Prozeda Solareg II BASIC HE User manual

Microcontroller-controlled temperature difference controller for solar thermal sys-
tems with high-efficiency pumps
Operating manual
Solareg II BASIC HE

2
Table of content
1 Application area/device features 3
1.1 Application area 3
1.2 Device features 3
2 Safety instructions 3
3 Mounting the device 4
3.1 Opening the device 4
3.2 Wall mounting 4
3.3 Connections 5
3.4 Temperature sensor connection 5
4 Short descriptions and device operation 5
4.1 Display layout 5
4.2 Operation 6
5 Menu structure 7
5.1 "Info" menu 7
5.2 "Programming" menu 7
5.3 "Manual Operation" menu 8
5.4 "System Settings" menu 8
6 System diagrams 9
7 Controller functions 10
7.1 General controller functions 10
7.1.1 RPM control 10
7.1.1.1 Standard 230 V AC pumps 10
230 V block modulation 10
7.1.1.2 HE pumps 10
Control of the solar circuit pump via analogue signal Type A 10
Control of the solar circuit pump via PWM signal 11
- Non-inverse PWM control 11
- Inverse PWM control 11
7.1.5 Drain-back function 12
7.2 Protective functions 13
7.2.1 Collector protection 13
7.2.2 Recooling (holiday function) 13
7.2.3 System protection 13
8 System monitoring 14
8.1 Sensor monitoring 14
8.2 Flow monitoring 14
9 Troubleshooting 15
9.1 Faults with error messages 15
9.2 Faults without error messages 16
10 SOLAREG II technical data 17
11 PT1000 resistance table 17
12 Guarantee terms and conditions 18
13 Declaration of conformity 18
Explanation of icons
Warning!
Icon indicates pos-
sibility of hazard
or error
Warning: 230 V AC
current!
Icon indicates
danger from high-
voltage, life-threat-
ening current.
List
Please note!
Operational advice
/ special informa-
tion
User action / pro-
cedure
Inspection / check

3
1 Application area/device features
1.1 Application area
SOLAREG II BASIC HE controllers are high-performance microprocessor-controlled
units for controlling the functions of solar thermal systems using high-eciency
pumps. SOLAREG II BASIC HE is the ideal controller for systems with one collector
array and one storage tank. The controllers are designed for use in dry areas and
for residential, business and commercial applications. If you want to use the unit
for other purposes, check applicable statutory regulations before use.
1.2 Device features
The SOLAREG II generation of controllers is equipped with the following features:
Intuitive user menus with icons and four control buttons■
Adjustable control values■
RPM control of the solar circuit pump via PWM, analogue signal or 230 V block■
modulation
Drain-back function■
Integrated operating hours counter for storage tank charging■
Extensive functions for system monitoring, using symbols to indicate errors■
and faults
Storage of all values, even during prolonged mains power supply outage■
Various protective functions: system and collector protection, recooling, anti-■
freeze protection and through-ow monitoring
Generous wiring space■
Available accessories:
PT1000 temperature sensor■
Sensor connection box■
Immersion sleeves■
2 Safety instructions
Always ensure that you isolate the device from the mains power supply before■
starting installation or wiring work on its electrical components. Make sure
that you never confuse the SELV (safety extra low voltage) connectors (sensor,
ow transmitter) with the 230 V connectors: this will destroy the device. Life-
threatening voltages may be present in both the device and the connected
sensors.
Solar power systems can generate high temperatures. There is therefore a risk■
of burn injuries! Exercise caution when installing the temperature sensors!
Mount the SOLAREG II in a location where it will not be subjected to excessive■
operating temperatures (>50 °C) by any external heat sources.
For safety reasons, the system should only be operated manually during test-
ing. In this operating mode, the system does not monitor maximum tempera-
tures or sensor functions. Do not operate the system if there is recognisable
damage to the controller, cables or the connected pumps and valves.
You must isolate the
control unit from mains
power before carrying out any
assembly or wiring work.
The connection and start-up of
the SOLAREG II should only be
carried out by qualified techni-
cal personnel. All work must
comply with the applicable
safety regulations.

4
3 Mounting the device
3.1 Opening the device
Before opening the device, disconnect mains power and ensure that it cannot be
switched back on! The upper part of the housing is locked to the lower part using
two latches. Release the housing cover by pulling the sides outwards (see picture)
to unlatch it, and then pivot the cover upwards until it "clicks" open.
3.2 Wall mounting
The device is mounted on the points marked. A drilling template is provided
with a device. Insert the "Quick Info" card provided with the device into the cor-
responding pocket on the back of the device. The "Quick Info" card rapidly famil-
iarises users with the device.
Only install the control
unit in dry interiors not
subject to a risk of explosions.
Do not install the unit onto
flammable surfaces
Before switching on or
starting up the system:
Ensure the cover is closed – it
must snap securely into place on
both sides!

5
3.3 Connections
Bear in mind the following points concerning the 230 V connections:
■ If the controller is wired directly into the mains, it must be possible to isolate
mains power by using a switch external to the controller.
The switch is not required if the main power supply is provided via a cable and
earthed mains plug.
The controllers are designed for use with 230 V/50 Hz mains power. Any pumps■
to be connected must also be rated for use at this voltage!
All earth leads must be attached to the terminals marked "PE".■
■The neutral lead terminals (N) are connected electrically and are not switched!
The A1 output serves to supply the pump with 230 V AC. Function selection■
is carried out using the terminal O1 and corresponding jumper setting: "ANA"
(analogue output) or "PWM" (PWM output). For pumps with analogue signal
control via a 0-10 V analogue signal and pumps with PWM control via a PWM
signal at a freq. of 2 kHz.
3.4 Temperature sensor connection
SOLAREG II BASIC HE devices use PT1000 precision platinum temperature sensors.
2 sensors are required, the third sensor is optional.
Mounting / wiring the temperature sensors:
■Mount the sensors on the collector and storage tank. Ensure proper heat
transfer, using heat-conductive paste if necessary.
Cross-sections for cable extensions (shielded):■
- Up to 15 m, 2 x 0.5mm2
- Up to 50 m, 2 x 0.75mm2
The shield is connected to earth (PE).
Temperature sensors are connected according to the system layout. You do■
not need to observe polarity for the two wires when cabling temperature
sensors.
■Sensor cables must be laid separately from 230 V wires.
Sensor collection boxes equipped with surge protection should be used for■
collector sensors and cable extensions.
4 Short descriptions and device operation
4.1 Display layout
During actual operation, only a selection of these symbols will be shown – de-
pending on the current menu.
Currently active menu◂
Current display assignment◂
Current readings, times or controller◂
states: here 59.6 °C.
Measuring point◂
Controller state/messages◂
Display symbols
All possible display symbols are
shown below.
ok?
hPa
start
%
stopdTmin max
F

6
4.2 Operation
The SOLAREG II can be operated simply and easily by using the four control but-
tons. You can use the control buttons to:
Access display values■
Make changes to unit settings■
The icons on the display let you navigate easily through the various control func-
tions.
The control buttons have the following functions:
Control but-
tons Function Description
"Up"
„+“
Go to menu item above■
Value modication: increments displayed
value by 1; if the button is pressed and
held, the value increments continuously
"Page left"
"Exit"
"Cancel"
Page left in main menu■
Exit a menu■
Exit a menu item■
Cancel a value change without saving it■
"Access"
"Down"
„-“
Access a main menu,■
Go to menu item below
Value modication: decrements dis-■
played value by 1; if the button is pressed
and held, the value decrements continu-
ously
"Page right"
"Select"
"Conrm"
Page right in main menu■
Select a menu item■
Conrm a value change and save it■

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5 Menu structure
5.1 "Info" menu
The Info menu shows the following readings and yield values:
Display
e.g. Meaning Can be reset
75 °C Displays current collector temperature No
min
12 °C
Displays minimum collector temperature.
Can be reset to current temperature. Yes
max
105 °C
Displays maximum collector temperature.
Can be reset to current temperature. Yes
52 °C Displays current storage tank temperature No
min
40 °C
Displays minimum storage tank tempera-
ture. Can be reset to current temperature. Yes
max
67 °C
Displays maximum storage tank tempera-
ture. Can be reset to current temperature. Yes
25 °C Displays S3 general temperature measuring
point (only shown if connected) No
1234 h Operating hours for charging storage tank
Can be reset to 0 h Yes
5.2 "Programming" menu
The Programming menu is used to display operating parameters and to change
these as required. The preset values generally ensure fault-free system operation.
Display
e.g. Meaning Value range Typical setting
Current
setting
max
65 °C
Storage tank:
Maximum permis-
sible temperature
15 – 95 °C 65 °C
dT max
7 K
Storage tank:
Switch-on dier-
ence
3 – 40K 7K
dT min
3 K
Storage tank:
Switch-o dier-
ence
2 – 35K 3K
min
100
Set minimum
pump capacity
using RPM con-
trol: 100% = RPM
control o
30% – 100% 100%
dT
1 K
Sets dT for the
dT-controlled
circulation when
using tube collec-
tors (K/sec)
1 – 5K 1K
The number of values
displayed depends on the
additional functions activated.

8
5.3 "Manual Operation" menu
Automatic operation is switched o during manual operation. The solar pump
can be manually switched on and o for servicing and test purposes.
Automatic operation is reactivated after exiting the menu or after 8 hours have
passed.
Display Meaning Value range
Manual switching on/o of solar pump 0 = O
1 = On
5.4 "System Settings" menu
The System Settings menu displays the hydraulic diagrams and additional func-
tions. Settings must only be changed by a specialist technician. Settings may only
be adjusted in the menu:
a) within one minute of the device being switched on;
or
b) by simultaneously pressing the buttons:
Display Meaning Value range Factory
setting
Current
setting
Line Value
0 0 Collector protec-
tion function
0 = O
1 = On
2 = Drain back
0 = O
1120 °C Collector protec-
tion function 110 – 150 °C 120 °C
2180
Fill time for drain-
back function (if
activated)
15 – 360 sec 180 sec
3 0
Recooling function
(only if collector
protection is on)
0 = O
1 = On 0 = O
440 °C
Recooling tem-
perature for storage
tank
30 – 90 °C 40 °C
5 0 Type of pump
control
0 = Standard pump:
A1 RPM-controlled
– 230 V block mod-
ulation
1 = HE pump:
Analogue or non-in-
verse PWM control
2 = HE pump:
Analogue or inverse
PWM control
1
Settings and changes in
this menu must only be
carried out by a specialist techni-
cian. Incorrect settings can
damage or adversely affect the
function of the solar power
system.
Settings and changes in
this menu must only be
carried out by a specialist techni-
cian. Incorrect settings can
damage or adversely affect the
function of the solar power
system.

9
6 System diagrams
1 collector, 1 storage tank
S1
A1
S3
S2
FUSE
A1 L1
N N
M M M M
O1 S1 S2 S3
PE - PE
PE - PE
PWM
ANA
230 V connections
L Mains phase
N Neutral conductor – mains and outputs
A1 Solar circuit pump supply voltage
Sensor connections
S1 Collector sensor
S2 Lower storage tank
S3 General temp. measuring point
O1 Small-signal output for pump control. PWM or analogue (jumper setting)
Operational safety for the
controller/system is only
guaranteed if these are used for
the intended purpose and if no
wiring errors have been made.
Failure to follow the connection
diagrams and safety instruc-
tions can endanger the pump/
system and human life. The
pump manufacturer's instruc-
tions and safety advice must
also be followed.
Selections are made via
the jumper on the connec-
tion assembly.
PWM position:
ANA position:
PWM
ANA
PWM
ANA

10
7 Controller functions
7.1 General controller functions
The controller compares the temperatures of the various measuring points and
charges the storage tank optimally. If the collector temperature exceeds the
storage tank temperature, the solar circuit pump is switched on. Monitoring and
protective functions ensure safe system operation.
7.1.1 RPM control
The A1 output can be operated using RPM control.
For the following control types
230 V block modulation■
Analogue signal■
PWM signal■
the value set limits the minimum control value.
The minimum pump RPM can be congured in a range between 30% and 100%. If
a value of 100% is set, then RPM control is switched o.
"Programming" menu
Display Meaning Value range Typical set-
ting
min
100
Set minimum pump capacity
using RPM control
100% = RPM control o
30% – 100% 100%
7.1.1.1 Standard 230 V AC pumps
230 V block modulation
Solar circuit pump (switched output A1) is RPM-controlled.
"Basic Setup" menu
Display Meaning Value range Factory set-
ting
Line Value
5 0 Type of pump control
0 = A1 RPM-control-
led – 230 V block
modulation
1
7.1.1.2 HE pumps
The temperature dierence controller in the solar circuit controls the solar pump
RPM in a range between 30% and 100%.
The minimum pump RPM can be congured in a range between 30% and 100%.
If a value of 100% is set, then RPM control is switched o. The pump RPM given by
the controller is indicated as "nSoll" in the curves shown overleaf.
Control of the solar circuit pump via analogue signal
Type A
Pump performance is controlled via a 0 to 10 V analogue signal at O1 (jumper
position ANA)
Output voltage denitions:
Pump o: 0.5 < U < 1.0
RPM control, linear curve 3 <= U <= 10 with minimum pump capacity set to 30%
Selections are made via
the jumper on the connec-
tion assembly.
ANA position:
PWM
ANA

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Control of the solar circuit pump via PWM signal
The controller emits a PWM signal at connection O1 for the control of PWM
pumps (jumper position PWM).
Base frequency = 2 kHz, approx. 12 V, approx. 5 mA
- Non-inverse PWM control
Non-inverse PWM control: Target RPM 0-100% equates to PWM 0-100%
"Basic Setup" menu
Display Meaning Value range Factory set-
ting
Line Value
5 1 Type of pump control 1 = Non-inverse PWM
control 1
Control output
A1 O1 O1
230 V AC
Analogue Type A
ANALOG Typ A
0
2
4
6
8
10
0 50 100 150
nSoll in %
U in Volt
bei nmin = 30 %
PWM Type A
PWM Typ A
0
20
40
60
80
100
0 25 50 75 100
nSoll in %
PWM in %
bei nmin = 30 %
A1 no RPM control, only switched operation on/o. Minimum switch-on time 5
sec.
- Inverse PWM control
Inverse PWM control: Target RPM 0-100% equates to PWM 100-0%
"Basic Setup" menu
Display Meaning Value range Factory set-
ting
Line Value
5 2 Type of pump control 2 = Inverse PWM
control 1
Selections are made via
the jumper on the connec-
tion assembly.
PWM position:
PWM
ANA
-1
1
3
5
7
9
11
13
15
0 125 250 375 500 625 750
t in µs
U in V
PWM = 25 %

12
Control output
A1 O1 O1
230 V AC
Analogue Type A
ANALOG Typ A
0
2
4
6
8
10
0 50 100 150
nSoll in %
U in Volt
bei nmin = 30 %
PWM Type B
PWM Typ B
0
20
40
60
80
100
0 25 50 75 100
nSoll in %
PWM in %
bei nmin = 30 %
A1 no RPM control, only switched operation on/o. Minimum switch-on time 5
sec.
7.1.5 Drain-back function
If this function is active when the solar circuit pump is switched o, then the
medium drains back into a collection container. This prevents the system freezing
or overheating. When the pump is switched back on, it is operated at maximum
capacity for the preset ll time before then switching to capacity control.
Recooling is not possible at this time (menu items 3 and 4 are not shown)
"Basic Setup" menu
Display Meaning Value range Factory set-
ting
Line Value
0 2 Collector protection function
0 = O
1 = On
2 = Drain back
0 = O
1120 °C Collector protection temperature 80 –150 °C 120 °C
2180 Fill time for drain-back function 15–360 sec 180 sec
Settings and changes in
this menu must only be
carried out by a specialist techni-
cian. Incorrect settings can
damage or adversely affect the
function of the solar power
system.

13
7.2 Protective functions
The controller is equipped with the following protective functions.
7.2.1 Collector protection
If the storage tank has reached the set maximum temperature and the collector
temperature exceeds the set collector protection temperature (line 1), the solar
circuit pump is switched on. The solar circuit pump is switched o once the col-
lector temperature is 10 K below the maximum value.
In this case, the storage tank is charged to 95° C, regardless of the set maximum
temperature.
7.2.2 Recooling (holiday function)
The collector protection function is only eective if the storage tank temperature
is below the temperature limit (95°). During a holiday period, for example, the
storage tank must therefore be discharged at night to the set recooling tempera-
ture.
Warning: do not activate this function at the same time as backup heating!
"Basic Setup" menu
Display Meaning Value range Factory set-
ting
Line Value
0 0 Collector protection function on/o 0 = O
1 = On 0 = O
1120
°C
Temperature at which the collector
protection function activates
110 – 150
°C 120 °C
3 0 Recooling protection function on/o
(only if collector protection is on)
0 = O
1 = On 0 = O
440 °C
Temperature to which the storage
tank is recooled with collector pro-
tection function activated
30 – 90 °C 40 °C
7.2.3 System protection
To protect system components, the solar circuit pump is switched o if the collec-
tor temperature exceeds the collector protection temperature (see 7.2.2) by 10 K.
If the temperature drops below this temperature, the controller once again
resumes normal operation.
This function is always activated.
Settings and changes in
this menu must only be
carried out by a specialist techni-
cian. Incorrect settings can
damage or adversely affect the
function of the solar power
system.

14
8 System monitoring
The occurrence of errors is generally indicated by a ashing symbol.
8.1 Sensor monitoring
The connected sensors and sensor cables are monitored for interruptions and
short-circuits. Errors are indicated by the symbol. The source of the error can
be found by paging up or down in the Info menu.
8.2 Flow monitoring
The controllers are programmed so as to display a message if the ow is inter-
rupted, e.g. via pump fault or vapour in the system. However, this notication
does not switch o the pump.
"Basic Setup" menu
Display Meaning
+No circulation in solar circuit

15
9 Troubleshooting
In principle, all system errors can be placed in one of two categories:
Faults that the controller can detect automatically and for which error mes-■
sages can be shown
Faults that cannot be reported by the controller■
9.1 Faults with error messages
Error displayed
on-screen
Possible causes Action to take
ashing
Disruption to sensor■
cable Check cable
Sensor defective■Check sensor resistance,
replace sensor if neces-
sary
ashing
Short-circuit in sensor■
cable Check cable
Sensor defective■
Check sensor resistance,
replace if necessary
Circulation fault:
no ow-through
+
ashing
Fault in pump connection■Check cabling
Pump defective■Replace pump
Air in the system■Vent system
Disruption to sensor■
cable Check cable
Sensor defective■Check sensor resistance,
replace sensor if neces-
sary

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9.2 Faults without error messages
For faults and malfunctions that cannot be displayed, you can use the following
table to identify them, plus evaluate the possible causes and sources of such
errors. If you cannot rectify the fault by using the description below, you will need
to contact your supplier or installer.
Error display Possible causes Action to take
No display pos-
sible
230 V mains power supply■
unavailable
Switch on or connect up
control unit
Check fuses for building
power supply
Fuse inside unit defective■Check fuse*, replace if
necessary with new 2A
(T) fuse.
Check 230 V compo-
nents for short-circuits
Unit defective■Contact your supplier
Pump is not
switched on
Unit is in manual opera-■
tion mode Exit "Manual Operation".
Switch-on condition not■
yet achieved. Wait until switch-on
condition achieved
"Pump" icon
turns, but pump
is not on
Disruption to pump con-■
nection. Check cable to pump
Pump has seized up.■Ensure pump can run
smoothly
No voltage at output.■Contact your supplier.
Temperature
display uctuates
strongly at short
intervals
Sensor cabling has been■
laid near to 230 V cables Reposition sensor
cabling, shield sensor
leads
Long sensor cables ex-■
tended using unshielded
leads
Shield sensor leads
Unit defective■Contact your supplier
Important: any faults
involving the 230 V AC
mains power supply must only
be rectified by a technician!

17
10 SOLAREG II technical data
Casing
Material 100% recyclable ABS casing for wall mounting
Dimensions (L x W x H) in mm,
weight 175 x 134 x 56; approx. 360 g
Protection class IP20 according to DIN 40050
Electrical specications
Supply voltage AC 230 V/50 Hz, -10 – +15%
Radio interference class N (as dened by VDE 0875)
Max. cable cross-section, 230 V
connections 2.5 mm² ne-/single-wire
Temperature sensor
measuring range
PT1000, 1 kΩ at 0 °C
- 30 °C .. +250 °C
Test voltage 4 kV 1 min according to EN 60730/DIN, VDE
0631, IEC 60664/IEC
Output voltage
Power per output
Control signal PWM (O1):
Control signal ANA (O1:
230 V AC
1 A / approx. 230 VA for cos φ = 0.7-1.0
2 kHz, max. 10 mA
0..10 V, max. 5 mA
Fuses Fine-wire fuses 5 x 20 mm, 2A (T)
2 amperes, time lag fuse
Other
Operating temperature 0– + 50 °C
Storage temperature -10 – + 65 °C
Humidity max. 60 %
11 PT1000 resistance table
Temperature sensors can be checked for proper function by using an ohmmeter
and consulting the following temperature resistance table:
Temperature
in °C
Resistance in
ohms
Temperature
in °C
Resistance in
ohms
-30 882 60 1232
-20 921 70 1271
-10 960 80 1309
01000 90 1347
10 1039 100 1385
20 1077 120 1461
30 1116 140 1535
40 1155 200 1758
50 1194
Specifications subject to
change as technical
improvements are made.

18
12 Guarantee terms and conditions
SOLAREG II controllers are manufactured with care and inspected using an auto-
mated test facility. If faults should occur, please make an initial check for operator,
conguration or system errors. You should also inspect connections to pumps
and temperature sensors.
PROZEDA GmbH guarantees workmanship according to the following conditions
for 24 months after purchase date.
a) This guarantee covers defective workmanship in the item purchased. This
guarantee is rendered null and void if the fault results from any of the follow-
ing: operator error, exceeding the technical specications, incorrect wiring or
improper technical modications to the device (by the purchaser or a com-
pany other than PROZEDA GmbH).
b) Guarantee claims must be made in writing, giving a detailed description of
the fault and including a copy of the purchase receipt.
PROZEDA GmbH will honour claims by choosing, at its discretion, between:
- Repair (overhaul); or
- Supplying a fully-functional replacement.
Repairs will take no longer than 1 month from receipt of the unit by PROZEDA
GmbH.
If the fault has not been remedied on the second repair attempt, then the
purchaser has the right to be supplied with a fully-functional replacement.
Replacement parts are supplied with a new guarantee according to these
terms and conditions.
c) Any other guarantee rights (cancellation, discounts) are hereby excluded.
Rights granted by this guarantee are due to the purchaser only and are not trans-
ferable.
If defects occur within the guarantee period, please rst inform your supplier/in-
staller. Product returns must always be accompanied by a description of the fault,
plus, if possible, a system diagram and wiring plan.
13 Declaration of conformity
We, Prozeda GmbH, hereby declare our sole responsibility for ensuring that the
SOLAREG Type 1332 product complies with the following directives:
DIRECTIVE 2004/108/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 15 December 2004
on the approximation of the laws of the Member States relating to electromagnetic compatibility and
repealing Directive 89/336/EEC
Law on the electromagnetic compatibility of equipment (EMC) of 26 February 2008
DIRECTIVE 2006/95/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 12 December 2006
on the approximation of the laws of the Member States concerning electrical equipment for use within
certain voltage limits
DIN EN 61326-1, VDE 0843-20-1:2006-10 Electrical measurement, control and
laboratory use - EMC requirements - Part 1: General requirements (IEC 61326-
1:2005); German version EN 61326 -1:2006
DIN EN 61326-2-2, VDE 0843-20-2-2:2006-10 Electrical measurement, control and laboratory use - EMC
requirements - Part 2-2: Particular requirements - Test, operating conditions and performance require-
ments for portable test, measurement
and monitoring equipment for use in low voltage power supply systems (IEC
61326-2-2:2005); German version EN 61326-2-2:2006
DIN EN 60730-1, VDE 0631 Part1:2009:06 -1 Automatic electrical control devices for household and
similar use - Part 1: General requirements (IEC 60730-1:1999, modied + A1:2003, modied + A2:2007,
modied); German version EN 60730-1:2000 + A1:2004 + A12:2003 + A13:2004 + A14:2005 + A16:2007
+ A2:2008

19

20
Operating manual for SOLAREG II BASIC HE 1332BED001-10B-E, last revised 06/2009