Kingspan Temperature differential controller User manual

Temperature differential controller
5 inputs, 2 outputs
Installation and operating instructions
EN
742.892 | Z01 | 11.50 | Subject to change due to technical improvements!

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Content
General safety instructions....................................3
EC declaration of conformity.................................3
1 Proper usage .........................................................4
2 About this manual .................................................4
2.1 Contents ................................................................... 4
2.2 Target audience ........................................................ 4
3 Installation ............................................................5
3.1 Opening / Closing the casing ....................................5
3.2 Mounting the casing ................................................ 6
3.3 Establishing the electrical connections......................7
3.4 Terminal pin assignments........................................ 10
4 Commissioning the device for the first time.......13
5 Construction ........................................................17
5.1 Casing..................................................................... 17
5.2 Display.................................................................... 17
6 Operation.............................................................20
6.1 Operating buttons .................................................. 20
6.2 Display when operating.......................................... 20
7 Modes of operation .............................................20
7.1 Changing the mode of operation ...........................20
7.2 Off mode ................................................................ 21
7.3 Manual mode ......................................................... 21
7.4 Automatic mode..................................................... 22
8 Settings menu......................................................23
8.1 Overview................................................................. 23
8.2 Calling up the settings menu and selecting a menu entry
26
8.3 Setting the time...................................................... 26
8.4 Setting the system .................................................. 26
8.5 Setting the functions ............................................. 26
8.6 Setting the parameters ..........................................26
8.7 Setting the priority .................................................27
8.8 Resetting to factory defaults................................... 27
9 Functions..............................................................28
9.1 Operation ............................................................... 28
9.2 Characteristics ........................................................ 29
9.3 Function descriptions.............................................. 31
10 Parameters ...........................................................43
11 Deinstallation and disposal .................................46
12 Information messages .........................................46
13 Troubleshooting...................................................46
13.1 General faults ......................................................... 47
13.2 Error messages ....................................................... 48
13.3 Checking the Pt1000 temperature sensors .............49

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General safety instructions
• This document is part of the product.
• Use the device only after reading and understanding this document.
• Keep this document in a safe place for the entire service life of the device. Pass this
document on to subsequent owners and operators of the device.
• Adhere to all safety instructions. Consult (further) professional personnel in the
event of any ambiguities.
• The measures described in this document may only be performed by qualified
technical professionals. Exception: End-customers may operate the device when they
have previously been trained by a technical professional.
• The solar system can be damaged by improper operation of the device.
• The device must not be connected to the power supply if it has an open or damaged
casing.
• The device must not be connected to the mains power supply when:
– the casing is open or damaged.
– cables are damaged.
• Factory labels and markings must never be altered, removed or rendered unreadable.
• Observe the prescribed conditions of use, see Section 14, p. 50.
• This device is not intended for:
– Children
– Persons with physical, sensory or mental impairment
– Persons without sufficient experience or knowledge unless they are instructed in
the use of the device, and initially supervised, by a person responsible for their
safety.
EC declaration of conformity
This product conforms to the applicable European directives with regard to its design
and its operating behaviour. This conformity has been verified. Further information in
this regard can be obtained from your dealer.
14 Technical data ......................................................50
14.1 Controller ............................................................... 50
14.2 Cable specifications ................................................ 51
Exclusion of liability.............................................51
Legal guarantee ...................................................51

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1 Proper usage
The temperature differential controller, subsequently referred to as the controller, is an
independently installed electronic temperature controller for on-surface installation.
Integration into a pump assembly is possible when the technical specifications of the
controller are adhered to.
The maintenance-free controller is exclusively intended for controlling solar and heating
systems.
2 About this manual
2.1 Contents
This manual contains all information required by a technical professional for setting up
and operating the temperature differential controller.
2.2 Target audience
The target audience of this manual are technical professionals who:
• have the knowledge of terminology and the skills necessary for setting up and oper-
ating solar systems.
• have the necessary training, knowledge and experience, and knowledge of the ap-
plicable regulations in order to evaluate and recognise the dangers inherent in the
following work:
– Installation of electrical equipment
– Production and connection of data communication cables
– Production and connection of mains grid power supply cables

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3 Installation
Note
The following section describes only the installation of the
controller
. Follow the instruc-
tions of each respective manufacturer when installing external components (collectors,
pumps, storage tanks, valves etc.)
3.1 Opening / Closing the casing
3.1.1 Removing the front panel
X
Grasp the front panel

by the grooves at the sides

and pull forwards

(Fig. 1).
Fig. 1:
Removing the front panel
3.1.2 Mounting the front panel
X
Carefully position the front panel

and then press it onto the casing until it latches
into place.
3.1.3 Removing the terminal cover
Danger
Risk of death by electrocution!
•
Disconnect the controller from the power supply before removing the terminal
cover.
•
Make sure that the power supply cannot be unintentionally switched on when the
device is open.
1.
Remove the screw

(Fig. 1).
2.
Remove the terminal cover

.
3.1.4 Mounting the terminal cover
1.
Position

the cover.
2.
Tighten the screw

to a torque of 0.5 Nm.

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3.2 Mounting the casing
√The mounting location must satisfy the prescribed conditions of use; more informa-
tion on this is provided in Section 14, p. 50.
√The mounting surface is vertical and allows good access for installation.
Danger
Risk of death by electrocution!
• Disconnect the controller from the power supply before opening the casing.
• Make sure that the power supply cannot be unintentionally switched on when the
casing is open.
• Do not use the casing as a drilling template.
1. If necessary, remove the terminal cover
2. Screw in the screw for the upper mounting hole (Fig. 2) until the screw head has
a clearance of 5 ... 7 mm from the mounting surface.
3. Hang the controller on the screw by the upper mounting hole and align it vertically.
4. Mark the position of the lower mounting hole through the casing.
5. Remove the controller and prepare the mounting hole for the lower screw.
6. Hang the controller by the upper mounting hole and then fasten the screw in the
lower mounting hole .
7. Mount the terminal cover.
Fig. 2: Rear side of the controller with the upper and lower mounting holes 

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3.3 Establishing the electrical connections
Danger
Risk of death by electrocution! Make sure that the following conditions are satisfied
when performing the work described in this section:
• All cables leading to the controller must be disconnected from the power supply and
it must be ensured that they cannot be unintentionally reconnected during installa-
tion.
• Each connection terminal must only be connected to a single conductor.
• The protective earth conductors (PE) from the mains cable and pump and valve
cables must be connected to the protective earth conductor terminal block.
• All cables must be laid so that persons cannot stand on them or trip over them.
• The cables must satisfy the requirements listed in Section 14.2, p. 51.
• The local power supply must match the specifications on the type plate of the con-
troller.
• The power supply cable is to be connected to the mains power as follows:
– using a plug connected to a wall mains socket or
– via an isolating mechanism allowing complete isolation in the case of permanent
wiring.
• The power supply cable must be laid in conformance to all applicable legal guide-
lines and regulations of the local electricity supplier.
Caution
Danger of damage and malfunction.
• Connect only components that do not overload the controller inputs and outputs;
more information is provided on the type plate and in Section 14, p. 50.
• For outputs R1 and R2 the following applies:
– Speed control must be deactivated when an external relay is connected.
– The correct pump type must be set (standard/high-efficiency pump).
More information on this is provided in Sections 4, p. 13 and 10, p. 43 (P18, P19).
Notes
• Any connection polarity may be used for the 1– 5and RSsignal inputs and outputs.
• Only type Pt1000 temperature sensors may be used.
• Lay the sensor cables at least 100 mm away from any power supply cables.
• Use shielded sensor cables when inductive sources are present, e.g. high-voltage
lines, radio transmitters, microwave devices.

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3.3.1 Position of the connection terminals
Fig. 3: Terminal clamps in the lower part of the controller (terminal cover removed)
Power connection terminal block
L1x phase conductor (mains input)
R1, R2 2x output (TRIAC, for pumps or valves)
Xnot used
Lconst. 2x phase conductor (outputs, permanent voltage)
N4x neutral conductor (common neutral conductors for mains power input
and outputs)
Note
Outputs R1 and R2 are protected by an electronic fuse.
Protective conductor terminal block:
PE 4x protective earth (common protective earth for power connection)
terminal block
Signals terminal block:
1–44x sensor input (Pt1000 temperature sensor)
51x sensor input (Pt1000 temperature sensor or pulse water meter input)
RS1x signal output (potential-free relay contact for safety extra-low voltage)
PWM R1
PWM R2 2x control output (for PWM-controlled high-efficiency pumps)
7x mass connection (common mass for sensor inputs and control outputs)
Pin strip, for internal use only
Cable openings on the rear side of the casing
Upper strain relief clamps (2 identical plastic links, each with 2 strain relief clamps,
supplied in the scope of delivery)
Lower strain relief clamps
Cable openings at the bottom of the casing

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3.3.2 Preparing the cable openings
The cables can be fed through openings in the rear wall of the casing or at the bottom
of the casing. The openings are pre-punched and must be prepared as required before
installation.
Prepare the cable openings in the rear wall of the casing as follows:
1. Break out the cable openings (Fig. 3) using a suitable tool.
2. Deburr the edges.
Prepare the cable openings at the bottom of the casing as follows:
1. Cut the required cable openings (Fig. 3) at the left and right using a suitable knife
and break them out.
2. Deburr the edges.
3.3.3 Connecting the cables
√All cables are voltage-free.
√The cable openings have been prepared.
XObserve the following points when connecting the cables:
• Connect the cable conductors to the correct terminals as described in Section 3.4,
p. 10.
• Mains input and outputs: First connect PE, then Nand L.
• Strain relief:
– First clamp the lower strain relief clamps and then the upper strain relief clamps.
– When using the upper strain relief clamps, use the plastic links as described
below.
– If the opening in the strain relief clamp is too large, e.g. in the case of thin ca-
bles, turn over the strain relief clamping bar (with the bend facing down).
– Only use the strain relief clamps for cables entering the bottom of the casing.
Use external strain relief clamps when feeding cables through the rear of the
casing.
3.3.4 Inserting/Removing plastic links
Insert the plastic links as follows:
1. Insert the right plastic strip with the latching protrusion first (Fig. 4).
2. Press the other side of the plastic strip down , until the spring clamp latches into
place.
3. Insert the left plastic strip the other way around (latching protrusion to the left,
spring clamp to the right).
Fig. 4: Inserting the right plastic link

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Remove the plastic links as follows:
1. Insert a flat-blade screwdriver under the right plastic link between the casing and
the spring clamp , (Fig. 5).
2. Carefully push the flat-blade screwdriver to the left . Lever the spring clamp to
the right until the plastic link is free.
3. Pull out the plastic link upwards by hand .
4. Remove the left plastic link accordingly.
Fig. 5: Removing the right plastic link
3.4 Terminal pin assignments
For each solar system that can be selected at the controller, the external components
(pumps, valves, temperature sensors) must be connected to particular terminals. The
following table provides information on this:
• Graphic and number of the solar system on the controller display. The graphic is only
intended to provide an overview and is not a technical drawing.
• Terminal pin assignments of the connected components
Display Legend Terminal layout
No system
Note
No system is used when only the functions are used. When
No system is selected then all inputs and outputs are freely
available for use by the functions. More information on this
is provided in Section 9, p. 28.
1 storage tank, 1 collector array
T1
T2
R1
T1: Collector array sensor
T2: Lower storage tank sensor
R1: Solar circuit pump
1,
2,
R1, N, PE (PWM R1, 1))

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Display Legend Terminal layout
1 storage tank with heating return increase, 1 collector array
R1
R2
T1
T2
T3
T4
T1: Collector array sensor
T2: Lower storage tank sensor
T3: Upper storage tank sensor
T4: Sensor heating return increase
R1: Solar circuit pump
R2: Heating return switching valve 3)
1,
2,
3,
4,
R1, N, PE (PWM R1, 1))
R2, N, PE
1 storage tank with external heat exchanger, 1 collector array
R2 R1
T1
T2
T3
T1: Collector array sensor
T2: Lower storage tank sensor
T3: External heat exchanger sensor
R1: Storage tank loading circuit pump
R2: Solar circuit pump
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE (PWM R2, 2))
1 storage tank with zone loading, 1 collector array
R1
R2
T1
T2
T3
T1: Collector array sensor
T2: Lower storage tank sensor
T3: Upper storage tank sensor
R1: Solar circuit pump
R2: Zone loading switching valve 4)
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE
1 storage tank, 2 collector arrays
R1
R2
T1
T3
T2 T1: Collector array 1 sensor
T2: Collector array 2 sensor
T3: Lower storage tank sensor
R1: Solar circuit pump for collector array 1
R2: Solar circuit pump for collector array 2
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE (PWM R2, 2))
2 storage tanks, 1 collector array (pump-controlled)
T1
T2
T3
R1
R2
T1: Collector array sensor
T2: Sensor lower area of storage tank 1
T3: Sensor lower area of storage tank 2
R1: Solar circuit pump, storage tank 1
R2: Solar circuit pump, storage tank 2
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE (PWM R2, 2))
2 storage tanks, 1 collector array (pump/valve controlled)
T1
T2
T3
R1 R2
T1: Collector array sensor
T2: Sensor lower area of storage tank 1
T3: Sensor lower area of storage tank 2
R1: Solar circuit pump
R2: Storage tank switching valve 5)
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE

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Display Legend Terminal layout
1 swimming pool, 1 collector array
R2
T1
T2
T1: Collector array sensor
T2: Swimming pool sensor
R2: Solar circuit pump
1,
2,
R2, N, PE (PWM R2, 2))
1 swimming pool with external heat exchanger, 1 collector array
R1 R2
T1
T2
T3
T1: Collector array sensor
T2: Swimming pool sensor
T3: External heat exchanger sensor
R1: Solar circuit pump
R2: Swimming pool loading circuit pump
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE (PWM R2, 2))
1 storage tank, 1 swimming pool, 1 collector array (pump-controlled)
T1
T2
T3
R1
R2
T1: Collector array sensor
T2: Lower storage tank sensor
T3: Swimming pool sensor
R1: Storage tank solar circuit pump
R2: Swimming pool solar circuit pump
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE (PWM R2, 2))
1 storage tank, 1 swimming pool, 1 collector array (pump/valve controlled)
R1 R2
T1
T2
T3
T1: Collector array sensor
T2: Lower storage tank sensor
T3: Swimming pool sensor
R1: Solar circuit pump
R2: Storage tank switching valve 6)
1,
2,
3,
R1, N, PE (PWM R1, 1))
R2, N, PE
Tab. 1: Terminal pin assignments
1) Terminal pin assignments for PWM-controlled high-efficiency pumps: The power supply must be
connected to output R1 (N, PE), the control cable for the pump electronics must be connected
to PWM R1 and .
2) Terminal pin assignments for PWM-controlled high-efficiency pumps: The power supply must be
connected to output R2 (N, PE), the control cable for the pump electronics must be connected
to PWM R2 and .
3) Installation regulation: When no power is supplied to the switching valve then no flow occurs
through the storage tank.
4) Installation regulation: When no power is supplied to the switching valve then the lower part of
the storage tank (T2) is loaded.
5) Installation regulation: When no power is supplied to the switching valve then the first priority
storage tank (T2) is loaded.
6) Installation regulation: When no power is supplied to the switching valve then the storage tank
(T2) is loaded.

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4 Commissioning the device for the first time
Danger
Risk of death by electrocution! Be sure to perform all the measures listed in Section 3
before starting the first commissioning.
Notes
• After commissioning the controller for the first time, it is configured in such a man-
ner that it can be used in most applications without changes.
• After completing the first commissioning, later recommissioning is not necessary.
• The following steps must also be performed after the device has been reset to the
factory defaults.
• When power is removed for a longer period of time, after switching on again the
clock must be reset (following steps 1 – 5).
Overview
ESC /
OK
SET
Time
System
Pump R1 (R2)
Type / minimum speed
Functions
ESC /
ESC /
ESC /
The first time the controller is switched on, the following
main settings are made blockwise via a guided configu-
ration process (Fig. left):
• Time
• System (hydraulic variant)
• Type (Standard/high-efficiency pump) and minimum
speed of the connected pumps (not System 0.1)
• Functions
Values can be subsequently changed during the guided
configuration process. The following applies:
• /ESC/blockwise navigation forwards and back
(Fig. left: = forwards; ESC/= back).
• Navigation (with /ESC/) is always possible after
completing a block.
• Subsequent modification of a block is started with
SET.

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Commission the controller for the first time as follows:
Setting the time
1. Apply power to the controller.
– The time 12:00 is displayed.
– 12 flashes (Fig. left)
– The backlighting is red.
2. Press  to set the hours.
3. Press SET. The minutes flash.
4. Press  to set the minutes.
5. Press SET.
Selecting a system
6. Press . System 1.1 is displayed, 1.1 flashes (Fig. left).
7. Press  to select another system.
8. Press SET.
If System 0.1 was selected in step 7, proceed with step 20.
Setting pump 1 (output R1)
9. Press . AC and (pump 1) flash (example in fig. left).
10.
Caution:
Standard pump: Select AC!
High-efficiency pump: Select HE!
Press  to select the type for pump 1.
11. Press SET.
12.
Caution:
When selecting HE (high-efficiency pump) pay attention
to the pump characteristics.
Only if HE was selected in step 10:
Press  to set the characteristic of the high-efficiency pump;
see Tab. 2 and Fig. 6, p. 16.
13. Press SET.
– If AA or Ab was selected in step 12 then SC is displayed;
off, and (pump 1) flash (example in Fig. left;
SC = Speed Control).
– If Cwas selected in step 12, proceed with step 18 (for 2
pumps) or step 20 (for 1 pump).
14. If required, press  to switch on the speed control (on flashes).
15. Press SET.
If off was selected in step 14, proceed with step 18 (for 2
pumps) or step 20 (for 1 pump).

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16. min, Value %, and (pump 1) flash.
Press  to set the minimum speed of pump 1 in %.
17. Press SET.
Make the settings for pump 2 (output R2) only if a system with 2 pumps was selected in step 7.
Otherwise continue with step 20.
18. Press . AC and (pump 2) flash (example in fig. left).
19. Perform steps 10 to 17 accordingly for pump 2.
Setting the function (necessary for System 0.1, set in other systems as required)
20. Press . F: is displayed.
21. Press SET. F:01 (function number) flashes.
22. Press  to select a different function. (Function description
in Section 9.3, p. 31)
23. Press SET. oFF is displayed.
24. Press SET. oFF flashes.
25. Press . on flashes.
26. Press SET. The function is activated.
27. Set the characteristics (see Section 9.1, p. 28).
28. Press ESC.
29. Press . Ok flashes.
Finishing initial commissioning
30. Press SET to finish initial commissioning. After pressing SET
the controller adopts the settings, performs a restart and
switches to the Off operating mode.
Or:
Press /ESC to display the previous settings and adjust them if
necessary.
Setting the operating mode
31. Remove the front panel.
32.
Caution
Danger of pump damage if run dry. Only switch the sys-
tem to manual or automatic mode when the system
is filled.
Press and hold the mode button for 2 seconds to
change the mode of operation; more information on this is
provided in Section 7.
33. Mount the front panel.

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Characteristics of high-efficiency pumps
Display Pump type Characteristic curve
AA High-efficiency pump with a PWM profile
for a rising characteristic curve (Fig. 6)
0% PWM: Pump off
100% PWM: Max. pump speed
Ab High-efficiency pump with a PWM profile
for a falling characteristic curve (Fig. 6)
0% PWM: Max. pump speed
100% PWM: Pump off
CPressure regulated high-efficiency pump –
(no control cable, switching on/off
via the supply voltage)
Tab. 2: Characteristics of high-efficiency pumps
PWM %
RPM
PWM %
RPM
Fig. 6: Characteristics of high-efficiency pumps with PWM profiles for a rising characteristic curve
(AA, left) and a falling characteristic curve (Ab, right)

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5 Construction
5.1 Casing
SC400 No. Element See sec-
tion
Mode button (under
front panel)
6.1, 7
Operating buttons: , SET,
ESC, 
6.1
Display 5.2
Front panel 3.1
Terminal cover 3.3.11)
Terminal cover fastening
screw
–
1) Section 3.3.1 describes the terminals under the
terminal cover.
Fig. 7: Front view of the controller
5.2 Display
5.2.1 Overview
3
2
4
1
Fig. 8: Overview of the display areas (all elements visible)
System graphics
Settings menu
Pictograms for functions
Operational and setting values
The display areas are described below.

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5.2.2 System graphical symbols
The following table describes the symbols used in the system graphics (in Fig. 8).
Symbol Description Symbol Description
Pipework Pump, switched on
Collector (array) Pump, switched off
Maximum collector tempera-
ture reached
3-way valve with flow direction
Storage tank Domestic water outlet
Swimming pool Cooler for active cooling
External heat exchanger Back-up heating
Temperature sensor Solid fuel boiler
Sufficient solar irradiation
available for loading
5.2.3 Settings menu
The settings menu (in Fig. 8) contains the following entries:
Time System
Functions Parameters
Priority Reset to factory defaults
5.2.4 Pictograms for functions
The following table describes the pictograms used for functions (in Fig. 8).
Symbol Description Symbol Description
Manual operation Holiday - recooling 2)
Pump is speed controlled 1) Alarm output 1)
Interval 2) Stagnation reduction 2)
Frost protection 2)
1) Symbol is visible while the function/parameter is being edited in the settings menu.
2) Symbol flashes: The function is activated and is actively intervening in the control process.
Symbol does not flash: The function is activated and is not actively intervening in the control
process or the function is currently being edited in the setting menu.

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5.2.5 Operational and setting values
The display of the operational and setting values (in Fig. 8) consists of the following
elements:
12356
4
Symbol for time control of functions. This symbol is displayed when:
• a time restriction / control has been set,
• the status of time restriction/control is displayed,
• the time restriction blocks a temperature control (symbol flashes).
Number of the time window that is currently being set/displayed or within which
the current time lies.
The time control of a function consists of 1 to 3 configurable time windows.
Example:
Time window 1 06:00 – 08:00
Time window 2 11:00 – 12:30
Time window 3 17:00 – 19:00
Additional information
on, off: Switching state/condition on, off
max, min: Maximum value, minimum value
Σ: Summed operational value since first commissioning, cannot be reset
Δ: Summed operational value since last reset to 0
Symbol is displayed when a temperature sensor is selected when setting a func-
tion.
Display of:
• Measurements
• Settings
• Error codes
• Additional information, e.g. software version
Physical unit of the value displayed in : °C, K, l/min, %‚ h, kWh, MWh, tCO2

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6 Operation
This section contains general information on operating the controller.
6.1 Operating buttons
The device is operated using the , , SET, ESC and buttons as follows:
• Scrolls up through the menu 1)
• Increases the setting value by 1 step
• Scrolls down through the menu 1)
• Decreases the setting vaule by 1 step
SET • Selects a setting to be changed (setting value flashes)
• Confirms a setting value or jumps one level down in the menu
structure 1)
• Calls up the settings menu (not in manual mode)
ESC • Discards an entered setting
• Jumps up by one operating level
Sets the operating mode
1) Exception: Initial commissioning
Note
We recommend that you write down all settings that you have changed.
6.2 Display when operating
• A flashing component in the system graphic means: The displayed operational or
setting value applies to the flashing component.
Exception: always flashes in manual mode.
• A flashing symbol is indicated in the figures by .
• Displays that are automatically alternately displayed are shown overlapping in the
figures. Example: Figure in Section 7.2, p. 21.
7 Modes of operation
7.1 Changing the mode of operation
Caution
Danger of pump damage if run dry. Only switch the system to manual or automatic
mode when the system is filled.
1. Remove the front panel.
2. Press the button for 2 seconds to change the mode of operation.
3. Repeat step 2 if necessary.
4. Mount the front panel.
Off Manual
operation Automatic
2 s 2 s 2 s