Consolar CONTROL 602 User manual

TDMA CONTROL 602-702 Eng Nov.doc
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CONTROL 602/702/
CONTROL 602/702/
TR
TR- -CONTROL II Touch CONTROL II Touch
The Solar and Heating Controllers
The Solar and Heating Controllers
Operating Instructions
Solar:
•Solar Control with Stratification Logic
•New: Operation of Solar Pump under partial shade conditions
•Capture the solar yield with or without a flow meter
•New: East / West with two pumps
•Cooling Function
•Control for two thermal stores
•Swimming pool function
Boiler control and integration:
•New: single-stage or modulating control of the boiler (power or
temperature)
•Solid fuel boiler control
•Return temperature raising or boiler buffering
Heating systems:
•Control of up to 3 heating circuits with the CONTROL 702
•New: screed drying function
Hot water system:
•New: Programmable timer for 3 hot water temperatures: set back /
normal / extra comfort
•Circulation control schedule
Additional Functions:
•Multi-functional Temperature differential Controller
•Multi-functional Temperature Switch
•New: Holiday mode allows disabling of auto-heating & dhw for a set
period of days
•New: service engineer’s telephone number can be stored and
displayed in the event of a fault occurring
•New: Data logger, Parameter storage and operating system update via
SD Card
•Optional: Remote control and room thermostat function through the
use of the TR-CONTROL 2 Touch
•Display texts in four languages
Note: The features available differ between both variants (see Function
Table).
The CONTROL 602 / 702 series are general-
purpose solar and heating controller with a range
of features for high energy-efficient operation of
the system.
For boiler and heating systems in old and new
buildings, the efficient operation is due to the large
range of functions available. The majority of
commercially available boilers, even modulating
boilers can be operated via the CONTROL 602 /
702.
The SD Card captures data, stores it and uploads
the setting in case of problems occurring. The data
can be transferred to other systems or remote
access to the plant can be achieved via a standard
LAN interface and web portal.

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1GENERAL INFORMATION 3
1.1 Information on the Documentation 3
1.2 Storgae 3
1.3 Symbols 3
1.4 Limitation of Liability 4
1.5 Copyright Protection 4
1.6 Warranty Provision 4
1.7 Support and Customer Service 4
1.8 CE –Declaration of Conformity 4
2SAFETY 5
2.1 Special Hazards 5
2.2 Conduct in Emergency Situations and Accidents 5
3TECHNICAL DATA 6
3.1 Technical Data CONTROL 602 6
3.2 Technical Data CONTROL 702 7
3.3 Technical Data TR-CONTROL II Touch 7
4OPERATION 8
4.1 Structure 8
4.2 Explanation of Symbols 8
4.3 Assisgnment of the Control Buttons 8
4.4 Menu Structure 9
4.5 Operation of the TR-CONTROL II Touch 10
5FUNCTIONS AND SETTINGS 11
5.1 Display Values (Temperature and Calculated Values) 11
5.2 Variant Options 11
5.3 Functions Error! Bookmark not defined.11
5.4 Solar system Operation Function (Solar Input) 14
5.5 Yield Measurement (Calculated Input) 18
5.6 Hot Water Operation Function (Water Input) 20
5.7 Heating System Operation Functions (Heating Input) 24
5.8 Boiler Control Function (Boiler Input) 30
5.9 T-PRO / T-PRO 2 / T-PRO 3 35
5.10Holiday Function 36
5.11Service Menu 37
5.12Firmware (Software) Updates via SD-Card 39
5.13CONTROL 602: Sample Variant A 41
5.14CONTROL 602: Sample Variant B 44
5.15CONTROL 702: Sample 48
5.16TR-CONTROL II Touch Special Functions 52
6ASSEMBLY CONTROL 602 54
6.1 Mounting of the CONTROL 602 54
6.2 Electrical Connections CONTROL 602 55
7ASSEMBLY CONTROL 702 59
7.1 Mounting of the CONTROL 702 59
7.2 Electrical Connections CONTROL 702 62
8ASSEMBLY AND OPERATION OF THE TR-CONTROL II TOUCH 66
8.1 Wiring up the TR-CONTROL II Touch 66
8.2Mounting the TR-CONTROL II Touch 66
8.3 Electrical Connections TR-CONTROL II Touch 67
8.4 Operation 68
9FAULT AND FUNCTION CHECK 69
9.1 Solar Control without Additional Functions 69
9.2 Solar Control with Active Frost Protection 69
9.3 Solar Control with Two Thermal Stores 70
9.4 Solar Control with Heating Function 71

TDMA CONTROL 602-702 Eng Nov.doc
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1General Information
In this technical documentation, the installation and operating instructions are the
‘Original Instructions’.
1.1 Information on the Documentation
This documentation provides information on installation and instructions for the use
and operation of the system. Conditions for safe operation, compliance with all
specified safety and handling instruction.
1.2 Storage
This document should be handed over to the owner of the system after successful
commissioning. It should remain with the owner and be made available for future
servicing and maintenance requirements of the system.
1.3 Symbols Used
-> WARNING NOTICES
DANGER!
Indicates an imminent hazardous situation, which leads to death or serious injury f not
avoided.
WARNING!
Indicates an imminent hazardous situation that can result in death or serious injury if
not avoided.
CAUTION!
Indicates an imminent hazardous situation that can lead to minor injuries, if not
avoided.
Attention!
Indicates an imminent hazardous situation that can lead to property damage if not
avoided.
-> TIPS AND ADVICE
NOTE!
Highlights useful tips and advice with recommendations for efficient and trouble-free
operation.
-> SPECIAL PRECAUTIONS
Risk of Electric Shock
Fall Risk – if necessary, wear a safety belt or wear appropriate protective clothing.

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1.4 Limitations of Liability
All information and instructions in this document have been compiled in accordance
with the applicable standards and regulations, plus our many years of experience.
The manufacturer assumes no liability for damages due to:
•Failure to follow the documentation
•Improper use
•Installation by non-trained personnel
•Unauthorised modification
•Use of unauthorised replacement parts
The actual scope of delivery can differ from the descriptions and illustrations given
here in case of special designs, additional ordering options or the latest technical
changes.
1.5 Copyright Protection
Copyright laws protect the content of information, text, illustrations and other
depictions. Any further use requires the approval of Consolar. Any unauthorised use
is forbidden and will lead to legal proceedings being implemented.
1.6 Warranty Provision
The warranty terms are in the separate document ‘Consolar warranty certificate’ and
in the price list.
1.7 Support and Customer Service
Technical information is available from the specialist companies we support.
Technical Support:
01452 772035
1.8 CE – Declaration of Conformity
We, Consolar Solare Energiesysteme GmbH, declare under sole responsibility that
the product CONTROL 602 and CONTROL 702 with the following standards:
2004/108/EG (EMC Directive)
DIN EN 61326-1; DIN EN 61326-2-2; DIN EN 55011; DIN EN 61000-3-2;
DIN EN 61000-3-3; DIN EN 61000-4-2; DIN EN 61000-4-3; DIN EN 61000-4-4;
DIN EN 61000-4-5; DIN EN 61000-4-6; DIN EN 61000-4-11
2006/95/EG (Low Voltage Directive)
DIN EN 61010-1

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2Safety
Please read the following instructions for installation and commissioning carefully
before you start installing the equipment and putting into operation. This will prevent
damage to the plant, which can result from improper handling. All work must be
carried out in accordance with relevant local and VDE guidelines by authorised
personnel only.
2.1 Special Hazards
DANGER of Electric Stock!
In case of contact with live components there is immediate danger to life. Damage to
the insulation or components can be fatal.
Therefore:
•If damage has been caused to the insulation, turn off the power immediately
and arrange for repair.
•Work on electrical systems should only be undertaken by suitably qualified
electricians.
•Before doing any work on electrical systems, check that the system is isolated
and safe.
•Ensure the fuse is not bypassed or the system overridden. When replacing
fuses, ensure the correct amperage fuse is used.
•Keep all moisture away from live parts, as this can cause short circuits.
2.2 Conduct in Emergency Situations & Accidents
Preventive measures
•Always be prepared for any accidents or fires that may arise.
•Have first-aid equipment and fire extinguishers handy.
•Personnel should familiarise themselves with first aid equipment and rescue
facilities.
•All access routes should be kept clear for emergency vehicles.
Correct action in case of
emergency
•Switch off plant immediately.
•Initiate first aid if required.
•Remove persons from danger.
•Inform Site Manager.
•Raise the fire alarm and/or medical assistance.
•Make sure access routes are clear for emergency vehicles.

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3Technical Data
3.1 Technical Data CONTROL 602
Base Unit:
Plastic housing 235 x 170 x 75 mm
Protection:
IP 20
Operating Voltage:
230 V ±10%, 50 Hz, AC
Power Consumption:
max. 10 W
Ambient Temperature
0°C...40°C
Outputs / Inputs
Switching Outputs
A1…A7: Semi-conductor Triac 230V, max. 2A, Fused with glass fuse 3
x15A slow blow, only suitable for the loads
Switch
A8: potential-free changeover relay, max. 240 V, max. 2A, not
protected
Analogue Outputs 1...2
a.) 0V ... 10V, minimum load resistance 1 kOhm
b.) PWM, max. 1 kHz, minimum load resistance 1 kOhm
Analogue Inputs ES
0V...10V, Load resistance 10 kOhm, resolution 10 Bit
supply voltage: 18V...24V, max. 100mA
Digital Inputs D1,D2
a.) Potential-free contacts
b.) Open Contact: low < 10V, high > 14V
Supply voltage: 18V...24V, max. 100mA
Ethernet interface
10/100 BASE-T
Temperature sensor inputs
10 x RTD Type Pt1000, Class B
Scale range: -40°C ... 350°C
Measuring range: -20°C ... 150°C
Accuracy in measuring range: +/- 1°C
Operation:
Menu driven
Service menu:
Each output can be switched manually.
Temp. in
°C
-10
0
10
20
30
40
50
60
70
80
90
100
110
R in Ohm
961,5
1000
1038,5
1077
1115,5
1154
1192,5
1231
1269,5
1308
1346,5
1385
1423,5
Note:
The details and advice in the Technical Documentation do not claim to be
comprehensive and are not a replacement for professional planning. Errors and
omissions accepted.

TDMA CONTROL 602-702 Eng Nov.doc
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3.2 Technical Data CONTROL 702
Base unit:
Plastic housing, ca. 235 x 170 x 130 mm
Protection:
IP 20
Operating Voltage:
230 V ±10%, 50 Hz, AC
Power consumption:
max. 10 W
Ambient temperature:
0°C...40°C
Output / Input:
Switching outputs:
A1…A17: Semi-conductor Triac 230V, max. 2A, fused with glass fuse 3
x 15A slow blow, only suitable for the loads
Switch:
A18…A19: potential free changeover relay, max. 240 V, max. 2A,
not protected
Analogue outputs 1...6
The Analogue outputs 3…6 are not used
a) 0V ... 10V, ± 5 %, minimum load resistance 1 kOhm
b) PWM, max. 1 kHz, minimum load resistance 1 kOhm
Analogue inputs ES
0V...10V, load resistance 10 kOhm, resolution 10 Bit
supply voltage: 18V...24V, max. 100mA
Digital inputs D1…D6
a) potential free contacts
b) Open Contact: low < 10V, high > 14V
supply voltage: 18V...24V, max. 100mA
Ethernet interface
10/100 BASE-T
Temperature sensor inputs
24 x resistance temperature sensors Type Pt1000, class B
Scale range: -40°C ... 350°C
Measuring range: -20°C ... 150°C
Accuracy in measuring range: +/- 1°C
Operation:
Menu driven
Service menu:
Each output can be switched manually.
Temp. in
°C
-10
0
10
20
30
40
50
60
70
80
90
100
110
R in Ohm
961,5
1000
1038,5
1077
1115,5
1154
1192,5
1231
1269,5
1308
1346,5
1385
1423,5
3.3 Technical Data TR-CONTROL II Touch
Base unit:
Plastic housing, ca. 132 x 90 x 21 mm
Protection:
IP 20
Power Input
Max. 2 W
Ambient temperature:
0°C...40°C
Room sensor accuracy
+/- 0.5 oC (with wall compensation)
Note:
The details and advice in the technical documentation do not claim to be
comprehensive and are not a replacement for professional planning. Errors and
omissions excepted

TDMA CONTROL 602-702 Eng Nov.doc
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4Operation
4.1 Structure
Display
Control Buttons
Status Indicators
Slot for SD-Card
Name plate with Serial Number
4.2 Explanation of Symbols
* LED Solar pump: Light On = Solar pump running; Light Flashing = Solar pump in intermittent mode (see 5.4.2)
4.3 Assignment of the Control Buttons
/ Forwards & Backwards within a Menu Option
Return to Previous Screen
Confirming Entry (Enter) or Change in Menu Offered
/ Increase/ Decrease/ Change of Parameters
Simultaneously pressing the and -> for Main MenuThe display values
flashes after it has been changed and by pressing will confirm the value
and store it.
Operating
Solar Pump *
East - West
Frost Protection
T-PRO
T-PRO 2
Fault
∇Submenu available (Press Enter Key)
Circulation Pump
Heating Requirement
Heating & Hot Water in Auto Mode
Hot Water in Auto Mode: Heating is Turned Off
Depending on the operational state the
following symbols may be displayed here:
SD Card is inserted
eingesteckt
Network connection exists
aktiv
Connection active to remote site
Circle –Professional menu / no circle –end
user menu

Hot Water Requirement

TDMA CONTROL 602-702 Eng Nov.doc
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4.4 Menu Structure
Note:
Only qualified personnel should do the input of the system parameters.
The chart below shows an example of the CONTROL 602, Version A menu structure.
Main menu
Sub menu
!"#$%!&$'%%%%%%%%%%%()*+,%
-.*%/0%1%%%%%%%%%%-2*%30%1%
Simultaneously
Press the
and
!"#$%!&$'%%%%%%%%%%()*+,%
-&45&6"7'6&8%
Setting Values:
/ and
with to
confirm.
!"#$%!&$'%%%%%%%%%%()*+,%
9":;%<":'&8%
*
!"#$%!&$'%%%%%%%%%%()*+,%
<"6#"$78%
Change to Sub
Menu
<"6#"$7%%%
%%%%%=%
*
!"#$%!&$'%%%%%%%%%%()*+,%
>&7%>?:"6%
*
!"#$%!&$'%%%%%%%%%%()*+,%
>&7%@?7%A"7&6%
Next Menu:
>76"7#B#;"7#?$%
C'$;7#?$*%%%%%%%%%%%%%%='7?%
*
!"#$%!&$'%%%%%%%%%%()*+,%
>&7%9":;%<":'&8%
=DD#7#?$":%C'$;7#?$%(%
E#&:D%
!"#$%!&$'%%%%%%%%%%()*+,%
>&7%@&"7#$F%
Previous Menu:
=DD#7#?$":%C'$;7#?$%)%
9??:#$F%
@?:#D"G8*%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%0%%%H"G%I8J%
=DD#7#?$":%C'$;7#?$%+%
@?7%A"7&6%9K"6F&%
Next Menu:
!"#$%!&$'%%%%%%%%%%()*+,%
>&6L#;&%
=DD#7#?$":%C'$;7#?$%,%
9#6;':"7#?$%
=DD#7#?$":%C'$;7#?$%3%
M?%C'$;7#?$%
=DD#7#?$":%C'$;7?$%/%
M?%C'$;7#?$%
>&:&;7%C'$;7#?$%(%
N?#:&6%O6&%@&"7%
Previous Menu:
>&:&;7%C'$;7#?$%)%
P"87QA&87%)%O'458%
>&:&;7%C'$;7#?$%+%
M?%C'$;7#?$%
Return to Previous Menu:
>&:&;7%C'$;7#?$%,%
M?%C'$;7#?$%
>?:"6%#$%4"R%
L#"*%E#&:D%>&$8?6%

TDMA CONTROL 602-702 Eng Nov.doc
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4.5 Operation of the TR-CONTROL II Touch
4.5.1 General Operations
Status Bar (The area aove the display screen)
Display-Screen
Info Bar (The area between the display screen and keypad)
Buttons
Buttons:
Back & forth within a menu
Back one menu level
Confirmation of entry (Enter) or change in the menu offered
Increase/ decrease/ change the parameters
Touching this area returns you to the main menu
Status Bar:
The following information is displayed here:
Top Right: = in Professional Menu - No O = Customer Menu
Top Left: X (red cross) = Fault - No X = No Fault
Info Bar:
The display shows the symbols below showing the operating conditions:
∇Submenu available (press Enter key)
After changing a value the figure flashes and an exclamation mark appears above the
enter button. On pressing the Enter button, the value is confirmed and saved. A green
tick appears above the enter button to show confirmation of the change.
SD Card inserted
Network connection exists
Connection active to remote site