Consolar CONTROL 602 User manual

TDMA CONTROL 602-702 Eng Nov.doc
1
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.

TDMA CONTROL 602-702 Eng Nov.doc
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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.

TDMA CONTROL 602-702 Eng Nov.doc
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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

TDMA CONTROL 602-702 Eng Nov.doc
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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.

TDMA CONTROL 602-702 Eng Nov.doc
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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
10
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

TDMA CONTROL 602-702 Eng Nov.doc
11
5Functions and Settings
5.1 User Levels
The controller has two user levels:
1. End User Level: – Delivery of the controller is in this menu level. The setting of all
necessary everyday items (eg. Hot water target temp, timers, room temperature, etc)
occurs in this level.
2. Professional Level: - To enable this menu the code 3003 must be inputed (Service
menu, Authorised – Service Menu section 5.11). The setting of all menu items (eg. Plant
variant, circuit paramenters, boiler parameters, etc.) occurs in this menu level. 30
minutes after the last entry, the controller automatically switches to the End User level.
5.2 Display values (Temperature and calc. values)
!"#$%!&$'%%%%%%%%%%%%%%%%()*+,%
-&45&6"7'6&%L":'&8%
Shows all measured temperatures, such as collector and store temperatures including
store top min/max temperatures.
!"#$%!&$'%%%%%%%%%%%%%%%%()*+,%
9":;%L":'&8%
Shows the various calc values, such as power, performance, and operation hours.
5.3 System Variants and Functions
!"#$%!&$'%%%%%%%%%%%%%%%%()*+,%
<"6#"$78%
With the CONTROL 602 the selection of the appropriate system variant must be chosen.
The CONTROL 602 is factory set to Variant A.
The CONTROL 702 only has one variant.
The menu system variants can only be set in the Professional menu (see Section 5.1)
%<"6#"$7%
=%S%N%
The variant required must be choen before any other setting on the CONTROL 602 can
be set. See table on page 12 for the functions available for each variant.
Basic function (Solar control): is always active; permantly set.
Additional function (e.g. radiation measurement): optional activatable. The
corresponding temperatures or settings only appear on the display when the feature is
activated.
Select function: Functions can be selected and activated between several different
functions.
=DD#7#?$":%C'$;7#?$*%
%
The particular function can be activated. If it is not required, it has ‘no effect’ and can
be set so that no sensor fault is reported. Refer to controller for connection details (See
section 5.13, 5.14 and 5.15)
>&:&;7%C'$;7#?$*%
%
With each ‘Select function’ only one function can be selected, the others will not be
active. See Variant A & B function list chart (section 5.13, 5.14 und 5.15).

TDMA CONTROL 602-702 Eng Nov.doc
12
5.3.1 Function Overview CONTROL 602 / 702
CONTROL 602
Variant A
CONTROL 602
Variant B
CONTROL 702
Solar
Solar pump with or without top
loading (Stratification function*9)
East-West with 2 Pumps*2
Yield measurement
Radiation measurement
Active frost protection
Two stores (priority, equal
priority) swimming pool*2
*1
*1
Cooling
Cooling with heating circuit
*3
Hot Water
DHW heating with separate
output
Circulation
Circulation and bath button
*7
*8
*6
Boiler
Boiler control for hot water and
heating
Heating
Pump control for boiler and store
Heating Circuits
Heating mixing valve Circuit 1
Heating mixing valve Circuit 2
Heating mixing valve Circuit 3
Buffer logic
Return temperature raising
T-Control
T-PRO
T-PRO 2
T-PRO 3
Solid fuel boiler
Solid fuel boiler with temperature
differential control
Quantity of heat
detection
Heat meter 1
Heat meter 2
Heat meter 3
Flow meter for measuring solar
output *4
Thermostat (TR-Touch) Htg circ 1
Thermostat (TR-Touch) Htg circ 2
Thermostat (TR-Touch) Htg circ 3

TDMA CONTROL 602-702 Eng Nov.doc
13
*1Only when cooling is possible, *2East/West with 2 Pumps and Swimming pool cnnot be activated together, *3 Only heating circuit is activated, *4
Only activated if heating circuit flow meter is available, *5Not available for East/West with 2 Pumpsh, *6Only available if the circulation is activated,
*7Only available when the circulation function and hot water function are activated by a remote control, *8Only possible when circulation function
and boiler control are enabled
= Basic function: always active
= Additional function: can be activated
= Select function 1 (one function can be activated) = Select function 4 (one function can be activated)
= Select function 2 (one function can be activated) = Select function 5 (one function can be activated)
= Select function 3 (one function can be activated) = Select function 6 (one function can be activated)
= Select function 7 (one function can be activated) = Select function 8 (one function can be activated)
= Select function 9 (one function can be activated) = Select function 10 (one function can be activated)
= Select function 11 (one function can be activated)
>76"7#B#;"7#?$%%
C'$;7#?$*%%='7?%S%2$%S%2BB%
Auto: Stratification function with automatic switching to solar winter operation.
On: Stratification function without automatic switching to solar winter
operation.
Off: Simple differential temperature control, e.g. for store without stratified
solar load.
For explanation of stratification function, see section 5.4.2.
Note: Stratification function ‘AUTO’ is possible in Variant A only if the heating
return temperature raising is activated.
Stratification function cannot be activated in ‘East-West with 2 pumps’
(automaticall set to off)!
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>&$8?6%%
Yield Measurement: to enable, select ‘Yield Sensor’ in the menu and then
activate.
Via collector sensor: the maximum allowable collector fluid temperature
(110...115 °C) that can enter the solar heat exchanger is calculated from the
store bottom temperature.
Via yield sensor: The maximum temperature that may occur in the solar heat
exchanger is measured at the yield sensor (heat exchanger inlet). The solar
pump will shut down when the temperature exceeds 100 °C at the yield sensor
or 140 °C at the collector sensor.
H@A%N";TQ'5%K&"7#$F%L#"%%%
9?$76?:%%%%%%%%%%%E&8%S%M?%
%
Hot water back-up heating should be controlled by using the CONTROL 602 /
702 ‘Return Temperature Raising’ function. The back-up heating option should
be set to ‘Yes’. During the heating of the hot water standby component the
return temperature raising (3-way diverter valve) is interrupted, to prevent a
hydraulic short-circuit. The interruption of Return Temperature Raising also
occurs during the summer operation.

TDMA CONTROL 602-702 Eng Nov.doc
14
5.4 Functions to Operate the Solar System (Solar Input)
!"#$%!&$'%%%%%%%%%%%()*+,%
>&7%>?:"6%
%
The microprocessor-controlled controller CONTROL 602 and CONTROL 702
are designed for optimum functionality and reliability of the Consolar solar
systems. Even for solar systems with other stores, these controllers can be
used. The controls allows for intelligent use of differing insolation and weather
conditions by automatically switching between three operating levels
depending on the solar loading..
5.4.1 Solar Pump Operation
9?::&;7?6%%%%%%%%%%E&8S%M?%
-'U&%C'$;7#?$%
This function allows the solar system to start, for example, with a temporarily
shaded collector. During this start-up period, the solar pump is switched
cyclically on and off for an adjustable duration.
%-?%>'U4&$'V%
If above was ‘Yes’ then you get the option by pressing the down arrow to go
to a submenu, where the following functions can be set or adjusted.
>7"67*%%%%%%%%%%%0W*00%K6%
-'U&%C'$;7#?$%
P$D*%%%%%%%%%%%%%0X*00%K6%
-'U&%C'$;7#?$%
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Z'$%-#4&%
[%Y%)0%>&;%
5.4.2 Operation of the Solar pump
Top Loading (Stratification Function): In good weather conditions, the full flow
of solar-fluid is only circulated without interruption once the collector reaches a
set minimum temperature (top loading temperature). The top loading
temperature is calculated automatically by the CONTROL 602 / 702 (DHW set
temperature + 5 K). The hysteresis is set at the factory with 2 K. The hot water
is then stratified loaded at the top of the Consolae store at a temperature 2..5
K lower.
Intermittent Operation: If there is not enough solar irradiation to heat the
collector on top loading, the controller switches on to intermittent operation.
That is, the CONTROL 602/702 waits a certain time, while the collector heats
up. This state is indicated by a flashing LED ‘Solar Pump’. After this fixed
period, it switches on the solar pump, unless during this period the solar
irradiation has increased and has reached the top loading setting and has
already started the solar pump. The run-time of the solar pump during
intermittent operation should be the length of time it takes to circulate the fluid
once through the system. In the Consolar store this lower temperature water is
automatically directed to the middle or lower storage areas. With intermittent
operation, usable temperature difference control. In summer, this avoids re-
starting the boiler.

TDMA CONTROL 602-702 Eng Nov.doc
15
Preheating: In winter and during the transitional periods (ie., spring and
autumn) when the solar energy is not sufficient for top loading, the controller
will go into preheat mode. The heated water is then used to heat the store’s
buffer area.
9K"$F&%7?%!?D&%
A#$7&6*%%%%%%%%%%0\\\30%19%
%
Here the temperature can be set when the changeover takes place in the solar
system for winter operation. The solar pump will operate on a pure
temperature difference control. Switching over to winter operation is by either
the heating return sensor or the heating flow sensor dependenrt upon which
variant of the CONTROL 602 is selected. This is only possible if the
Stratification function is set to AUTO.
CONTROL 602
Control Setting
Sensor
Variant A
•Return temperature raising
•Heating return temperature
sensor
Variant B
•Heating control
•Flow sensor
H#BB&6&$;&%>?:"6*%
%%%%%%%%%%%%%%%%%%)\\\()%.%
%
The temperature difference between the collector sensor and the store
temperature is set here. If the collector sensor is higher than the bottom store
sensor by the amount set, then solar charging will take place. For small pipe
diameters and good thermal insulation, a small value can be set. For longer
pipelines, large diameter pipes, poor insulation or poor sensor configuration,
the temperature difference must be greater.
Example:
A 15 mm diameter pipe, 20 m long, pump with low power consumption and
good thermal pipe insulation, the value of 6 K can be set. In setting 6 K, the
solar pump will turn on when the temperature is ar least 6 K above the
temperature of the bottom store sensor. If the temperature difference between
collector and the bottom stoer temperature falls below 4 K (hysteresis of 2 K,
set at the factory), the solar pump shuts off
Solar pump: Allocation input - Function - Output
Input
Function
Collector sensor
(Supplied)
Top Loading (Stratified loading
function)
Solar Differential
Maximum Solar input
Store sensor bottom
(Supplied)
Solar Differential
Flow/Return flow sensors
(Art. Nr. RE 046)
Switch to Winter
Output: Solar pump

TDMA CONTROL 602-702 Eng Nov.doc
16
5.4.3 East-West-Control with two pumps
The ‘East-West with two pumps’ is for systems with two collector panals (fields),
which have different orientation. For example, one facing East and another
facing West. This function controls two separate solar pumps. Here, the
sensor F2 (store bottom sensor) is used to control both solar pumps, as a
reference sensor. If this function is activated, it automatically changes the
‘stratification functon’ to Off. When the solar yield function has been selected,
the controller starts to count when either of the two pumps run..
East-West with two Pumps: allocation input - Function - output
Input
Function
Collector sensor Field 1 (F1)
Activation conditions for solar
pump control 1 (Temperature
difference)
Collector sensor Field 2
CONTROL 602 Variant A (F8)
CONTROL 602 Variant B (F9)
CONTROL 702 (F11)
Activation conditions for solar
pump control 2 (Temperature
difference)
Store top sensor (F3)
Max. Permissible store
temperature (90°C)
Store bottom sensor (F2)
Differential Solar
Output:
Solar pump Field 1 (output A1)
Solar pump Field 2 (CONTROL 602 Output A3 in Variant A and Ouput A4 in
Variant B; CONTROL 702 Output A2)
5.4.4 Cooling, Swimming Pool and two store control
This function is to prevent overheating of the collector or put heat to a second
store (or pool). The solar pump will continue during the cooling of the store as
long as the maximum collector or store temperature is not exceeded.
Select Function Cooling:
If the ‘store top sensor’ has reached the set ‘cooling temperature’, the output
‘cooling’ state is operated. This output can drive for example; a charging
pump to cool the store or redirect the heat to another store.
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Here the desired cooling temperature can be set.
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The hysteresis of cooling control can be set.
For example, with a cooling temperature of 85 °C and a Hysteresis of 5 K, the
output is activated at 85 °C and deactivated at 80 °C.
Seclect Function - Cooling via Heating Circuit:
When the store temperature is above a set value, the store can be cooled by
using heating circuit 1. The mixing valve and pump of heating circuit 1 is
operational.
The cooling temperature and hysteresis settings are described below.

TDMA CONTROL 602-702 Eng Nov.doc
17
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The desired heating circuit flow set temperature in cooling mode is set here.
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Select Function Two Store Priority: If the ‘store top sensor’ has reached the set
‘cooling temperature’, the output is switched to two store mode, for example,
to move a three-port valve to redirect the heat flow to another store.
Simultaneously, the store bottom sensor will switch to store bottom sensor 2.
The hysteresis setting is described in select function Cooling.
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The desired switching temperature for the function ‘Two store priority’ and
‘Swimming pool’ are set here.
Select Function Two Store Equal: When the second thermal store bottom
sensor temperature is lower than that of the first, the ‘Two store’ function is
activated, This activates a tree-port valve so that the heat flow is diverted to
another thermal store, and simultaneously switches from the first to second
lower thermal store sensor. The hysteresis of 2 K is set in the factory.
Select Function Swimming Pool: When the store top sensor has reached the set
temperature the heat is switched to the pool heat exchanger. On contact
closure, the solar pump is switche doff and the pool pump is turned on, to
direct the heat flow into the pool heat exchanger. Simultaneously the store
bottom sensor switches to the second store bottom sensor.
The changeover temperature and hysteresis settings are described under two
Store Priority Select Function.
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Here the swimming pool maximum temperature is set via the ‘second store
bottom sensor’.
Cooling, Two Store control and Swimming pool: allocation
Input - Function – output
Input
Function
Store Sensor Top
(Supplied)
Store max, Cooling, Two Store,
Swimming Pool
Store Sensor Bottom 2
(Art. Nr. RE 046)
Two Store, Swimming Pool
Output: Cooling, Two Store or Swimming Pool

TDMA CONTROL 602-702 Eng Nov.doc
18
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If the store top sensor reaches above the set temperature, the solar pump is
switched off.
Note:
In some cases (such as a holiday in order to protect the system conponents) it
may be advisable to lower the maximum storage temperature to less than 90
°C. The cooling temperature should also be set below the maximum store
temperature, so that the collector does not stagnate.
5.4.5 Frost protection of solar circuit
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When the ‘Frost Protection’ option has been chosen, the sytstem for frost
protection is implemented. When the frost protection sensor falls below 5 °C
the solar pump is activated and when the teperature rises to 9 °C the pump
switches off. The frost protection circuit operates with vacuum tube collectors
and those that have water in the solar circuit. An overrun frost protection timer
(adjustable) allows the pump to run for a short period after the temperature
rises above the upper limit. Consolar does not recommend solar fluid that is
only water, as it may become frozen under adverse weather conditions and
cause the solar pump to fail.
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5.5 Yield Measurement (Calc Values)
The solar yield is determined from the temperature differential between the
yield sensors on the heat exchanger inlet & outlet and the flow rate. The flow
rate can also be entered as a constant value, if no flow meter is installed.
However, the yield measurment can be fraught with msclculations and can be
up to 50% out, because the viscosity of the heat transfer fluid is highlt
temperature dependent.
Through these two settings, the parameters for the density and heat capacity of
the heat transfer medium can be determined. These parameters depend on
the temperature, mixing ratio of water/antifreeze and what type of antifreeze
used, from a propylene gycol mix: such as Tyforcor L; Tyfocor LS; Antifrogen
L; P-NF Liquid Reinsol; Ethylene Glycol; Tyforcor; Antifrogen N.
Obtainable from Consolar if Tyfocor LS (Item No. KR 130/135) whose
percentage of the antifreeze is set to 40%.
If a flow meter is installed for the CONTROL 602 Variant A choose ‘Select
Function 4’ or for Variant B choose ‘Select Function 6’ “Heat Meter”. For the
CONTROL 702 this is a basic function and does not have to be separately set.
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If a flow meter is connected, the pusle rate of each metering unit can be
entered to allow for the automatic calculation of volume flow. Available from
Consolar is a flow meter (No. RE096) which is set at the controller with 0.026
l/pulse.
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If a flow meter is connected, the flow rate must be set to 0 l/min. If no flow
meter is connected, the flow rate must be determined by using q Taco setter
and the vlue entered.
Note:
In ‘East-West with 2 Pumps’ if you enter the flow of one collector array, the
controller will assume that both arrays are the same!

TDMA CONTROL 602-702 Eng Nov.doc
19
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Yield Measurement: Allocation Input-Function-Output
Input
Function
Yield Sensor Flow (Solar Hot)
(Art. Nr. RE 046)
Temperature differential for Yield
calculation
Yield Sensor Return (Solar Cold)
(Art. Nr. RE 046)
Temperature differential for Yieldn
calculation
Flow Meter (Art. Nr. RE 096)
Flow measurement
No Output
5.5.1 Radiation Measurment (Input Data)
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Here the solar radiation is measured. This requires a radiation sensor to be
connected.
In this menu option, the proportionality factor between the measured volatage
and the solar radiation can be set. The value of the Radiaition Sensor is 100
W/ Vm2(RE354) and is preset in the controller.
Solar Radiation: Allocation input - Function - output
Input
Function
Radiation Sensor
(Art. Nr. RE 354)
Measurement of Solar Radiation
No Output
5.5.2 Heat Meter
For the CONTROL 602 select function 3 and 4 (Variant A) and 5 and 6
(Variant B) to activate the calculation of heat quality. The heat meter with
pulse output (No. RE064) is connected to the digital inputs D1 and D2. The
measured amount of energy can then be read directly on the controller in
‘Calc Values’. The CONTROL 702 can have three heat meters, which can be
activated in Select Function 9, 10 & 11.
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Here the pulse rate of the heat meter can be set. Wioth each pulse recorded,
the appropriate amount of heat is displayed on the controller. The rate is
stated in the manufacturer’s literature for the heat meter.
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In this menu item you can enter the details of the heat meter to be used.
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With the and , the name / type of meter can be entered with numbers or
letters. The curor than jumps automatically to the next character. When the
name is entered and confirmed with the you can the use the to input
details of other heat meters if fitted.

TDMA CONTROL 602-702 Eng Nov.doc
20
5.6 Functions for operating domestic hot water system
(Set Hot water)
5.6.1 Time controlled heating of the hot water supply
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If the temperature of the store top sensor falls below the minimum set value, the
hot water back up heating and boiler On/Off functions are activated. The
minimum temperature can be raised as a one off via, for example, the
circulation and bath button. Hot water back up heating can also be
overridden at particular times via an integrated time switch.
The boiler On/Off is activated by the hot water back-up heating requirement
as well as by heating demand. The back-up heating is only activated by a hot
water back-up heating demand.
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When the ‘store top sensor’ reaches the set “Hot water heating set-point
temperature” the outputs ‘DHW heating’ and ‘boiler On/Off’ are switched off
and the loading of the hot water volume is complete.
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The hysteresis for the DHW back-up heating can be set here. If for example, a
DHW required a temperature of 60 °C and a hysteresis of 5 K are chosen, the
contacts for the DHW back-up heating and the Boiler On/Off will close when
the temperature reaches 55 °C and switches them on. When the temperature
reachs 60 °C the contact opens and switches off the back up heating
requirement.
Note:
Be aware of Legionella Regulations
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The hot water back up heating minimum temperature can be set here. The
DHW temperature will not fall below this minimum temperature, even when the
time switch is off.
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The hot water back-up heating function will continue to run for the set time
period after the set point has been reached. This function allows the thermal
store to be loaded above the minimum hot water demand volume. This
reduces the number of stop/start operations of the boiler, thereby prolonging
its life.
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This function can reduce the boiler run time for hot water heating and thus the
fuel consumption. If the “optimised hot water back-up heating” option is set to
“Yes”, the hot water target temperature will be calculated by the controller as
a function of the store bottom temperature.
If the store bottom temperature is high, the hot water setpoint will automatically
be reduced.