emz smart Sol User manual

These Assembly and Operating Instructions are an integral part of the product.
> Read Assembly and Operating Instructions carefully before using the product.
> Keep them in a safe place during the product‘s service life.
Translation from the German original edition ©emz 2011 - Subject to modications.

3
Table of Contents
Table of contents Page
Important fundamental information 4
Symbols used 5
Description 6
Dimensions 7
Technical Data 8
Designation of the components 10
Operation of the controller 12
Display 13
Opening the terminal cover 14
Wall-mounting 15
Connection to power supply 16
Optional features 18
Hydraulic systems 20
Optional disable recharge 36
Optional soft water station AQA solar 40
Commissioning mode 41
Automatic mode 46
Operation mode 47
Malfunction 60
Replacement of fuse 66
Professional mode 67
Disassembly/Disposal 85
Warranty and liability 86
Copyright 87
Commissioning report 88
Error report 89
EC Declaration of conformity 90
Index 91

4
Important fundamental information
These instructions describe installation, commissioning, operation, repair
and disassembly of the differential temperature controller smart Sol for
solar thermal plants.
For operation of the entire plant, the technical documentation of all the
components used such as solar collectors, boiler, tank, pumps, mixers
and valves etc. must be complied with.
The controller is handled by the operator of the entire solar
thermal plant, i. e. as a rule by technical non-experts.
Make sure not to use the controller until you have thoroughly read and
understood these Assembly and Operating Instructions and the safety provisions.
Comply with all safety provisions and involve a specialist in case of doubt.
Keep these Assembly and Operating Instructions and all reference
documents so that they are available if required.
When relocating or when selling the device, hand the documents over to your successor.
Danger!
Assembly, connection, commissioning, repair and disassembly of
the controller may only be performed by a qualied specialist!
Important!
The tter installing the controller must inform the plant operator about
operation, functioning and the method of action of the smart Sol!
Danger!
The device in operation may only be made accessible to
adults disposing of appropriate knowledge and experience!
Danger!
The controller by no means replaces the safety
components required under plant engineering aspects!

5
Symbols used
Note!
Useful information regarding handling of the device and the plant!
When handling the differential temperature controller smart Sol
and the entire plant, please make sure that the following safety provisions
in the Assembly and Operating Instructions are complied with!
Danger!
Immediate danger for assets, life and limb!
Important!
Important information compliance with which is essential!

6
Description
The differential temperature controller smart Sol is an independent electronic
controller for surface-mounting which is used for the control of solar thermal plants.
The controller is equipped with a robust three-part plastic housing
which can only be opened by means of tools (screw driver PH2).
Operation is effected by means of only two control elements;
indications appear against a backlit colour display.
Before connection of the electrical system, the controller
must be mounted rmly to a perpendicular, robust surface (wall).
For its own supply and the supply of the outputs, the controller must be connected
to an electrical energy supply system in accordance with the technical data.
Assembly, connection, commissioning, repair and disassembly
of the controller are only admissible in a specialist workshop.
To ensure correct operation, temperature sensors type Pt 1000
must be used - the sensor design does not affect function.
Each temperature sensor has two connectors which are equivalent,
i. e. interchangeable. Thus, polarity reversal is not an issue.
The sensor lines can be extended up to a length of 100 m, to
this effect, a cable cross section of 2 x 1.5 mm2 is recommended.
Note!
The device must be connected to the power supply via an earth contact
plug or, in case of stationary electrical installation, via a disconnector
ensuring complete isolation according to the erection regulations!
Important!
Make sure that only a dry or slightly moistened cloth is used for clean-
ing and servicing of the housing, the control elements and the display.
The surfaces must never get into contact with cleaning products
or solvents - mat, brittle or slightly dissolved plastic parts must
be replaced immediately!
A device with damaged housing must not be operated!

7
Dimensions
5 mm
57,5 mm
115 mm
dmax 5mm/9mm
120 mm
27 mm
26 mm
57,5 mm
46 mm
173 mm

8
Technical Data
Intended Use
The differential temperature controller may be used exclusively as controller for the con-
trol of solar thermal plants. It must be operated within the scope of all the specications
described. Installation and set-up of the controller may only be performed by specialists.
The tter must have read and understood the operating manual.
The tter explains all the relevant functions to the operator.
For operation, it is essential that the housing is closed and free of damage.
Scope of supplies
1 Differential temperature controller smart Sol
1 Instruction manual
Differential temperature controller smart Sol
Type of mounting Wall-mounting
Housing Plastics, in several parts
Type of protection IP 20
Dimensions Width x Height x Depth [mm] 115 x 173 x 46
Weight [g] Basic version 370
Storage/operating temperature [°C] 0-40, non-condensation
Handling via rotary encoder and pushbuttons
Display TFT colour display 47 x 35 mm, backlit
Connection to power supply
Design 3 spring-type terminals PE, N and L
Service voltage [VAC] 230 ±10%
Line frequency [Hz] 50 ±1%
Auxiliary consumption typ. [W] 1,74
Power consumption max. [W] 3.5
Fuse Micro fuse, type 5 x 20 mm, T2A
Rated pulse voltage [V] 2500

9
Technical Data
Interfaces TS 1 / TS 2 / TS 3 / TS 4
Design 2 spring-type terminals each
Assignment as inputs
Admissible temperature probe Temperature sensor Pt 1000
Optional assignment of
TS3 / TS4 to the impeller sensor DFZ 1-100 pulses/litre
Optional assignment as
output on TS 4 PWM signal 100Hz...2kHz or
analogue output 0...10V, max. 10mA
Triac outputs RO 1 / RO 2
Design 3 spring-type terminals each, PE, N and L
Output voltage [VAC] 230 ±10%
Output power max.
per output [VA] 200
Output current max.
per output [A] 1
Switching output REL: Floating change-over contact
Design 3 spring-type terminals
Switching voltage max. [V] 253
Switching capacity max. [VA] 800
Switching current max. [A] 4
Max. cross sections to be connected
Cable end sleeve: 0.25 to 0.75 mm2
Single-wire 0.50 to 1.50 mm2
Fine-wired 0.75 to 1.50 mm2

10
Designation of the components
Display
Rotary encoder
with OK button
esc button
Screw fastening
of terminal cover
Terminal
cover
Housing
cover

11
Designation of the components
Fuse
Housing
base
Strain relief
device
Terminals
Drillhole for
securing bolt
Spare fuse
Break-out
segments

12
Operation of the controller
The entire set-up and operation of the differential temperature controller
smart Sol is effected via only two control elements on the device front.
All settings and interrogations are effected via the rotary encoder.
To nd a required menu item, turn the rotary encoder to ›scroll‹
through the menu - the selectable option appears on a coloured
background on the display.
To conrm the selected menu item, press the rotary encoder.
An appropriate submenu is called up, or selection is activated.
Press the esc button to make the menu return by one level from any subitem.
If no input is made within the preset time (30-255 s),
the controller returns automatically to the initial level.

System 11
13
Display
1.3.2 Tube collector
04. 07. 2011 10:35
n solar 1
t solar 2
n solar 2
t start
t end
100%
20s
30%
6:00
7:00
Display elements; example: information screen
For indication of the operating mode and for communication in case of set-up,
malfunction, modication and evaluation, the differential temperature controller
smart Sol is equipped with a coloured full graphics display which is permanently backlit.
The display is active as long as there is supply voltage on the controller.
After a preset time (30 - 255 s), backlighting is dimmed to 10%.
Active system
with current
temperatures
Date and time
Display elements; example: communication screen
Activatable
menu item
Selection menu
Date and time
Professional mode
Manual mode
Message
Number and name of menu

14
Danger!
Mortal danger due to electrocution! Whenever work is performed on the
open terminal cover, all poles of the power supply must be
disconnected reliably and protected against being switched on again!
Opening the terminal cover
1 Release the lock screw.
2 Swing terminal cover
forward ...
3 ... push it upwards ...
4 ... and remove it.
Store the terminal cover
carefully and protect
it against damage!
To close the terminal cover,
reverse the opening procedure.

15
Wall-mounting
Important!
The device corresponds to protection type IP 20 - make sure the
appropriate prerequisites exist on the envisaged place of installation.
Do not use the housing base as drill template.
A device with damaged housing must not be operated!
1 Fasten the top securing bolt so
that a space of 2 to 3 mm is
created between the wall and
the screw head.
2 Move the device so that the
upper fastening port is located
above the screw head ...
3 ... and push it downwards.
4 Fasten the lower securing bolt.
If necessary, use dowel
pins for wall-mounting!

16
Connection to power supply
Strain relief
device
Screw connection
strain relief device
Terminal block
RO2/RO1/Power
ResistorTerminal block
REL
Terminal block
TS1-TS4
Luster terminal
Danger!
Mortal danger due to electrocution! Whenever work is performed
on the open terminal cover, all poles of the power supply must be
disconnected reliably and protected against being switched on again!
The differential temperature controller smart Sol is connected to the
power supply via three groups of spring-type terminals which are
visible once the terminal cover is opened.
To introduce the cables, release the three screws on the strain relief device;
if necessary, remove the strain relief device.
In case of ush mounting of the cables, the break-out segments in the housing
base can be removed carefully and the cables routed through these ports.
The central terminal block is the interface to a oating change-over
contact - here, it may be necessary to route electrical resistors into the
spring-type terminals and to connect part of the cables via luster terminals.
The spring-type terminals for the power supply, RO1, RO2 and REL, and for TS1,
TS2, TS3 and TS4 can accommodate solid wires up to a cross section of 1.5 mm2.
Appropriate stranded wires must be preassembled with cable end sleeves.
For the strain relief device function, TS1 to TS4 and REL require
cable cross sections of at least 5mm, for Power, RO1, RO2 at least 7mm.

17
max.
35 mm
9-10 mm
Connection to power supply
The strain relief device can only ensure solid
clamping if the cables are not stripped to a length
of over 35 mm.
Insulation of the individual wires must be
removed over a length of 9 - 10 mm to ensure
safe electric contact in the spring-type terminal.
Stranded wires must be provided with cable end sleeves!
For connection, press the actuation pushbutton
of the spring-type terminal using a screwdriver and
insert the wire to its stop in the appropriate port.
Release the actuation pushbutton and pull the
cable slightly to ensure that it is safely clamped.
Important!
Before closing the terminal cover, make
sure the strain relief device is tightened safely.
Check once more that all cables are in good
condition and connected correctly.

18
Optional features
Optional volumetric ow sensor:
Measurement of solar radiation (heat quantity):
The solar yield is calculated from the ow rate and the differential temperature.
The differential temperature is the difference in the temperature of the collector
sensor and the solar circuit return line sensor. There are various technical options:
a) Use of a vortex volumetric ow sensor with 2 analog signals for ow rate and
temperature. The vortex sensor can be inserted directly at the plug connector provided
behind the TS3/4 terminals. All plant layouts permit solar radiation. When a vortex
sensor is connected to plug UI1/UI2, the cover plate at the housing must be broken out.
Plug connector for vortex
sensor behind the
terminals
TS3/TS4.
Pin assignment
Plug connector for vortex sensor:
1 = UI1 = Temperature sensor
2 = UI2 = Flow rate sensor
4 3 2 1
+5V GND UI2 UI1
b) Impeller sensor (incrementation input)
An impeller sensor can be connected to TS3 or TS4 and must be adjusted during
installation. The temperature sensor for the solar return line is connected to TS3 or TS4
and must then be set in the menu 1.1.4 Heat quantities. Solar radiation measurement
using an impeller sensor is possible for plant layouts 1, 2, 3, 4, 5, 7, 10, 12 and 14.
Optional micro SD card:
The solar controller features the following data interfaces:
The recesses in the left-hand side of the
housing base accommodate an USB connector
and a slot for a data medium (micro SD card).
These interfaces can be used e. g. to read error messages or
saved data or to transfer software updates to the controller.
Access to the data on the micro SD card
is possible via the USB connector.
Only the SD cards authorized by emz may be used.
The micro SD card is detected by the controller automatically.
Before removing the micro SD card from the controller, the item
›Remove SD card safely‹ must be selected under ›1.2 Settings‹.

19
Optional features
Optional high-efciency pump:
A high-efciency pump can be connected via RO1 or RO2.
The appropriate control signal is issued at TS4.
Thus, TS4 is no longer available as input.
The control signal may be an analog voltage 0 - 10V or a PWM signal.
For further details, please refer to the pump specication.
For denition and settings, the professional mode under 1.1.4 has been provided.
RO1 or RO2:
230V supply of the
high-efciency pump
TS4: PWM-control signal
for the high-efciency
pump
Left-hand terminal: GND
Right-hand terminal: Signal
Connection of a switching valve to RO1/RO2
Connection diagram for a switching valve to RO2:
blue
black
brown
USV
L
Additional options:
• Option ›Disable recharge NLU‹: Description as of page 36.
• Option ›Soft water station AQA solar‹: Description on page 40.
• Option ›Power reserve‹:
This option can be used to buffer the time up to 8 hours in case of power failure.
• Option ›acoustic signal transmitter‹: The signal transmitter issues an acoustic
signal once an error has occurred. This can aso be deactivated in the menu.

20
Hydraulic systems
Note!
Dene structure and design of the plant already when planning
the entire solar thermal system and align the design with the
one of the hydraulic systems of the controller!
If you want to complete an existing system or replace
the existing controller, please make sure that
smart Sol is compatible with the existing conguration!
The sensors are connected to TS1 to TS4, the order not being
signicant; pumps and valves are connected to RO1 / RO2 - The
interfaces are assigned to the functions in question on commissioning.
Boiler with disable
recharge feature,
efciency optimization
Boiler with disable
recharge feature
time-/temperature-
controlled, in combination
Boiler, e. g. using fossil
fuels/ solid fuels/
heat pump etc.
Hydraulic
heat exchanger
Temperature probes
Solenoid valve
Solar collector panel
Secondary yield
Solar collector panel
Main yield
Warm water /
buffer tank with two
heat exchangers
Warm water /
buffer tank with one
heat exchanger
Warm water /
buffer tank without
heat exchanger
Heating pump
Return line
Supply line