Technische Alternative ESR 31 User manual

ESR 31
Version 2.0 EN
Simple solar control unit
Operation
Installation instructions
en

This instruction manual is available in English at www.ta.co.at
Diese Anleitung ist im Internet auch in Deutsch unter www.ta.co.at verfügbar.
Ce manuel d’instructions est disponible en langue française sur le site Internet
www.ta.co.at
Questo manuale d’istruzioni è disponibile in italiano sul sito Internet
www.ta.co.at
Estas instrucciones de funcionamiento están disponibles en español, en
Internet www.ta.co.at.

Table of contents
Safety requirements ..............................................................................................................5
Maintenance..................................................................................................................................5
Generally applicable rules for the correct use of this control unit............................................6
Hydraulic diagrams................................................................................................................7
Program 0 –2 -Solar thermal system.........................................................................................7
Program 4 –7 - Loading pump control .......................................................................................8
Program 8, 9 - Air flap control for an earth collector....................................................................9
Program 12 - Burner requirement using holding circuit.............................................................10
Program 16, 17 Preparation of hot water (only ESR31-D)........................................................10
Operation..............................................................................................................................12
The main level.............................................................................................................................13
Changing a value (parameter)..................................................................................................15
The parameter menu PAR ..........................................................................................................16
Code number CODE................................................................................................................16
Software version VR / VD.........................................................................................................17
Program number PR ................................................................................................................17
Set values (min, max, diff)........................................................................................................17
Automatic / manual mode.........................................................................................................19
O AUTO...............................................................................................................................19
C AUTO...............................................................................................................................19
The menu MEN............................................................................................................................20
Brief description........................................................................................................................20
Language DEUT, ENG.............................................................................................................21
Code number CODE................................................................................................................21
Sensor menu SENSOR............................................................................................................21
Sensor settings....................................................................................................................22
Sensor type .........................................................................................................................23
Creating a mean (average) AV ............................................................................................24
System protection functions SYS PF........................................................................................24
Collector excess temperature CET ......................................................................................25
Collector anti-freeze FROST................................................................................................25
Start function STARTF (ideal for tube collectors)......................................................................26
After-running time ART.............................................................................................................27
Pump speed control PSC (only ESR31-D)................................................................................28
Absolute value control..........................................................................................................30
Differential control................................................................................................................31
Event control........................................................................................................................32
Control output COP 0-10 V / PWM...........................................................................................35
Function check F CHCK...........................................................................................................37
Heat quantity counter HQC ......................................................................................................38
External sensors EXT DL.........................................................................................................43
Status display Status.............................................................................................................44
Installation instructions.......................................................................................................46
Sensor installation......................................................................................................................46
Sensor lines ................................................................................................................................46
Installing the device....................................................................................................................47
Electrical connection..................................................................................................................47
Tips on troubleshooting......................................................................................................48
Table of settings ..................................................................................................................49
Technical data......................................................................................................................51

5
Safety requirements
All installation and wiring work on the controller must only be carried
out in a zero-volts state. These instructions are intended exclusively for
authorised professionals.
The opening, connection and commissioning of the device may only be
carried out by competent personnel. In so doing, all local security re-
quirements must be adhered to.
The device corresponds to the latest state of the art and fulfils all necessary safety condi-
tions. It may only be used or deployed in accordance with the technical data and the safety
conditions and rules listed below. When using the device, the legal and safety regulations
apposite to the particular use are also to be observed. Incorrect use will result in the negation
of any liability claims.
► The device must only be installed in a dry interior room.
► It must be possible to isolate the controller from the mains using an all-pole isolating de-
vice (plug/socket or double pole isolator).
► Before starting installation or wiring work, the controller must be completely isolated from
the mains voltage and protected against being switched back on. Never interchange the
safety extra-low voltage connections (sensor connections) with the 230V connections. De-
structive and life-threatening voltages at the device and the connected sensors may occur.
► Solar thermal systems can become very hot. Consequently there is a risk of burns. Take
care when fitting temperature sensors!
► For safety reasons, the system should only be left in manual mode when testing. In this
operating mode, no maximum temperatures or sensor functions are monitored.
► Safe operation is no longer possible if the controller or connected equipment exhibits visu-
al damage, no longer functions or has been stored for a lengthy period of time under un-
suitable conditions. If this is the case, place the controller and equipment out of service
and secure against unintentional use.
Maintenance
If used properly, the system does not require maintenance. A cloth moistened with a soft
alcohol (such as spirit) should be used for cleaning. Harsh solvents such as chlorethenes or
tri-gases are not admissible.
As the components relevant to accuracy are not subjected to loads if used properly, long-
term deviation is very low. The unit thus cannot be adjusted. Hence, no calibration is possi-
ble. The construction characteristics of the unit must not be changed for repairs. Spare parts
must correspond to the original parts and be used as intended.

6
Generally applicable rules for the correct use of this control unit
The manufacturer of the control unit cannot be held liable for any indirect damage to the
system if the party that installs the system does not install any additional electromechanical
devices (thermostat, possibly in combination with a one-way valve) to protect the system
from damage as a result of a malfunction under the following conditions:
Solar thermal system for swimming pools: An excess temperature thermostat and a
self-actuating one-way valve (normally closed) must be installed in the supply line in
combination with a high-performance collector and heat-sensitive system components
(such as plastic lines). The valve can also be supplied from the control unit’s pump
outlet. Thus, all of the heat-sensitive parts are protected from excess temperature if
the system is at standstill, even if steam (stagnation) occurs in the system. This ar-
rangement is prescribed in particular for systems with heat exchangers as a failure of
the secondary pump would otherwise cause great damage to the plastic tubes.
Conventional solar thermal systems with external heat exchangers: in such systems,
the secondary heat transfer medium is usually pure water. If the pump runs at temper-
atures below freezing because the control unit has failed, there is a danger of the heat
exchanger and other parts of the system being damaged by frost. In this case, a ther-
mostat has to be installed directly after the heat exchanger on the supply line of the
secondary side to switch off the primary pump automatically if the temperature drops
below 5°C regardless of the control unit’s output.
In combination with floor and wall heaters: here, a safety thermostat is prescribed as
with conventional control units for heaters. It must switch off the heating circulation
pump to prevent indirect damage due to excess temperature regardless of the output
of the control unit.
Stagnation- Solar thermal systems - tips for system standstill:
In principle, stagnation is not a problem and cannot be ruled out, for instance due to a
blackout. In summer, the limited storage capacity of the control unit can cause the system to
shut down repeatedly. A system thus always has to be intrinsically safe. This safety is en-
sured if the expansion tank has the proper dimensions. Tests have shown that the heat trans-
fer medium (antifreeze) is under less stress during stagnation that shortly before the steam
phase.
The data sheets of all collector manufacturers have standstill temperatures above 200°C,
but these temperatures generally only occur in the operating phase with “dry steam”, i.e.
when the heat transfer medium in the collector has completely evaporated or when the steam
has completely emptied the collector. The humid steam dehumidifies quickly and loses its
heat conductivity. Thus, it can be generally assumed that these high temperatures cannot
occur at the measuring point of the collector sensor (if installed in the collecting tube as usu-
al) as the remaining thermal line cools down the medium with its metal connections from the
absorber to the sensor.

7
S1
AS2
S3
Hydraulic diagrams
Program 0 –2 -Solar thermal system
Program 0 = factory settings
The solar pump Aruns when S1 has a temperature of diff higher than S2 and S2 has not
exceeded the threshold max.
In addition, the pump’s protective function takes effect: During a standstill, steam can oc-
cur in the system. When automatically switched on again, the pump does not have the re-
quired pressure in the steam phase to lift the fluid level to the collector’s supply line (highest
point in the system). This represents a considerable load on the pump. The collector’s excess
temperature shut-down function can be used to block the pump whenever a certain tempera-
ture has been reached at the collector’s sensor until a second threshold, which can also be
set, is fallen short of again. The settings ex works are 130°C for the blockage and 110°C for
the release. The settings can be changed in the menu MEN, sub-menu SYS PF/CET (collec-
tor excess temperature).
Program 1
With this program, the solar thermal system has an additional storage limit max2 via sen-
sor S3. There is no guarantee that the actual storage temperature will lead to a cut-off in
time, especially if the reference sensor S2 is installed at the return outlet for the heat ex-
changer.
Program 2
As program 0, however with additional 10 V burner requirement via S3 at control output.
A = S1 > (S2 + diff) & S2 < max
Control output COP: 10 V = S3 < min2 (burner on)
0 V = S3 > max2 (burner off)
Subsequently, an auxiliary relay can be connected to the control output HIREL-STAG, which
forwards the burner requirement in potential-free format. The active control output is indicat-
ed by the flashing burner symbol in the display.
S1
S2
max
diff
Required settings :
max …limit TK S2
max2 … see program 1 or 2
min2 … see program 2
diff … coll. S1 –TK S2
Additional required settings:
max2… COP off (0V) S3 (ex works = 65°C)
min2… COP on (10V) S3 (ex works = 40°C)
S3 for program 1 and 2

8
A
S2
S1
S3
Note:
In programs 0 - 2, the system condition "Collector - excess temperature reached" is indicated
in the menu Status by the advice CETOFF for Collector Excess Temperature switch off.
Some countries only offer subsidies for the installation of solar thermal systems if the control
units have a function check to detect a sensor defect and a lack of circulation. In the menu
command F CHCK, the mechanic can activate this function check for the ESR31. It applies
likewise for this program and is deactivated in the factory settings. For details, see “Status
display Status”.
Program 4 –7 - Loading pump control
Program 4
The loading pump Aruns when S1 has exceeded the threshold min, the temperature of
S1 is diff higher than S2, and S2 has not yet crossed the threshold max.
Program 5
The loading pump function has an additional storage limiter max2 via sensor S3.
Program 6
As program 4, however with additional 10 V burner requirement via S3 and S2 at control
output.
A = S1 > min & S1 > (S2 + diff) & S2 < max
Control output COP: 10 V = S3 < min2 (burner on)
0 V = S2 > max2 (burner off)
Subsequently, an auxiliary relay can be connected to the control output HIREL-STAG, which
forwards the burner requirement in potential-free format. The active control output is indicat-
ed by the flashing burner symbol in the display.
S1
min
diff
S2
max
Required settings :
max …limit TK S2
max2 … see program 5 or 6
min … switch-on temp. boiler S1
min2 … see program 6
diff … boiler S1 –TK S2
Additional required settings:
max2… COP off (0V) S2 (ex works = 65°C)
min2… COP on (10V) S3 (ex works = 40°C)
S3 for program 5 and 6

9
Program 7
S1 S3
min min 2
diff diff 2
S2
max
Required settings :
max … limit TK S2
min … switch-on temp. energy generator 1 S1
min2 … switch-on temp. energy generator 2 S3
diff … energy generator 1 S1 –TK S2
diff2 … energy generator 2 S3 –TK S2
The loading pump function has an additional threshold min2 via sensor S3 and tempera-
ture difference diff2 between S3 and S2. Hence, the system can be switched off via two
energy generators (S1 and/or S3).
Program 8, 9 - Air flap control for an earth collector
Program 8
A = ON
S1 max
A = OFF
S1 min
A = ON
Required settings :
max … upper switch-on threshold S1
min … lower switch-on threshold S1
The output switches when S1 > max or < min. An air/water heat pump thus has a flap for
the airflow from the earth collector above the outside ambient temperature max (regenera-
tion) and below the outside ambient temperature min (heating). S2 and S3 have no function.
Program 9
A = OFF
S1 max
A = ON
S1 min
A = OFF
Required settings :
max … upper limit S1
min … lower limit S1
The output switches when S1 < max and > min. Hence, while program 8 switches above
and below a temperature window, program 9 switches within a temperature window.

10
Program 12 - Burner requirement using holding circuit
The output switches on when S2 < minand only switches off when S1 > max. In other
words, boiler requirement when S2 falls short of minin the upper storage area and switch-
off when S1 exceeds maxin the lower part of the tank. The output terminal is not poten-
tial-free.
Program 16, 17 Preparation of hot water (only ESR31-D)
Diagram for program 16 without flow
switch S3
Diagram for program 17 with flow switch
S3
Required settings :
max… limit S1
(ex works = 65°C)
min… switch-on threshold S2
(ex works = 40°C)
Required settings :
DVA … desired value for absolute value
control S2
DVD … desired value for differential con
troll S1–S2
Program 17: Setting of sensor 3 as a digital
input in the menu MEN/Sensor
Program 18: setting of sensor S2 as VTS
(vortex temperature sensor)
and sensor S3 as VF2 (vortex volume flow
encoder) in the menu MEN/Sensor
Menu PAR: min threshold of the flow in l/h
(ex works = 5 l/h)
possible other settings in the PSC-menu
(PRO/INT/DIF/MIN/MAX)
A
CW

11
Generally for all programs (16, 17):
No thermostat function or differential switching function is activated. Calling one of these
two programs the measuring speed of the input S2 is automatically increased from AV 1.0 to
AV 0.4 (see in the menu MEN under SENSOR) and the speed control is activated as an
alternative parameter list with the following factory settings(see in the menu MEN under
PSC):
Abs. value control AC….. I 2 Desired value DVA…..48 °C
Differential control DC.. N12 Desired value DVD…..7.0 K
Event control EC…...... ---
Proportional part PRO…. 3 Integral part INT………… 1 Differential part DIF…….. 4
Minimum speed MIN…....0 Maximum speed MAX…30 Delay time ALV ………… 0
In addition, the set values for the desired hot water temperature (DVA) and the mixing dif-
ference (DVD) is put down in the parameter menu to provide the user with quick access.
For more detailed data related to speed process and stability see: Pump speed control
PSC.
Program 16
By using the speed control the heat exchange outlet can be kept permanently at a con-
stant temperature via the ultrafast sensor S2 (non-standard accessory). Low stand-by loss-
es may occur. A volume flow switch S3 is not necessary.
Program 17
The speed control is only activated, if the volume flow switch S3 (non-standard accessory)
indicates a flow. Very few stand-by losses may occur. When starting, the system is a little
lazier and a volume flow switch is necessary.

12
Operation
The large display contains all of the icons for all of the important information and a field for
plain text. Navigation with the co-ordination keys is adapted to the display structure.













 = Navigation keys to select the display and change parameters.
= Enter a menu, release a value to change using the navigation keys.
 = Return to the last menu level selected, exit the setting of parameters for a value.
In the main level, the left/right arrows  are the navigation keys to select the desired
display, such as collector or storage tank temperature. A different sensor symbol flashes for
each pressure and the corresponding temperature is displayed.
Sensor symbol flashes: the temperature for
this sensor is displayed
Pump symbol flashes:
the output is active
(pump is running)
Current temperature of
sensor 1

13
The main level
Temperature
Sensor 1
Temperature
Sensor 2
Temperature
Sensor 3
External value 1
Only displayed if
external DL is
activated
External value 6
Only displayed if
external DL is
activated
Speed stage
ESR31-D only
and active PSC
Analogue stage
only if control out-
put activated
Volume flow
only displayed if
heat counter is
activated
Current power
only displayed if
heat counter is
activated
MWh only dis-
played if heat coun-
ter is activated
kWh only displayed
if heat counter is
activated
Status display
"OK" only displays
if active
function control
Parameter
menu PAR
Menu MEN
Temperature
Sensor 1

14
T1 to T3 Displays the value measured at the sensor (S1 - T1, S2 - T2, S3 –T3).
E1 to E6 Displays the values from external sensors which are read via the DL-bus. Only
activated inputs are displayed.
ERR means that no valid value has been read. In this case the external value is
set to 0.
SPS Speed stage (only ESR31-D), indicates the current speed stage. This menu
item is only displayed if the speed control is activated.
Display range: 0 = output is off
30 = speed control is running at the highest stage
ANL Analogue level indicates the current analogue level of the 0-10V output - only
displayed if the 0-10V output control system has been activated.
Display range: 0 = output voltage = 0V or 0% (PWM)
100 = output voltage = 10V or 100% (PWM)
l/h The volume flow, indicates the flow rate of the volume flow encoder (only possi-
ble to input 3), or the volume flow rate of an external sensor via DL, or the fixed
volume flow in litres per hour.
kW The current output of the heat counter indicated in kW.
MWh Megawatt hours, indicates the megawatt hours of the heat counter.
kWh Kilowatt-hours, indicates the kilowatt-hours of the heat counter.
When 1000 kWh have been reached the counter restarts at 0 and the MWh are
increased by 1.
Menu items l/h, kW, MWh, and kWh are only displayed if the heat counter has been activat-
ed.
Status: Display of the system’s status. Depending on the program selected, various
system statuses are monitored. If any problems have occurred, this menu con-
tains all of the information.
PAR:The navigation keys on the parameter level (, ) allow you to select the icons
under the temperature display and the text line. The parameter selected can
now be released for selection with the down key (enter). The parameter
blinks to indicate release. Press one of the navigation keys to change the value
by one increment. Keep the key pressed to keep the value running. The
changed value is adopted when the UP key (return) is pressed. To prevent
unintended changes in parameters, entry in PAR is only possible using the
code 32.
MEN:The menu contains basic settings to determine additional functions such as the
sensor type, language, the system protection functions, etc. Use the keys for
navigation and to make changes as usual. The dialogue is only set up via the
text line. As the settings in the menu change the basic features of the control
unit, entry is only possible with a code that only the technician knows.
The settings of the parameters and menu functions ex works can be restored at any
time using the down key (entry) when plugging the unit in. If this occurs, WELOAD will
appear in the display for three seconds.
Warning! All parameters and menu points already set will be deleted.

15
Further sensor display types:
Radiation in W/m²
(radiation sensor)
Digital state
(0=OFF, 1=ON)
(digital input)
Flow in l/h (sensor
3 = VFS 2-40)
If in the SENSOR menu (main menu MEN) one sensor is set to OFF or a volume flow encod-
er VSG is defined, then the value display of this sensor is hidden at the main level.
Changing a value (parameter)
If a value is to be changed, press the down arrow key. This value will then blink and can
be set to the desired value with the navigation keys.
Use the arrow key up to save the value.

16
The parameter menu PAR
(Version number, program number, min, max, diff, auto/manual mode)
In the following example the PAR menu has
been selected for program 5 so that all setting
parameters (max2, min) can be displayed.
Code to enter menu
Version number
Program number
Max limit switch-off
threshold
Max limit switch-on
threshold
Max2 limit switch-
off threshold
Max2 limit switch-on
threshold
Min limit switch-on
threshold
Min limit switch-off
threshold
Difference switch-on
threshold
Difference switch-
off threshold
Automatic / Manu-
al mode output
Automatic / Manual
mode control output
Code number CODE
The other menu items of the parameter menu are only displayed after input of the correct
code number (code number 32).

17
Software version VR / VD
Software version of the device (VR = version with relay output, VD = speed version). It can-
not be changed as it indicates the intelligence of the device and must be provided if there are
any queries.
Program number PR
Selection of the appropriate program according to the selected diagram. For a solar thermal
system, that would be the number 0 or 1.
Set values (min, max, diff)
The device does not have any switching differentials (difference between temperatures to
switch on or off); rather, all of the threshold values are divided into switch-on and switch-off
values. In addition, some programs have several similar thresholds such as max, max2. To
make a distinction, the index for max is also displayed in the left parameter line.
CAUTION: When setting the parameter, the computer always limits the threshold value (such
as max on) when it approaches a certain temperature of the second threshold (such as
max off) to prevent negative hysteresis. If a threshold cannot be changed any longer, the
second threshold has to be changed first.
max When this temperature has been reached, the output is blocked (ex works = 65°C).
max The output blocked at max is released again when this temperature has been
reached. max generally serves to limit storage. Recommendation: The switch-off
point should be some 3-5K higher than the switch-on point in the storage area and
some 1-2K higher than in the pool area. The software does not allow for differences
less than 1K (ex works = 60°C).
Setting range: -30 to +149°C in increments of 1°C (for both thresholds, but max
has to be at least 1K greater than max)
min  When this temperature has been reached at the sensor, the output is released
(display only with the corresponding program diagram) (ex works = 5°C).
min  The output previously released via min is blocked again when this temperature
has been reached. min generally protects the boilers from soot. Recommendation:
The switch-on point should be some 3-5K higher than the switch-off point. The soft-
ware does not allow for differences less than 1K (ex works = 0°C).
Setting range: -30 to +149°C in increments of 1°C (for both thresholds, but min
has to be at least 1K greater than min)
diff  If the temperature difference between the two set sensors surpasses this value, the
output is released. For most programs, diff is the basic function (differential control-
ler) of the system. Recommendation: For solar applications, diff should be set
to around 7-10K (factory settings WE = 8K). Slightly lower values suffice for the
loading pump program (ex works = 8K).
diff  The output previously released when diff was reached is blocked again when
this temperature difference is reached. Recommendation: diff should be set to
around 3-5K (WE = 4K). Although the software allows for a minimum difference of
0.1K between the switch-on and switch-off points, no value less than 2K can be en-
tered for sensor and measurement tolerance (ex works = 4K).
Setting range: 0.0 to 9.9K in increments of 0.1K
10 to 98K in increments of 1K (for both thresholds, but diffhas
to be at least 0.1K / 1K greater than diff)

18
Schematic representation of setting values

19
Automatic / manual mode
O AUTO
The output is set to automatic mode and can be switched for test purposes to manual mode
(O ON, O OFF). When the manual mode has been selected, an icon appears at the top. If
the hand symbol is displayed, the control function is deactivated. (ex works = AUTO)
Settings: AUTO the output switches according to the program diagram
ON the output switches on
OFF the output switches off
C AUTO
The control output is set to automatic mode and can be switched for test purposes to manual
mode (C ON, C OFF). When the manual mode has been selected, an icon appears at the
top. If the hand symbol is displayed, the control function is deactivated. (ex works =
AUTO)
Settings: AUTO the control output delivers a control voltage between 0 and 10 volts de-
pendent on the settings in the COP menu.
ON the control voltage is always 10 volts
OFF the control voltage is always 0 volts
In all menus, the
hand symbol
indicates that the
output has been
manually switched
on or off
Automatic mode
Manual ON
Manual OFF
In all menus, the
hand symbol
indicates that the
control output is
manually at 10 or 0
volts
Automatic mode
Manual 10 volts
Manual 0 volt

20
The menu MEN
The menu contains basic settings to specify additional functions such as sensor type, func-
tion check, etc. Navigation and changes are done as usual with the keys , while the
dialogue is only set up in the text line.
As the settings in the menu can change the basic features of the control unit, only a tech-
nician who has the code can open this level.
Language
Code to enter the
menu
Sensor menu
System protection
function
Start function
After-running time
of output
Pump speed con-
trol
Control output
Function check
Heat quantity
counter
External sensors
via DL bus
Brief description
ENGL Language selection: The entire menu can be switched to the desired user lan-
guage even before the code is provided. The following languages are available:
German (DEUT), English (ENGL).
CODE Code number for entering the menu. The rest of the menu items are only dis-
played once the correct code number is entered.