Solareg ii Genius plus Installation and operating instructions

Operation manual

Microprocessor-controlled control unit for solar thermal systems

SOLAREG®II

GENIUS

plus

Important!

Please read the instructions carefully before installing and operating the unit!

Failure to do this can void product warranty!

This unit described has been manufactured and inspected according to CE regulations.

Assembly and Operation Manual GENIUS plus

Assembly and Operation Manual 2 1317BED012-10B-E, Revised 11/2009

Multi-circuit controller GENIUS plus

Table of contents:

1SYMBOLS AND ABBREVIATIONS...................................................................................................................3

2USAGE SCENARIO / FEATURES.....................................................................................................................4

2.1 BASIC INFORMATION .....................................................................................................................................4

2.2 USAGE SCENARIO .........................................................................................................................................4

2.3 UNIT FEATURES ............................................................................................................................................4

3SAFETY ADVICE ...............................................................................................................................................5

4UNIT INSTALLATION ........................................................................................................................................6

4.1 OPENING THE UNIT........................................................................................................................................6

4.2 WALL INSTALLATION......................................................................................................................................6

5ELECTRICAL CONNECTIONS – OVERVIEW ..................................................................................................7

5.1 GENERAL CONNECTION GUIDELINES:..............................................................................................................8

5.2 230 VCONNECTORS .....................................................................................................................................8

5.3 CONNECTING SENSORS.................................................................................................................................9

5.4 SURGE PROTECTION MODULE........................................................................................................................9

6OPERATION / DISPLAY ..................................................................................................................................10

6.1 OVERVIEW OF DISPLAY AND CONTROL BUTTONS ...........................................................................................10

6.2 SCREEN .....................................................................................................................................................11

6.3 EXPLANATION OF ICONS ..............................................................................................................................11

6.4 BUTTON FUNCTIONS....................................................................................................................................12

6.5 CONTROL UNIT USAGE EXAMPLE ..................................................................................................................13

6.5.1 Changing dT max temperature for the storage tank ............................................................................13

6.5.2 Configuring a multi-function regulator ..................................................................................................15

7USER MENUS ..................................................................................................................................................20

7.1 OVERVIEW:MENU LAYOUT...........................................................................................................................21

7.2 "INFO"MENU ........................................................................................................................................21

7.3 "PROGRAMMING"MENU ........................................................................................................................22

7.4 "MANUAL OPERATION"MENU ................................................................................................................22

7.5 "SYSTEM SETTINGS"MENU ...................................................................................................................22

8CONTROL UNIT FUNCTIONS .........................................................................................................................22

9DATA INTERFACE - DATASTICK®.................................................................................................................23

9.1 DATASTICK®...............................................................................................................................................23

9.2 DATA LOGGING ...........................................................................................................................................23

10 TROUBLESHOOTING......................................................................................................................................24

10.1 REPORTABLE FAULTS..................................................................................................................................24

10.2 NON-REPORTABLE FAULTS ..........................................................................................................................25

11 TECHNICAL DATA ..........................................................................................................................................26

12 PT1000 RESISTANCE TABLE ........................................................................................................................26

13 GUARANTEE TERMS AND CONDITIONS .....................................................................................................27

14 DECLARATION OF CONFORMITY.................................................................................................................27

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Multi-circuit controller GENIUS plus

1 SY MB O LS AN D A BB R E VI AT IO N S

Explanation of the icons used in this Operation Manual:

Warning!

Icon indicates possibility of hazard or error

Warning: 230 V current!

Icon indicates danger from high-voltage, life-threatening current.

•List

Please note!

iOperational advice / special information

§User action / procedure

?Inspection / check

Frequently-used abbreviations

Abbreviations and symbols are sometimes

used to improve legibility in this documenta-

tion and on the display of the control unit

itself. Their meanings are presented in the

following table.

Abbrevia-

tion

Meaning Abbre-

viation

Meaning

Start Initial value °C Degrees Celsius

Stop Final value h Operating hours

> Larger than dT Temperature difference

K Degrees Kelvin, equates to 1

degree of temperature difference

kWh Energy output in kWh

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2 US AG E S C E N AR IO /FE AT UR ES

2.1 Basic information

The controller is designed as a system

control unit, i.e. it is suitable for a variety

of systems, depending on the functional

layout and options selected.

The information given below therefore

refers to the general functionality of the

controller.

The various functional layouts and cor-

responding connection diagrams are de-

scribed in separate documents.

Since the controller can be used in many

different ways, it is important that you

read the Operation Manual before con-

necting and starting up the unit!

2.2 Usage scenario

The controller is used to control the func-

tionality of solar thermal plant by providing

ancillary and protective features.

The controller is designed to be used in dry

areas such as residential, office and com-

mercial interiors.

If you want to use the unit for other pur-

poses, check applicable statutory regula-

tions before use.

2.3 Unit features

The control unit can be used with many

types of system. Independently of the usage

scenario, the unit has the following standard

features:

•Easy, menu-driven operation using

icons, simple text messages and four

control buttons.

•All presets and control values can be set

digitally

•Integrated operating hours counter for

storage tank charging

•Powerful system monitoring functional-

ity, with errors and faults displayed using

icons and simple text

•Integrated energy output measure-

ment: the output measurement set (op-

tional accessory) can be used to record

the energy produced by the solar plant

•Indefinite storage of all configured values

if power supply fails.

•A variety of protective features, such

as:

- System protection

- Collector protection

- Recooling

- Frost protection

•DataStick® interface

A DataStick® (optional accessory) provides

a simple way to carry out data logging.

Available accessories (optional):

•PT1000 temperature sensors

•Flow transmitters for output measure-

ment

•Radiation sensors

•DataStick® for data logging and pro-

gramming using a PC

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3 SAF ETY AD VICE

You must isolate the control unit from mains power before carrying out any

assembly or connection work.

The installation and start-up of the control unit should only be carried out by

qualified technical personnel. All work must comply with the applicable na-

tional and local safety regulations.

Always ensure that you isolate the

equipment from mains power before

starting installation or connection work

on the unit's electrical components.

Make sure that you never confuse the

SELV (safety extra low voltage) connec-

tors (sensors, flow transmitters) with the

230 V connectors. This may produce

life-threatening current and cause ir-

reparable damage to the device, at-

tached sensors and equipment.

Solar plant can generate high tempera-

tures. There is therefore a risk of burn

injuries! Take care when installing the

temperature sensors!

When installing sensors, avoid locations

(such as heat sources) that generate

temperatures outside the equipment's

maximum range (>50 °C).

The control unit is not splash- or drip-

proof. Ensure that it is installed in a dry

place.

For safety reasons, the system should

only be operated manually during test-

ing. In this mode of operation, no maxi-

mum temperatures or sensor functional-

ity are monitored.

The system must not be put into opera-

tion if there is recognisable damage to

the control unit, the cables or to the at-

tached pumps and valves.

Before using piping or installation mate-

rials, or attaching pumps and valves,

check that these are suitable for the

temperature levels generated by the

system.

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4 UN I T I NS T AL L AT I ON

Only install the control unit in dry interiors not subject to a risk of explosions.

Do not install the unit onto flammable surfaces.

4.1 Opening the unit

Before opening, ensure the unit is isolated

from mains power. If a locking screw has

been attached to the cover of the unit, you

will need to remove this first. The top of the

casing snaps onto the lower part of the unit

on both sides. You can release the top of

the casing by pulling gently on the sides of

the cover (see picture) and then pivoting the

cover upwards.

Continue to pull the

cover upwards until

it snaps into place.

This will enable you

to easily in

stall and

connect up the con-

trol unit

Before switching on or starting up the system:

ensure you have closed the cover – you must be able to hear

and feel it snap into place! Re-attach the locking screw

4.2 Wall installation

If installing the unit on a wall, proceed as follows:

•Drill the mounting holes to match the drilling

template provided

•Screw in the two upper screws so that they pro-

ject 6 mm from the wall

•Open the unit as described above and hang it on

to these two screws. You can now screw in the

two lower screws.

•Tighten all screws only as much as neces-

sary, to avoid damaging the lower part of the

unit casing!

126mm

118mm

84mm

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5 EL E C T RIC A L C O NN EC TI O NS –OVERVIEW

Please ensure that you follow the safety advice given

in Section 3

Only open the unit once you have ensured that it has been iso-

lated from mains power and cannot be switched on by acci-

dent.

Before switching on or starting up the system:

ensure that you have closed the cover – you must be able to hear and

feel it snap into place! Make sure you screw in the locking screw on the

front cover!

All electrical connections are made to the

subassembly in the lower part of the unit.

(SELV) connectors for sensors and flow

transmitters are located on the right-hand

side of the subassembly. The 230 V con-

nectors are located on the left-hand side.

The number and location of 230 V and sen-

sor connectors is described on the data

sheet corresponding to the layout used.

6 x 230V out-

puts

power

supply

7 x Sensors 3 x univ.

Inputs

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5.1 General connection guidelines:

•When connecting all cables, strip the cable covering to a length of approx. 6-8 cm and the

wires to a length of approx. 10 mm.

•For flexible cables, a strain relief device must be present on the interior or exterior of the unit.

On the 230 V side, this can be done by mounting a max. of 4 M12 cable screws. The ends of

the wires must be covered with wire end ferrules. The cables are fed through the apertures

provided and attached to the unit.

•All earth leads must be attached to the terminals marked "PE" (potential earth).

5.2 230 V connectors

One mains power connector is provided,

plus a total of 6 230 V/50 Hz outlets.

Bear in mind the following points concerning

the 230 V connectors:



If the control unit is wired directly into

the mains, it must be possible to isolate

mains power by using a switch external

to the unit.

If the unit is connected using a cable

and earthed plug, this switch is not nec-

essary.

The control unit is designed for use with

230 V/50 Hz mains power. Any attached

pumps and valves must also be rated for

use at this voltage!

iThe neutral lead terminals (N) are con-

nected electrically and are not switched!

iAll switched outputs (A1 to A6) are

electronic 230 V AC make contacts. If

you need potential-free contacts, then

suitable accessory parts can be sup-

plied.

iDepending on the functional layout

used, all outputs can be used as

switched outputs or – using block

modulation – as pump power controls.

iAll output activity is monitored elec-

tronically. A functional check is made

automatically once a day, and can also

be started manually from the "Manual

Operation" menu.

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5.3 Connecting sensors

The control unit works with high-precision platinum PT1000 temperature sensors. Between 2

and 10 sensors will be needed, depending on the system setup and functional layout. In some

layouts, the use of radiation sensors and flow transmitters will also be required. Inputs 1 to 7

are suitable for temperature sensors. Inputs 8 to 10 are universal inputs, which can be used for

temperature sensors, radiation sensors or digital inputs.

Temperature sensor installation / ca-

bling:

§Mount the sensors in the corresponding

places on the collector and storage

tank. When doing so, ensure good tem-

perature transfer, using heat-conductive

paste if necessary.

§The temperature sensor cabling can be

extended if required. Cross-sections re-

quired: lengths up to 15 m, 2 x 0.5 mm²;

lengths up to 50 m, 2 x 0.75 mm². Use

shielded extension cables for long con-

nections (e.g. to collector).

Do not insert shielded cable on the

sensor side – clip it and strip it!

§Temperature sensors are connected

according to the system setup. You do

not need to observe polarity for the two

wires when cabling temperature sen-

sors.

When laying sensor cabling, keep it

away from 230 V cables: these can be a

source of electrical interference under

adverse conditions. Keep cabling at

least 15 cm apart.

5.4 Surge protection module

The control unit is provided with fine-level surge protection for all sensor inputs. As a

rule, you will not need to take additional precautions for interior sensors. However, we

recommend additional protection for collector sensors and exterior sensors (sensor

connection box with surge protection). Exterior protective devices must not contain

any additional capacitors, since these may distort measurement readings.

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6 OP ERAT IO N /DI SP L AY

6.1 Overview of display and control buttons

Number Description

1 Screen with graphical icons and 3-line simple text display

2 Page up / + control button

3 Exit / Cancel / ESC control button

4 Page down / - control button

5 Select / Confirm / Enter control button

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6.2 Screen

The screen displays graphical icons and simple text messages. The three-line simple text dis-

play is used to show display and programming values, relating these to measuring points.

Main menus

Measuring point reference

Value / unit

Additional information

Status display

6.3 Explanation of icons

The following table describes the meanings of the various icons used.

Status display

Regulator active

Icon rotates if solar circuit pump is

switched on

Displays active switched outputs Numbers of active switched outputs

Indicates a system error Display flashes if an error occurs in the

system

ok?

Used to confirm the saving of

changed values

Value displayed can be

rejected or confirmed

Icon Description Display during operation

Main menu

"Info" menu

"Programming" menu

"Manual operation" menu

"System Settings" menu

Icon flashes if selectable.

Select with button

If only one icon is displayed, this menu is

active

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6.4 Button functions

The control unit can be operated simply and

easily with the 4 control buttons. You can

use the control buttons to:

•Display readings

•Make changes to unit settings

The icons used for the display guide you

quickly through the various options, clearly

showing the current menu selection, reading

or parameter.

The control buttons have the following func-

tions:

Button Function description

"Up"

"+"

•Page forward in the menu

•Value modification: stepwise increase of the value dis-

played

If the button is pressed and held, values increase continu-

ously

"Access"

"Down"

"-"

•On the start screen: accesses a main menu

•Page back in the menu

•Value modification: stepwise decrease of the value dis-

played

If the button is pressed and held, values decrease continu-

ously

"Page left"

"Exit"

"Cancel"

•Page left in a main menu

•Exit from a menu

•Exit from a menu item

•Cancel a modification made to a value without saving

"Page right"

"Select"

"Confirm"

•Page right in a main menu

•Select a menu item

•Confirm and save a modification made to a value

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6.5 Control unit usage example

6.5.1 Changing dT max temperature for the storage tank

Once you have made yourself familiar with

the descriptions of the menus in the "User

menus" section, you can proceed by making

some operational changes. The example

below describes one such operational pro-

cedure. The starting point here is the "Info"

menu, showing the current collector tem-

perature. Objective: change the parameter

"Storage tank dT max" from 7 K to 5 K, us-

ing the "Programming" menu.

Escape: Exit the "Info" menu

Page right: Select "Programming" menu

Select "Programming" menu

In the "Programming" menu, page un

til the submenu "Storage

tank" is shown.

Select submenu "Storage tank"

In the submenu, page until the value "Storage tank dT max" is

shown.

Collector

40.7.C

0<-.C->53

Flashes

12:09:24

Flashes

12:09:24

Storage tank

65.C

maximum

Storage tank

Values]

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Select value: the value "Storage tank dT max" now be

gins to

flash

Decrease the value until the chosen value is selected. Value

continues to flash.

Select "Confirm value"

Icon

ok?

flashes.

Confirm the change. Change is applied.

Leave value as-is: change is not applied

2 x

Exit submenu "Storage tank"

Exit "Programming" menu

Storage tank

7 K

dT max

Storage tank

5 K

dT max

Storage tank

5 K

dT max

ok?

Flashes

12:09:24

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6.5.2 Configuring a multi-function regulator

Select the multi-function regulator (MFR for short) you want in the

"System Settings" menu.

Factory setting: MFR = Off

Select (activate) the submenu of the selected MFR.

Function is "Off", i.e. no regulator functionality is currently active.

Select the specific MFR function to use.

For this example we will use a difference regulator.

Available functions: thermostat cooling, thermostat heating, threshold

switch, increase return flow, wood boiler, difference regulator, circula-

tion, alarm and timer

The MFR's functionality can be linked to specific time frames.

"Off": No time frame active

MFR function = continuously active

Time frame linking is active, i.e. the selected function cannot be acti-

vated continuously, but is time-limited and only works within the speci-

fied time frame.

Selects the temperature sensor for the energy source.

(Any available temperature sensor can be selected, even if it is cur-

rently being used by another function.)

MultiReg 1

off]

MultiReg 1

Off

Function

MultiReg 1

Diff.Regl.

Function

MultiReg 1

Off

Time frame

MultiReg 1

Time frame

MultiReg 1

TF 7

Source sensorÎ

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Selects the temperature sensor for the energy sink.

(Any available temperature sensor can be selected, even if it is cur-

rently being used by another function.)

In principle, each MFR can be linked to a single available solar circuit

(SCR) or another MFR.

Selecting SCR means that the selected MFR function will be linked to

the functional status of the solar circuit (SCR). Solar circuit SCR active

indicates one of the solar storage tanks is being charged.

Selecting MFR2 means that the selected MFR function will be linked to

the functional status of the MFR2.

Selecting the link type "inactive" means that MFR1 can only become

active if MFR2 is not active.

Selecting the link type "active" means that MFR1 can only become

active if MFR2 is also active.

This concludes the basic configuration of the MFR.

Exit the submenu MFR1 in the "System Settings" menu.

The activated function is shown as text on the screen.

MultiReg 1

TF 8

Sink sensorL

MultiReg 1

None

Link select

MultiReg 1

SCR

Link select

MultiReg 1

MFR2

Link select

MultiReg 1

inactive

Link type

MultiReg 1

active

Link type

MultiReg 1

on]

Diff. regl.

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Corresponding settings in the "Programming" menu

The MFR1 is configured in the "Programming" menu by selecting the

submenu MFR1

Limiting the maximum temperature of the energy sink, e.g. for the

storage tank accepting energy.

The function is switched off once the energy sink sensor reaches the

switch-off temperature.

Limiting the minimum temperature of the energy source, e.g. for the

storage tank releasing energy.

The function is only switched on once the energy source sensor

reaches the switch-on temperature – in addition to the temperature

difference required between the energy source and sink.

Switch-on difference between energy source and energy sink.

Switch-off difference between energy source and energy sink.

Start time of the 1st time frame for the MFR.

MultiReg 1

Values]

Diff. regl.

65.C

maximum

Diff. regl.

15.C

minimum

Diff. regl.

7 K

dTmax

Diff. regl.

3 K

dTmin

Diff. regl.

0:00

Time 1: Start

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Stop time of the 1st time frame for the MFR.

Defining a timeframe from 0:00 to 23:59 means the function will be

permanently activated.

Start time of the 2nd time frame for the MFR.

Stop time of the 2nd time frame for the MFR.

If the start time and stop time of a time frame are identical, this time

frame will be deactivated, i.e. will not be taken into account.

Start time of the 3rd time frame for the MFR.

Stop time of the 3rd time frame for the MFR.

Time frame is also deactivated.

Corresponding display in the "Info" menu

Display of the temperature of the energy source sensor in the "Infor-

mation" menu, with minimum and maximum values. The correspond-

ing measuring point – here T7 – is also displayed.

Diff. regl.