voltage-free.
√ The cable openings have been prepared.
X Observe the following points when connecting the cables:
• Connect the cable conductors to the correct terminals as described in Section
4.4, p. 10.
• Mains input and outputs: First connect PE, then N and L.
• Strain relief:
– First clamp the lower strain relief clamps and then the upper strain relief clamps.
– When using the upper strain relief clamps, use the plastic links as described
below.
– If the opening in the strain relief clamp is too large, e.g. in the case of thin ca-
bles, turn over the strain relief clamping bar (with the bend facing down).
– Only use the strain relief clamps for cables entering the bottom of the casing.
Use external strain relief clamps when feeding cables through the rear of the
casing.
4.3.4 Inserting / Removing plastic links
Insert the plastic links as follows:
1. Insert the right plastic link with the latching protrusion first (Fig. 4).
2. Press the other side of the plastic link down , until the spring clamp latches into
place.
3. Insert the left plastic link the other way around (latching protrusion to the left,
spring clamp to the right).
Fig. 4: Inserting the right plastic link
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).
10
742.114 | 14.50
EN
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: Removing the right plastic link
4.4 Terminal pin assignments
For each solar energy system that can be selected at the controller, the external components (pumps, valves, temperature sensors) must be connected to particular terminals.
The following table provides information on
• the graphic and number of the solar energy system on the controller display (the
graphic is only intended to provide an overview and is not a technical drawing) and
• the terminal pin assignments of the connected components.
Display Legend Terminal layout
No system
Note
No system is used when only the functions are used. When No
system is selected, then all inputs and outputs are freely available
for use by the functions. More information on this is provided in
Section 10, p. 28.
1 storage tank, 1 collector array
T1
T2
R1
T1: collector array sensor
T2: lower storage tank sensor
R1: solar circuit pump
1,
2,
R1, N, PE (0–10 R1,
1)
)
11
742.114 | 14.50
EN
Display Legend Terminal layout
1 storage tank with heating return increase, 1 collector array
R1
R2
T1
T2
T3
T4
T1: collector array sensor
T2: lower storage tank sensor
T3: upper storage tank sensor
T4: heating return increase sensor
R1: solar circuit pump
R2: heating return switching valve
3)
1,
2,
3,
4,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE
1 storage tank with external heat exchanger, 1 collector array
R2 R1
T1
T2
T3
T1: collector array sensor
T2: lower storage tank sensor
T3: external heat exchanger sensor
R1: storage tank loading circuit pump
R2: solar circuit pump
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE (0–10 R2,
2)
)
1 storage tank with zone loading, 1 collector array
R1
R2
T1
T2
T3
T1: collector array sensor
T2: lower storage tank sensor
T3: upper storage tank sensor
R1: solar circuit pump
R2: zone loading switching valve
4)
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE
1 storage tank, 2 collector arrays
R1
R2
T1
T3
T2
T1: collector array 1 sensor
T2: collector array 2 sensor
T3: lower storage tank sensor
R1: solar circuit pump, collector array 1
R2: solar circuit pump, collector array 2
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE (0–10 R2,
2)
)
2 storage tanks, 1 collector array (pump-controlled)
T1
T2
T3
R1
R2
T1: collector array sensor
T2: lower storage tank 1 sensor
T3: lower storage tank 2 sensor
R1: solar circuit pump, storage tank 1
R2: solar circuit pump, storage tank 2
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE (0–10 R2,
2)
)
2 storage tanks, 1 collector array (pump-/valve-controlled)
T1
T2
T3
R1
R2
T1: collector array sensor
T2: lower storage tank 1 sensor
T3: lower storage tank 2 sensor
R1: solar circuit pump
R2: storage tank switching valve
5)
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE
12
742.114 | 14.50
EN
Display Legend Terminal layout
1 swimming pool, 1 collector array
R2
T1
T2
T1: collector array sensor
T2: swimming pool sensor
R2: solar circuit pump
1,
2,
R2, N, PE (0–10 R2,
2)
)
1 swimming pool with external heat exchanger, 1 collector array
R1
R2
T1
T2
T3
T1: collector array sensor
T2: swimming pool sensor
T3: external heat exchanger sensor
R1: solar circuit pump
R2: swimming pool loading circuit
pump
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE (0–10 R2,
2)
)
1 storage tank, 1 swimming pool, 1 collector array (pump-controlled)
T1
T2
T3
R1
R2
T1: collector array sensor
T2: lower storage tank sensor
T3: swimming pool sensor
R1: storage tank solar circuit pump
R2: swimming pool solar circuit pump
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE (0–10 R2,
2)
)
1 storage tank, 1 swimming pool, 1 collector array (pump-/valve-controlled)
R1
R2
T1
T2
T3
T1: collector array sensor
T2: lower storage tank sensor
T3: swimming pool sensor
R1: solar circuit pump
R2: storage tank switching valve
6)
1,
2,
3,
R1, N, PE (0–10 R1,
1)
)
R2, N, PE
Tab. 1: Terminal pin assignments
1)
Terminal pin assignments for 0–10 V-controlled high-efficiency pumps: The power supply must
be connected to output R1 (N, PE); the control cable for the pump electronics must be connected to 0–10 R1 and
2)
Terminal pin assignments for 0–10 V-controlled high-efficiency pumps: The power supply must
be connected to output R2 (N, PE); the control cable for the pump electronics must be connected to 0–10 R2 and .
3)
Installation regulation: When no power is supplied to the switching valve, then no flow occurs
through the storage tank.
4)
Installation regulation: When no power is supplied to the switching valve, then the lower part
of the storage tank (T2) is loaded.
5)
Installation regulation: When no power is supplied to the switching valve, then the first priority
storage tank (T2) is loaded.
6)
Installation regulation: When no power is supplied to the switching valve, then the storage
tank (T2) is loaded.
13
742.114 | 14.50
EN
5 Commissioning the device for the first time
Danger
Risk of death by electrocution! Be sure to perform all the measures listed in Section 4
before starting the first commissioning.
Notes
• After commissioning the controller for the first time, it is configured in such a man-
ner that it can be used in most applications without changes.
• After completing the first commissioning, later recommissioning is not necessary.
• The following steps must also be performed after the device has been reset to the
factory defaults.
Overview
Operation mode Off is
switched on.
ESC /
OK
SET
Time
System
Pump R1 (R2)
Type / minimum speed
Functions
ESC /
ESC /
ESC /
The first time the controller is switched on, the following
main settings are made blockwise via a guided configuration process (Fig. left):
• Time
• System (hydraulic variant)
• Type (Standard/high-efficiency pump) and minimum
speed of the connected pumps (not System 0.1)
• Functions
Values can be subsequently changed during the guided
configuration process. The following applies:
• /ESC/ blockwise navigation forwards and back
(Fig. left: = forwards; ESC/ = back).
• Navigation (with /ESC/) is always possible after
completing a block.
• Subsequent modification of a block is started with
SET.
Commission the controller for the first time as follows:
Setting the time
1. Apply power to the controller.
– The time 12:00 is displayed.
– 12 flashes (Fig. left)
– The backlighting is red.
2. Press to set the hours.
3. Press SET. The minutes flash.
4. Press to set the minutes.
5. Press SET. The time is displayed.
14
742.114 | 14.50
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 (pump 1) flash (example in fig.
left).
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.
Only if HE was selected in step 10:
Press to set the characteristic of the high-efficiency pump; see Tab. 2 and Fig. 6, p. 16.
13. Press SET.
– If bA or bb was selected in step 12 then SC is
displayed; off, and (pump 1) flash (example in Fig. left; SC = Speed Control).
– If C was selected in step 12, proceed with
step 18 (for 2 pumps) or step 20 (for 1 pump).
14. If required, press to switch on the speed control (on flashes).
15. Press SET.
If off was selected in step 14, proceed with step 18
(for 2 pumps) or step 20 (for 1 pump).
16. min, Value %,
and (pump 1) flash.
Press to set the minimum speed of pump 1
in %.
17. Press SET.
15
742.114 | 14.50
EN
Set 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 num-
ber) flashes (example in Fig. left).
or
Press to skip the setting of the functions; Ok
flashes. Continue with step 30.
22. Press to select a different function. (Function
description in Section 10.3)
23. Press SET. oFF is displayed.
24. Press SET. oFF flashes.
25. Press . on flashes.
26. Press SET. The function is activated.
27. Set the characteristics (see Section 10.1).
28. Press ESC.
29. Press . Ok flashes.
Finishing initial commissioning
30. Press SET to finish initial commissioning. The
controller switches to the operating mode Off
(Example in Fig. left).
or
Press /ESC to display the previous settings and
correct them if necessary.
Set the operating mode (off, manual, automatic)
31. Remove the front panel (Fig. left and Section 4.1.1).
16
742.114 | 14.50
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 operating
mode; more information on this is provided in Section 8.
33. Mount the front panel. The controller is now ready
for operation.
Characteristics of high-efficiency pumps
Display Pump type Characteristic curve
bA
High-efficiency pump with a 0–10 V
profile for a rising characteristic curve
(Fig. 6)
0 V: Pump off
10 V: Max. pump speed
bb
High-efficiency pump with a 0–10 V
profile for a falling characteristic curve
(Fig. 6)
0 V: Max. pump speed
10 V: Pump off
C
Pressure regulated high-efficiency pump –
(no control cable, switching on/off
via the supply voltage)
Tab. 2: Characteristics of high-efficiency pumps
U/V
RPM
U/V
RPM
Fig. 6: Characteristics of high-efficiency pumps with 0–10 V profiles for a rising characteristic curve
(bA, left) and a falling characteristic curve (bb, right)
17
742.114 | 14.50
EN
6 Structure
6.1 Casing
11
13
2
16
15
14
ESC
SET
No. Element
See
Section
Mode button (under
front panel)
7.1
8
Operating buttons , SET,
ESC,
7.1
Display 6.2
Front panel 4.1
Terminal cover 4.3.1
1)
Terminal cover fastening
screw
–
1)
Section 4.3.1 describes the terminals under the
terminal cover.
Fig. 7: Front view of the controller
6.2 Display
6.2.1 Overview
B
l
g
p
Fig. 8: Overview of the display areas (all elements visible)
System graphics
Settings menu
Pictograms for functions
Operational and setting values
The display areas are described below.
Loading...