Professional Documents
Culture Documents
Installation and Operating Instructions: Solar Controller
Installation and Operating Instructions: Solar Controller
SOLAR CONTROLLER
TDS 100
6720613720-00.1 SD
UK/IE
6 720 644 596 (2010/04)
CONTENTS
CONTENTS
Contents 2
3 Regulations 10
5 Operation 14
5.1 Elements of the solar pump station 15
5.2 Elements of the controller 16
5.3 Operating modes 17
5.4 Displaying temperature values 17
5.5 Main menu (For qualified technicians only) 18
5.6 Expert menu (For qualified technicians only) 21
7 Fault Finding 23
7.1 Faults with display indications 23
7.2 Faults without display indications 24
9 System Details 28
This manual is intended for both general users and qualified technicians. Chapters and sections
intended only for qualified technicians are marked with the words For qualified technicians only.
CORRECT USE
The differential temperature controller (called the controller in the following) may only be used for
the operation of solar thermal systems under the ambient conditions specified
( section 2.4).
The controller must not be used outdoors, in damp rooms or in rooms where easily flammable gas
mixtures could form.
B Only operate the solar heating system as intended and when it is in perfect working order.
ELECTRICAL CONNECTIONS
Any tasks that require the controller to be opened must be carried out only by qualified electricians.
DISPOSAL
B Dispose of packaging in an environmentally responsible manner.
B When replacing components, dispose of the old part in an environmentally responsible manner.
1.2 SYMBOLS
Safety instructions in this document are identified by a warning-triangle symbol and are
printed on a grey background.
Signal words indicate the seriousness of the hazard in terms of the consequences of not following the
safety instructions.
Notes are identified by the symbol shown on the left. They are bordered by horizontal
lines above and below the text.
Notes contain important information in cases where there is no risk of personal injury or damage to
property.
7747006071.06-1.SD
If the controller has been built into a solar pump station, the cables will have been partly pre-fitted.
In normal operating mode, the display screen on the controller stays illuminated in green/yellow for
five minutes after the last button was pressed (this can be activated by e. g. pressing the
rotary selector ).
T1 DT on max
ax
m
in
/m
+ T
T3
I reset
max
%
T2 h
3 2
7747006071.01-1.SD
1 Collector array
2 Solar pump station
3 Solar cylinder
4 Controller TDS 100
OPERATING PRINCIPLE
When the set temperature difference between the collector array ( Fig. 3, no. 1) and the solar
cylinder ( Fig. 3, no. 3) is exceeded, the pump in the solar pump station is switched on.
The pump transports the heat transfer medium via the circuit through the collector array to the
consumer. This consumer is generally a solar cylinder. There is a heat exchanger in the solar cylinder.
This transfers the heat collected from the sun from the transfer medium to the water intended for
domestic use or heating.
2.4 SPECIFICATIONS
Power consumption 1W
Max. current consumption at pump output 1.1 A (connect one pump only!)
Tab. 2 Specifications
The temperature sensors must be disconnected from the controller in order to measure
their resistances.
3 REGULATIONS
Observe Observe all standards and guidelines applicable to the installation and operation of the
system in your country and region.
TECHNICAL REGULATIONS APPLICABLE IN THE U.K. FOR THE INSTALLATION OF THERMAL SOLAR
HEATING SYSTEMS
B Electrical connection:
Current IEE wiring regulations
B Connection of thermal solar systems:
EN 12976: Thermal solar systems and components (factory made systems)
ENV 12977: Thermal solar systems and components (custom built systems)
BS5918: Latest version: Solar heating systems for domestic hot water.
B Installation and fittings of hot water heaters:
BS5546:2006 Specification for installation of hot water supplies for domestic purposes, using
gasfired appliances of rated input not exceeding 70kW.
BS6700:2006 Specifications for design, installation testing and maintenance of services
supplying water for domestic use within buildings and their curtilages.
CAUTION: Risk of injury and damage to the housing from incorrect mounting.
B Do not use the rear panel of the housing as a drilling jig.
B Drill the upper mounting hole ( Fig 4., no. 1) and screw in the accompanying screw until 5 mm
clear of the surface. Unscrew the screw at the bottom of the controller and remove the cover. Hang
the controller on the wall by means of the opening in the rear panel. Mark out the lower mounting
holes ( Fig. 4, no. 2), remove the controller, drill the holes and insert wall plugs. Remount the
controller and insert the mounting screws through the lower mounting holes, left and right. Ensure
the controller is level and screw firmly in place.
1
5 mm
120 mm
166 mm
6 mm
7747006071-05.1 SD
4 4 3 2 7747006071-02.1 SD
B Connect the cables in accordance with the terminal diagram ( Fig. 6).
B Use a screwdriver to open and close the quick-connect terminals.
B After completing work, close the controller with the cover and the screw.
1 L N R1 N S1 S2 S3
F1
230V AC 7747006071-03.1 SD
5 T1 T2 T3 2
4 3
Fig. 6 Terminal diagram
5 OPERATION
NOTES FOR THE USER
Your professional heating technician will set the solar heating system when commissioning it, and it
will run automatically.
B Do not switch off the solar heating system during long absences (e.g. when going on holiday).
When installed according to the manufacturer's specifications, the solar heating system is
intrinsically safe.
B Do not modify the controller settings.
B After a power failure or a long absence, check the operating pressure on the pressure gauge of the
solar heating system ( section 8.4, page 27).
2
3
7747004985.09-1.SD
1 5 5 1
2
ax T1
3 /m
in
m
4 9
T3
max
8
T2
7 5 6
7747006071-04.1 SD
1 Display
2 Rotary selector
3 Back button
4 Menu button
5 Symbol for temperature sensor
6 Displays of temperature values, operating hours etc.
7 Indicator for maximum cylinder temperature reached
8 Animated solar heating circuit
9 Indicator for collector minimum or maximum temperature reached
AUTOMATIC MODE
When the activation temperature difference between the two temperature sensors is reached, the
connected pump starts running. The transport of the heat transfer fluid is shown by the animation on
the display ( Fig. 8, no. 8).
When the deactivation temperature difference is reached, the pump is switched off.
To protect the pump, it is automatically activated for about three seconds approximately 24 hours after
its last run.
Temperature values are matched to their source by the location numbers on the pictogram.
If no entry is made for more than 60 seconds, the controller leaves the main menu.
Setting
range
Display Function [preset] Set to
Speed regulation
This function increases the efficiency of the solar heating on/off
+ system. The system attempts to regulate the temperature [on]
difference between temperature sensors T1 and T2 to the
value of the activation temperature difference.
Setting
range
Display Function [preset] Set to
Information
This function displays the software version.
Setting
range
Display Function [preset] Set to
Manual mode on
Base settings
All functions and parameters are reset to their base settings
(except for operating hours). After the reset, all parameters
must be checked and may need to be re-adjusted.
B To go to the expert menu: press the menu button and hold for about five seconds.
B Use the rotary selector to select the desired setting or function P1 to P4.
B To change the setting: press the rotary selector and then turn.
B To save the setting: press the rotary selector again.
B To leave the expert menu: press the button .
Setting range
Display Function [preset] Set to
B When commissioning the solar heating system, read and keep in mind the technical documents for
the solar pump station, the collectors and the cylinder.
B Only put the solar heating system into operation when all pumps and valves are in proper working
order.
Together with the solar pump station, observe the following steps:
B Check that the system is free of air.
B Check and adjust the flow rate.
B Enter the controller settings in the commissioning and maintenance report ( Installation and
maintenance instructions for the solar pump station).
B For normal operation, set the controller to Auto ( section 5.5, page 18).
7 FAULT FINDING
Pump is switched off. Temperature sensor not Check the sensor connection.
connected or incorrectly Check the temperature
connected. sensor for damage or
incorrect installation position.
Type of fault
Display is blank. Pump not running although activation conditions are met.
The cylinder is not being No power supply; fuse or Check fuse and replace if
supplied by the solar power cable faulty. necessary. Ask an electrician to
heating system. check the electrical system.
The cylinder is not being Pump switched off in manual Use the manual mode function
supplied by the solar mode. to switch to automatic.
heating system.
Cylinder temperature T2 is When the temperature drops 3 K
close to or above the set below the maximum cylinder
maximum cylinder temperature, the pump will
temperature. switch on.
Pump not running although the circuit animation is showing on the display.
The cylinder is not being The line to the pump is Check the line.
supplied by the solar interrupted or not connected.
heating system.
Pump is faulty. Check the pump and replace if
necessary.
The cylinder is not being The pump is stuck due to a Unscrew and remove the slotted
supplied by the solar mechanical blockage. screw on the pump head and use
heating system. a screwdriver to release the
pump shaft. Do NOT strike the
pump shaft with the screwdriver.
Pump is being activated/ Temperature sensor not Check position, installation and
deactivated too early / too correctly installed. Incorrect type of sensor;
late. temperature sensor installed. add heat insulation if necessary.
Type of fault
Risk of scalding Cylinder temperature limit and Set the cylinder temperature limit
mixing valve are set too high. and blending valve to a lower
setting.
Potable water too cold (or volume of warm potable water is too low).
Nonetheless, we recommend that you have your system maintenanced every two years by your local
qualified technician. In this way you can ensure smooth and efficient operation and early detection and
elimination of any possible damage.
WARNING: Risk of injury through contact with heat transfer fluid (water / propylene
glycol mixture)
B If heat transfer fluid comes into contact with eyes: holding eyelids wide open,
thoroughly wash eyes with running water.
B Keep heat transfer fluid out of reach of children.
Your technician has been instructed, during commissioning of the solar heating system, to ensure the
heat transfer fluid is protected from freezing, down to at least -30 C.
Enter the values in the log on page 28 (which may also be copied). The completed log
can help qualified technicians when checking your solar heating system and performing
maintenance.
Pressure fluctuations in the solar heating circuit due to temperature changes are normal
and do not lead to faults in the solar heating system.
B Check the operating pressure on the pressure gauge ( Fig. 7) when the system is cold (about
20 C).
IF PRESSURE DROPS
A pressure drop can be caused by the following:
There is a leak in the solar heating circuit.
An automatic air vent has expelled air or vapour.
Due to the self-cleaning effect when rain falls, the collectors do not need cleaning.