Refu sol PV Heater DCLV User manual

PV Heater DCLV
Producing warm water with photovoltaics
Operation- and installation instructions
Version 02.6

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Title
PV Heater DCLV Production of warm water
Type of Documentation
Operation- and installation instruction
Purpose of the
Documentation
In this documentation the use of PV Heater DCLV has been described.
Released by
AEI Power GmbH Uracher Street 91 •D-72555 Metzingen
Telephone: [phone] •Fax [phone]
[e-mail]
Reservation of Rights
All the data in this documentation was generated with a lot of care and
has been
checked. Despite that there could be errors or deviations
because of the technical progress, which could not be completely
excluded.
No responsibility or guarantee is taken for completeness.
The present updated version can be obtained at
http://www.advanced-energy.com.
Copywright
The data obtained in this documentation is the property of AEI Power
GmbH. The evaluation as well as the publication of this
documentation, even in extracts, requires the wri
tten approval of
AEI Power GmbH.
Trade Symbol
REFU sol®is a registered trademark.
Marking Version Number
Version Number
BA_PV_Heater_V02.6_EN
06/2015

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Contents
1Using this operation instruction...............................................................................................5
1.1 Symbols and Text Markings............................................................................................5
1.2 Warning Instructions........................................................................................................5
1.2.1 Set up of a Warning Instruction.......................................................................................5
1.2.2 Classes of Warnings........................................................................................................5
1.3 Suggestions.....................................................................................................................6
2Suggestions on Safety...............................................................................................................7
2.1 14Introduction......................................................................................................................7
2.2 Appropriate use ...............................................................................................................7
2.3 Technical specification PV-module .................................................................................7
2.4 Target group....................................................................................................................7
2.5 Disclaimer........................................................................................................................7
2.6 Warning instructions in or on the equipment...................................................................9
3Scope of Supply........................................................................................................................10
3.1 Packing List ...................................................................................................................10
3.2 Unpacking and checking out the scope of supply.........................................................10
4Structure and function.............................................................................................................11
4.1 Equipment safety and personnel protection..................................................................11
4.2 Protection from surge and lightning strike.....................................................................11
4.3 Installation suggestions for the complete system..........................................................11
4.4 Configuration of the photovoltaic system ......................................................................12
4.5 Equipment and functional description ...........................................................................13
4.5.1 Internal connections ......................................................................................................14
5Installation.................................................................................................................................15
5.1 Required tools................................................................................................................15
5.2 PV Heater DCLV to be assembled to Water Storage....................................................16
5.3 Optional web connection...............................................................................................23
5.4 Optional control on ENABLE input (X3) ........................................................................24
5.4.1 Location on board..........................................................................................................24
5.4.2 Properties ......................................................................................................................24
5.4.3 Operation.......................................................................................................................24
6Configuration with advanced energy connection tool .........................................................25
6.1 Prerequisites..................................................................................................................25
6.2 Automated Device Search.............................................................................................25
6.3 Configure Network Connection PV Heater with DCHP.................................................26
6.4 Manually Configure Network Connection PV Heater ....................................................26
6.5 Direct Connection of PV Heater - Windows-PC ............................................................27
6.6 Set up the Maximum Water Temperature .....................................................................27

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6.7 The Functions of the Relay............................................................................................27
6.8 Enable Switch................................................................................................................28
6.9 Remove Permanent Error..............................................................................................28
6.10 Set Time ........................................................................................................................28
6.11 Update...........................................................................................................................28
6.12 Float Through ................................................................................................................29
7Monitoring Portal AE SiteLink (REFUlog)..............................................................................30
7.1 General Information.......................................................................................................30
7.2 Integration of PV Heater in AE SiteLink (REFUlog) ......................................................30
8Maintenance and Repair ..........................................................................................................32
8.1 Replacement battery .....................................................................................................32
9Case of Error.............................................................................................................................33
9.1 Determine the error code "WARNING"..........................................................................33
9.2 Determine the error code "ERROR"..............................................................................33
10 Accessories...............................................................................................................................36
11 Dismantling and Returning......................................................................................................37
12 Disposal.....................................................................................................................................38
13 Technical Data ..........................................................................................................................39
14 Contact ......................................................................................................................................40
15 Certificates................................................................................................................................41
16 Warranty ....................................................................................................................................42
17 Notes..........................................................................................................................................43

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1 Using this operation instruction
This operation instruction is a part of the product
⇒Operation instruction should be read before installation of the equipment.
⇒Operation instructions should be made available at the equipment during the complete life of
the product.
⇒Operation instruction should be made available to prospective users of the equipment.
1.1 Symbols and Text Markings

Assumptions
⇒
Instructions one step
1.
Instructions multiple steps
•
Ennumeration
Highlighting
Highlighting within a text

Results
1.2 Warning Instructions
1.2.1 Set up of a Warning Instruction
WARN WORD
Type and source of the danger are described here.
⇒Here one provides the measures for avoiding the danger.
Example
DANGER
Death or severe physical damages to the body because of high leakage
current while opening the equipment.
⇒Before connecting the power supply the earthing must be checked
without fail.
1.2.2 Classes of Warnings
There are three classes of warnings.
DANGER
“DANGER” designates a safety instruction, which if ignored immediately leads
to death or severe physical damages!
WARNING
“WARNING” designates a safety instruction, which if ignored can lead to death
or severe physical damages to the person!

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CAUTION
“CAUTION” designates a safety instruction, which if ignored could lead to
damaged goods or light physical damages!
1.3 Suggestions
Note: A suggestion describes information, which is important for the optimum and
economic operation of the system.

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2 Suggestions on Safety
2.1
14
Introduction
Before the installation and the commissioning of this equipment all the data that is delivered along
with the equipment is to be carefully read.
The following suggestions are to be noted before the installation of the equipment for avoiding
physical damages and/or damages to the equipment. The safety instructions are to be maintained at
any point of time.
In case of sale, lease or any other kind of transfer of the equipment, the product documentation is to
be likewise enclosed.
Before the installation and commissioning it should be ensured that, the PV and the heating system
available, as well as the warm water storage correspond to the regulations and the actual technology
levels. In case of doubt, before the installation the existing PV and the heating system, as well as the
hot water storage is to be checked by a recognized professional.
2.2 Appropriate use
AE PV Heater should be used only with AE PV heating element that is delivered.
WARNING
Danger of infection through insufficient disinfected water.
⇒The thermal disinfection must be guaranteed by the heating system that
is available.
⇒Existing heating system must always remain in operation.
PV Heater DCLV serves for the generation of hot water in residential or commercial installations. The
equipment shall be supplied with its own separate PV system and being fitted into an existing heating
system. AE PV heater DCLV should be used only in connection with the AEREFUsol screwed in PV
heating element that is delivered along with the equipment. Every usage that goes beyond that is
considered as not in accordance with the regulations. The connection of additional electrical supplies
is specifically not permitted.
2.3 Technical specification PV-module
PV-Modules of the class A as per IEC 61730 must be used.
2.4 Target group
The use of the equipment is suited for persons, who have a minimum technical knowledge and the
skills and capabilities.
Out of this, persons, (including children) with limited physical, sensory or physical abilities or lacking
the required electrical knowledge are excluded. In this case, the support is needed through the
corresponding technical personnel.
2.5 Disclaimer
The general conditions for the supply and performance of AEI Power GmbH are applicable
•In case of damages because of ignoring the warning instructions given in this installation
manual or a use outside the ambit of regulations, AEI Power GmbH does not take any liability
or responsibility.
•The PV Heater have both water and electricity contact. Any changes other than the permitted
exchange of the heating rod with an original AE replacement heating rod (hereinafter

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changes) thus to the PV Heatern jeopardize their safe operation and can cause considerable
damage.
•Because of this it is not allowed to make changes or repair attempts to the PV Heaters. AE
assumes no responsibility, if damage due to a change or a repair attempt at a PV Heater
arises. Changes to the PV Heater lead to the exclusion of warranty, if the changes are the
cause for a warranty claim.
•Before the commissioning the operation, maintenance and security measures should be read
through.
•The error free and safe operation of this equipment pre supposes an appropriate and
professional transport, storage, assembly and installation as well careful operation and
maintenance.
•Accessories and spare parts that are approved by the manufacturer are permitted.
•The safety specifications and guidelines of the country, in which the system is being used, are
to be considered.
•The environment conditions specified in the product documentation must be maintained.
•The technical data, the measurement, connection and installation conditions are to be derived
from the product documentation and maintained unconditionally.
•For damages in connection with higher power and catastrophe cases, we do not take any
liability.

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2.6 Warning instructions in or on the equipment
The sticker is found in the interior of the equipment right next to
the connections for the PV-modules.
Below the meaning of individual symbols and texts from the top
to the bottom:
•PV-Modules to be connected parallel.
•PV-Modules never to be connected in series.
•Before the installation the operation instructions to be read.
•The voltage per PV input should not exceed 50 V.
•After the installation and before the commissionin
g the
water level in the heating system is to be checked.
Image 1: Adhesive in the equipment
Pay attention that the product documentation must be read
before the installation.
Image 2: Adhesive

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3 Scope of Supply
3.1 Packing List
PV Heater DCLV contains:
Stk.
Designation
Type No.
1
PV Heater
401R1K5
1
The enclosed set contains:
34468
2
2-polar plug part
17062
1
3-polar plug part
17064
1
4-polar plug part
34410
4
Combination screws M4x16
13968
10
Cable binder
11243
1
Operation and. installation instructions
34464
The additionally required AE PV heating element – set No. 0034480 is delivered in a separate
packaging.
3.2 Unpacking and checking out the scope of supply
⇒Completeness of the packing content to be checked as per 3.1.
In case of the incomplete scope of supply viz. Damages or defects, an installation and
commissioning is not permissible. In this case, AE service is to be contacted.

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4 Structure and function
4.1 Equipment safety and personnel protection
The AE PV Heater device prodives the following safety functions:
•Recognizing of Earth connection and insulation error PV-modules and screw heater.
•Recognizing and protective circuit in case of wrong DC-polarity.
•Recognizing and regulation in case of surge on the screw heater.
•Redundant temperature monitoring and switching off in case of emergency.
•Recognizing of errors or failures in PV-modules and screw heater.
•Personal protection guaranteed by protective extra low voltage (PELV).
•Internal temperature monitoring and switch off.
CAUTION
Damages to equipment because of defects caused possibly high back
current in parallel connection of modules.
⇒Possible back current of modules to be checked by experts.
4.2 Protection from surge and lightning strike
PV-supply inputs for PV Heater DCLV are protected by the use of surge conductors against surge
from internally and externally. The electronic facilities and communication lines fulfill the requirements
for protection against external surges.
In case of an existing lightning protection system a lightning protection specialist has to evaluate, as
to how far the complete system must be connected with the PV Heater DCLV in the lightning
protection.
4.3 Installation suggestions for the complete system
While planning, installation and after the following first commissioning of the complete PV- System the
following must be considered:
•The local standards and laws concerning grounding, construction, cabeling and conncetion.
•Installation suggestions of the PV-module manufacturer
•Standards presently valid at the location, specially the standards:
oIEC 60364 (Erection of low voltage systems)
oIEC 61643 (Surge arrester for low voltage systems)
oIEC 821749 / EN 62446 (Minimum requirements for PV-systems)
oEN 61000-4 (EMC)

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4.4 Configuration of the photovoltaic system
WARNING
Disturbance or damage to the equipment and danger of damage
because of high voltage.
⇒Never connect photovoltaic-modules in series connection.
⇒Maximal voltage of 50 V and maximum current of 30 A
per MPPT input to be noted unconditionally.
⇒Ensure that, the socket of the PV-system is easily accessible, so that
the system can always be connected quickly without voltage.
Image 3: Principle sketch of the complete system
Parallel connection, 1-3 module per MPPT, return current to be checked
•MPPT 18-40 V
•Max. 50 V
•Max. 20 A
•Overload possible up to 30 A

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4.5 Equipment and functional description
PV Heater DCLV uses the power generated from the solar cells for generation of hot water with the
help of a screw-in heating element integrated into the hot water tank.
A connection of up to 9 modules is possible on low voltage level. As hereby a voltage of 50 VDC is
not exceeded, the PV Heater DCLV can be installed even by persons, who have no knowledge on
electro technical systems.
Front Side
1: Connection for 3 Photovoltaic strings
2: Display Element
3: ON/OFF switch on the lower side or bottom
side of the equipment
Image 4
Back Side
1: Ethernet Connection
2: Screw Heater
3: Air outlet opening
4: Air input opening
Image 5
Bottom / ON/OFF switch
Image 6

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Display Element
ON (green blinking 90% on):
Equipment is active
WARN (yellow): Insulation error. The LEDs 1-3
display an error code.
ERROR (red): The LEDs 1-
3 display an error
code.
1. Error code to be determined (see para. 8,
page. 30)
2. AE Service to be contacted.
1-3 (yellow): In normal operation display of the
actual active power for the lines 1 to 3. The
duty cycle within a 2 second interval showes
by the situation “LED on” and “LED off” the
presently provided power
as part of 100%
power.
Examples:
LED 1 illuminates continuously: over line 1 the
complete power is delivered.
LED 1 is likewise on and off for one second:
Over line
1 half of the possible power is
delivered.
LED 1 on for 0,5 seconds and off for 1,5
seconds: Over line 1, 25
% of the possible
power is delivered.
Image 7
4.5.1 Internal connections
Description of internal connections
Connection
Function
Pinning (Numbers from top to
bottom)
X2
Potiential free contact
max. 24V/3A DC or AC
1-2: n.c.
2-3: n.o.
X3
Enable input
X4
Without function
Must not be used!
X14
Water temperature
Temperature sensor for heating
element
X15
External Temperature
sensors 1 and 2
1-2: External Sensor 1 (PT1000)
3-4: External Sensor 2 (PT1000)

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5 Installation
WARNING
Danger to life because of possible lightning.
⇒Installation should not be carried out during a thunderstorm.
CAUTION
Material damages because of inappropriate installation.
⇒The screw-in heating element must be assembled before
equipment installation by an expert in heating systems in the warm
water storage tank. For details, see operation instructions AE PV
heating element.
⇒The hot water storage tank must correspondingly filled with water.
⇒For the connection to the solar modules PV-lines or cables with a
dia of 4 mm2or 6 mm2must be used. The use of adder sleeves is
not permitted..
⇒Only vertical mounting is permissible (see step 19). Switch board
must always be on the bottom side.
⇒The air input and output vents of the equipment should never be
covered, to avoid any overheat and damage.
⇒The place of assembly must be freely accessible for service and
maintenance.
⇒For guaranteeing the operational safety of the equipment the LEDs
must always be visible and the Power ON switch on the
equipment’s bottom side must always be accessible.
⇒Equipment must be protected from the penetration of water.
5.1 Required tools
A countersunk screw driver, engineers pliers and side cutting pliers are needed.

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5.2 PV Heater DCLV to be assembled to Water Storage
The hot water storage tank must
be correspondingly filled with
water.
ON/OFF
switch must remain
OFF (0).
1. Screw M5 on the upper side of
the housing to be loosened with
the screw driver.
2. Housing cover to be folded down
from the top and removed.
Image 8
3. Position of the threaded bore on
the screw-in heating element to
be determined.
Image 9

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4. Ring (Inner housing) to be turned
in such a way, that the screw
holes match with the thread
bores of the screw-in heating
element. Notch (arrow) must lie
in the center between two
threaded bores.
Image 10
5. Housing to be placed and
possibly aligned with a
mechanic’s level.
Image 11

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6. The four accompanying
screws M4x16 are to be
placed and tightened over a
cross.
Image 12
7. The six pin plug of the cable of
the screw in heating body is to
be inserted pair wise in the
connector X5, X7 and X9. Be
sure there is no loose
connection.
Image 13

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8. The main sensor cable (Type
PT1000) is to be plugged into
connector X14 located in the
upper right of the housing.
The connector X15 below
provides optionally a second
(pin 1+2) and third (pin 3+4)
external sensor to be
connected. Pin 1 in the
connector is the most upper
pin in the adjacent figure.
Image 14
9. Sensor cable to be fastened
with cable ties on the housing.
10. Long ends of the cable tie to be
cut.
Image 15

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11. Insulation to be removed
11 mm from the photovoltaic
string cable.
12. Plus and Minus of the string
cable with the help of the
integrated polarity tester on
the PCB to be checked.
Green LED (arrow) glows:
Alignment plus and minus
match.
Red LED glows:
⇒Plus and minus to be
interchanged.
Image 16
13.
Insert string cables in
accordance with the polarity
(red = plus, blue = minus) in the
insertion funnels of the PCB
terminals. Avoid touching the
bare ends of the wires.
Image 17
14. Press lever down until it stops,
to safely connect the conductor.
The lever must be completely
depressed (B). The conductor
connection is not guaranteed
when a lever is not closed.
Image 18