Caleffi solar iSolar 2 User manual

Thank your for buying this product.
Read this manual carefully to get the best perfomance from this unit.
Mounting
Connection
Operation
Troubleshooting
Examples
*49005030* 49005030

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Table of contents
Safety instructions....................................................................................2
Technichal data and overview of functions ............................................3
1. Installation........................................................................................... 5
1.1 Mounting......................................................................................................5
1.2 Electrical wiring..........................................................................................5
1.2.1 Data communication / Bus ......................................................................6
1.2.2 Standard solar system...............................................................................6
2. Operation and function .....................................................................7
2.1 Buttons for adjustment.............................................................................7
2.2 System monitoring display .......................................................................7
2.2.1 Channel display...........................................................................................7
2.2.2 Tool bar........................................................................................................7
2.2.3 System screen.............................................................................................8
2.3 Flashing codes.............................................................................................8
2.3.1 System-Screen flashing codes .................................................................8
2.3.2 LED flashing codes.....................................................................................8
3. Commissioning ................................................................................... 9
4. Control parameter and display channels .......................................10
4.1 Overview ...................................................................................................10
4.1.1-6 Display channels.......................................................................................11
4.1.7-19 Adjustment channels...............................................................................12
5. Troubleshooting................................................................................17
5.1 Various........................................................................................................18
6. Accessory ..........................................................................................20
Imprint ..............................................................................................20
Safety advice
Please pay attention to the following
safety advice in order to avoid danger
and damage to people and property.
Appropriate usage
This product is to be used in solar
thermal systems in compliance with
the technical data specified in these
instructions (see p. 3).
Improper use excludes all liability
claims
Instructions:
Attention should be paid to
- valid local regulations
- the statutory provisions for preven-
tion of industrial accidents,
- the statutory provisions for environ-
mental protection,
- the Health and Safety at Work Act
1974
- Part P of the Building Regulations
2005
- BS7671 Requirements for electrical
installations and relevant safety re-
gulations of DIN, EN, DVGW, TRGI,
TRF and VDE.
These instructions are exclusively
addressed to authorised skilled per-
sonnel.
- Only qualified electricians should
carry out installation and mainte-
nance work.
- Initial installation should be carried
out by named qualified personnel
Declaration of conformity
We, CALEFFI NORTH AMERICA, Inc., declare under our sole responsibility that
our product iSolar 2 complies with the following standards:
EN 55 014-1
EN 60 730-1
According to the regulations of the above directives, the product is labelled with
:
89/336/EWG
73/ 23/EWG
Subject to change without prior no-
tice. Errors excepted

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• system-monitoringdisplay
• upto4temperaturesensors
Pt1000
• heatquantitymeasurement
• functioncontrol
• VBus®
• user-friendlyoperation
through simple handling
• pumpspeedcontrol,solarope-
rating hours counter
Technical data
Housing:
plastic, PC-ABS and PMMA
Protection type: IP 20 / DIN 40050
Ambient temp.: 32 ... 104 °F
Dimensions: 172 x 110 x 46 mm
Mounting: wall mounting, mounting
into patch-panels is possible
Display: System screen for systems
visualisation,16-segment display,7-seg-
ment display, 8 symbols for system
status and operating control lamp
Operation: 3 push buttons at the
front of the housing
Functions: Differential tempera-
ture controller with optional system
functions. Function control according
to BAW-guidelines, operating hours
counter for solar pump, tube collector
function,pump speed control as well as
heat quantity measurement.
Inputs:
for 4 temperature sensors Pt1000
Outputs: 1 Semiconductor relay
Bus:VBus®
Power supply:
115 V~
Mode of operation:
Type 1.y
Switching capacity:
semiconductor relay:
1 (1) A (115) V~
The iSolar 2 is a controller for stan-
dard solar thermal systems. It provi-
des a clear operating concept and is
equipped with a system-monitoring
display. Flashing symbols for sensors,
pumps and valves show temperatures,
temperature differences and active ac-
tuators.
Scope of delivery:
1 x iSolar 2
1 x accessory bag
1 x fuse T4A
2 x screws and dowels
4 x strain relief and screws
Additionally enclosed in the full kit:
1 x sensor FKP6
1 x sensor FRP6

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Examples iSolar 2
For detailed connection
diagrams see chapter 1.
Standard solar systems

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display
push button
fuse 4A
cable gland with strain relief
front cover
1.1 Mounting
The unit must only be located in dry interior locations. It
is not suitable for installation in hazardous locations and
should not be placed close to any electromagnetic fields.The
controller must additionally be supplied from a double-pole
switch with contact gap of at least 3 mm.Please pay attention
to separate routing of sensor cables and mains cables.
1. Unscrew the cross-head screw from the cover and
remove it along with the cover from the housing.
2. Mark the upper fastening point on the wall and drill and
fasten the enclosed wall plug and screw leaving the head
protruding.
3. Hang the housing from the upper fastening point and
mark the lower fastening point through the hole in the
terminal box (centres 130 mm).Drill and insert the lower
wall plug.
4. Fasten the housing to the wall with lower fastening screw
and tighten.
1. Installation WARNING!
Alwaysswitch-offpowersupplyand
disconnect the controller from the
mains before opening the housing!
1.2 Electrical connection The power supply to the controller must be carried out
via an external power switch (last step!) and the supply
voltage must be 115 V~ (50 ... 60 Hz). Flexible cables must
be attached to the housing with the enclosed strain relief
and the corresponding screws.
The controller is equipped with either 1 relay to which
loads such as pumps, valves, etc. can be connected:
• Relay 1
18 = conductor R1
17 = neutral conductor N
13 = ground clamp
Temperature sensors (S1 to S4) have to be connected
to the following terminals (either polarity):
1 / 2 = sensor 1 (e.g. sensor collector 1)
3 / 4 = sensor 2 (e.g. sensor tank 1)
5 / 6 = sensor 3 (e.g. tank top sensor)
7 / 8 = sensor 4 (e.g. return temperature sensor)
The power supply connection has to be carried out via
the following terminals:
19 = neutral conductor N
20 = conductor L
12 = ground clamp
mains terminals
fuse
load terminals
sensor terminals
fastening
fastening
ground terminals
Electrostatic discharge can lead to damage to elec-
tronic components!
Dangerous voltage!
VBus®

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S1
S2
S4 / TRF
1.2.2 Allocation of terminals for system 1 Standard solar system with 1 tank,1 pump and 3 sensors.
The sensor S4 /TR can be optionally used for heat quantity
measurement.
R1
Arr 1
S3 Symbol Specification
S1 collector sensor
S2 tank base sensor
S3 tank top sensor, (optional)
S4 / TR sensor for heat quantity
measurement (optional)
R1 solar pump
1.2.1 Datacommunication/Bus The controller comes with aVBus®for data communication
and energy supply of external modules. The connection
is effected with optional polarity at the clamps marked
with„VBus®“.Via this data Bus you can install one or more
VBus®modules, e.g.:
• heat quant. measurement module WMZ-M1
• large display GA3
• Data logger, DL1
• Smart Display SD3
Additionaly, the controller can be connected to the PC with
the help of a RS-COM adapter. With the Service Center
Software (RCS) the controller parameters can be changed,
measurements can be read out,processed and visualised.The
software enables an easy function control and adjustment
of the system.
VBus®
connection clamps

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1
3
2
backwards forward
SET
(selection / adjustment mode)
The system monitoring display consists of 3 blocks: channel
display, tool bar and system screen (active arrange-
ment).
The channel display consists of two lines.The upper line
is an alpha-numeric 16-segment display (text display) for
displaying channel names and menu items. In the lower
7-segment display, the channel values and the adjustment
parameters are displayed.
Temperatures and temperature differences are indicated
in°C or K respectively.
2.2.1 Channel display
channel display
2.2.2 Tool bar
The additional symbols in the tool bar indicate the actual
system status.
tool bar
2. Operation and function
2.1 Buttonsforadjustment
The controller is operated via the 3 push buttons below the
display.The forward-button (1) is used for scrolling forward
through the display menu or to increase the adjustment va-
lues.The backward-button (2) is similarly used for scrolling
backwards and reducing values.
In order to access the adjustment mode, scroll down in the
diplay menu and press the forward button (1) for approx.
2 seconds after you have reached the last diplay item. If an
adjustmentvalueis shown on the display, the „SEt“ icon
is displayed. Now, you can access the adjustment mode by
using button 3.
• Press buttons 1 and 2 in order to select a channel
• Briey press button 3, „SEt“ will ash
• Adjust the value by pressing buttons 1 and 2
• Briey press buttons 3, so that „SEt“ permanently
appears, the adjusted value will be saved.
2.2 System monitoring display
Complete Monitoring-Display
Symbol standard flashing
relay 1 active
tank maximum limitation
active / maximum tank
temperature exceeded
collector cooling function or
recooling function active
antifreeze- function activated collector minimum limitation
or antifreeze function active
collector emergency shutdown
or tank emergency shutdown
active
+ sensor defect
+ manual operation active
SET-mode, change of adjust-
ment value is possible

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The system screen (active arrangement) shows the scheme
which has been selected.The screen consists of several
system component symbols, which are - depending on the
current status of the system - either flashing, permanently
shown or „hidden“.
sensors
collector 1
pumps
additional symbol: opera-
tion of the burner
tank
tank heat exchanger tank 2 or after-heating (with
additional symbol)
tank top sensor
collectors
with collector sensor pump
tank 1 and 2
with heat exchanger
After-heating
with burner symbol
temperature sensor
2.2.3 System screen
system screen
green: everything OK
red/green flashing: initialisation phase
manual operation
red flashing: sensor fault
(sensor symbol is flashing quickly)
2.3 Flashing codes
2.3.2 LED flashing codes
2.3.1 System screen codes
•Pump symbols are flashing during initialisation phase
•Sensor symbols are flashing if the corresponding sensor
display channel is selected.
•Sensor symbols are flashing in the case of a sensor fault.
•Burner symbol is flashing if the after-heating is active

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3. Commissioning
Whenthecontrolleriscommissionendforthersttime,thearrangementhasto
be selected first
Overview of arrangements:
Arr 1 : standard solar system
1
3
2
backwards forwards
SET
(selection / adjustment mode)
Operation
control lamp
Arr 1
1.Switch on power supply. During the initialisation phase,
the operating control lamp flashes red and green. After
initialisation, the controller is in the automatic mode with
typical settings. The pre-programmed system scheme is
Arr 1.
2. - select adjustment channel Arr
- change to the -mode (see 2.1)
- select the arrangement via the Arr-index number
- save the adjustment by pressing the button
Now the controller is ready for operation with typical set-
tings to suit that system and normally the factory settings
will give close to optimum operation.

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4. Control parameters and display channels
4.1 Overview of channels
Legend:
x
Corresponding channel is available.
x*
Corresponding channel is available when the corresponding
option is enabled

Only if the option heat quantity measurement is activated
(OHQM), will the corresponding channel be available.
MEDT
Only if an antifreeze (MEDT) other than water orTyfocor
LS/G-LS(MEDT0or3) is used, will the channel anti-
freeze concentration (MED%) be displayed.

Only if the option heat quantity measurement is deactiva-
ted (OHQM), will the corresponding channel be available.
Please note:
Only if temperature sensors are connected, will S3 and S4
be displayed.
channel description page
COL x Temperature collector 1 11
TST x Temperature tank 1 11
TSTL x Temperature tank 1 base 11
TSTU x Temperature tank 1 top 11
S3 x Temperature sensor 3 11
TRF Temperature return sensor 11
S4 Temperature sensor 4 11
n % x Pump speed relay 1 11
h P x Operating hours relay 1 11
kWh Heat quantity kWh 12
MWh Heat quantity MWh 12
Arr 1 Arrangement 9
DT O x Switch-on temperature difference 13
DT F x Switch-off temperature difference 13
DT S x Set temperature difference 13
RIS x Rise 13
S MX x Maximum temperature tank 1 13
EM x Emergency temperature collector 1 14
channel description page
OCX x Option collector cooling collector 1 14
CMX x* Maximum temperature collector 1 14
OCN x Option minimum limitation collector 1 14
CMN x* Minimun temperature collector 1 14
OCF x Option antifreeze collector 1 14
CFR x* Antifreeze temperature collector 1 14
OREC x Option recooling 15
O TC x Option tube collector 15
OHQM x Option heat quentity measurement 12
FMAX Maximum flowrate 12
MEDT Antifreeze type 12
MED% MEDT Antifreeze concentration 12
nMN x Minimum pump speed relay 1 16
HND1 x Manual operation relay 1 16
HND2 x Manual operation relay 2 16
LANG x Language 16
UNIT x Change over °FAH / °CEL 16
PROG XX.XX Program number
VERS X.XX Version number

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4.1.1 Collector temperature
Display of the current collector temperature.
•COL : collector temperature (1-collector system)
COL:
Collector temperature
display range: -40 ...+482 °F
4.1.2 Tank temperatures
Display of the current tank temperature.
•TST : tank temperature (1-tank system)
•TSTL : tank base temperature,
• TSTU : tank top temperature
TST,TSTL,TSTU:
Tank temperatures
Display range: -40 ...+482 °F
4.1.3 Sensor 3 and sensor 4
Display of the current temperature at the corresponding
additional sensor (without control function).
•S3 : temperature - sensor 3
•S4 : temperature - sensor 4
Please note:
Only if the temperature sensors are connected (displa-
yed), will S3 and S4 be displayed.
S3,S4:
Temperatures at the sensors
S3 and S4
Display range: -40 ...+482 °F
4.1.4 Other temperatures
Display of the current temperature at the sensor.
•TR : temperature - return
TRF:
other measured temperatures
Display range: -40 ...+482 °F
4.1.5 Current pump speed
Display of the current pump speed of the corresponding
pump.
•n % : current pump speed (1-pump system)
n %:
current pump speed
Display range: 30 ...100 %
4.1.6 Operating hours counter
h P / h P1 /h P2:
Operating hours counter
Display channel
The operating hours counter accumulates the solar opera-
ting hours of the respective relay (hP/ h P1 / hP2). Full
hours are displayed.
The accumulated operating hours can be set back to zero.
As soon as one operating hours channel is selected, the sym-
bol is displayed. Press the SET (3) button for approx. 2
seconds in order to access the RESET-mode of the counter.
The display symbol will flash and the operating hours
will be set to 0. Confirm the reset with the button in
order to finish the reset.
In order to interrupt the RESET-process, do not press a
button for about 5 seconds. The display returns to the
display mode.

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4.1.7Heatquantitymeasurementoption
OHQM:Heat quantity
measurement
Adjustment range: OFF...ON
Factory setting: OFF
Heat quantity measurement is possible if a flowmeter is
used. For this purpose, the heat quantity measurement
option (OHQM)has to be enabled.
The flow rate should be read from the flowmeter (l/min)
and has to be adjusted in the channel FMAX. Antifreeze
type and concentration of the heat transfer medium have
to be adjusted in the channels MEDT and MED%.
Antifreeze type:
0 : water
1 : propylene glycol
2 : ethylene glycol
3 : Tyfocor®LS / G-LS
FMAX:
Flow rate in l/min
Adjustment range 0 ... 20
in 0,1-steps
Factory setting: 6,0
kWh/MWh: Heat quantity
in kWh / MWh
Display channel
MEDT: Antifreeze type
Adjustment range: 0...3
Factory setting: 1
MED%: Antifreeze concen-
tration (Vol-) %
When MEDT 0 or 3 is used,
the parameter MED% is
‚hidden‘.
Adjustment range: 20...70
Factory setting: 45
The flow rate as well as the reference sensors S1 (flow) and
S4 (return) are used for calculating the heat quantity sup-
plied. It is shown in kWh in the channel kWh and in MWh
in the channel MWh.The overall heat quantity results from
the sum of both values.
The accumulated heat quantity 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. Press
button SET (3) for about 2 seconds in order to access the
RESET mode of the counter. The display symbol will
flash and the heat quantity value will be set to 0. In order to
finish this process, press the button to confirm.
In order to interrupt the RESET process, no button should
be pressed for about 5 seconds.The controller automatically
returns to the display mode.

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4.1.8 ∆T-regulation
Please note: Switch-on temperature difference DO must
be at least 2 °Ra higher than the switch-off temperature-
difference DF.
DT O:
Switch-on temperature diff.
Adjustment range:
2,0 ... 40,0 °Ra
Factory setting: 12.0
DT F:
Switch-off temperature diff.
Adjustment range
1,0 ... 38 °Ra
Factory setting 8.0 °Ra
4.1.9 Maximum tank temperature
If the adjusted maximum temperature is exceeded, the tank
will no longer be loaded in order to avoid damage caused by
overheating. If the maximum tank temperature is exceeded,
will be shown.
Please note:The controller is equipped with a tank emer-
gency shutdown function,which prevents the tank from being
loaded when the tank temperature exceeds 295°F.
S MX:
Maximum tank temp.
Adjustment range:
-40 ... +480 °F
Factory setting: 140 °F
DT S:
Set temperature difference
Adjustment range:
3,0..60,0 °Ra
Factory setting: 20.0 °Ra
RIS:
Rise
Adjustment range:
2 ... 40°Ra
Factory setting: 4 °Ra
This function is a standard differential control. If the switch-
on differential is reached (DT O),the pump is operated.The
pump runs at 100% speed for 10 seconds.After this period,
the pump runs at minimum pump speed (nMN= 30 %). If
the temperature difference reaches the adjusted set value
(DT S), pump speed will increase by one step (10%). If the
difference increases by 2 K (RIS), pump speed will increase
by 10 % respectively until the maximum pump speed of 100
% is reached.The response of the controller can be adapted
via the parameter „Rise“. If the temperature difference falls
below the adjusted switch-off temperature difference
(DT F), the controller switches off.

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CMN:
Minimum collector tempe-
rature
Adjustment range:
14 ... 195 °F
Factory setting: 50 °F
CMX:
Collector maximum temp.
Adjustment range:
210 ...380 °F
Factory setting: 250 °F
4.1.11System cooling When the adjusted maximum tank temperature is reached,
the system stagnates. If the collector temperature increases
to the adjusted maximum collector temperature (CMX),
the solar pump is activated until the collector temperature
falls below the maximum collector temperature.The tank
temperature may increase (subordinate active maximum
tank temperature), but only up to 203 °F (emergency shut-
down of the tank).
OCX:
System cooling option
Adjustment range: OFF ... ON
Factory setting: ON
4.1.12 Minimum collector function
OCN:
Mimimum collector function
Adjustment range: OFF / ON
Factory setting: OFF
The minimum collector temperature is the minimum
temperature which must be exceeded for the solar pump
(R1) to switch on.The minimum temperature prevents the
pump from being switched on too often at low collector
temperatures. If the temperature falls below the minimum
temperature, (flashing) is shown on the display.
CFR:
Antifreeze temperature
Adjustment range:
14 ...50 °F
Factory setting: 40 °F
4.1.13 Antifreeze function
OCF:
Antifreeze function
Adjustment range: OFF / ON
Factory setting: OFF
The antifreeze function activates the loading circuit between
the collector and the tank when the temperature falls below
the adjusted antifreeze temperature. This will protect the
fluid against freezing or coagulating. If the adjusted antifreeze
temperature is exceeded by 2 °F, the loading circuit will be
deactivated.
Please note:
Since this function uses the limited heat quantity of the tank,
the antifreeze function should be used in regions with few
days of temperatures around the freezing point.
4.1.10 Collector emergency shutdown
temperature
If the adjusted collector emergency shutdown temperature
(EM) is exceeded, the controller will switch off the solar
pump (R1) in order to protect the system against overheating
(collector emergency shutdown). The factoring setting is
285 °F but it can be changed within the adjustment range of
230 ...400 °F. (flashing) is displayed.
EM:
Collector emergency shut-
down temperature
Adjustment range:
230 ... 400 °F
Factory setting: 285 °C
If OREC is additionally enabled: If the tank temperature is higher than the maximum tank
temperature (S MX) and if the collector temperature is at
least 10 °Ra below the tank temperature, the solar system
remains activated until the tank is cooled down below the
adjusted maximum temperature (S MX) via the collector
and the pipework.
If the system cooling function is enabled, (flashing) is
shown on the display. Due to the cooling function, the sy-
stem will have a longer operation time on hot summer days
and guarantees thermal relief of the collector field and the
heat transfer fluid.

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4.1.15 Tube collector function If the controller detects an increase in collector temperature
by 4 °Ra compared to the previously stored collector
temperature, the solar pump will be switched-on at
100 % for about 30 seconds in order to detect the fluid
temperature. The current collector temperature will be
saved as a new reference value.If the measured temperature
(new reference value) is exceeded by 4 °Ra, the solar pump
will run for 30 seconds. If the switch-on difference between
the collector and the tank is exceeded during the runtime of
the solar pump or the standstill of the system,the controller
will automatically switch to solar loading.
If the collector temperature deacreases by 4 °Ra during
standstill, the switch-on value for the tube collector function
will be recalculated.
O TC:
Tube collector function
Adjustment range:
OFF ...ON
Factory setting: OFF
4.1.14 Recooling function If the adjusted maximum tank temperature (S MX) is
reached, the controller keeps the solar pump running in
order to prevent the collector from being overheated.
The tank temperature may increase but only up to 203 °F
(emergency shutdown of the tank).
The solar pump is switched on once the collector
temperature is lower than the tank temperature. It is
switched off when the tank is cooled down to the adjusted
maximum temperature via the collector and the pipework.
OREC:
recooling function option
Adjustment range:
OFF ...ON
Factory setting: OFF

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For control and service work, the operating mode of the
controller can be manually adjusted. For this purpose, select
the adjustment value HND1 / HND2.The following adjust-
ments can be carried out:
4.1.17 Operating mode
• HND1 / HND2
Operating mode
OFF : relay off (flashing) +
AUTO : relay in automatic operation
ON : relay on (flashing) +
HND1 / HND2:
Operating mode
Adjustment range:
OFF,AUTO, ON
Factory setting:AUTO
4.1.16 Pump speed control
A relative minimum pump speed is allocated to the output
R1 via the adjustment channel nMN.
Attention:
Whenloadswhicharenotspeedcontrolled(e.g.
valves)areused,thevaluemustbechangedto100%
in order to deactivate pump speed control.
nMN:
Pump speed control
Adjustment range: 30 ...100
Factory setting: 40
4.1.18 Language
In this channel, different languages are available.
• dE : German
•En : English
• It : Italiano
• Fr : French
LANG:
Language choice
Adjustment range:
dE, En, It, Fr
Factory setting: En
4.1.19Unit
The menu unit can be adjusted:
• °FAH
•°CEL
UNIT:
Adjustment of unit
Adjustment range: FAH, °C
Factory setting: FAH

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5.Troubleshooting
fuse T4A If a malfunction occurs, a message is displayed in the display
of the controller:
Operating control lamp
Warning symbol
Operating control lamp off
Check the power supply
o.k.
The fuse of the controller could be blown.
It can be replaced after the front cover
has been removed (spare fuse is enclosed
in the accessory bag).
Operating control lamp flashes red.The symbol and
the are shown.
Sensor fault. An error code instead of
a temperature is shown on the sensor
display channel.
-88.8888.8
Cable is broken.
Check the cable.
Short-circuit.
Check the cable.
Disconnected Pt1000 temperature sensors
can be checked with an ohmmeter. In the
following table, the resistance values
corresponding to different temperatures
are listed.
°F Ω°F Ω
14 961 131 1213
23 980 140 1232
32 1000 149 1252
41 1019 158 1271
50 1039 167 1290
59 1058 176 1309
68 1078 185 1328
77 1097 194 1347
86 1117 203 1366
95 1136 212 1385
104 1155 221 1404
113 1175 230 1423
122 1194 239 1442
Resistance values of the
Pt1000-sensors

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Pump starts for a short moment, switches-on/off
again,etc.
Is the temperature diffe-
rence at the controller
too small?
no yes
Wrong position of the
collector sensor?
yes
Change∆Ton and ∆Toff
correspondingly.
Mount the collector sen-
sor at solar flow (warmest
collector output); use the
immersion sleeve of the
respective collector.
Pump starts up very late.. The temperature difference between the tank and the coll-
ector increases enormously during operation;the collector
circuit cannot divert the heat.
Collector circuit pump
defective ?
no yes
Heat exchanger calcified?
yes
Check / replace it
Decalify it
no
Heat exchanger blocked?
yesno
Clean it
Heat exchanger too
small?
yes
Repalce with correctly
sized one
no
Plausibility control of the
tube collector function
Change∆Ton and ∆Toff
correspondingly
Switch-on-temperature
difference ∆Ton too
large?
no yes
Non-ideal position of coll-
ector sensor (e.g. flatscrew
sensor instead of sensor in
immersion sleeves?)
o.k.no
Pump is overheated, but no heat transfer from the colle-
ctor to the tank, flow and return have the same tempe-
rature; perhaps also bubble in the lines
Vent the system; increase
system pressure to at
least static primary pres-
sure plus 0,5 bar; if neces-
sary increase the pressure,
switch the pump on and
off for a short time
Air in the system?
no yes
Is the collector circuit
blocked at the dirt trap?
yes
Clean the dirt trap
5.1Various:
Activate tube collector
function if necessary.
yes
o.k.

© 08140 isolar2.monus.indd
19 |
Tanks cool down at night.
Does the collector
circuit pump run in the
night?
no yes
Check controller.
At night, the collector
temperature is higher
than the outdoor tem-
perature.
no yes
Check the non-return
valve in flow and return
pipe with regard to the
functional efficiency.
Sufficient tank insulation?
yes no Increase insulation.
Insulation close enough
to the tank?
yes no
Replace insulation or in-
crease it.
Are the tank connections
insulated?
yes no Insulate the connections.
Warm water flow up-
wards?
no yes
Change connection and
let the water flow side-
wards or through a siphon
(bow downwards); less
tank losses now?
Does warm water circu-
lation run for a very long
time?
no yes
Use the circulation pump
with timer and switch-off
thermostat (energy effi-
cient circulation)
The solar circuit pump does not run although the collector
is significantly warmer than the tank.
Does the control LED
flash?
yes no
Does the pump start up
in manual operation?
yes
No current; check fuses
/ replace them and check
power supply.
The adjusted temperature
difference for starting the
pump is to high; choose a
value which makes more
sense.
no
Is the pump current re-
leased by the controller?
yes
Is the pump stuck?
Turn the pump shaft using
a screwdriver; now pas-
sable?
Pump is defective - re-
place it
Are the controller fuses
o.k.?
Controller might be de-
fective - replace it.
no yes
no
no yes
Replace the fuses.
Circulation pump and
blocking valve should be
switched-off for 1 night;
less tank losses?
yes no
Check whether the pumps
of the after-heating cir-
cuit runs at night, check
non-return valve; problem
solved?
no
no yes
o.k.
Check the non-return
valve in warm water cir-
culation- o.k.
yes no
Further pumps which are
connected to the solar
tank must also be che-
cked.
The gravity circulation in
the circulation line is too
strong; insert a stronger
valve in non-return valve
or an electric 2-port val-
ve behind the circulation
pump; in pump operation,
the 2-port valve is open,
otherwise it is closed, co-
nect pump and 2-port
valve in parallel; activate
circulation again!
Clean or replace
a
a b
b

© 08140 isolar2.monus.indd
|20
Distributed by: CALEFFINORTHAMERICA,Inc.
3883 W. Milwaukee Rd.
Milwaukee,WI 53208
Tel.: [phone]
Fax: [phone]
www.caleffi.us
sales@caleffi.com
6.Accessory
Overvoltage protection device
In order to avoid overvoltage damage at collector sensors
(e.g. caused by local lightning storms), we recommend in-
stalling the overvoltage protection SP1.
Sensors
Our product range includes high-precision platin tempe-
rature sensors, flatscrew sensors, outdoor temperature
sensors, indoor temperature sensors, cylindrical clip-on
sensors and irradiation sensors, also as complete sensors
with immersion sleeve.
Flowmeter
If you wish to carry out a heat quantity measurement,
you need a flowmeter for measuring the flow rate in your
system.
Please note:
The design and the specifications can be changed without prior notice.
The illustrations may differ from the original product.
Reprinting / copying
This mounting- and operation manual including all
parts is copyrighted. Another use outside the copy-
right requires the approval of CALEFFI NORTH AME-
RICA, Inc.. This especially applies for copies, translations,
micro films and the storage into electronic systems.
Editor: CALEFFI NORTH AMERICA, Inc.
Important notice:
We took a lot of care with the texts and drawings of this
manual and to the best of our knowledge and consent.As
faults can never be excluded, please note:Your own calcu-
lations and plans, under consideration of the current stan-
dards and DIN-directions should only be basis for your
projects.We don´t offer a guarantee for the completeness
of the drawings and texts of this manual - they only repre-
sent some examples. They can only be used at your own
risk. No liability is assumed for incorrect, incomplete or
false information and / or any resulting damages.