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TFF 200/300/400 0201

VAS 451890 - 0107

Warning to the user

a. Do not remove or adjust any component part of this unvented water heater. Contact the installer.b. If this unvented water heater develops a fault, such as a fl ow of hot water from the discharge pipe, switch the heater off

and contact the installer.

Warning to the installer

a. This installation is subject to Building Regulation approval. Notify the Local Authority of an intention to install.b. Use only manufacturer’s recommended replacement parts.

c. Installed by:

Name:

Address:

Phone no.:

Completion date:

Directions for use

1 Safety instructions............................................................................................................................................................ 3

2 Installing the storage tank............................................................................................................................................... 4

3 Commissioning the storage tank.................................................................................................................................... 10

4 Anode and water quality.................................................................................................................................................................... 10

5 Electrical heating element................................................................................................................................................................ 11

6 Warranty conditions.............................................................................................................................................................................. 11

7 Service....................................................................................................................................................................................................... 11

8 Maintanence.............................................................................................................................................................................................. 13

9 Technical specifi cations....................................................................................................................................................................... 14

SECTION I: TANK INSTALLATION

Figures and illustrations used. Due to the possibility of setting and printing errors, and to the need for continuous technical change, please understand that we cannot accept liability for the correctness of the data. The current version of the General Terms of Business applies.

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1. Safety instructions

Please read the following installation and commis-sioning instructions thoroughly before you commis-sion the device. This can prevent damage to your system caused by incorrect handling.Uses other than the intended use or unapproved modifi cations to the installation and design nullify all warranty claims.The following regulations of technology must be re-spected as well as directives of respective countries:

DIN 1988Technical regulations for drinking water plumbing.

DIN 4753Water heaters and water heating systems for drinking and service water; Requirements, marking, equipment and testing.

EN 12975Thermical solar systems and their components.

1.1 Storing

When receiving the VELUX solar hot water unit and before installation please store in an upright position in a dry and weather secure storing facility.

Please read and understand these instructions before starting the work.Please leave this leafl et with the user following installation.

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SECTION I: TANK INSTALLATIONSECTION I: TANK INSTALLATION

2. Installation

The tank must be assembled and installed by a certi-fi ed specialist company!When transporting and opening the packaging, the instructions in the note attached to the head of the buff er must be followed. The dimensions of the tank may not exceed the max. insertion dimensions!The storage tank must be installed in a frost-proof room with short cable routes. When installing the unit in an attic, a suitable collecting basin with a drain unit must be provided.The weight of the fi lled tank may not exceed the max. permitted ceiling loading! See the weight of the tank when full under section 9.The storage tanks, enameled in accordance with DIN 4753, part 1, are suitable for normal drinking water. Mixed installation is permitted.

It must be connected in accordance with DIN 1988 and DIN 4753, part 1. All connection sockets not used must be closed with plugs.The operating overpressure ratings specifi ed on the type plate may not be exceeded. If necessary, a pres-sure reducer must be installed.The enclosed adjusting feet allow the storagetank to be adapted for height diff erences at its installation location.The unit has to be installed in such a way that main-tenance can be carried out conveniently. Make sure there is enough header above the tank to enable the anode to be checked and possibly replaced.

Components check list:

Before commencing installation, check that all components for your VELUX solar hot water unit are contained in the package. The following components are supplied as standard with your VELUX solar hot water unit:

• Cold water combination valve pack Valve comprising pressure reducing valve, strainer, check valve and expansion relief valve. Tundish Expansion core unit• Factory fi tted Temperature/Pressure Relief Valve• Factory fi tted indirect Thermostat and Thermal Cut-out• 2 Motorised valves• Solar pack Pump and control unit for easy mounting Expansion vessel Installation kit for expansion vessel Mixer valve Air separator Glycol

Please note! Cylinder relief valve connections should not be used for any other purpose and no valves should be fi tted between the expansion valve and the storage cylinder.

2.1 Connection diagram cold water in accordance with BS7206

Stop valve

Water main

Expansionvalve

Expansionvessel

Temperaturerelief valve

Hot water

Solar flow

Solar return

Discharge

Pressurereducing valve

Check valve

Thermal cut-outThermostat

Motorized valve

Heating flow

Heating return

Motorized valve

2.2 Tank connection points

ITEM DESCRIPTION INSTRUCTION

1 TPR valve Factory fi tted

2 Motorised valve See paragraph 2.4

3 Thermal cutout Factory fi tted

4 Motorised valve See paragraph 2.4

5 Solar pump and control See section l & ll

A

WW

HW

FH

Z

HR

FS

KW

EHP

F

See diagram in section 1, paragraph 2.8For connection of the discharge pipe work.

Boiler circuit

Collectur circuit

See diagram in section l, paragraph 2.1For connection of unvented kit components to the cold water inlet.

2.3 Discharge pipework

The discharge pipe (D1) from the vessel up to and including the tundish is generally supplied by the manufacturer of the hot water storage system. Where otherwise, the installation should include the dishcarge pipe(s) (D1) from the safety devise(s). In either case the tundish should be vertical, located in the same space as the unvented hot water storage system and be fi tted as close as possible and wihtin 500 mm of the safety device, e.g. the temperature relief valve.

The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to per-sons in the vicinity of the discharge, be of metal and:

a. be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9 m long, i.e. discharge pipes between 9 m and 18 m equivalent resistance length should be at least two sizes larger than the miminal outlet size of the safety device, between 18 and 27 m at least three sizes larger, and so on. Bends must be taken into account in caluclating the fl ow reistance. Refer to the discharge pipe arrangement, the copper discharge pipe table and the worked example;

An alternative approach for sizing discharge pipes would be to follow BS 6700:1987 Specifi cation for design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages, Appendix E, section E2 and table 21.

b. have a vertical section of pipe at least 300 mm long, below the tundish before any elbows or bends in the pipework;

c. be installed with a continuous fall;

d. have discharges visible at both the tundish and the fi nal point of discharge but where this is not pos-sible or is practically diffi cult there should be clear visibility at one or other of these locations. Exam-ples of acceptable discharge arrangements are:

i. ideally below a fi xed grating and above the water seal in a trapped gully;

ii. downward discharges at low level, i.e. up to 100 mm above external surfaces such as car parks, hard standings, grassed areas, etc. are accpeta-ble provided that where children may play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility;

iii. discharges at high level, e.g. into a metal hop-per and metal down pipe with the end of the discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature discharges of water and 3 m from any plastic guttering system that would collect such discharges (tundish visible);

iv. where a single pipe serves a number of discharg-es, such as in blocks of fl ats, the number served should be limited to no more than 6 systems so that any installation discharging can be traced reasonably easily. The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe (D2) to be connected. If unvented hot water storage systems are installed where discharges from safety devices may not be apparent, i.e. in the dwell-ings occupied by blind, infi rm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.

NOTE: the discharge will consist of scalding water and steam. Asphalt, roofi ng felt and non-metal-lic rainwater goods may be damaged by such discharges.


1

35

4

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Boiler circuit

SV/SR

2

Typical discharge pipe arrangement

Safety device(eg. temperature relief value).

500 mm maximum

300 mm minimum

Metal discharge pipe (D1) from temperature relief valve to tundish.

Tundish

Metal discharge pipe (D2) from tundish, withcontinuous fall.See Building Regulation G3 section 3.9d i-iv, Tabel 4 and worked example.

Discharge below fi xed grating (Building Regulation G3 section 3.9d gives alternative points of discharge).

Fixed louvred grating

Trapped gully

2.3.1 Sizing of copper discharge pipe ’D2’ for common temperature relief valve outlet sizes

Valve outlet size

Minimum size of discharge pipe D1*

Minimum size of discharge pipe

D2* from tundish

Maximum resistance allowed, expressed as a length of straight

pipe (ei. no elbows or bends)

Resistance created by each elbow or bend

G½ 15 mm22 mm28 mm35 mm

up to 9 mup to 18 mup to 27 m

0.8 m1.0 m1.4 m

G¾ 22 mm28 mm35 mm42 mm


1.0 m1.4 m1.7 m

G1 28 mm35 mm42 mm54 mm


1.4 m1.7 m2.3 m

Worked example

The example below is for a G½ temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7 m from the tundish to the point of discharge.

From Tabel 2.3.1Maximum resistance allowed for a strength length of 22 mm copper discharge pipe (D2) from a G½ temperature relief valve equates to 9 m.Substract the resistance for 4 No. 22 mm elbows at 0.8 m each = 3.2 m. Therefore the maximum permit-ted length equates to 5.8 m.

5.8 m is less than the actual length of 7 m therefore calculate the next largest size.Maximum resistance allowed for a straight length of 28 mm pipe (D2) from a G½ temperature relief valve equates to 18 m.Substract the resistance for 4 No. 28 mm elbows at 1 m each = 4 m. Therefore the maximum permitted length equates to 14 m.As the actual length is 7 m, a 28 mm (D2) copper pipe will be satisfactory.

2.4 Motorised valves

See instruction supplied with the valve.

NB: High limit stat to be set at 80-85°C.

High limit stat is set at 80-85°C.

Control stat is set at 70-75°C.

2.5 Dual thermostat2.5.1 Connection diagram


c 2 1

°c +

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c 2

°c +

Control Limit

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3. Commissioning

Before commissioning, check whether the water supply is open and the storage tank is full. Initial fi lling and commissioning must be carried out by a certifi ed specialist company!The entire system, including parts assembled in the manufacturer’s factory, must be tested to ensure that it is watertight and operational. The safety valve must be checked regularly to ensure that it functions safely.

We recommend that you have the system serviced annually by a specialized company.We recommend that the storage tank be cleaned and checked annually.Careful operation can save a considerable amount of energy. Do not run the storage tank at more than 60°C, as this results in heat loss and limescale.The ideal temperatures are 50-60°C.

4. Anode and water quality

In accordance with DIN 4753, the magnesium anode must be tested by the customer service department after 2 years for the fi rst time (after that annually) and replaced if necessary.In hard water areas scaling can be reduced by restricting the water temperature. For descaling see section 8.

5. Electrical heating element

Electrical heating elements may only be connected by certifi ed electrical installers in accordance with the corresponding switching diagram. The country-specifi c regulations in eff ect must be observed.The electrical heater (if applicable) must be descaled annually and also at regular intervals depending on the hardness of the water. A function control must be connected.

The electric threaded heating elements are only permitted to be used as backup heating.Only electrical heating elements with thermostat and thermal cut-out from VELUX should be used for this product.

Note: Electrical heating elements must never be fi tted without thermal cut-outs.

6. Warranty conditions

The vendor guarantees the storage tank enameling and rust-proofness for 5 years from the date of manufacturing, provided the protective magnesium anode has been tested regularly.All spare parts are guaranteed for 2 years.

i. Servicing should only be carried out by a compen-tent installer in the installation and maintenance of unvented solar water heating systems.

ii. Any spare parts used MUST be authorised VELUX parts.

iii. Disconnect the electrical supply before removing any electrical equipment covers.

7. Service7.1 Important


iv. NEVER bypass any thermal controls or operate system without the necessary safety valves.

v. Water contained in the VELUX solar hot water system may be very hot, especially following a thermal control failure. Caution must be taken when drawing water from the unit.

2.5.2 Specifi cation

ITD Dual Thermostat

Temperature Range (Control) (°C) 0-90

Temperature Range (Limit) 90/110°C (factory set to 90°C)

Switching Diff erential 4 ± 1K

Switch Confi guration PDT (control) SPST (limit)

Switch Voltage Rating 220/240 Vac

Switch Current Rating 10(2.5)A

Maximum Ambient Temperature (Head) 80°C

Maximum Medium Temperature 150°C

Dimensions of thermostat head (mm) 100 wide x 110 high + 56.5 deep

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7.2 Spare parts

A full range of spare parts are available for the VELUX solar hot water system range. Refer to the Technical Data label on the unit to identify the model installed and ensure the correct part is ordered.


ITEM DESCRIPTION ITEM NAME ITEM NO. TFF 200 0201 TFF 300 0201 TFF 400 0201

Storage tank covers

Cap, silver (D = 540 mm) ELB200AH-S 121736 •

Cap, silver (D = 600 mm) ELB3AH-S 121737 •

Cap, silver (D = 704 mm) ELB4/5AH-S 120069 •

Flange covers

Flange cover DN 110, silver FPADN110S 120041 • • •

Flange

Dummy fl ange DN 110 FP18000 120029 • • •

Flange lid, perforated for RWT, DN 110 FP18015 120028 • • •

Seals

Seal for fl ange lid, DN 110 FPD180 120038 • • •

Seal for fl ange lid, perforated FPD180G 120039 • • •

Mg anodes

Ø 26 x 550 anode, not insulated MGA-ELB 200R2E 120046 •

Ø 26 x 900 anode, not insulated MGA-SKL400 120047 •

Ø 26 x 1100 anode, not insulated MGA-SKL300/500 120043 •

Thermometers

Thermometer TFF 200 0201 BTM120R 120055 •

Foil cases

Foil case TFF 200 0201, silver ELB200R2E-FM 120049 •

Foil case TFF 300 0201, silver SKL300-FM-S 120050 •

Foil case TFF 400 0201, silver SKL400-FM-S 120051 •

Thermometers

Pressure reducing valve COLK 350 250 •

Pressure reducing valve COLK 350 300 • •

Expansion vessel XVES 600 023 •



Expansion vessel XVES 600 041

TPR PTEM 575 804 • • •

Tundish TUND 219 001 • • •

Double thermostat • • •

Motorised valves TBC • • •

8. Maintainance

8.1 Requirements

To ensure the continued optimum performance of the VELUX Solar Hot Water unit it should be regularly maintained. This is of particular importance in hard water areas or where the water supply contains particulate matter. Maintenance should be carried out by a competent person and any replacement parts used should be authorised VELUX spare parts. It is

8.2 Check Operation of Safety Valves

Slowly open the Temperature and Pressure Relief Valve by twisting its cap for a few seconds. Check water is discharged and that it fl ows freely through the tundish and discharge pipe work. Check valve reseats correctly when released.

8.3 Draining the VELUX Unit

Switch off the electrical supply to the immer-sion heater(s) and shut down the boiler on indirect units. Turn off the mains water supply to the VELUX unit. Attach a hosepipe to the drain cock having suffi cient length to take water to a suitable discharge point below the level of the unit, at least

8.4 Descaling Immersion Heather

Open the cover(s) to the immersion heater housing(s) and disconnect wiring from immersion heater(s). Remove the thermostat and unscrew the immersion heater. Carefully remove any scale from the surface of the element(s). DO NOT use a sharp implement as

recommended that maintenance is carried out every 12 months and includes the checks detailed below.In hard water areas consideration should be given to periodically descaling the immersion heater elements if fi tted. To do this the VELUX unit will need to be drained.

Note: The water discharged may be very hot.Repeat the procedure for the Expansion Relief Valve (located on the Cold Water Combination Valve or Expansion Valve Core Unit).

one metre below the unit is recommended. Open hot water tap nearest to the VELUX unit to relieve the system pressure. Open drain cock. If water fails to drain from the VELUX Unit vent the unit by manu-ally opening the Temperature/Pressure Relief Valve.

damage to the element surface could be caused. En-sure sealing surfaces are clean and seals are undam-aged; if in doubt fi t a new gasket. Replace immersion heater. Rewire the immersion heater(s) in accordance with instructions and close and secure terminal cover.

12 VELUX

14 VELUX 15 VELUX


8.6 Log Book

On completion of any maintenance or service of the VELUX Solar Hot Water Unit fi ll-in a record of actions taken and the date the work was undertaken. The record should be kept with the instruction for use.

8.5 Refi lling System

DO NOT switch on the immersion heater(s) or boiler until the system has been completely refi lled. Close the drain tap. With hot tap open, turn on mains water supply. When water fl ows from the hot tap allow to fl ow for a short while to purge air and to

fl ush through any disturbed particles. Close hot tap and then open successive hot taps in system to purge any air. The electrical supply can now be switched on.

TFF 200 0201

TFF 300 0201

TFF 400 0201

Contents l 180 280 375

Diameter, insulated mm 540 600 700

Height, insulated mm 1432 1794 1591

Tilted height mm 1530 1930 1745

Weight kg 85 120 140

Max. permissible water pressure

bar 5.5 5.5 5.5

Max. permissible heating pressure

bar 5.5 5.5 5.5

Max. permissible solar loop pressure

bar 5.5 5.5 5.5

Max. permissible operating temp. water

°C 95 95 95

Max. permissible operating temp. heating

°C 110 110 110

Max. permissible operating temp. solar loop

°C 110 110 110

Upper heating/reheating register m2 0.7 0.81 1.00

Lower heating area/solar register

m2 0.95 1.49 1.83

Solar heat exchanger vol. l 6.4 10.4 12.8

Heating system heat exchanger vol.

l 4.8 5.6 6.9

Performance indicator NL top NL / kW 2.4 / 25 2.5 / 27 5.7 / 31

9. Specifi cations

TFF 200 0201

TFF 300 0201

TFF 400 0201

Performance indicator NL bottom

NL / kW 4.2 / 31 4.1 / 45 9.4 / 51

Heating fl ow, HV R 1" 1" 1"

mm 1147 1424 1355

Heating return, HR R 1" 1" 1"

mm 787 1064 1007

Solar fl ow, SV R 1" 1" 1"

mm 687 965 909

Solar return, SR R 1" 1" 1"

mm 687 965 909

Hot water, WW R ¾" 1" 1"

mm 1369 1728 1526

Cold water, KW R ¾" 1" 1"

mm 55 90 55

Circulation, Z R ½" ½" ½"

mm 900 1179 1112

Sensor thermometer wells mm ø 16 x 200 ø 16 x 200 ø 16 x 200

Heating FH mm 1012 1289 1224

Solar FS mm 292 378 324

1½" sleeve for electrical heating EHP

mm 737 1015 957

Thermometer T mm 1226

Flange F, Di/TK/Do mm 110/150/180 110/150/180 110/150/180

Anode A mm ø 26 x 550 ø 26 x 1100 ø 26 x 900

mm Top Top Top

Maximum water supply pres-sure to the pressure reducing valve

bar 16 16 16

Operating pressure bar 3 3 3

Expansion vessel charge pressure

bar 3 3 3

Expansion relief valve setting bar 6 6 6

Mass of unit when full kg 285 420 540

Set opening pressure (bar) of the combined temperature and pressure relief valve(s)

bar 7 7 7

The set opening temperature (°C) of the temperature relief or temperature and pressure relief valve(s)

°C 90 90 90

Specifi cations (continuation)

SV/SR

A

WW

HW

FH

Z

HR

FS

KW

EHP

F

SECTION II: SOLAR PUMP STATION

17 VELUX

1. Safety instructions

1 Safety instructions........................................................................................................................................................... 17

2 Dimensions, Components............................................................................................................................................... 18

3 Technical Specifi cations.................................................................................................................................................. 19

4 Function of the Gravity Brakes..................................................................................................................................... 19

5 Fill/Drain Fitting..................................................................................................................................................................................... 20

6 Flow Indicator.......................................................................................................................................................................................... 20

7 Air Jet............................................................................................................................................................................................... 20

8 Connection Nozzle................................................................................................................................................................................ 21

9 Connecting the Valve Coupling for Membrane Expansion Vessels........................................................................... 21

10 Solar Control/Electric Installation............................................................................................................................... 21

11 Maintenance.............................................................................................................................................................................................. 21

12 List of Spare Parts................................................................................................................................................................................. 22

13 Pump description................................................................................................................................................................................... 23

14 Safety precautions for the operator............................................................................................................................................. 24

Carefully read the following instructions for installa-tion and use before you start operating your device. In this way, you can avoid damages to your device due to incorrect handling. Improper use and unau-thorised modifi cations of the installation and design result in the expiration of all liability claims. The fol-lowing regulations of technology must be respected as well as directives of respective countries:

DIN 4751Water Heating Systems.

DIN 4757Solar Heating and Solar Thermal Systems.

EN 18380Heating and Process Water Systems.

EN 18382Electric Cable and Wiring Equipment in Buildings.

EN 12975Thermical solar systems and their components.

18 VELUX 19 VELUX

SECTION II: SOLAR PUMP STATIONSECTION II: SOLAR PUMP STATION

2. Dimensions, components

Two-line return unit, insulated, DN 20, with solar control, air collector, fi ll fi tting, and fl ow indicator.

Figure 1: Overview

14

Tube connection Ø 22

Connection, fl at sealing G 1"

22

15

13

7

10

6

5

122

3

11

410

1

12

9

8

Maximum operating pressure: 6 bar

Maximum operating temperature (return): 120°C

Maximum operating temperature (fl ow): 140°C

Medium: Water with a maximum propylene glycol content of 50%

Nominal diameter: DN 20

Connections: Flat sealing, swivel nut G1, 1¼"

Sealings: EPDM

Casing: GK-CuZn37Pb (2.0340.02)

Fittings: CuZn39Pb3 (2.0401)

Insulation: EPP foam

Thermal conductivity: 0.038 W/mK

3. Technical Specifi cations

77.5 175 75.5

335 ca. 202.6

622

ca. 6

48.5

Figure 2: Dimensions

4. Function of the Gravity Brakes (1/2)

Opening pressure of the gravity brakes: 20 mbar each.The gravity brakes are integrated in the fl ow and return ball valves. They are operated by turning the handles of the ball valves. To prevent gravity circulation, the valve discs should not be vented. The gravity brakes are in operating position (closed). The slots in the handles are in a vertical position (Figure 3a).

To fi ll and completely empty the solar system, open the gravity brakes by turning the handles to the right. The slots in the handles are positioned at an angle of 45° (Figure 3b).Turn the handles to the right by a total of 90°. The slots in the handles are in a horizontal position. The ball valves are closed (Figure 3c).

Figure 3a: Ball Valve open. Figure 3b: Gravity Brakes open. Figure 3c: Ball Valve closed.

20 VELUX 21 VELUX


5. Fill/Drain Fitting (6)

Use the fi ll and drain valves on the fi ll/drain fi tting to fi ll and drain the solar system (Figure 4).To drain the system, the slot in the spindle must be in a horizontal position (Figure 4b). Figure 4a: Drain Fitting

completely open.Figure 4b: Drain Fitting closed.

6. Flow Indicator (7)

The adjustment of the fl ow rate of the thermal carrier medium takes place by controlling the speed levels (I, II, III) of the circulation pump and the throt-tle in the fi ll/drain fi tting (Figure 4). The fl ow indicator shows the set fl ow rate (Figure 5). The indicator range is between 1 and 13 l/min.

7. Air Jet (8)

The residual air in the thermal carrier medium is collected in the air jet and can be vented manually by means of the venting nipple (Figure 1, pos. 9). To do this, attach the enclosed hose to the nozzle of the venting nipple and collect the escaping medium in a suitable vessel. Remove the hose after venting. Venting should only be performed by trained professionals. Uncontrolled venting can lead to malfunction of the solar system due to loss of pressure.

CAUTION! Risk of scalding!

The air and the thermal carrier medium escaping while venting the system can reach tempera-tures of over 100°C.Afterwards, fi rmly close the nipple. Monitor the system pressure while venting. If necessary, refi ll the solar system with thermal carrier medium.

Read volume fl ow values at this edge of the rotameter.

Figure 5: Flow Indicator.

131197531

4 Connection RP ¾" female thread.

11MEV connection, fl at sealing G¾" male thread.

Figure 6: Membrane Expansion Vessel Connection.

8. Connection Nozzle (10)

An immersion sleeve with a G½" male thread for attaching a temperature sensor can be connected to the fl ow ball valve (Figure 1, pos. 1).

9. Connecting the Valve Coupling for Membrane Expansion Vessels (Fig. 7)

Pos. 17, 18, 20, and 21 are not included. Figure 7: Valve Coupling Connection.

18*

20*

17*

18*

19 21*

10. Solar Control/Electric Installation (16)

Note: • The electric installation must be performed by

an authorised professional!• Fuses, wiring, and grounding must be installed in

compliance with local regulations.• The solar control must be protected against

overcurrent damage.• Disconnect the system from the mains before

opening the casing of the solar control!

The pump cable and the power cord are already con-nected to the solar control.Remove the screw in the cover of the solar control (pos. 16) to access the sensor terminal.Connect the sensors according to the installation guide of the solar control.See the installation guide of the solar control for a description of the functions and instructions for use.

11. Maintenance

For maintenance tasks (e.g., replacing the pump), close the fl ow and return ball valves and the shut-off in the drain fi tting (Figure 1, pos. 1 and 2).

22 VELUX 23 VELUX


12. List of Spare Parts

Pos. Item Item N°. Description Qty

1 SKBVL 130072Flow ball valve with integrated gravity brake (20 mbar), assembly dimension 135 mm

1

2 SKBRLZ 130071Return ball valve with integrated gravity brake (20 mbar), assembly dimension 123,5 mm

1

3 MM10-RLG 130067 Pressure gauge 1

4 SV6-RLG 130046 Solar safety valve, 6 bar, TÜV-certifi ed 1

5 UPST206 130036 Circulation pump ST 20/6 1

6 KFE-RLG 130064 Fill/drain fi tting 1

7 PSKR-DMS 130034 Flow indicator 1-13l/min, swivel nut G1 x Ø 22 1

8 AIRJET 130130 Air jet with manual venting nipple 1

9AIRJET-

HEN130059 Manual venting nipple 1

10 TH-RLG 130043 Immersion sleeve ½" 2

11MAGAK-

RLG130051 Membrane expansion vessel connection 1

12 BTM-2 130065 Dial thermometer 2

13/14 IHSPSKRO 130301 Insulation half shell, front/back 1

15 PSKR-FD 130149 Flat sealing 1" EPDM 4

17 MAGAS 130054Connection hose for expansion tanks, fl ex. 500 mm reinforced hose, with ¾" union nut

–

18 MAGAS-D 130050 IT seal for fl ex. connection, MAGAS hose, ¾" –

19 RLGK 130069 Tubra Veku-Fix E DN 20 with drainage 1

20 AGHB 141309 Retaining clip for expansion tanks, for AG18S and AG25S –

22 RLG-AR 130128 Tank connection pipe for PSKR 2

Note:

IG = Female threadAG = Male threadG = ThreadDN = German Standard Diameter (GSD)MAG = Membrane expansion tank

Extract from the Installation and Maintenance Instructions of the pump

EC declaration of conformityWe hereby declare that this unit complies with the folllowing relevant provisions:

EG machinery directive89/392/EWG in this version, 91/368/EWG, 93/44/EWG, 93/68/EWG

Fig. 4

Fig. 3

Fig. 5

Fig. 2

STL.../6-3

Hea

d (m

)

Water fl ow (m3/h)

13. Pump description

Resistance to electromagnetism89/336/EWG in this version, 92/31/EWG, 93/68/EWG

Applied harmonized standards in particular:EN 809, EN 50 081-1, EN 50 082-1, EN 50 081-2, EN 50 082-2.

24 VELUX 25 VELUX


1. GeneralInstallation and service by qualifi ed personnel only.

1.1 Fields of applicationType ST: for solar thermal systems.

1.2 Connection and output dataMinimum input pressure at the air intake*at temperatures +50°C: 0,05 barat temperatures +95°C: 0,3 barat temperatures +110°C: 1,0 barPermissible temperature range: -10°C up to +110°CMaximum permissible ambient temperature: +40°C

*These values are valid up to 300 m above sea level. For higher elevations add: 0,01 bar/100 m.The minimum inlet pressure must be maintained in order to avoid cavitation noise.

Permissible fl uids:Water and water/glycol mixtures up to a ratio of 1:1. Glycol mixtures require a reassessment of pump hy-draulic data in line with the increased viscosity and depending on mixing ratios. Only approved marks of additives with corrosion inhibitors must be used in strict compliance with manufacturers’ instructions.

2. Safety Rules2.1 Safety Rules For The OperatorLocal regulations for the prevention of accidents must be observed. Danger from electrical energy must be excluded (conforming to local or general regulations such as IEC, VDE, etc.).

2.2 Safety Rules for Inspections and Installation WorkIt is the operator’s responsibility to ensure that inspections and installation work are carried out by authorized and qualifi ed personnel only, having themselves made fully conversant with these instructions.Work must principally be carried out only with the plant switched off and at complete standstill.

2.3 Abnormal Operating ConditionsOperational safety of the plant is only ensured if used in accordance with these instructions. The limits stated there must not be exceeded under any circumstances.

3. Description of Product and AccessoriesThe pump ST/STL is a solar thermal pump with special hydraulic (pump housing coated) for using in solar thermal systems.Motor overload protection is not required. The motor operates non-overloading.

Speed setting:All pumps are equipped with a rotary switch in the terminal box to enable manual 3-speed control (1 = min) (2-3 = max). At minimum speed the maxi-mum speed is reduced to approx. 40 … 50%. The power input is reduced to approximately 50%.

4. Sitting/Installation4.1 Installation– Direction of fl uid fl ow must correspond with the

arrow on the pump housing (Fig. 2, pos. 1).– If using pump housings with integrated exhaust

cavity it must be observed that the connection for the vent or the vent pipe is vertical (12h position).

– When connecting the pump to the conduit of pipes, the pump can be secured against twisting using a spanner on the key surfaces which have been created for this purpose (Fig. 3).

4.2 Electrical wiring– Cable leads to be routed in such a way to avoid

any contact with pipe work and/or pump or stator housings.

– Check that the mains current and voltage comply with the data on the rating plate.

– Eff ect all wiring according to Wiring diagram (Fig. 4).– Pump/installation must be earthed in compliance

with regulations.

14. Safety precautions for the operator

5. Commissioning5.1 System fi lling and ventingThe pump is normally vented automatically after a short operational period. Short-term dry-running will not harm the pump. Direct venting of the pump, if necessary, is done according to the following procedure:– Switch off the pump,– close discharge isolating valve,– carefully slacken and remove the vent plug (Fig. 5).

Beware of possibly released hot liquid or vapour, depending on fl uid temperature and system pres-sure. Danger of scalding exists!

– Carefully move pump shaft several times by means of screwdriver,

– protect electrical parts from leaking water– Switch-on the pump– After 15 … 30 secs close vent plug again,– open isolating valve again.

ATTENTION! It is possible that the pump shaft jams with the vent plug open, depending on system pressure.The pump can become extremely hot, depending on the operational state of the pump or the pipe system (fl uid temperature). Danger of scalding exists when touching the pump!

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SECTION III: SOLAR CONTROL SYSTEM

Security devices...................................................................................................................................... 28

Technichal data and function survey..................................................................................................... 29

1 Installation.......................................................................................................................... 30

1.1 Mounting................................................................................................................................................................................ 30

1.2 Electrical wiring.................................................................................................................................................................. 31

1.3 Allocation of clamps......................................................................................................................................................... 32

1.3.1 Standard solar system..................................................................................................................................................... 32

1.3.2 Solar system and heat exchange................................................................................................................................ 32

1.3.3 Solar system and after-heating................................................................................................................................... 33

1.3.4 Solar system and store charge in layers................................................................................................................. 33

1.3.5 2-store-solar-system valve logic................................................................................................................................. 34

1.3.6 2-store-solar-system pump logic................................................................................................................................ 34

1.3.7 Solar system with 2 collectors.................................................................................................................................... 35

1.3.8 Solar system with after-heating by solid fuel boiler......................................................................................... 35

1.3.9 Solar system with heating circuit reverse raising............................................................................................. 36

2 Operation and function...................................................................................................... 36

2.1 Pushbuttons for adjustment........................................................................................................................................ 36

2.2 System monitoring display........................................................................................................................................... 37

2.2.1 Channel indication............................................................................................................................................................. 37

2.2.2 Tool bar................................................................................................................................................................................... 37

2.2.3 System screen.................................................................................................................................................................... 38

2.3 Blinking codes..................................................................................................................................................................... 39

2.3.1 System screen blinking codes..................................................................................................................................... 39

3 Commissioning.................................................................................................................... 39

4 Controller parameter and indication channels................................................................. 41

4.1 Channel overview.............................................................................................................................................................. 41

4.1.1 - 6 Indication channels........................................................................................................................................................... 43

4.1.7 - 21 Adjustment channels....................................................................................................................................................... 44

5 Tips for fault localization................................................................................................... 52

6 Accessories/Spare Parts.................................................................................................... 55

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SECTION III: SOLAR CONTROL SYSTEMSECTION III: SOLAR CONTROL SYSTEM

Please read the manual for mounting and installa-tion carefully before commissionig the controller. This way damages to the system can be avoided. Please also note that the installation must be adapted to the conditions provided by the customer. The installation and operation must be executed according to the approved technical regulation. The rules for accident prevention are to be paid atten-tion to. The improper use as well as the incorrect modifi cation of installation and construction result in the exclusion of any kind of liability. Especially the following technical rules must be considered:

DIN 4757, part 1Solar heating plants with water and water mixtures as heat transfer medium; Standards for safety regulations.

DIN 4757, part 2Solar heating plants with organic heat transfer mediums; Standards for the safety regulations.

DIN 4757, part 3Solar heating plants; solar panels; terms; safety regulations: checking of the shutdown temperature.

DIN 4757, part 4Solar thermal plants; solar panels; determination of degree of effi ciency, capacity of warmth and press-sure drop. In addition European CE-standards are being devel-oped presently:

PrEN 12975-1Thermal solar plants and their components; collec-tors, part 1: general standards.

PrEN 12975-2Thermal solar plants and their components; collec-tors, part 2: test methods.

PrEN 12976-1Thermal solar plants an their components; prefabri-cated plants, part 1: general standards.

PrEN 12976-2Thermal solar plants an their components; prefabri-cated plants, part 2: test methods.

PrEN 12977-1Thermal solar plants and their components; user-specifi c fabricated plants, part 1: general standards.

PrEN 12977-2Thermal solar plants and their components; user-specifi c fabricated plants, part 2: test methods.

PrEN 12977-3Thermal solar plants and their components; user-specifi c fabricated plants, part 3: effi cieny test of hot water tank.

Security Devices

Universal system controller for solar- and heating systems

• System monitoring display• Up to 4 temperature sensors Pt1000• 2 semi-conductor relays for pump speed control• 9 basic systems selectable• Heat balancing• Function control• User-friendly operation by simple handling• Housing in outstanding design and compact

dimensions, easy to install

Technical data

Housing: Plastic, PC-ABS and PMMA

Protection type: IP 20/DIN 40050

Environmental temp.: 0 ... 40°C

Size: 173 x 110 x 47 mm

Mounting: Wall mounting, mounting into patch-panels is possible.

Display: System screen for system visualisation, 16-segment display, 7-segment display, 8 symbols for system status.

Operation: By 3 pushbuttons in the front of the housing.

Functions: Temperature diff erence controller with optional add-on system functions. Function control according to BAW-guidelines, operating hours coun-ter for solar pump, tube collector special function, pump speed control and heat quantity balancing.

Inputs: For 4 temperature sensors Pt1000.

Outputs: 2 semi-conductor relays.

Power supply: 210 ... 250V~, 50 ... 60Hz.

Total power supply: 4 (2) A 250 V~

Mode of operation: Typ 1.y

Breaking capacity per relay:Semi-conductor relay: 1,6 (1) A 250 V~

!

111

30

62

172

49

Technical data and funtion survey

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The unit must only be located internally. It is not suitable for installation in hazardous locations and should not be exposed to any electromagnetic fi eld. The controller must additionally be equipped with an all-polar gap of at least 3 mm or with a gap according to the valid installaton regulations, e.g. LS-switches or fuses. Please pay attention to a separate laying of the cable lines and installation of ac power supply.

Warning!Switch-off power supply before opening the housing.

1. Installation1.1 Mounting

1. Unscrew the cross-recessed screw of the cover and remove it from the housing.

2. Mark the upper fastening point on the underground and premount the enclosed dowel and screw.

3. Hang up the housing at the upper fastening point and mark the lower fastening point on the underground (hole pitch 130 mm), afterwards put the lower dowel.

4. Fasten the housing at the underground.

Display

Pushbuttons

Can fuse A4

Cable conduits with strain relief

Cover

Hanging

Base

130

Fixation

1.2 Electrical wiring

The power supply of the controller must only be made by an external power supply switch (last step of installation!) and the line voltage must be 210 ... 250 Volt (50 ... 60 Hz). Flexible lines are to be fi xed at the housing by enclosed strain relief sup-ports and screws. The controller is equipped with 2 standard relays, to which the consumers e.g. pumps, valves etc. can be connected:• Relay 1

18 = conductor R117 = conductor R113 = ground clamp

• Relay 216 = conductor R215 = neutral conductor N14 = ground clamp

The temperature sensors (S1 up to S4) have to be connected to the following terminals independently from the polarity:

1/2 = Sensor 1 (e.g. Sensor collector 1)3/4 = Sensor 2 (e.g. Sensor store 1)5/6 = Sensor 3 (e.g. Sensor collector 2)7/8 = Sensor 4 (e.g. Sensor store 2)

The power supply is eff ected to the clamps:19 = neutral conductor N20 = conductor L12 = ground clamp

Please note: The relays are semi-conductor-relays for pump speed control – they need a minimum load of 20 W (power consumption of the consumer) for faultless function. If auxiliary relays, motor valves, etc. are connected, the condenser which is enclosed in the mounting material, must be connected parallely to the relevant relay output. Attention: for connection of auxiliary relays or valves, the minimum pump speed must be adjusted to 100%.

Dangerous voltage on contact! Electrostatic discharge can lead to damages of electronic components!

1 2S1 S2 S3

3 4 5 6S4

7 8 141312

T4A 220 ... 240V~

171615 201918N R1 N LN R2

1 (1) A (1

220 ... 240)V~(1) A (220 ... 240)V~

R1R2Temp. Sensor Pt1000

Sensor clampsEarthing clamps

Consumer clamps

Net clamps

Fuse

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S1

S2S4/TRF

R1S3

ARR 1

Standard solar system with 1 store, 1 pump and 3 sensors. The sensor S4/TRF can optionally be used for heat quantity balancing.

1.3 Allocation of clamps1.3.1 Allocation of clamps for system 1

S1

S3

S4

R1

R2S2

Store 1 Store 2

ARR 2

Solar system and heat exchange of existing store with 2 stores, 4 sensors and 2 pumps.

1.3.2 Allocation of clamps for system 2

Symbol Specifi cation

S1 Collector sensor

S2 Store sensor lower

S3 Store sensor at the top (optionally)

S4/TRF Sensor for heat quantity measure-ment (optionally)

R1 Solar pump


S1 Collector sensor


S3 Store sensor at the top

S4 Store sensor 2

R1 Solar pump

R2 Pump for heat exchange

Solar system and after-heating with 1 store, 3 sen-sors and 2 pumps (for solar heating and after-heating). The sensor S4/TRF can optionally be used for heat quantity balancing.


R2

S1

S2

R1S3

S4/TRF

ARR 3

Solar system and store charge in layers with 1 store, 3 sensors, 1 solar pump and 1 3-way-valve for store charge in layers. The sensor S4/TRF can optionally be used for heat quantity balancing.


S2

R1

S3R2

S1

S4/TRF

ARR 4


S1 Collector sensor



S4/TRF Sensor for heat quantity balancing

(optionally)

R1 Solar pump

R2 Pump for heat exchange


S1 Collector sensor




(optionally)

R1 Solar pump

R2 3-way-valve

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2-store-solar system with valve logic with 2 stores, 3 sensors, 1 solar pump and 1 3-way-valve. The sensor S4/TRF can optionally be used for heat quantity balancing.


R2

S4/TRF

S1

R1

S2 S3

Store 1 Store 2

ARR 5

2-store-solar system with pump logic with 2 stores, 3 sensors and 2 solar pumps. The sensor S4/TRF can optionally be used for heat quantity balancing.


S1

S2 S3R1 R2

Store 1 Store 2

S4/TRF

ARR 6


S1 Collector sensor

S2 Store sensor 1

S3 Store sensor 2


(optionally)

R1 Solar pump

R2 3-way-valve


S1 Collector sensor

S2 Store sensor 1

S3 Store sensor 2

S4/TRF Measuring sensor (optionally)

R1 Solar pump 1

R2 Solar pump 2

Solar system with east-west collectors, 1 store, 3 sensors and 2 solar pumps.


R1 R2

S1

S2

S3

ARR 7

Solar system with after-heating by solid fuel boiler with 1 store, 4 sensors, 1 solar pump and 1 pump for after-heating.


S1

S4

S2

S3

R1

R2

ARR 8


S1 Collector sensor 1

S2 Store sensor

S3 Collector sensor 2

S4 Measuring sensor (optionally)

R1 Solar pump collector 1

R2 Solar pump collector 2


S1 Collector sensor



S4 Sensor for solid fuel boiler

R1 Solar pump

R2 Pump for solid fuel boiler

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Solar system and heating circuit reverse raising with 1 store, 4 sensors, 1 solar pump and 1 3-way-valve for heating circuit reverse raising.


S1

S3

S2

S4

R2

R1

ARR 9 Symbol Specifi cation

S1 Collector sensor



S4 Heating circuit return

R1 Solar pump

R2 3-way-valve

Power connection must be established at fi rst. The controller passes an initialisation phase. After the initialisation the controller is in automatic operation (factory settings). The preadjustet system scheme is ARR 1. The controller is now ready for operation and ought to enable an optimum operation of the solar system by the factory setting adjusted. The controller is operated by 3 pushbuttons below the display. Pushbutton 1 is used for scrolling forward through the index menu or for increasing adjustment values. Push-button 2 is accordingly used for contrary function.In oder to get to the settings (adjustment channels), get to the last indication channel and then keep but-ton 1 pressed for about 2 seconds. If an adjustment value is shown on the display, is indicated. In this case you can press the key " " (3) in order to change into input mode.

2. Operation and function2.1 Push buttons for adjustment

• Select a channel by keys 1 and 2• Shortly press key 3, so that fl ashes• Adjust the value by keys 1 and 2• Shortly press key 3, so that permanently

appears• The adjusted value is now saved

1 Forward

3 SET (selection/adjustment mode)

2 Backwards

!

Total Monitoring-Display.

Only channel indication.

Only tool bar.

Symbol Standard Flashing

Relay 1 activ

Relay 2 activ

Maximum store limitationactive / maximum storetemperature exceeded

Collector cooling function activerecooling function active

Collector minimum limitation active antifreeze function active

Collector security shutdown activeor store securtiy shutdown active

Option antifreeze function active

Sensor defect

Manual operation active

An adjustment channel is changed SET-mode

2.2 System monitoring display

The system monitoring display consists of 3 blocks: indication of the channel, tool bar and system screen (active system scheme).

2.2.1 Channel indication

The indication channel consists of two lines. The upper line is an alphanumeric 16-segment indication, in which mainly the channel names/menu items are shown. In the lower 7-segment indication, the channel values and the adjustment parameter are indicated. Temperatures and temperature diff erences are indicated in °C or K.

2.2.2 Tool bar

The additional symbols of the tool bar indicate the current system status.

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2.2.3 System screen

The system screen (active system scheme) shows the schemes selected on the controller. It consists of several system component symbols, which are – depending on the current status of the system – either fl ashing, permanently shown or hidden.

Only system screen.

Sensors

Valve

Sensor

Additional symbolfor operation of the burner

Store heat exchanger

Store

Store 2 or after-heating(with additional symbol)

Collector 1

Valves

Pumps

Sensor store up

Collector 2

Heating circuit

Collectors with collector sensor

Store 1 and 2 with heat exchanger

3-way-valvesThe fl ow direction or the current breaking capacity are always shown.

Temperature sensor

Heating circuit

Pump

After-heating with burner symbol

2.3 Blinking codes2.3.1 System screen blinking codes

• Pumps are blinking during starting phase.

• Sensors are blinking if the respective sensor-indication channel is selected.

• Sensors are quickly blinking in case of sensor defect.

• Burner symbol is blinking if after-heating is activated.

1. AC power supply must be activated. The control-ler passes an initialisation phase. After having fi nished the initialisation, the controller is in automatic operation with factory settings. The preadjusted system scheme is ARR 1.

2. – Select ARR – Change into -mode – Select the system scheme by ARR

characteristics – Adjustment is saved by pressing button

Now the controller is ready for operation and should enable an optimum operation of the solar system by the factory settings made.

3. CommissioningOn commissioning you have to adjust primarily the language and the system scheme!

1 Forward

3 SET (selection/adjustment mode)

2 Backwards

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System survey:

ARR 1: Standard solar system

ARR 2: Solar system with heat exchange

ARR 3: Solar system with after-heating

ARR 4: Solar system with store charge in layers

ARR 5: 2-store solar system with valve logic

ARR 6: 2-store solar system with pump logic

ARR 7: Solar system with 2 collectors and 1 store

ARR 8: Solar system with after-heating by solid fuel boiler

ARR 9: Solar system with heating circuit reverse raising

ARR 1 ARR 2 ARR 3

ARR 4 ARR 5 ARR 6

ARR 7 ARR 8 ARR 9

4. Controller parameter and indication channels4.1 Channel overview

Legend:

X

Corresponding channel is available.

X*

Corresponding channel is available if the appropriate option is activated.

Please note:S3 and S4 are only indicated in case of sensors connected.

1

Corresponding channel is only available if the option heat quantity measurement is activated (OHQM).

2

Corresponding channel is only available if the op-tion heat quantity measurement is deactivated (OHQM).

MEDT

The channel anti-freeze content (MED%) is only shown if water or vacuum-antifreeze FSV (MEDT 0 or 3) are not used as anti-freeze.

ARR Channel1 2 3 4 5 6 7 8 9

Specification Page

COL x x x x x x x x Temperature collector (1) 43

COL1 x Temperature collector 1 43

COL2 x Temperature collector 2 43

TST x x Temperature store 1 43

TSTL x x x x Temperature store (1) below 43

TST1 x x x Temperature store 1 below 43

TSTU x x x x x Temperature store (1) above 43

TST2 x x x Temperature store 2 below 43

TFSB x Temperature solid fuel boiler 43

TRET x Temperature heating circuit 43

S3 x Temperature sensor 3 43

TRF Temperature return sensor 43

S4 x x Temperature sensor 4 43

n % x x x x Pump speed relay (1) 43

n1 % x x x x x Pump speed reley 1 43

n2 % x x x x Pump speed relay 2 43

h P x x x x Operating hours relay (1) 44

h P1 x x x x x Operating hours relay 1 44

h P2 x x x x x Operating hours relay 2 44

kWh Heat quantity kWh 45

MWh Heat quantity MWh 45

ARR 1 2 3 4 5 6 7 8 9 System

DT 0 x x x x x x Switch-on temperature difference (1) 45

DT10 x x x Switch-on temperature difference 1 45

DT F x x x x x x Switch-off temperature difference (1) 45

DT S x x x x x x Nominal temperature difference (1) 45

RIS x x x x x x Increase (1) 45

DT1F x x x Switch-off temperature difference 1 45

DT1S x x x Nominal temperature difference 1 45

RIS1 x x x Increase 1 45

S MX x x x x x x Maximum temperature store (1) 46

S1MX x x x Maximum temperature store 1 46

DT20 x x x Switch-on temperature difference 2 45


DT2S x x x Nominal temperature difference 2 45

RIS2 x x x Increase 2 45

S2MX x x x Maximum temperature store 2 46

EM x x x x x x x x Emergency temperature collector (1) 47

EM1 x Emergency temperature collector 1 47

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OCN

OCF

EM2

OCX2

OCN2

OCF2

PRIO

ARR 1 2 3 4 5 6 7 8 9

Specification Page

OCX x x x x x x x x Option collector cooling collector (1) 47

OCX1 x Option collector cooling collector 1 47

CMX x* x* x* x* x* x* x* x* Maximum temperature collector (1) 47

CMX1 x* Maximum temperature collector 1 47

x x x x x x x x Option minimum limitation collector (1) 47

OCN1 x Option minimum limitation collector 1 47

CMN x* x* x* x* x* x* x* x* Minimum temperature collector (1) 47

CMN1 x* Minimum temperature collector 1 47

x x x x x x x x Option antifreeze collector (1) 48

OCF1 x Option antifreeze collector 1 48

CFR x* x* x* x* x* x* x* x* Antifreeze temperature collector (1) 48

CFR1 x* Antifreeze temperature collector 1 48

x Emergency temperature collector 2 47

x Option collector cooling collector 2 47

CMX2 x* Maximum temperature collector 2 47

x Option minimum limitation collector 2 47

CMN2 x* Minimum temperature collector 2 47

x Option antifreeze collector 2 48

CFR2 x* Antifreeze temperature collector 2 48

x x x Priority 48

tSP x x x Stop time 49

tRUN x x x Ciruclation time 49

OREC x x x x x x x x x Option recooling 49

O TC x x x x x x x x x Option vacuum tube collector 49

DT3O x x x Switch-on temperature difference 3 45


DT3S x x Nominal temperature ΔT3 45

RIS3 x x Increase ΔT3 45

MX3O x x Switch-on treshold for maximum temp. 46

MX3F x x Switch-off treshold for maximum temp. 46

MN3O x x Switch-on treshold for minimum temp. 46

MN3F x x Switch-off treshold for minimum temp. 46

AH O x Switch-on temp. for thermostat (1) 50

AH F x Switch-off temp. for thermostat (1) 50

OHQM x x x x Option heat quantity balancing 44

FMAX Maximum flow 44

MEDT Antifreeze type 44

MED% MEDT MEDT MEDT MEDT MEDT Antifreeze content 45

nMN x x x x Minimum pump speed relay (1) 51

n1MN x x x x x Minimum pump speed relay 1 51

n2MN x x x x Minimum pump speed relay 2 51

HND1 x x x x x x x x x Manual operation relay 1 51

HND2 x x x x x x x x x Manual operation relay 2 51

LANG x x x x x x x x x Language 51

PROG xx.xx xx.xx

Program number

VERS Version number

Channel

4.1.1 Indication of collector temperatures

Shows the current collector temperature.• COL: Collector temperature (1-collector-system)• COL1: Collector temperature 1• COL2: Collector temperature 2

4.1.2 Indication of store temperatures

Shows the current store temperature.• TST: Store temperature (1-store-system)• TSTL: Store temperature lower• TSTU: Store temperature above• TST1: Temperature store 1• TST2: Temperature store 2

4.1.3 Indication of sensor 3 and sensor 4

Shows the current temperature of the corresponding additional sensor (without control function).• S3: Temperature sensor 3• S4: Temperature sensor 4

Please note: S3 and S4 are only indicated if the temperature sensors are connected.

4.1.4 Indication of other temperatures

Shows the current temperature of the corresponding sensor.• TFSB: Temperature solid fuel boiler• TRET: Temperature heating reverse raising• TRF: Temperature return fl ow

4.1.5 Indication of current pump speed

Shows the current pump speed of thecorresponding pump.• n%: Current pump speed (1-pump-system)• n1%: Current pump speed pump 1• n2%: Current pump speed pump 2

COL / COL1 / COL2:Collector temperature Display range:-40 ... +250°C

TST / TSTL / TSTU / TST1 / TST2:Store temperatures Display range:-40 ... +250°C

S3 / S4: Sensor temperatures Display range: -40 ... +250°C

TFSB / TRET / TRF:Other measuring temperatures Display range: -40 ... +250°C

n% / n1% / n2%:Current pump speed Display range: 30 ... 100%

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4.1.6 Operating hours counter

The operating hours counter adds up the solar oper-ating hours of the respective relay (h P/h P1/h P2). Full hours are shown on the display.

The operating hours added up can be reset. As soon as one operating hours channel is selected, the symbol is permanently shown on the display. The button (3) must be pressed for approx. 2 seconds in order to get into the RESET-mode of the counter. The display-symbol is fl ashing and the operating hours will be set to 0, if confi rmed by button within 5 seconds.

In order to fi nish the RESET-procedure, the button must be pressed to confi rm.

4.1.7 Heat quantity balancing

A heat quantity balancing is possible for the basic systems (ARR) 1, 3, 4, 5 and 6 in conjunction with a fl owmeter. For this purpose option heat quantity balancing in channel OHQM has to be activated.

The volume fl ow readable at the fl owmeter (l/min) must be adjusted in the channel FMAX. Antifreeze type and concentration of the heat transfer medium are indicated on the channels MEDT and MED%.

Type of antifreeze:

0: Water1: Propylene glycol/Antifreeze FS2: Ethylene glycol3: Vacuum antifreeze FSV

Please note: Channels FMAX and MEDT are only available during the activated option heat quantity measurement (OHQM).

h P / h P1 / h P2:Operating hours-counterDisplay channel

OHQM: Heat quantity balancing Adjustment range: OFF ... ON Factory setting: OFF

FMAX: Volume fl ow in l/min Adjustment range: 0 ... 20 in steps of 0.1 Factory setting: 6.0

MEDT: Type of antifreeze Adjustment range: 0 ... 3 Factory setting: 1

The heat quantity transported is measured by the indication of the volume fl ow and the reference sen-sor of feed fl ow S1 and return fl ow TRF. It is shown in kWh-parts in the indication channel kWh and in MWh-parts in the indication channel MWh. The sum of both channels forms the total heat output.The heat quantity added up can be reset. As soon as one of the display channels of the heat quantity is selected, the symbol is permanently shown on the display. The button (3) must pressed for approx. 2 seconds in order to get into the RESET-mode of the counter. The display-symbol is fl ashing and the value for heat quantity will be set to 0, if the button is pressed within 5 seconds. In order to fi nish the RESET-operation, the button " " must be pressed in order to confi rm within 5 seconds once again.In order to cancel the RESET-operation, no button should be pressed for about 5 seconds. The control-ler returns automatically into the indicaton mode.

Please note: Channels kWh and MWh are only available during the activated option heat quantity measurement (OHQM).

4.1.8 ΔT-regulation

Initially the controller works in the same way as a standard diff erential controller. If the switch-on diff erence (DTO/DT1O/DT2O/DT3O) is reached, the pump is activated and after having got an impulse (10 s) a minimum pump speed (nMN = 30%) is run. If the adjusted nominal value of the temperature dif-ference (DT S/DT1S/DT2S/DT3S) is reached, the pump speed is increased by one step (10%). If the diff erence increases by 2 K (RIS/RIS1/RIS2/RIS3), the pump speed is increased by 10% respec-tively until the maximum pump speed of 100% is reached. The response of the controller can be adapted by means of the parameter "Raise". If the adjusted switch-off temperature is under run (DT F/DT1F/DT2F/DT3F), the controller switches off .Please note: Switch-on temperature diff erence DO must be at least 0,5 K higher than the switch-off temperature diff erence DF.

MED%: Concentration of anti-freeze in (Vol-)%.MED% is blinded out by MEDT 0 and 3.Adjustement range: 20 ... 70Factory setting: 45

kWh / MWh: Heat quantity in kWh/MWh Display channel

DT 0 / DT10 / DT20 / DT30: Switch-on temperatureAdjustment range: 1.0 ... 20.0 K Factory setting: 6.0

DT F / DT1S / DT2S / DT3F: Switch-off temperature diff erenceAdjustment range: 0.5 ... 19.5 K Factory setting: 4.0 K

DT S / DT1S / DT2S / DT3S: Nominal temperature diff erence Adjustment range: 1.5 ... 30.0 K Factory setting: 10.0 K

RIS / RIS1 / RIS2 / RIS3: Raise Adjustment range: 1 ... 20 K Factory setting: 2 K

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4.1.9 Maximum store temperature

If the adjusted maximum temperature is exceeded, a further loading of the store is stopped so that a damaging overheating can be avoided. If the maxi-mum store temperature is exceeded, is shown on the display (fl ashing).

Please note: The controller is equipped with a se-curity-switch-off of the store, which avoids a further loading of the store if 95°C is reached at the store. The symbols and (both fl ashing) are shown on the display.

4.1.10 ΔT-regulation (solid fuel boilders and heat exchange)

Maximum temperature limitation

The controller is equipped with an independent temperature diff erential regulation for which mini-mum and maximum temperature limations as well as corresponding switch-on and -off temperatures can be separately adjusted. Only possible for ARR = 2 and 8 (e.g. for solid fuel boilers or heat exchange regulation).

Is the adjusted value MX3O exceeded, the relay 2 will be deactivated. By falling below MX3F, the relay will be switched on again.

Minimum temperature limitation

When the adjusted value falls below MN3O, there-lay will be deactivated. By exceeding parameter MN3F, the relay will be activated again. Parallely, the switch on- and switch off temperaturediff erenc-es DT3O and DT3F apply for both: the maximum- and minimum temperature limit.

Recommendation: when using buff er tanks for system 8, following adjustments should be made: MX3O approx. 80°C/MX3F approx. 75°C.

Please note: the parameter MX3O and MX3F always apply to the heat sink, the parameter MN3O and MN3F to the heat source.

S MX / S1MX / S2MX: Maximum store temp. Adjustment range: 4 ... 95°CFactory setting: 60°C

MX3O / MX3F: Maximum tempe-rature limitation Adjustment range: 0.5/0.0 ... 95.0/94.5°C Factory setting: MX3O 60.0°CMX3F 58.0°C

MN3O / MN3F:Minimum temperature limitation Adjustment range: 0.0/0.5 ... 90.0/89.5°C Factory setting:ARR = 2MN3E 5.0°CMN3A 10.0°CARR = 8MN3E 60.0°CMN3A 65.0°C

4.1.11 Limit collector temperatureCollector emergency shutdown

If the adjusted collector temperature limit (EM/EM1/EM2) is exceeded, the solar pump (R1/R2) is deactivated in order to avoid a damaging overheat-ing of the solar components (collector emergency shutdown). The factorysetting for the limit tem-perature is 140°C, but it can be changed within the adjustment range of 110 ... 200°C. is displayed (fl ashing).

4.1.12 System cooling

If the adjusted maximum store temperature is reached, the solar system switches-off . If now the collector temperature rises to the adjusted maxi-mum collector temperature (CMX/CMX1/CMX2), the solar pump remains activated until this limit temperature value is again underrun. The store temperature might continue to rise (subordinated active maximum store temperature), but only up to 95°C (emergency shutdown of the store). In order to recool the store to its maximum temperature, the use of the recooling function OREC is recommended.In case of active system cooling is shown on the display (fl ashing). Due to the cooling function the solar system can be kept operable for a longer period on hot summer days. A thermal release of the collector and the heat transfer medium is ensured as well.

4.1.13 Option minimum collector limitation

The minimum collector temperature is a minimum switch-on temperature, which has to be exceeded so that the solar pump (R1/R2) is switched-on. The minimum temperature is meant to avoid a steady starting-up of the solar pump (or solid fuel boiler charging pumps) for low collector temperatures. If the minimum temperature is underrun, is shown on the display (fl ashing).

EM / EM1 / EM2:Limit collector tem-peratureAdjustment range:110 ... 200°C,Factory setting: 140°C

OCX / OCX1 / OCX2:Option system cooling Adjustment range: OFF ... ON Factory setting: OFF

CMX / CMX1 / CMX2: Maximum collector temperatureAdjustment range: 100 ... 190°C Factory setting: 120°C

OCN / OCN1 / OCN2:Mimimum collector limitationAdjustment range: OFF/ON Factory setting: OFF

CMN / CMN1 / CMN2: Minimum collector temperatureAdjustment range:10 ... 90°CFactory setting: 10°C

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4.1.14 Option antifreeze function

The anti-freeze function activates the loading circuit between collector and store if the adjusted anti-freeze function is underrun in order to protect the medium against freezing up or getting "thick" ( is shown in the display (fl ashing)). If the adjust-ed anti-freeze protection temperature is exceeded by 1°C, the loading circuit will be deactivated.

Please note: As there is only a limited heat quantity of the store available for this function, the anti-freeze function should only be used in regions with few days of temperatures around freezing point.

4.1.15 Oscillating charge

Respective adjustment values:

Factory setting Adjustment range

Priority [PRIO] 1 0-2Oscillating break-time [tSP] 2 min. 1-30 min.Oscillating charge-time [tRUN] 15 min. 1-30 min.

The above-mentioned options and parameter are only signifi cant for multi-store systems (system ARR = 4, 5, 6). If priority 0 is adjusted, the store swhich show a temperature diff erence to the collector are loaded in numerical order (store 1 or store 2). In general only one store is loaded at that time. For ARR = 6 parallel loading is also possible.

OCF / OCF1 / OCF2:Antifreeze function Adjustment range: OFF/ONFactory setting: OFF

CFR / CFR1 / CFR2:Antifreeze tempera-ture Adjustment range:-10 ... 10°CFactory setting: 4.0°C

Priority logic:

0 = Store 1/2 coequal1 = Priority store 12 = Priority store 2

Priority:

Oscillating break time / oscillating charge-time / collector rising temperature:

The controller checks the stores regarding loading facilities (switch-on diff erence). If the priority store cannot be loaded, the lower-ranking store is checked. If the lower-ranking store canbe charged, this is eff ected by the so-called "oscillating charge time" (tRUN). After the expiration of the oscillat-ing charge time, loading is stopped. The controller controls the increase of the collector temperature. If this temperature increases by the rise temperature of the collector (ΔT-Col 2 K, fi xed software value), the expired break time is again reset to zero and the oscillating break time (tSP) starts over again. If there after the switch-on conditions of the prioritys-tore are not reached, the loading of the lower-rank-ing store will be continued. If the priority switch has reached its maximum temperature, the oscillating charge is not carried out.

4.1.16 Recooling function

If, as a result of of the system cooling OCX, the store temperature is higher than the store maximum temperature (S MX/S1MX/S2MX) and the collec-tor temperature is at least lower than 5K, the solar system continues running until the store is cooled down to the adjusted store maximum temperature (S MX/S1MX/S2MX) via collector and pipes. In multi storage systems the recooling is generally eff ected at store 1.

4.1.17 Tube collector special function

If the controller measures an increase of 2 K com-pared to the collector temperature stored at last, the solar pump is switched-on to 100% for about 30 seconds to detect the present temperature of the medium. After the expiration of the solar pump runtime the current collector temperature is stored as a new reference value. If the measured tempera-ture (new reference value) is again exceeded by 2 K, the solar pump switches-on for 30 seconds.

OREC: Option recooling Adjustment range:OFF ... ONFactory setting: OFF

O TC: Tube collector special-function Adjustment range: OFF ... ON Factory setting: OFF

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Should the switch-on diff erence between collector and store be exceeded during the runtime of the solar pump or the standstill of the system, the con-troller automatically switches over to solar charging.If the collector temperature falls by 2 K during the standstill, the switch-on value for the special tube collector function will be recalculated and the solar pump won’t be switched-on.

Application area: Vacuum tube collectors (possibly fl at plate collectors as well) in order to avoid switch-on delays during a store load, as well as to avoid a run of the solar pump during the night (the tempera-tures measured during the day can be "stored" until night by the vacuum in the collector tubes).

4.1.18 Thermostat function (ARR = 3)

The thermostat function works independently from the solar operation and can e.g. be used or use of surplus energy or an after-heating.

• AH O < AH FThe thermostat function is used for after-heating.

• AH O > AH FThe thermostat function is used for use of surplus energy.

is shown on the display if the second relay output is activated.

AH O: Thermostat-switch-on temperatureAdjustment range: 0.0 ... 95.0°CFactory setting: 40.0°C

AH F: Thermostat-switch-off temperature Adjustment range: 0.0 ... 95.0°C Factory setting: 45.0°C

After-heating Use of surplus energy

4.1.19 Pump speed control

A relative minimum pump speed is specifi ed for pumps connected at the outputs R1 and R2 via adjustment channels nMN, n1MN and n2MN.

ATTENTION: When using consumers (e.g. valves) which are not pump speed controlled, the value must be adjusted to 100% in order to deactivate the pump speed control.

4.1.20 Operating mode

For control- and service work the operating mode of the controller can be manually adjusted by selecting the adjustment value Manual Mode, for which the following adjustments can be made:

• HND1 / HND2 Operating modeOFF: Relay off ,

display: (fl ashing) +

AUTO: Relay in automatic operation

ON: Relay on,display: (fl ashing) +

4.1.21 Language

The menu language can be adjusted in this channel.

• dE: German• En: English

nMN / n1MN / n2MN: Pump speed control Adjustment range:30 ... 100Factory setting: 30

HND1 / HND2: Operating modeAdjustment range: OFF, AUTO, ON Factory setting: AUTO

LANG: Adjustment of languageAdjustment range: dE, EnFactory setting: dE

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5. Tips for fault localization

If a malfunction occurs, a notifi cation is given on the display of the controller:

On the display the symbol and the symbol appears.

Sensor defect. An error code is shown on the relevant sensor indication channel instead of a temperature.

Pt1000-temperature sensors pinched off can be checked with an ohmmeter. In the following the resistance values corresponding to different temperatures are listed.

Line break.Check the line.

Short-circuit.Check the line.

- 888.8888.8

Resistance values of the Pt1000-sensors

no yes

yes

Pump starts up very late and stops working soon.

no yes

yes

Control / replace

Decalcification

no

yesno

Clean

yes

no

no yes

o.k.no

Air in the system ?

no yes

yes

yes

o.k.

Pump is overheated, but no heat transfer from collector to the store, feed flow and return flow are equally warm, perhaps also bubble in the lines.

Bleed the system; the primary pressure of the expansion tank has to exceed the static pressureby approx. 0,5 bar, the system pressure has to exceed it by approx. 0,5 up to 1 bar (depending on the dimensioning of theexpansion tank); switch the pump on and off for a short time.

Is the collector circuit plugged at the dirt trap?

Switch-on-temperature difference ΔTon too large?

Collector sensor unfavour-able placed e.g. contact sensor instead of immersion sleeve sensor?

If necessary activate tube collector function.

Mount the collector sensor at solar feed flow(warmest collector output); use the immersion sleeve of the respective collector.

Plausibility control ofthe option tubecollector specialfunction?

Clean the dirt trap

Is the temperature diffe-rence at the controller too small?

Wrong placing of thecollector sensor?

Collector circuit pump defect ?

Heat exchanger calcified?

Heat exchanger plugged?

Heat exchanger too small?

New calculation of the dimension.

Change ΔTon and ΔToff accordingly.

Change ΔTon and ΔToff accordingly.

Pump starts for a short moment, switches-off,switches-on again, etc.

The temperature difference between store and collector increases enormously during operation; the collector circuit cannot dissipate the heat.

1 2S1 S2 S3

3 4 5 6S4

7 8 141312

T4A 220 ... 240V~

171615 201918N R1 N LN R2

1 (1) A (1

220 ... 240)V~(1) A (220 ... 240)V~

R1R2Temp. Sensor Pt1000

Fuse

Warning symbol

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no yes

no yes

no yes

no yes

Does the pump start up in manual operation?

Are the fuses of the controller o.k.?

Replace the fuses. Controller seems to be defective − replace it.

Is the pump defective− replace it.

Is the current of the pump released bythe controller?

The adjusted tempera-ture difference for starting the pump istoo high; choose a value which makes more sense.

Start the pump shaftup by a screwdriver;is it ready for operation now?

yesno

yesIs the pump stuck?

noyes

no

no yes

yes no

no

no yes

o.k.

yes no

Does collector circuit pump run during the night?

Check the controller functions

Check the return flow pre-venter in feed flow and return flow with regard to the functional efficiency.

Change connection and let the water flow sidewards or through a siphon (bow down-wards); less store losses now?

Use the circulation pumpwith timer and switch-off thermostat (energy efficient circulation)

Make sure that the pumps of the after-heating circuit are not in nightly use and that the return flow inhibitor is fault-less; problem solved?

Please also check further pumps which are connected to the solar store.

Clean or replace.

Collector temperature is at night higher than ambient temperature.

Warm water outflow upwards?

Does warm water circulation run for a very long time?

Switch-off the circulation pump and the blocking valves for 1 night; less store losses?

Control the return flow preventer in warm water circulation - o.k.

The gravitation circulation in the circulation line is too strong; insert a stronger return flow preventer or an electrical 2-way valve behind the circulation pump; the 2-way valve is open in pump operation, otherwise it is closed, connect pump and 2-way valve in parallel; activate the circulation again!

Stores are cooled during the night. The solar circuit pump does not work although the collector is obviously warmer than the store.

6. Accessories / Spare Parts

Name Item no. Description

SKSC2 141 135 Supplementary controller incl. sen-sors, heating circuit solar controller, 2 semiconductor outputs, 4 sensor inputs

SKSPT1000KL 141 138 Temperature sensor for collectors with PT1000 characteristics

SKSPT1000S 141 107 Temperature sensor for stores with PT1000 characteristics

SBATHE 141 110 Stainless steel immersion sleeve for swimming pool sensors. For applica-tion in chlorine water.

SKSGS 140 032 Spare fuse 4 A

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GB: VELUX Company Ltd.Woodside WayGlenrothes EastFife KY7 4NDScotlandPhone: +44 1 592 77 22 11Fax: +44 1 592 77 18 39www.velux.co.uk

IRL: VELUX Company Ltd.Unit 1, Willsborough Cluster Willsborough Industrial Estate ClonshaugnDublin 17IrelandPhone: +353 1848 8775Fax: +353 1848 8787www.velux.ie

Download - TFF 200/300/400 0201 - SIG Energy Management Solar Thermal Cylinder User... · TFF 200/300/400 0201 VAS 451890 - 0107 Warning to the user a. Do not remove or adjust any component

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