REGULA medius 600 SR User manual

Controller unit for solar thermal systems
medius 600 SR
Installation and operating instructions
English version of original German installation and operating instructions
Version: 1.0
July 2012

Terminology
In order to facilitate the use of the assem ly and operating instructions, the
following terminology will e used:
•These installation and operating instructions will hereinafter e designated as
"Instructions".
•The medius 600 SR controller will hereinafter e designated as "Controller".
•The thermal solar power plant will hereinafter e designated as "Solar power
plant".
•Freely defina le Prozeda function modules, complete with selecta le inputs
and outputs, will hereinafter e designated as "Multi-function controllers"
(MFC).
•Prozeda Gm H will hereinafter e designated as the "Manufacturer".
Declaration of conformity
We, Prozeda Gm H, here y declare in sole responsi ility that the product medius
600 SR complies with the following directives:
•Electromagnetic compati ility (2004/108/EC )
•Electrical equipment designed for use within certain voltage limits
(2006/95/EC)
•CE marking (93/68/EEC).
Standards that were used:
•DIN EN 60730-1
•DIN EN 61326-1
•DIN EN 61326-2-2

This manual is designed to help you use the controller properly, safely and economically.
Target group
This manual is addressed to all persons who carry out any of the following tasks:
•Installing the controller
•Connecting the controller
•Putting the controller into operation
•Setting the controller
•Maintaining the solar power system
•Eliminating faults on the controller and the solar power system
•Disposing of the controller
These persons must have the following knowledge and skills:
•Knowledge about establishing electrical connections
•Knowledge about the hydraulic operation of solar power systems
•Knowledge of the applicable regulations at the point of use and the ability to apply
them
These persons must have read and understood the contents of this manual.
Availability
This manual is part of the controller. Always keep it in an easily accessible location. Include
this manual with the controller should the controller change hands.
If this manual gets lost or becomes unusable, you can contact the manufacturer for a new
copy.

Style conventions used in the text
Specific style conventions are assigned to different elements in the manual. This makes it
easy to recognise the type of text concerned:
Standard text,
"Menu", "Menu item", "Button designations",
•lists and
actions.
Notes accompanied by this symbol contain information about how to operate the
controller economically.
Style conventions for hazard warnings
This manual makes reference to the following categories of hazard warnings:
DANGER
Information or instructions accompanied by the word DANGER provide a
warning about a hazardous situation that will lead to fatal or serious
injuries.
WARNING
Information or instructions accompanied by the word WARNING provide a
warning about a hazardous situation that may possibly lead to fatal or
serious injuries.
CAUTION
Information or instructions accompanied by the word CAUTION provide a
warning about a situation that can lead to minor or moderate injuries.
Style conventions for warnings of damage to property or
the environment
ATTENTION
Information and instructions of this kind provide a warning about a
situation that can lead to damage to property or the environment.

Table of contents
1Safety........................................................................................................................ 7
1.1 Proper use.............................................................................................................................................. 7
1.2 Basic safety information .................................................................................................................... 7
2Description of the controller ................................................................................... 9
2.1 Overview................................................................................................................................................. 9
3Installing the controller......................................................................................... 10
3.1 Fastening the controller ..................................................................................................................11
4Connecting the controller ..................................................................................... 12
4.1 Connecting cables to the controller ............................................................................................12
4.2 Connecting the controller to the power supply.......................................................................14
4.3 Connecting temperature sensors.................................................................................................14
4.4 Assignment of the terminals to the system components.....................................................15
5Operating the controller........................................................................................ 22
5.1 Description of the display elements............................................................................................22
5.2 Using the operating buttons.......................................................................................................... 24
6Displaying and changing the values in the menus............................................... 26
6.1 Displaying values in the "Info" menu...........................................................................................26
6.2 Displaying and changing values in the "Program" menu .....................................................29
6.3 Controlling switching outputs in the "Manual mode" menu............................................... 32
6.4 Displaying and changing values in the "Basic settings" menu............................................32
7Setting the control functions ................................................................................ 38
7.1 Setting the charging principle.......................................................................................................38
7.2 Setting the "Storage tank priority" function..............................................................................39
7.3 Setting the "Parallel charging" function .....................................................................................39
7.4 Setting the pump control system................................................................................................. 40
7.5 Setting the "Tube collector" functions........................................................................................42
7.6 Bypass function / external heat exchanger ............................................................................... 43
8Setting multi-function controllers (MFC).............................................................. 43
8.1 Setting the "Cooling" function.......................................................................................................44
8.2 Setting the "Heating" function ...................................................................................................... 44
8.3 Setting the "Temperature difference controller" function....................................................44
8.4 Setting the "Threshold value switch" function.........................................................................45
8.5 Setting the "Return flow boost" function................................................................................... 45
8.6 Setting the "Wood-fired boiler" function................................................................................... 45
8.7 Setting the "Circulation" function................................................................................................. 46
8.8 Setting the "Alarm" function .......................................................................................................... 46
8.9 Setting the "Timer" function...........................................................................................................46
8.10 Setting the logical link...................................................................................................................... 47

9Setting protective functions..................................................................................47
9.1 Setting the "Collector protection" function...............................................................................47
9.2 "Storage tank protection" function ..............................................................................................48
9.3 "System protection" function.........................................................................................................48
9.4 "Pump protection" function............................................................................................................48
9.5 "Heat exchanger protection"..........................................................................................................48
9.6 Setting the "Recooling" function...................................................................................................49
9.7 Setting the "Drain-back" function.................................................................................................49
9.8 Setting the "Anti-freeze protection" function...........................................................................50
10 Measuring energy output......................................................................................50
10.1 DFG (Flow sensor)..............................................................................................................................51
10.2 VFS (Vortex flow sensor) ..................................................................................................................51
10.3 DFA (Flow indicator)..........................................................................................................................51
11 Restore factory settings.........................................................................................52
12 Networking the controller with other devices......................................................52
13 Faults ......................................................................................................................53
13.1 Faults with fault message................................................................................................................53
13.2 Faults without fault message .........................................................................................................55
14 Technical data ........................................................................................................57
15 Accessories .............................................................................................................58
16 Disposing of the controller....................................................................................59

Safety
7
1Safety
This chapter contains information on:
•the proper use of the controller and
•the safe use of the controller.
Read this chapter through carefully before you install, connect or operate the controller.
1.1 Proper use
The controller is used for monitoring and controlling a solar thermal system.
Appropriate use of the controller includes the following requirements:
•Use the controller exclusively in dry rooms in residential, commercial and/or industrial
environments.
•Use only sensor connection boxes supplied by the manufacturer.
•Use the RS485 interface (ProBus) only for networking further devices from the
manufacturer Prozeda.
The definition of proper use also encompasses observing and complying with all of the
information contained in this manual - in particular compliance with all safety information
and instructions.
Any other use, or any use exceeding the specifications, will be deemed to be improper use
and may lead to personal injury or damage to property and shall render the warranty void.
Use of the controller in the following situations in particular is considered to be improper
use:
•If you modify the controller independently and without prior authorisation
•If you operate the controller in a humid or wet environment
The manufacturer shall not be liable for damages arising from inappropriate use.
1.2 Basic safety information
This section contains basic safety information relating to working with the controller. You
will find additional safety information relating to specific actions and workflows at the
beginning of the section concerned.
Preventing risks of explosion
•Never use the unit in areas where there is a risk of explosion.

Safety
8
Preventing risks of fatal injury from electric shocks
•Make sure that all regulations applicable at the point of use are complied with.
•Always make sure that the controller is disconnected from the power supply before
carrying out any work on it.
•Make sure that the connections of the protective extra-low voltage areas do not get
mixed up with the power supply connections.
•On completion of installation work, refit the terminal cover and tighten the locking
screw using a screwdriver.
•Make sure that the electrical connection of the controller can be disconnected from the
mains externally if required.
•Make sure that all cables are secured by strain relief devices.
•Use the device only if it is in a fault-free condition.
Preventing risks of fire
•Install the controller on a non-flammable subsurface.
Preventing risks of injury from burns
•Carry out installation work on the solar power system only when it has cooled down.
•The process water can reach very high temperatures. Exercise particular care when
configuring settings on the controller.
•Take water samples after completion of the settings and check them using a suitable
thermometer.
Preventing damage to property
•A damaged controller may cause malfunctions in the system as well as damage to its
components. Use the controller only if it is in a fault-free condition.
•Install the controller with due observance of its protection class. Information about this
can be found in the chapter Technical Data from page 57 onwards.
•Make sure that no moisture gets into the controller.
•If any moisture gets into the controller, disconnect the controller from the power
supply.
•Make sure that the maximum permissible ambient temperature is not exceeded.
Information about this can be found in the chapter Technical Data from page 57
onwards.
•Make sure that all components to be connected to the switching outputs are suitable
for an operating voltage of 230 V/50 Hz.

Description
of the controller
9
•When in "manual mode", the system must only ever be operated for a short time and
only for test purposes.
•Install sensor lines separately from 230 V lines.
•Use only sensor connection boxes supplied by the manufacturer.
2Description of the controller
The controller is used for monitoring and controlling a solar thermal system. The
controller allows the system to be configured in accordance with the local situation at the
place of use and with the requirements of the user. In addition, the controller can be used
to carry out system protection functions.
2.1 Overview

microSD card interface

Display

Operating buttons

Terminal cover

Locking screw
The display (2) shows the menus for monitoring and controlling the solar power system.
The operating buttons (3) allow you to display and change the parameters.

Installing the controller
10
For data exchange purposes the controller is equipped with a microSD card interface (1).
3Installing the controller
DANGER
Risk of fatal injuries due to explosions or fire.
Never use the controller in areas where there is a risk of explosion.
Install the controller on a non-flammable subsurface.
DANGER
Risk of fatal electric shock when working on the opened controller.
Make sure that the controller is disconnected from the mains voltage
before removing the terminal cover.
Make sure that the power supply has been secured to prevent it from
being switched on again.
Check that the controller is free from voltage.
Screw the terminal cover securely back in place when work has been
completed.
ATTENTION
Risk of damage and malfunctions due to improper storage before
connection.
Store the controller at room temperature for at least four hours before
connecting it.
Select an installation location which meets the following requirements:
•The installation location must be at eye level.
•The installation location must be close to the storage tank and the solar circuit pump.
•It must have access to the power supply.
•There must be sufficient space in front of the controller to allow it to be operated.
•If you wish to lead cables and lines through the back of the controller, there must be
sufficient space for the cable gland.