Shuang Ri SR881 User manual

Manual of Solar Pump Station SR881
2011.02.15

Solar working station operation manual SR881
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Contents
Solar pump station installation and operation manual............................................................4
1. Solar pump station with integrated controller....................................................................... 4
1.1 Scope of delivery.................................................................................................................... 4
1.2 About this manual...................................................................................................................4
1.3 Safety instructions.................................................................................................................. 4
1.4 Station dimensions:................................................................................................................ 5
1.5 Specification of components.................................................................................................5
1.6 Technical Data: .......................................................................................................................6
2. Mounting station........................................................................................................................6
3. Commissioning of station........................................................................................................7
3.1 Flushing and filling the solar system................................................................................... 7
3.2 Flow check............................................................................................................................... 8
3.3 Electrical connection.............................................................................................................. 8
3.4 Accessories for the station(A06)..........................................................................................9
Manual of integrated controller of solar station......................................................................10
1. Safety information...................................................................................................................10
1.1 Important remark..................................................................................................................10
1.2 Description of symbols ........................................................................................................10
1.3 Description of operation button..........................................................................................10
1.4 Terminal layout...................................................................................................................... 11
2. Commissioning of integrated controller ..............................................................................13
2.1 Set time/week........................................................................................................................13
2.2 Menu structure......................................................................................................................14
2.3 Menu description..................................................................................................................15
2.4 System description...............................................................................................................16

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3.Function operation and parameter setup (user grade) .....................................................17
3.1 Timing heating.......................................................................................................................17
3.2 CIRC DHW pump control function.....................................................................................20
4.Function operation and parameter setup ( engineer grade) ............................................23
4.1 Access main menu...............................................................................................................23
4.2 Access submenu ..................................................................................................................23
4.3 Main menu DT O & DT F Temperature difference function...........................................24
4.4 Main menu - TEMP Temperature.......................................................................................25
4.4.1 EMOF maximum switch-off temperature of collector (Collector Emergency Shut
Down Function) ...........................................................................................................................25
4.4.2 EMON maximum switch-on temperature of collector (Collector Emergency Shut
Down Function) ...........................................................................................................................26
4.4.3 CMX Maximum limited collector temperature (collector cooling function)..............26
4.4.4 CMN low temperature protection of collector...............................................................27
4.4.5 CFR frost protection of collector.....................................................................................28
4.4.6 SMX Maximum temperature of tank..............................................................................29
4.4.7 REC Tank re-cooling function.........................................................................................29
4.4.8 C- F Celsius and Fahrenheit temperature switch........................................................30
4.5 Main menu - FUN Auxiliary function..................................................................................30
4.5.1 DVWGAnti-Legionella function......................................................................................31
4.5.2 nMIN Solar circuit pump speed adjusting（RPM speed controlling）....................32
4.5.2.1 DTS Standard temperature difference（for circuit pump’s speed adjusting）...32
4.5.2.2 RIS Temperature increase rate (for circuit pump speed adjusting).......................33
4.5.3 FTYPType of Flow meter (optional)..............................................................................33
4.5.4 OHQM Thermal energy measuring................................................................................33

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4.5.4.1 FMAX Flow rate.............................................................................................................35
4.5.4.2 MEDT Type of heat transfer liquid..............................................................................35
4.5.4.3 MED% Concentration of heat transfer liquid.............................................................35
4.5.5 INTV Pump interval function...........................................................................................36
4.5.5.1 tSTP Pump interval- time.............................................................................................37
4.5.5.2 tRUN Pump running time.............................................................................................37
4.6 HND Manual mode...............................................................................................................37
4.7 PASS Password setting.......................................................................................................38
4.8 LOAD Recovery factory setting..........................................................................................39
4.9 On/OFF button......................................................................................................................39
4.10 Holiday function..................................................................................................................39
4.11 Manual heating ...................................................................................................................40
4.12 Temperature check ............................................................................................................41
5. Protection function..................................................................................................................41
5.1. Memory protection ..............................................................................................................41
5.2 Screen protection.................................................................................................................41
5.3 pump idling protection..........................................................................................................41
6. Trouble shooting .....................................................................................................................42
6.1 Trouble protection.................................................................................................................42
6.2 Trouble checking ..................................................................................................................42
7. Quality Guarantee ..................................................................................................................44
8. Technical data..........................................................................................................................44
9. Accessories to this controller................................................................................................45

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Solar pump station installation and operation manual
1. Solar pump station with integrated controller
Integrated solar controller
outstanding design
Safety assembly with safety valve and manometer
High-Quality casing for reduce heat loses
Flow rate check
1.1 Scope of delivery
1* solar pump station
1* integrated solar controller
1* flushing and filling unit (option)
1* collector sensor PT1000
2* store sensor NTC10K
1* wall mounting bracket
1* accessory bag（include 2 * screw and dowel ; 2 * strain relief）
1* manual
1.2 About this manual
This solar pump station is a preinstalled and leak-tested group of fitting for transferring heat
from the collector to the store. It contains important fittings and safety devices for the
operation of the solar thermal system:
Ball valves in flow and return in combination with check valves to prevent gravity
circulation.
Flow rate check for displaying the flow rate
Manometer for displaying the system pressure
Safety valve to prevent inadmissible overpressure
Flushing and filling unit (optional) for flushing, filling and emptying the solar thermal
system.
1.3 Safety instructions
The installation and commissioning of the solar station as well as the connection of
electrical components requires technical knowledge commensurate with a recognized
vocational qualification as a fitter for plumbing, heating and air conditioning technology, or
a profession requiring a comparable level of knowledge. The following must be observed

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during installation and commissioning:
The relevant regional and national regulations.
The technical and safety instructions of these instructions.
Warning: risk of scalding
There is danger of steam emission with safety valves. Therefore a discharge pipe must be
connected to the safety assembly.
Attention: damage of solar pump station
The group of fittings must be installed with sufficient spacing to the collectors because
temperatures in the vicinity of the collectors can be very high. An intermediate vessel
may be necessary for installation in the attic.
It is imperative that you make sure the PTFE sealing elements of the solar pump station
do not come into contact with substances containing mineral oil. Mineral oil products
cause lasting damage to the material, whereby its sealant properties are lost.
If necessary, ask the manufacturer whether the solar fluid, fats or installation aids
contain mineral oils.
We don’t assume liability nor provide warranty for damage to solar station resulting
from sealants damaged in this way.
1.4 Station dimensions:
Height ( with insulation)：400mm
Width (with insulation)：200mm
Depth (with insulation)：145mm
Distance centre：1600mm
Distance axis/wall：55mm
Pipe connections: 3/4’ IT
Connection for expansion vessel set: 3/4’ET, flat sealing
Outlet safety valve: 1/2 IT
1.5 Specification of components
1.5.1 Safety valve: 6bar
1.5.2 Manometer: 0-6bar
1.5.3 Non-return valve: opening pressure 200mmH2O
1.5.4 Circuit pump: Wilo 15-6
1.5.5 Digital flow counter (alternative Mechanical flow counter)

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1.5.6 Return outlet connection (from collector):
3/4 IT
1.5.7wiring terminal of controller
1.5.8 EPP insulation case
1.5.9 Flow outlet connection (to collector):3/4’
IT
Material:
Fitting: brass
Seals: PTFE
Insulation: EPP, λ= 0.041W/ (m.K)
1.6 Technical Data:
Max. permitted pressure: 6bar
Max. permitted operating temperature: 120 oC
Digital flow rate: 1-20L/Min
Mechanical flow rate: 2-8L/Min
2. Mounting station
Determine the mounting site of the station.
Take the station out of packing; Remove the
front half of the insulation.
Hold the enclosed wall mounting bracket
against the wall and mark the fastening holes,
drill holes and insert dowels.
Fasten the wall mounting bracket to the wall
with the screws.
Push the station against the wall mounting
bracket, the station catches and is then
attached to the wall.
Connect the station to the solar thermal system.
Check the inlet pressure of the expansion vessel and if necessary, adjust it to the local
conditions, Pinlet(bar) = 1bar+∆ Th(m)*1/10 （∆Th=height difference between collector
and station）.
Connect the electrical components of the solar station, Attach the store and collector
sensor and connect there to the controller, plug the controller into the socket.
Tighten all union nuts and screw connections.
1.5.1
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
1.5.9
1.5.8
1.5.7

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Attach the front half of the insulation to the station.
3. Commissioning of station
Attention: Risk of scalding!
In order to prevent the boiling of solar fluid in the collectors, the system should not be
flushed or filled during periods of strong sunshine.
Attention: Risk of frost!
Solar thermal system cannot be completely emptied after flushing. There is a danger of frost
damage if water is used for flushing. Only use solar fluid to flush and fill the solar thermal
system. Use water –propylene glycol mixture as solar fluid (Maximum 50% propylene
glycol).
3.1 Flushing and filling the solar system
Flushing and filling unit is optional component, it can be installed horizontally at the lowest
point of the solar circuit (see figure). A filter must be installed between the store and solar
pump in order to prevent the flushed-out scale from store re-entering the solar circuit.
Flushing and filling steps:
Disconnect the expansion vessel from the solar thermal system.
Connect the pressure hose of a flushing and filling station to the fill ball valve (1) of
flushing and filling unit.
Connect the flushing hose of a
flushing and filling station to the
drain ball valve (3) of flushing
and filling unit.
Close the ball valve (2) in the
centre of the flushing and filling
unit.
Open the filling ball valve (1) and
drain ball valve (3).
Flush the solar thermal system
using the flushing and filling station for at least 15minutes to remove all air from the
system.
During the flushing, bleed the solar thermal system several times at the airstopp until
the discharged solar fluid is free of air bubbles.

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Close the drain ball valve(3) of flushing and filling unit, and continues run the pump and
increase the system pressure to approx.5 bar, system pressure can be read from the
manometer.
Close the filling ball valve (1) of the flushing and filling unit, and then close the filling
pump.
Check the manometer to see whether the system pressure reduces and eliminate leaks
where necessary.
Reconnect the expansion vessel to the solar thermal system.
3.2 Flow check
The flow counter is used for measurement and display of flow rate, in order to guarantee the
flawless function of the measuring device the system must be flushed and free from foreign
substances.
Digital flow meter（1-20L/min）Mechanical flow meter（2-8L/min）
3.3 Electrical connection
Warning: disconnect the controller from power supply before opening the housing!
The controller is already integrated in the station
and ready to plug in, display and digital counter
are already preinstalled at factory. For
maintenance or service work, it needs to take
out the controller from station, doing follows
below steps:
Switch off the system, disconnect plug from
the mains.
1
2
Flow control valve
流
Flow rate scale

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Remove the front half of the insulation.
Unscrew the cross-recessed screw 1 of the front cover of controller and left moving out
the cover 2.
Disconnect the wires from controller, take out the controller.
Doing reverse steps to remount the controller.
For further information on electrical connection of the controller, please see manual of
controller (terminal layout).
3.4 Accessories for the station(A06)
Flushing and filling unit isn’t enclosed in the delivery scope. Please buy separately.
(A06)

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Manual of integrated controller of solar station
1. Safety information
1.1 Important remark
We have carefully checked the text and figures of this manual and provided the best of our
knowledge and ideas, however inevitable errors maybe exist. Please note that we cannot
guarantee that this manual is given in the integrity of image and text, they are just some
examples, and they apply only to our own system. Incorrect, incomplete and erroneous
information and the resulting damage we do not take responsibility.
1.2 Description of symbols
Safety instruction:
The safety instructions in the manual are marked with a warning triangle. They
indicate measures, which can lead to personal injury and safety risks.
Operation steps: small triangle “►”is used to indicate operation step.
Notes: Contains important information about operation or function.
1.3 Description of operation button

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LED indicating light
LED indicating light displays the temperature of store. The first LED indicating light is on, it
means the temperature of store is 10oC, the second light is on, it means store temperature
is 20oC, others is same. See figure:
10℃20℃30℃40℃50℃60℃70℃Heating on On/off
1.4 Terminal layout
No.
Button description
Function
1
LCD Display
2
“Off/on” button
Switch on/off power of controller
3
“Tim. Heat” button
Switch on/off the timing heating function
4
“Man. Heat” button
Manual switch on/off the heating function
5
“LED on/ off” button
Switch on/off LED power
6
“Holiday” button
Activate/deactivate holiday function
7
“Clock” button
Clock function
8
“-” Parameter adjust button
Parameter adjust, value decrease
9
“ESC” button
Exit program setup
10
“SET” button
Confirm setting
11
“+” Parameter adjust button
Parameter adjust, value increase
12
LED indicating light

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Power terminal : L, N,GND
Input ports L, N is power connection terminal, please connect correctly.
is Ground line terminal.
Sensor input ports
Input sensor ports T0: for NTC10K, B=3950 sensors, used for measuring the temperature of
collector and measuring the heat output.
Input sensor ports T1: for Pt1000 sensors, used for measuring the temperature of collector
and measuring the heat output.
Input sensor ports T2, T3，T4: for NTC10K, B=3950 sensors, used for measuring the
temperature of tank.
Advice regarding the installation of temperature sensors:
Only original factory enclosed Pt1000 temperature sensors are approved for use with the
collector, it is equipped with 1.5meter silicon cable and suitable for all weather conditions,
the temperature sensor and cable are temperature resistant up to 280oC, not necessary to
distinguish the positive and negative polarity of the sensor connection.
Only original factory enclosed NTC10K,B=3950 temperature sensors are approved for use
with tank and pipe, it is equipped with 1.5meter PVC cable, and they are temperature
resistant up to 105oC, not necessary to distinguish the positive and negative polarity of the
sensor connection.
All sensor cables carry low voltage, and to avoid inductive effects, must not be laid close to
230 volt or 400-volt cables (minimum separation of 100mm)
If external inductive effects are existed, e.g. from heavy current cables, overhead train
cables, transformer substations, radio and television devices, amateur radio stations,
microwave devices etc, then the cables to the sensors must be adequately shielded.
Sensor cables may be extended to a maximum length of ca. 100 meter, when cable’s length
is up to 50m, and then 0.75mm2 cable should be used. When cable’s length is up to 100m,
and then 1.5mm2 cable should be used.

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Output ports
Output P1：For solar circuit pump and also suitable for RMP control, Semiconductor relay
(SCR relay), Max. Switching current 1A,
Output P2：Electromagnetic relay, its max. switching current 3.5A.
Output H1：For back-up electrical heater, electromagnetic relay, and max. Switching current
10A, H1 connection ports are always open.
2. Commissioning of integrated controller
Connect the sensors, pumps or switching valves to the controller before you
connect the power supply! After switching on power to the controller, firstly it will ask
for to set the time, password and parameters of system.
2.1 Set time/week
►Press “Clock” button, time displays on screen, our selection area “00” blinks on display
screen.
►Press “+”“-”button to set hour of clock
►Press “Clock” button again, minute area“00”blinks
►Press “+”“-”button to set minute of clock.
►Press “Clock” again, week area “MO” blinks
►Press “+”“-”button to set week.
►Press “ESC” button to exit set program, or wait for 20 seconds to exit program
automatically.
Code
Weekday
MO
Monday
TU
Tuesday
WE
Wednesday
TH
Thursday
FR
Friday
SA
Saturday
SU
Sunday

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2.2 Menu structure
Submenu:
Through submenu, user can set the parameter as desired value, please check it carefully.

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2.3 Menu description
Code
(Main menu）
Code
(Submenu)
Code
(Submenu)
Menu Description
Remark
DT O
Switch-on temperature difference
DT F
Switch-off temperature difference
TEMP
Temperature
EM
Limited temperature of collector
(Emergency turnoff temperature of
collector)
EMOF
The maximum switch-off temperature
of collector
EMON
The maximum switch-on temperature
of collector
CMX
Maximum temperature of collector
(Collector cooling function)
CMN
Low temperature protection of collector
CFR
Frost protection of collector
SMX
Maximum temperature of tank
REC
Tank re-cooling function
C-F
Celsius and Fahrenheit temperature
switch
FUN
Auxiliary function
DVWG
Anti legionnaires' function
nMIN
Speed controlling of circulation pump
(RPM pump controlling）
DTS
Standard temperature difference
(for circulation pump speed adjust)
RIS
Increase scale (circulation pump
speed adjusting parameter set)
FTYP
Type of Flow meter
01
mechanical flow meter
02
digital flow meter
OHQM
Thermal energy measuring
FMAX
Flow rate
When use digital
flow counter, no
value displays on
screen
MEDT
Type of heat transfer liquid
MED%
Concentration of heat transfer liquid
INTV
Pump interval function
tSTP
Pump interval time
tRUN
Pump running time
HDN
Manual controlling
PASS
Password set
LOAD
Recovery to factory set

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2.4 System description
Note:
T3 is alternative sensor, when no sensor (T3) is installed on the top part of tank, controller
will use the signal of sensor T2 automatically to control the auxiliary heating or the
circulation pump.
1 collector array –1 storage tank –1 pump and auxiliary heating
Description:
The solar circuit pump (P1) is switched on as soon as the switch-on temperature difference
(△Ton) between the collector array (T1) and the storage tank (T2) is reached. If the
temperature difference between the collector array (T1) and storage tank (T2) drops below
the switch-off temperature difference (△Toff), or the temperature of storage tank (T3)
reaches the preset maximum storage temperature, then the solar circuit pump (P1) is
switched off.
Back-up heating by auxiliary boiler (detailed see paragraph 4.3):
Within the preset schedule of back-up heating, if the temperature T3 is below the switch-on
temperature, then the back-up heating（H1）is triggered, when T3 is heated to the
switch-off temperature, back-up heating H1 is ceased.
T0: Temperature sensor for thermal energy measuring (optional sensor)
T1: Temperature sensor for collector array
T2: Temperature sensor on the bottom part of tank 1.
T3: Temperature sensor on the top part of tank (optional sensor)
T4:Temperature sensor on pipe for CIRC function(optional sensor)
P1: Solar circuit pump
H1: output for back-up electrical heater

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3.Function operation and parameter setup (user grade)
3.1 Timing heating
Description:
Electrical heater, gas boiler or oil boiler can be integrated into solar system used as back-up
of system, and they can be triggered automatically at preset schedule by preset temperature.
Within a preset schedule, when the temperature (T3) of top part of tank drops below the
preset switching-on temperature of this function, back-up heating starts to work, when T3
rises up to the preset turning off temperature, back-up heating is stopped. Within 24 hours,
three time sections can be set with this controller.
Factory set:
The first schedule: back-up heating function starts at 4:00 and ends at 5:00 am. Within this
time section, switch-on temperature is 40oC; switch-off temperature is 45oC.
The second schedule: from 10:00 to 10:00 am, it means there is no back-up heating in this
time.
The third schedule: back-up heating function starts at 17:00 and ends at 22:00 pm. Within
this time section, the switch-on temperature is 50oC; switch-off temperature is 55oC.
The switch-on temperature adjustable range: 10oC ~ (OFF-2oC)
The switch-off temperature adjustable range: (ON+2 oC) ~ 80oC
If you want to shut off one timing heating, then you can set the turning on time and turning
off time same value (for example, the second time section no this function, then you can set
turning on/off time is 10:00 ~ 10:00)
When time is outside of the preset schedule, back-up heating doesn’t work automatically
even when the tank temperature reaches the switch –on temperature of heating.
Note:
When there is no sensor installed in the top part of tank (no T3 sensor), controller will
take the signal of T2 (sensor in bottom of tank) automatically to control this function.
The time in this controlled is 24 hours, when you set schedule, the switch-off time of
heating should be larger than switch-on time. For example: if you set the switch-on
time of heating is at 17:00, but switch-off time of heating is 6:00, then this setting
doesn’t take effect, that means within this time section, heating function doesn’t work.

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The correct set is like flowing: it should be divided into two time sections, one time
section is from 17:00 to 23:59, the other time section is from 00:00 to 06:00.
Setup steps:
►Press button “Tim. Heat” to access THET program to set parameter, “tH 1o 04:00”
displays on screen, the switch-on time and temperature for the first schedule of heating
function can be set.
►Press “SET” button, “04” of hour time blinks on screen
►Press “+”“-” button to adjust hour of time
►Repress “SET” button again, “00” of minute time blinks
on screen
►Press “+”“-” button to adjust minute of time
►Repress “SET” button, temperature “40℃” blinks on screen
►Press “+”“-” button, to set the switch-on temperature of heating
►Then, Press “ESC” to exit this set
►Repress button “Tim. Heat”, “tH 1F 05:00” displays on screen, the switch-off time and
temperature for the first schedule of heating function can be set.
►Press “SET” button, “05” of hour time blinks on screen.
►Press “+”“-” button to adjust hour of time
►Repress “SET” button, “00” of minute time blinks on
screen
►Press “+”“-” button to set minute of time
►Repress “SET” button, temperature “45℃” blinks on screen
►Press “+”“-” button, to set switch-off temperature of heating
►Press “ESC” to exit this set program, parameters are saved automatically
-------------------------------------------------------------------------------------------------------------------
►Repress button “Tim. Heat”, “tH 2o 10:00” displays on screen, the switch-off time and
temperature for the second schedule of heating function
can be set.
►Press “SET” button, “10” of hour time blinks on screen.
►Press “+”“-” button to adjust hour of time
►Repress “SET” button, “00” of minute time blinks on screen
►Press “+”“-” button to set minute of time
►Repress “SET” button, temperature “50℃” blinks on screen

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►Press “+”“-” button, to set switch-off temperature of heating
►Press “ESC” to exit this set program, parameters are saved automatically
►Repress button “Tim. Heat”, “tH 2F 10:00” displays on screen, the switch-off time and
temperature for the second schedule of heating function can be set.
►Press “SET” button, “10” of hour time blinks on screen.
►Press “+”“-” button to adjust hour of time
►Repress “SET” button, “00” of minute time blinks on
screen
►Press “+”“-” button to set minute of time
►Repress “SET” button, temperature “55℃” blinks on screen
►Press “+”“-” button, to set switch-off temperature of heating
►Press “ESC” to exit this set program, parameters are saved automatically
--------------------------------------------------------------------------------------------------------------------
►Repress button “Tim. Heat”, “tH 3o 17:00” displays on screen, the switch-off time and
temperature for the third schedule of heating function can be set.
►Press “SET” button, “17” of hour time blinks on screen.
►Press “+”“-” button to adjust hour of time
►Repress “SET” button, “00” of minute time blinks on
screen
►Press “+”“-” button to set minute of time
►Repress “SET” button, temperature “50℃” blinks on screen
►Press “+”“-” button, to set switch-off temperature of heating
►Press “ESC” to exit this set program, parameters are saved automatically
►Repress button “Tim. Heat”, “tH 3F 22:00” displays on screen, the switch-off time and
temperature for the third schedule of heating function can be set.
►Press “SET” button, “22” of hour time blinks on screen.
►Press “+”“-” button to adjust hour of time
►Repress “SET” button, “00” of minute time blinks on
screen
►Press “+”“-” button to set minute of time
►Repress “SET” button, temperature “55℃” blinks on screen
►Press “+”“-” button, to set switch-off temperature of heating
►Press “ESC” to exit this set program, or wait for 20 seconds to exit automatically, the
setup parameters are saved automatically.