Steca TR A301 User manual

SOLARTHERMIE - SOLAR THERMAL SYSTEMS - SOLAR TÉRMICO - SOLAIRE THERMIQUE - SOLARE TERMICO
Installation and operating instructions
Temperature difference controller
3 inputs, 1 PWM control signal for an ECM pump
738.955 | Z01 | 10.40 | Subject to change due to technical improvements!
EN
These operating instructions are part of the product.
Read the instructions carefully before use,
keep them over the entire lifetime of the product,
and pass them on to any future owner or user of this product.
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Inhalt
1 About these instructions .......... 3
1.1 Applicability .................................3
1.2 Users ............................................3
1.3 Description of symbols ................4
2 Safety ........................................ 5
2.1 Proper usage ...............................5
2.2 Improper usage ...........................5
2.3 Dangers during assembly /
commissioning .................................6
2.4 Detecting faults ...........................7
2.5 Exclusion of liability .....................7
3 Description................................ 9
3.1 Controller in the solar circuit .......9
3.2 Casing overview .........................10
4 Installation ............................. 11
4.1 Opening / closing the casing ......11
4.2 Installation .................................12
4.3 Electrical connection ..................13
5 Display overview..................... 17
6 Commissioning ...................... 18
7 Description of the controller
functions................................. 20
7.1 Switch-on / switch-off
temperature difference ..............20
7.2 Maximum storage tank
temperature ..............................20
7.3 Maximum collector temperature .21
7.4 Tube collector function ..............21
7.5 Anti-freeze function ...................22
7.6 Holiday function ........................23
7.7 Flow test service function ..........24
7.8 Speed control ............................24
8 Operation................................ 26
8.1 Setting the controller (main menu) 26
8.2 Setting the controller (settings
menu) ........................................31
9 Maintenance ........................... 38
9.1 Causes of problems ...................38
9.2 Testing the temperature sensor .... 42
10 Dismantling and disposal ....... 43
11 Legal guarantee ..................... 44
12 Technical data ......................... 46

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1About these instructions
1.1 Applicability
These instructions describe the installation, com-
missioning, function, operation, maintenance and
dismantling of the temperature difference controller
for controlling an ECM high-efficiency pump within a
solar thermal system (ECM = Electronic Commutated
Motor). When installing the remaining components,
e.g. solar collectors, pump assemblies and storage
units, be sure to observe the appropriate installation
instructions provided by each manufacturer.
1.2 Users
Installation, commissioning, operation, maintenance
and dismantling of the controller may only be per-
formed by trained professional personnel. Before
commissioning, the controller must be professionally
assembled and installed by professional personnel in
accordance with the applicable regional and transre-
gional regulations as well as the safety instructions and
general instructions within these installation and oper-
ating instructions. The professional personnel must be
familiar with these operating instructions.
Use the controller only after first thoroughly reading
and understanding these operating instructions and
the safety instructions. Adhere to all safety instruc-
tions. In the event of any ambiguities regarding the
operation and alteration of parameters or functions,
consult professional personnel.

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1.3 Description of symbols
1.3.1 Structure of the warning notices
SIGNAL WORD
Type, source and consequences of the danger!
Measures for avoiding danger.
1.3.2 Danger levels in warning notices
Danger level Likelihood of
occurrence
Consequences
resulting from
non-compliance
DANGER Imminent
threat of danger
Death, serious
bodily injury
WARNING Possible
threat of danger
Death, serious
bodily injury
CAUTION Possible
threat of danger
Minor
bodily injury
CAUTION Possible
threat of danger
Property damage
1.3.3 Notes
Note
Note on easier and safer working habits.
Measure for easier and safer working habits
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Pictogram with cor-
responding warning
symbol.

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1.3.4 Other symbols and markings
Symbol Meaning
✓Condition for action
Call to action
Result of action
• List
Emphasis on
issue at hand
Emphasis on issue at hand
2Safety
2.1 Proper usage
The temperature difference controller – hereinafter
referred to as controller – is an independently installed
electronic temperature controller for on-surface installa-
tion. The controller may only be used for controlling solar
thermal systems within the permissible ambient condi-
tions (see section 12 "Technical data").
2.2 Improper usage
The controller must not be operated in the following
environments:
outdoors
in damp rooms
in rooms where highly flammable gas mixtures can
occur
in rooms in which the operation of electrical and
electronic components may cause dangers to arise
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2.3 Dangers during assembly /commissioning
The following dangers exist during installation / com-
missioning of the controller and during operation (in
case of installation errors):
Risk of death by electrocution
Risk of fire due to short-circuit
Damage to any of the constructional fire safety
measures present in the building due to incorrectly
installed cables
Damage to the controller and connected devices
due to improper ambient conditions, inappropriate
power supply and connecting prohibited devices or
faulty devices and incorrect assembly or installation
Therefore, all safety regulations apply when working
on the mains supply. Only electricians may perform
work that requires opening the controller (such as con-
nection work).
When laying cables, ensure that no damage occurs
to any of the constructional fire safety measures in
the building.
Make sure that the permissible ambient conditions
at the mounting location are not exceeded (see
section 12).
Be sure to comply with the specified degree of
protection.
Factory labels and markings may not be altered,
removed or rendered unreadable.
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Before connecting the device, make sure that the
power supply matches the specifications on the
type plate.
Make sure that all devices which are connected to
the controller conform to the technical data of the
controller.
Secure the device against unintentional start-up.
All work on an open controller must be performed
with the mains supply disconnected.
Protect the controller against overloading and
short-circuiting.
2.4 Detecting faults
Check the display regularly.
In case of faults, isolate the cause (see section 9).
As soon as it becomes evident that safe operation
is no longer possible (e.g. visible damage), discon-
nect the device from the mains supply immediately.
Have professional personnel remedy the fault.
2.5 Exclusion ofliability
The manufacturer cannot monitor the compliance
to these instructions as well as the conditions and
methods during the installation, operation, usage and
maintenance of the controller. Improper installation of
the system may result in damage to property and, as a
result, to bodily injury.
Therefore, we assume no responsibility and liability
for loss, damage or costs which result from or are
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in any way related to incorrect installation, incorrect
execution of installation work, improper operation and
incorrect usage and maintenance.
Similarly, we assume no responsibility for patent right
or other right infringements of third parties caused by
usage of this controller.
The manufacturer reserves the right to make changes
to the product, technical data or installation and oper-
ating instructions without prior notice.

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3Description
3.1 Controller in the solar circuit
3.1.1 The purpose of the controller
The controller provides speed control of the ECM pump
in a solar thermal system (see section 7 "Description of
the controller functions").
3.1.2 The structure of the solar circuit
Temperature difference controller
Storage tank
ECM
pump
Temperature sensor 1
(collector sensor)
Temperature sensor 2
(lower area of storage tank)
Collector

T1
T2



Solar circuit
V
Optional:
Grundfos Direct
SensorsTM VFS 1-12
T

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3.1.3 The function of the solar circuit
The controller constantly compares the temperatures
between the collector (T1) and the lower area of the
storage tank (T2). Once the sun heats the collector and
there is a temperature difference of 8 K between the
collector and the storage tank, the pump is switched
on.
The pump extracts the heat transfer fluid from the
lower cooler area of the storage tank and pumps it to
the collector. The heat transfer fluid in the collector is
heated by the sun and flows back to the storage tank.
The heat transfer fluid heats the domestic water via a
heat exchanger located in the storage tank.
3.2 Casing overview
 Auto
 On
 Off
Operating buttons
Arrow up
SET button
Arrow down
Display
Display for controller operation
and system settings
Operating switch
The following modes of
operation
can be selected:
- On
for commissioning
and functional test
- Auto
for normal operation
- Off
to switch-off the pumps
Connections
grid, pump, temperature sensors

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4Installation
4.1 Opening /closing the casing
DANGER
Risk of death by electrocution!
Disconnect the controller from the power supply
before opening the casing.
Make sure that the power supply cannot be unin-
tentionally switched back on.
Do not damage the casing.
Only switch the power supply back on after the cas-
ing has been closed.
The top of the casing is held in place by two retaining
pegs on the upper edge of the bottom half of the cas-
ing and fastened with a screw.
4.1.1 Opening the casing
Loosen the screw and remove the upper casing in
an upwards direction.
4.1.2 Closing the casing
Place the upper casing over the lower casing at an
angle. Insert the hinge grooves into the retaining
pegs of the lower casing.
Pivot the upper casing down and feed the operat-
ing buttons through the matching holes.
Fasten the casing tightly with the screw.
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Hinge grooves
Operating
buttons
Upper casing
Lower casing
Screw

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4.2 Installation
WARNING
Risk of electrical shock and fire if mounted in a
damp environment!
Only assemble the controller in an area where the
degree of protection is sufficient.
4.2.1 Mounting the controller
CAUTION
Risk of injury and damage to the casing when drill-
ing!
Do not use the casing as a drilling template.
Choose a suitable mounting location.
Drill the upper fastening hole.
Screw in the screw.
Remove the upper casing.
Hang the casing in the recess .
Mark the position of the lower fastening holes ,.
Remove the casing again.
Drill the lower fastening holes.
Re-hang the casing in the recess .
Screw the casing firmly using the lower fastening holes
 and .
Mount the upper casing.
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105
1
137,2
3 2
116
134

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4.3 Electrical connection
DANGER
Risk of death by electrocution!
Disconnect the controller from the power supply
before opening the casing.
Observe all applicable legal guidelines and regula-
tions of the local electricity supplier.
NOTE
The device is to be connected to the grid by means
of a plug with grounding contact, or in the case of a
fixed electrical installation via a disconnection device
for complete disconnection in accordance with the
installation guidelines.
4.3.1 Preparing the cable feed
The cables may enter the device through the rear of
the casing or the lower side of the casing.
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Feeding cable through rear of casing (fig. 1):
WARNING
Risk of electrical shock and fire due to cables com-
ing loose!
Install an external strain relief for the cables.
Remove the plastic flaps  from the rear side of
the casing using an appropriate tool.
Feeding the cable through the lower side of
the casing (fig. 2):
WARNING
Risk of electrical shock and fire due to cables com-
ing loose!
Fasten the cables to the casing using the strain-relief
clamps provided.
Cut the left and right plastic flaps  using an
appropriate tool and break them out of the casing.
4.3.2 Connecting the cables
If a protective conductor is provided or required
for the pump, connect the protective conductor
to the terminal clamps of the controller. When
connecting the protective conductor, observe the
following points:
Make sure that the grounding contact is also
connected to the controller's mains supply side.
NOTE
Observe the instructions in the ECM pump data sheet.
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SET
6
Fig. 2: cable feed from below
SET
7
Fig. 1: cable feed from the rear

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Each terminal may only be connected to a single
connecting wire (max 2.5 mm2).
The spring terminals are approved for connection
of cables as follows:
single wire (solid): ≤ 2.5 mm²
fine strand (flexible): ≤ 2.5 mm² (the stranded
wires must be twisted with 1 twist per 20 mm)
fine strand (with core end sleeves): ≤ 1.5 mm²
Only use the original temperature sensors (Pt1000)
that are approved for use with the controller.
Observe the following points:
Polarity of the sensor contacts is not important.
Do not lay sensor cables close to 230 volt or 400
volt cables (minimum separation: 100 mm).
If inductive effects are expected, e.g. from heavy
current cables, overhead train cables, transformer
substations, radio and television devices, amateur
radio stations, microwave devices etc. , then the
sensor cables must be adequately shielded.
Sensor cables may be extended to a maximum
length of 100 m.
For extension cables, select the following cable
cross sections:
0.75 mm2 up to 50 m long
1.5 mm2 up to 100 m long
Connect the cables in accordance with the terminal
plan.
Use only the Grundfos Direct SensorTM VFS 1-12
that is approved for the controller.
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L NN R1 C T1 T2
4.3.3 Terminal plan
Protective
conductor
PWM control signal
for ECM pump
Temperature sensor 1
(collector)
Grid 230 V~
Power supply for the ECM
pump 230 V~
ATTENTION: Voltage always
present!
Temperature sensor 2
(lower area of storage tank)
4.3.4 Actuating the connecting terminals
NOTE
The connecting terminal may only be actuated with
an appropriate tool. An unsuitable tool or too much
mechanical pressure can damage or even destroy the
connecting terminal.
Optional:
Grundfos Direct
SensorsTM VFS 1-12

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5Display overview
2
° E
D
T1
T1
T2
!
min


T1 max
max ºC ºF
1 Temperature sensor symbols
Top T1 = collector sensor
Bottom T1 = sensor for tube
collector function
T2 = sensor for lower area of
storage tank
2 Display for temperature values,
operating hours and fault
symbols, e.g. short circuit, inter-
ruption (see page 40) or "SYS" =
system error (see page 41)
3 Display for temperature unit °C / °F
4 ECM pump operating hours
5 Setting the maximum storage
tank temperature (max) and
display of min/max temperature
values
6 Tube collector function
7 Setting the temperature unit °C / °F
8 Speed control
9 Holiday function (see page 35)
10 Anti-freeze function (see page 34)
11 Symbols for pump operation and
heat transfer fluid circulation
12 Display for "Maximum storage
tank temperature has been
reached"
13 Warning sign in the case of a
fault e.g. short circuit, interrup-
tion (see page 40) or "SYS" =
system error (see page 41)
14 Display when the maximum
collector temperature is reached,
means possible evaporation of
the collector fluid
15 Display when the switch-on tem-
perature difference is reached,
means "sufficient heat available"
15
14
13
12
11
1
9
3
4
810
56
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6Commissioning
6.1 Testing the pump
CAUTION
Damage to pump caused by dry operation!
Make sure that the solar circuit is filled with heat
transfer fluid.
The controller casing is closed.
All connections are properly made.
The solar energy system is filled.
Connect the mains supply.
To switch on the pump, set the operating switch to
the upper position (on).
The display is lit with a red background.
on appears in the display. After approx. 3 sec-
onds on flashes in alternation with the display.
To switch off the pump, set the operating switch to
the lower position (off).
The display is lit with a red background.
off appears in the display. After approx. 3 sec-
onds off flashes in alternation with the display.
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✓
✓
✓
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
T1
T2

 on

T1
T2

 on


T1
T1
T2


 off
T1
T1
T2


 off
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CAUTION
The incorrect operating mode may cause the sys-
tem to shut down or impair proper functioning!
After testing the pump, always set the operating
switch to automatic operation.
To set the controller to automatic operation, move
the operating switch to the middle position (Auto).
Aut is shown in the display for approx. 3 sec-
onds.
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T1


 Auto
T1


 Auto
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7Description of the controller
functions
7.1 Switch-on /switch-off temperature dif-
ference
The controller constantly compares the temperatures
between the collector (T1) and the lower area of the
storage tank (T2). As soon as the temperature in the
collector (T1) is 8 K (constant fixed value) higher than
the temperature in the storage tank (T2), the following
display appears:
The sun symbol is displayed
If no safety limits prohibit the pump from operating,
the PWM control signal for the pump appears at out-
put C. The display shows this message.
The pump symbol rotates
If the temperature difference falls below 4 K (constant
fixed value), the PWM control signal for the pump at
output C is switched off. The sun symbol is no longer
shown on the display.
NOTE
The power supply for the ECM pump at output R1
always remains switched on. The ECM pump is control-
led exclusively by the PWM control signal at output C.
7.2 Maximum storage tank temperature
The maximum storage tank temperature function is to
prevent the hot water tank from overheating. If the
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