Temperature Difference Controller

Installation and Operating Manual

Contents

1 SECURITY INSTRUCTIONS AND RESTRICTION OF LIABILITY .................................................. 3

1.1 Sign for security instructions .................................................................................. 3
1.2 General safety instructions ..................................................................................... 3
1.3 Regarding these instructions .................................................................................. 4
1.4 Restriction of liability .............................................................................................. 4

2 INSTALLATION ..................................................................................................................... 5
2.1 Installation Site ....................................................................................................... 5
2.2 Mounting ................................................................................................................ 5
2.3 Regulator Connection ............................................................................................. 6
2.4 Opening/Closing the Regulator ............................................................................... 8
2.5 Commissioning........................................................................................................ 9

3 DISPLAY-OVERVIEW .......................................................................................................... 10

4 OPERATING THE REGULATOR ............................................................................................ 11

5 REGULATOR SETTINGS....................................................................................................... 13

6 NOTES ON TROUBLESHOOTING ......................................................................................... 16

7 GUARANTEE ...................................................................................................................... 18

8 TECHNICAL DATA .............................................................................................................. 19

9 INDEX................................................................................................................................ 19

GmbH Environmentally friendly,

Germany chlorine-free bleached paper
Item no. 709.752
Printed in Germany
Level 04/05
Subject to changes

2
1 Security instructions and restriction of liability

1.1 Sign for security instructions

Security instructions for personal safety are marked with this sign and are printed in bold
letters.
Instructions that refer to the functioning safety of the system are also printed in bold
letters.

1.2 General safety instructions

For your own safety please note the following for installation:

Please see that fire safety cable systems and similar things are not impaired!
The controller must not be installed and used in moist areas (e. g. bathrooms) or in rooms in
which flammable gas mixtures (by gas bottles, paint, solvents etc.) are likely to occur!
Do not store any of the above and similar things in rooms where the solar controller is installed!
The controller must not be installed on a conductive base!
Use well-isolated tools only!
Do not use technical equipment that is defective or broken!
The construction safety measures can deteriorate if the controller is used in a way other than the
one determined by the manufacturer.
The preset signs and marks must not be changed, removed or made illegible.
All operations must be conducted in accordance with the national electricity regulations and local
rules!
For installation in foreign countries please see your corresponding institutions for information on
regulations and safety measures.
Keep children away from electronics!

For your own safety please note the following for electrical installation:

The controller has been built for the use at 230 V (±15 %) AC at a frequency of 50 Hz [optional
115 V (±15 %), 60 Hz]. Using this regulator for other voltage values is not allowed. Please also
note that the admissible nominal currents must not be exceeded.
If there is a grounded conductor planed or laid down for pump or reversing valve it MUST also be
connected. There are corresponding supply terminals. Please make sure that the earthing contact
is led to the controller also on the power supply side.

3
Wires that are not permanently connected with the building have to be equipped with a pull relief
outside the controller.
The regulator is only for the prescribed applications. No liability is taken over for other utilization.
All operations on an open regulator are only to be conducted cleared from the power supply. All
safety regulations for working on the power supply are valid. Connecting and/or all operations
that require opening the regulator (e.g. changing the fuse) are only to be conducted by specialists.
The controller is protected against overload and short circuit.

1.3 Regarding these instructions

These operating instructions describe the functioning and installation of a controller for thermal
solar systems for feeding solar heat into a water or buffer store.
For the installation of the other components please follow the corresponding installation
instructions of the manufacturer.
Before starting operation read the paragraph "installation" no. 2 and make sure that all
measurements have been prepared before.
Only begin with the installation when you have understood this instruction and proceed in
sequence!
These instructions must be handed out to all persons that work with this system.
These instructions are part of the system controller and must be handed over in case the controller
is sold.

1.4 Restriction of liability

The manufacturer cannot monitor the compliance with these instructions or the circumstances
and methods used for installation, operation, utilization and maintenance of this controller.
Improper installation can cause damages to material and persons.
This is the reason why we do not take over responsibility and liability for losses, damages or cost
that might arise due to improper installation, operation or wrong utilisation and maintenance or
that occur in some connection with the aforementioned.
Moreover we do not take over liability for patent infringements or infringements - occuring in
connection with the use of this controller - on third parties´ rights.
The manufacturer preserves the right to put changes to product, technical data or installation and
operation instructions without prior notice.

Caution:
Opening the device – except for the top cover – and improper operation voids the
guarantee.

4
2 Installation

2.1 Installation Site

The regulator is designed for assembly on vertical walls. Installation of the regulator is only
permitted in an area that provides appropriate protection (see technical data).
The ambient temperature at the installation site may never fall short of or exceed the maximum
ambient temperature allowed.

2.2 Mounting
Wall mounting
The internal regulator cover (fig. 1, pos. 5) protects the regulator’s electronics and may not be
removed for installation purposes.
A screw must first be screwed into the wall to fasten the regulator. The regulator will
subsequently be hung onto the screw with the cut-out (fig. 1, pos. 1). The regulator can be used
as a template to mark both additional mounting holes (fig. 1, pos. 2 and 3).
Warning: Only use the regulator as a marking template, never as a drilling template.

Fig. 1: Installation diagram

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2.3 Regulator Connection

The cable can be fed through the underside of

the regulator (fig. 1, pos. 6) or back panel of
the housing depending on the installation. The
cable entry in the housing tray must first be cut
out (fig. 2) to insert the cable from the
underside of the regulator. Each cable inlet
requires 2 vertical incisions in the wall of the
plastic tray. A cable knife or an electrician’s side
cutting pliers can be used as a cutting tool.

Fig. 2: Cut out cable entry

Flexible wiring must be secured in the regulator with the attached strain relief clamps.

If the regulator must be wired through the back panel of the housing tray (fig. 1, pos. 7), the
punch out holes can be used for the cable entry. For this, an external strain relief is provided.

THE CONNECTION WORK DESCRIBED HERE IS ONLY POSSIBLE WHEN THE

REGULATOR’S CLAMP COVER IS OPEN. DISCONNECT THE MAINS! ALL APPLICABLE
INSTRUCTIONS FOR WORKING ON THE MAINS MUST BE OBSERVED! THE MAINS MAY
FIRST BE SWITCHED ON WHEN THE REGULATOR HOUSING IS CLOSED. IN ADDITION,
THE INSTALLER MUST ENSURE NOT TO INFRINGE THE IP DEGREE OF PROTECTION
WHEN INSTALLING THE REGULATOR.

The mains, pump and sensor connections must be

connected according to the terminal plan (fig. 4). If an
Earth conductor is intended or required for the pump, the
Earth conductor must be connected. The corresponding
Earth conductor wire terminals are provided. Ensure that
the ground contact is also connected to the regulator’s
mains supply side.

Fig. 3: Actuating the terminal

clamp

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Each clamp may only be allocated one connecting cable (up to 2.5mm2). Connector sleeves must
be used with finely stranded cables.

Fig. 4: Terminal connection diagram

Temperature Sensor:

Warning: Only the original sensors permitted for the regulator may be used. This is the PT1000
sensor type. Temperature sensors and silicon cables are heat resistant up to +180°C. The polarity
of the sensor contacts is irrelevant. All sensor leads are low voltage and must be installed
separately from the 230V or 430V lead sensors to prevent any inductive interference (at least
100mm apart). If external inductive interference is to be expected, e.g. by heavy current cables,
contact wires, transformer stations, radios and television sets, amateur radio stations, microwave
devices or similar devices, the conducting cables carrying the measuring signal must be shielded.
The sensor cable can be extended to a length of roughly 100m. Use a cross section of the
extension cable from 1.5mm² to 100m and 0.75mm² to 50m.

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2.4 Opening/Closing the Regulator
The top cover is secured by two holding bars (fig. 5, pos. 1) on the top edge of the regulator and
a screw on the housing.
Close the regulator by angularly setting the top cover on the regulator housing – as displayed in
figure 5. The holding bars must be on the corresponding hinge notches.
Now, the top cover can be folded down and the push buttons can be threaded through. A
fastening screw is used to securely close the housing.

fastening
screw

Fig. 5: Closing the regulator housing

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2.5 Commissioning

After the regulator housing has been closed, the power supply can be turned on.

To test if the solar circuit’s pump has been installed correctly

(independent of thee regulation functions), it is helpful to briefly
turn it on and off by hand. For this purpose, there is a mode
switch on the left side of the housing.

mode switch
Every change of the switching position is followed by a 3 sec.
lasting display of the current control mode.
(‚on’ / ‚Aut’omatic / ‚off’)

Fig.6: Mode switch

Switch in central position means automatic

mode.
The backlight display is yellow.

Turn the switch to the upper position to start

the pump.
The word ‘on’ flashes in the display as a
reminder.
The backlight display is red.

Turn the switch to the lower position to switch

off the pump.
The word ‘off’ flashes in the display as a
reminder.
The backlight display is red.

Warning: If the system is ready for operation (system is filled, solar circuit is not
blocked), the regulator can be set to automatic mode after commissioning.

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3 Display-Overview
1
12
2
11
3
10
4
9

8 7 6 5
1) symbols for temperature sensors
2) display for temperature values and error symbols e.g. short circuit, open circuit (see page 11) or
‚SYS‘ = system error (see page 17)
3) holiday function (see page 14)
4) antifreeze function (see page 15)
5) change-over °C / °F (see page 13)
6) pipe collector function (see page 13)
7) setting off storage tank max. temperature (see page 13)
8) symbols for solar circuit (pump and circulation)
9) symbol for storage tank max. temperature is reached (see page 12)
10) error icon e.g. short circuit, open circuit (see page 11) or ‚SYS‘ = system error (see page 17)
11) symbol for steam in collector (see page 12)
12) symbol for enough heat provided (see page 12)

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4 Operating the Regulator

During normal operation the ▲▼ keys are used to

browse through the recorded temperature values.
The (T1,T2,T3) sensor symbols in the system
diagram, show which measurement value is
currently being displayed.

The temperature in the upper part of the storage tank is only displayed if the T3 sensor has been
connected.

In the event a sensor or its supply line short In the event a sensor or its supply line is
circuits, an animated Short Circuit Symbol interrupted, an animated Interruption Symbol is
is displayed instead of the temperature. displayed instead of the temperature.

If such a sensor fault occurs, the backlight display alternately flashes red/yellow and a warning
symbol is displayed to indicate the fault.

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 The regulator constantly compares the temperature on
the collector (T1) and in the lower part of the storage
tank (T2). If while charging the storage tank, a sufficient
temperature difference (8K) is recognized, this is
indicated by the sun in the display.

If no safety control or functions prohibit the pump

operation, an animated pump operation now begins to
move in the display.
If the temperature difference drops below 4K, the pump
operation is deactivated and the sun disappears.

If in the lower part of the storage tank (T2), the set

maximum storing temperature is reached (factory setting
60°C), the charging stops. (Pumps are stationary).
A new charging procedure is first possible at a temperature
4K under the maximum storing temperature.

The ‚max’ indicator flashes in the storage tank symbol to

illustrate that although the sun is displayed, the pump is
stationary.

If the solar circuit stops (e.g. due to a full tank) at a high

irradiance, the solar fluid in the collector can assume a
temperature higher than 130°C and vaporize. To protect the
pump, the pump operation is blocked until the temperature
drops below 127°C (storage tank cools down in the
meantime).

THE STEAM INDICATOR FLASHES ON THE COLLECTOR

SYMBOL TO ILLUSTRATE THAT ALTHOUGH THE SUN IS
DISPLAYED, THE PUMP IS STATIONARY.

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5 Regulator Settings

Press the ‘SET’ button for 2 seconds to open

the settings menu. At first, the current valid
maximum storing temperature value is
SET displayed.

To illustrate which value is referred to, the ‘max’ indicator in the storage tank symbol and
the T2 sensor flash.

Press the ‘SET’ button again for 2 seconds to adjust the value (value also flashes). Change the
value with the ▲▼ buttons. Press and hold the ‘SET’ button for approximately two seconds to
save the value.

Press the ▼ button to reach the next setting.

Here the temperature display’s unit of measurement can

be changed.
Press the ‘SET’ button for approximately 2 seconds to
change the display from degree Celcius (°C) to degree
Fahrenheit (°F) or vice versa.

Press the ▼ button to reach the next setting.

The vacuum collector function can be activated with this

setting. Due to the design, the collector temperature cannot
be exactly recorded by the vacuum collectors (no
submerged sensors; sensor is outside of the collector’s
pipe).

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In this case, it is necessary to briefly startup the solar circuit to conduct the heat from the
collecting pipe to the solar circuit. For this purpose, every 30 minutes the vacuum collector
function is activated for 30 seconds.

Press the ‘SET’ button for approximately 2 seconds to change the T1 sensor symbol from the
collecting pipe position (directly on the collector) to the position outside the collector. The
vacuum collector function is now activated.

Press the ‘SET’ button again to deactivate the vacuum collector function.

Press the ▼ button to reach the next setting.

The holiday function can be activated with this setting. The

holiday function is a storage recool function. If the operator
does not use the warm water, the storage tank may reach
its maximum temperature early the day. In this case
vaporization may occur within the solar unit and thus
subjecting the unit to a higher thermal load.

Note:
This function should only be used if you are not at home
for a longer term. Please deactivate this function after
returning back home to prevent unnecessary loses of
energy!
If while the holiday function is activated, a temperature 10K below the maximum storing
temperature is reached, this is recognized by the regulator. In order to be able to charge the
storage tank the next day for a longer time and thus subjecting the unit to a lower thermal load,
the storage tank (e.g. during the night) attempts to cool down to 35°C. For this purpose, if the
storage tank is 8K warmer than the collector, the pump is activated. If the temperature difference
between the pump and the collector is only 4K, the pump is deactivated again.

Pressing the ‘SET’ button for approximately 2 seconds deactivates the pump again.
To confirm this, the holiday symbol appears with a check mark. During normal operation the
activated function is displayed by the holiday symbol.

Press the ‘SET’ button again to deactivate the holiday function.

Press the ▼ button to reach the next setting.

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 The anti-freeze function is activated with this setting.
Note:
The anti-freeze function is only helpful with systems that
have solar circuits without anti-freezing agents.

FOR SAFETY REASONS SUCH SYSTEMS SHOULD ONLY BE

USED SEASONALLY OR FOR SHORT TERM START-UP
PURPOSES!
If while the anti-freeze function is activated, the collector temperature falls below +5°C, the solar
circuit pump is activated. This causes warm water to be pumped through the collector and
prevents freezing. The pump is deactivated again, once the collector reaches a temperature of
+7°C.

Pressing the ‘SET’ button for approximately 2 seconds activates the anti-freeze function. To
confirm this, the anti-freeze symbol appears with a check mark. During normal operation the
activated function is displayed by the anti-freeze symbol.

Press the ‘SET’ button again to deactivate the anti-freeze function.

Press the ▼ button to reach normal operation mode.

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6 Notes on Troubleshooting

Warning! Before opening the housing, the power must be disconnected from the
device!

The regulator was designed to be continually used for several years. Nevertheless, faults may
occur. Most of the time, the fault’s cause is not sought in the regulator, rather in the peripheral
system elements. The following description of a few common faults should help the installer and
the operator to isolate the fault and activate the system as quickly as possible to avoid
unnecessary costs. Naturally, not all possible faults can be listed. However, you will find the most
common causes of faults that cover the majority of the fault conditions related to the regulator.
Send the regulator in after you have first ensured that none of the described malfunctions have
occurred.

Regulator shows no function.

Secondary condition: Possible cause:

The regulator’s display is blank. No power supply, check fuse and electric mains.

The solar circuit pump connected on the regulator does not run, although its switch-on
conditions are met (sun in the display).
Secondary condition: Possible cause:

Pump symbol rotates in the display. Pump’s connecting line is not connected,
interrupted or fuse in the regulator is burnt-out
(replacement fuses provided in the housing, see
fig. 1, pos. 4). Only use fuses of type 250V 4A MT.

Pump symbol does not rotate; no fault, regulator deactivated the pump because
„max“ flashes in the storage symbol maximum storing temperature has been reached
(Details see page 12).

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Pump symbol does not rotate; No fault, regulator has deactivated the pump
Steam symbol flashes on the collector because the collector maximum temperature (130°C)
symbol has been exceeded.
(Details see page 12)

Pump symbol does not rotate; Mode switch is on manual operating position
Backlight display is red; „OFF“ blinks in ‚Pump Off‘ (Details see page 9).
display

Pump symbol does not rotate;
Backlight display flashes red and green
alternately;
one of the T1/T2 temperatures displays a
sensor fault.
There is a sensor fault (short circuit or interruption);
check the sensor supply lines and its correct
connection on the regulator.

Display showing a flashing „SYS“

SYS stands for system error. That means in spite of the pump running there is a difference
temperature of more than 80 Kelvin measured between collector and storage tank. The reason for
such a huge temperature difference could be a damaged or faulty connected pump, a closed valve
or air in the solar circuit. As air inside the piping can’t be overcome by a conventional pump,
circulation of the solar circuit is stopped. Check your solar-system for these sources of error to
avoid damages.
You can quit the error message afterwards by pressing any key.

Temperature sensor troubleshooting

The temperature recording is performed by so-called resistance sensors.

These sensors are type PT1000. The resistance value changes depending on the temperature. An
ohmmeter can be used to check for defective sensors. Unclamp the corresponding temperature
sensor from the regulator and then measure the resistance value. The typical resistance values,
depending on the temperature, are listed in the following table. Please observe that slight
deviations are permitted.

17
Resistance values of the PT1000 temperature sensor

Temperature [°C] -30 -20 -10 0 10 20 30 40 50 60 70

Resistance [Ω] 882 922 961 1000 1039 1078 1117 1155 1194 1232 1271

Temperature [°C] 80 90 100 110 120 130 140 150 160 170 180
Resistance [Ω] 1309 1347 1385 1423 1461 1498 1536 1573 1611 1648 1685

7 Guarantee

The manufacturer assumes the following guarantee obligations towards the end user:
The manufacturer will remove all manufacturing and material faults that appear in the regulator
and affect the correct functioning of the device during the guarantee period. Normal wear does
not constitute a fault. The warrantee is void if, after completion of the purchase contract with the
end user, the fault is attributable to the end user or a third party, is caused in particular by
improper installation or commissioning, improper or negligent handling, excessive claims,
inappropriate resources, faulty construction work, inappropriate building grounds or improper
operation or use. The warrantee is only valid if after discovery the fault is immediately claimed to
your specialized dealer. The claim is to be sent by the specialized dealer to the manufacturer. A
copy of the purchase contract must be enclosed.

An exact fault description is required for a rapid settlement. The warrantee expires 24 months
after the purchase contract has been completed by the end user, unless the manufacturer has
expressively agreed to an extension period in writing. The manufacturer‘s warrantee based on the
purchase contract with the end user is not affected by these present guarantee obligations.

The manufacturer is entitled to carried out the warrantee by repairing the fault or delivering a
replacement. This does not include exchange, shipping or reinstallation costs. If repairs or
replacement delivery are/is not possible or not carried out within an appropriate time despite a
reasonable grace period determined by the customer, the decrease in value caused by the fault
will be replaced or provided that is in the user’s interests not sufficient, the contract will be
changed.

Further claims against the manufacturer based on this guarantee obligation, in particular
customer claims for damages due to lost profit, compensation for use and direct damages are
excluded, provided claims must not be made according to law.

18
8 Technical Data

Operating voltage 230Volt (± 15 %), 50Hz

[optional 115Volt (± 15 %), 60Hz]
Internal consumption ≤ 1W
3 inputs for recording temperatures PT1000
1 output All-or-nothing relay, switching power max. 800W
fuse: 250V 4A MT
Output protected against overloading and short circuits.
Display Animated LCD display, 2 colored backlighting
Appropriate protection IP 20/DIN 40050
Operation temperature range 0 to +45°C
Installation Wall mounting
Weight 250 g
Housing recyclable, 3 part plastic housing
Dimensions LxBxH [mm] 136 x 133 x 37
Temperature sensor
2x PT1000 1.5m silicon cable, measuring range up to +180°C

9 Index

anti-freeze function ..................................................................................................................... 15

aut ..................................................................................................................... see commissioning

Cable entry .................................................................................................................................... 6

Commissioning .............................................................................................................................. 9
Connection .................................................................................................................................... 6

Display-Overview ......................................................................................................................... 10

Guarantee.................................................................................................................................... 18

holiday function .......................................................................................................................... 14

Installation..................................................................................................................................... 5
Installation Site .............................................................................................................................. 5

19
interrupt ...................................................................................................................................... 11

maximum storing temperature .................................................................................................... 13

Mode switch.................................................................................................................................. 9
Mounting ...................................................................................................................................... 5

off ..................................................................................................................... see commissioning

on .....................................................................................................................see commissioning
Opening/Closing ............................................................................................................................ 8
Operating .................................................................................................................................... 11

Pt1000....................................................................................................... see temperature sensors

Resistance values ......................................................................................................................... 17

Restriction of liability ..................................................................................................................... 4

Security instructions....................................................................................................................... 3
Settings ....................................................................................................................................... 13
short circuit ................................................................................................................................. 11
Switch ........................................................................................................................................... 9
SYS ......................................................................................................................... see system error
system error................................................................................................................................. 17

Technical Data ............................................................................................................................. 19

Temperature sensors...................................................................................................................... 7
Terminal connection diagram ........................................................................................................ 7
Troubleshooting .......................................................................................................................... 16

vacuum collector function ........................................................................................................... 13

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