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))