Thermomax SMT 100 User manual

SMT 100
SOLARCONTROLLER
www.Thermomax.com

CONTENTS
SECTION1-INTRODUCTION ................................................................................... 2
SECTION2-INSTALLATION/APPLICATION ........................................................ 3
2.1-SMT100Unit .............................................................................…...…. 3
2.2-Sensors ...........................................................................................….. 4
2.3 - Power Connections and Wiring Diagram .............................…….. 4
2.3.1- AOne PumpSystem ...…………..........………………..… 5
2.3.2 - Two Pump Cascade System ……………..........………... 6
2.3.3 - Normal AUX Heat Extraction ……………..........…….…... 7
SECTION3-SMT100OPERATION/FUNCTION ..........................................…... 9
3.1- Description .………………………………............………………….. 9
3.1.1 - Display Select Indicators ……………………………….. 9
3.1.2 - Temperature Display …………………..……...…………. 10
3.1.3 - Temperature Set Increase / Decrease Switches ……… 10
3.1.4 - Display Selector Switch …………………………………. 10
3.2 - Principle of Operation …………………………………………… 10
3.2.1 - Pump Operation …………………………………………… 10
3.2.2 - Auxiliary operation ………………………………………… 10
3.2.3 - Frost Protection …………………………………………… 11
3.2.4 - Storage Tank Limit Temperature …………………………11
3.3 - Programming the SMT 100: ………………………………………... 11
3.3.1 - Displaying the Collector temperature …………….…….. 11
3.3.2 - Displaying the Tank temperature …………..……………. 11
3.3.3 - Displaying the Actual Temperature ……………….… 11
3.3.4 - Setting the Minimum Collector temperature TC ……… 11
3.3.5 - Setting the Tank or Auxiliary Temperature ……………... 11
3.3.6 - Setting the Temperature ..……………..…………...…. 12
3.3.7 - Setting the Frost Protection Temperature / Storage
Tank Limit Temperature ………………………………….. 12
3.4 - Additional Features: ………………….……………………………… 12
3.4.1 - Maximum and Minimum Record Temperatures ………. 12
3.4.2 - Manual Pump Override …………………………...……… 13
3.4.3 - Keypad Lock ……………………………………………….. 13
3.4.4 - Sensor Fault …………………………………………….…. 13
SECTION4-FAULT FINDING .................................................................…………… 14
SECTION5 - SPECIFICATIONS ...............................................................………….. 15
1

SECTION 1 INTRODUCTION
The SMT 100 is a multi-functional integrated unit providing complete control for the
solar heating system. By using microprocessor technology it ensures that the
collected energy from the sun is transferred efficiently and harnessed under optimum
conditions, while providing valuable information with clarity and ease of use for the
user.
The SMT 100 controller provides the following functions:
SUMMARYOFFEATURES
•Digital display of collector (manifold) temperature.
•Digital display of differential temperature.
•Digital display of tank (cylinder) temperature.
•Precise pump control for efficient heat collection.
•Auxiliary (tank) thermostat for heat boosting or re-routing excess heat.
•Anti-frost over-ride for system protection.
•Maximum and minimum temperature recorded for collector, return and tank
temperatures.
Note: The Collector, Tank, and Actual temperatures (temperature difference
between the Collector and Return temperatures) are viewed when the keypad lock is
engaged. The keypad lock must be disengaged to set TC, TT, and .
Note: The information supplied in this manual is for guidance only - no part of this
may be used for any agreement, whether express or implied, or to form any contract.
Thermomax reserves the right to change specifications without prior notice.
2

SECTION 2 INSTALLATION
NOTE: This installation procedure is for guidance only, and the installer should
verify its suitability.
It is assumed that the solar equipment is physically installed and tested, and is ready
for operation and connection to the electric supply.
SAFETY PRECAUTIONS
The following safety precautions are strongly recommended:
1Before attempting to install and operate the unit read this instruction manual
carefully.
2Installation and any maintenance required should only be carried out by
suitably qualified personnel.
3It is recommended that the unit be connected to the mains supply via a
suitably rated isolating switch.
4WARNING: When the unit is connected to the mains supply and the cover is
opened, circuits at mains voltage will be exposed. Therefore when installing
the unit ensure all required connections (including battery connection, if
included), are made and covers replaced before turning on the mains supply.
Ensure that all the connections made are secure. If any maintenance work
e.g. installing a new battery, is required ensure that the unit is isolated from
the mains supply before removing the cover. Never leave the unit unattended
if the cover has been removed and the mains supply is connected.
5Do not exceed unit ratings as shown on the ratings label.
6It is advisable to route mains cables away from low voltage or sensor cables.
2.1 SMT 100 UNIT
NOTE: For viewing comfort, the control box should be positioned at eye
level. It is always good practice to keep electronic controls away from
extremes of cold, heat and electrical plant, as extremes of temperature may
reduce the lifetime of the device, and heavy electrical loads, switches, relays
or contractors too close to the device may cause electrical and electro-
magnetic interference when switched on or off. It is also recommended that
for clear visibility, the device should be installed away from direct sunlight. (In
the case of a complete “pump-control unit”, the control box is already
installed.
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4
1Remove the two side restraining screws at both sides of the device.
2Separate the “Top”, controller -section from the Connecting “base”
3If your cables are to enter the enclosure from behind the unit, then knock out
the appropriate entries in the “base” of the SMT 100.
4Use the “base” of the enclosure to mark the four corner mounting holes.
Remove “base” and drill all necessary holes in the wall or mounting panel.
5Connect supply cables, heating pumps and auxiliary output according to the
wiring diagrams shown in section 2.3.
2.2 SENSORS
Included are three temperature sensors, collector, tank and return. If
required, sensors are available with extended cable lengths or alternatively,
sensor extenders are available, also in a variety of lengths. If the sensors
need to be extended but factory-made extenders are not available, they can
be extended using a suitable 4 core or 3-core cable, according to the diagram
shown below.
As with all PT100 sensor applications, a good connection is vital. It is
therefore recommended that wherever there is any doubt, a factory-extended
sensor or a sensor extender should be used.
2.3 POWERCONNECTIONSANDWIRINGDIAGRAM
Note: This device should be properly earthed. Flexible wires simplify
connection to the terminals. All connections should be secure and
adequately tightened, though not over-tightened, as loose power
connections will over-heat, and may cause fire. It is important that the
specified output loads are not exceeded. Where these loads may be
exceeded, external contactors should be used. It is good practice to keep
mains cables away from sensor cables and other low voltage signal cables.
Note: If the outputs from the Auxiliary relay are required to drive a heater with
a current rating greater than 3A then a contactor should be used.
Thermomax can supply an intermediate device, which may be connected to
the SMT 100 to drive an auxiliary load of up to 16A - Part No: C0328.

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2.3.1 AONE PUMP SYSTEM
In this configuration, when the tank temperature is below the set-point,
TT, the AUX. relay is energised, and when rises above TT, the AUX. relay
is de-energised (see SMT 100 Diagram).
1Connect the output terminal of the AUX. relay to the auxiliary heater or to a
contactor (external relay) if the heater has a greater current rating than 3A.
This is illustrated in the diagram below:
2Connect the pump cable to the PUMP terminals of the control unit.
3Connect the “neutral” (N) of the auxiliary heater or contactor, to the supplied
neutral terminal block on the power board.
4Connect the mains supply to the terminals marked MAINS.
5Connect the earth to the pump and contactor (if applicable).
Replace the “top” section of the control unit, and then fasten using the two
side fixing screws. The unit is now ready to be powered up.
When <TT : = ON
When >TT : = OFF

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2.3.2 TWOPUMPCASCADESYSTEM
In this configuration will run when the tank temperature is below the
set point TT, and Pump will run (Pump will switch off) when rises
above TT.
1Insert a link between “L” terminal of the PUMP relay and the common
terminal “C” of the AUX relay, (see cascade diagram).
2Connect and (see cascade diagram)
3Connect the mains supply to the terminals marked MAINS
4Connect the earth to the pump.
Replace the “top” section of the control unit, and then fasten using the two
side fixing screws. The unit is now ready to be powered up.
When < TC: =OFF; =OFF
When > TC : If < TT::=ON; =OFF
and - > If > TT::=OFF; = ON

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2.3.3 NORMALAUXHEATEXTRACTION
When < TC: =OFF; =OFF
When > TC :If < TT::= ON; =OFF
and - > If > TT::= ON; =ON
Extracting excess heat or diverting excess heat.

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SUGGESTEDCIRCUITS
1Example of solar hot water system with electric auxiliary heater. An external
timer (switch-on time for example from 1700 to 1900) should govern the
auxiliary heater and the thermostat switch set at TT. This means the
immersion will be activated only if the temperature of the tank (hot water
cylinder) at 1700 hours is lower than the set temperature.
NOTE: If the outputs from the Auxiliary relay are required to drive a heater
with a current rating greater than 3A than a contactor should be used.
Thermomax can supply an intermediate device, which may be connected to
the SMT 100 to drive an auxiliary load of up to 16A – Part No. C0328.
2Example of a solar hot water system gas or oil auxiliary heating. Logic as 1
above.
3Example of solar hot water system with two users. is the main solar
storage tank, which has an auxiliary heater as in 1 and 2. is the second
user (swimming pool or floor heating etc). The heated water from the
collector will be circulated by the pump, to user when the temperature
in Tank reaches the set temperature TT - i.e. stops and will run
(cascade!).
4Example of a solar pre-heating system. When the temperature of the solar
hot water tank reaches the pre-set level of TT, the water out of the hot water
tap is completely solar heated. For temperatures below the pre-set level, the
solar system is pre-heating the water in the main hot water tank. This
function is regulated by means of a 3 way motorised valve, which is activated
by the solar controller.

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SECTION 3 SMT 100 OPERATION
In order to understand the operation of the SMT 100 this section should be read
carefully.
3.1 DESCRIPTION
DISPLAY SELECT TEMPERATURE
INDICATORS DISPLAY
DISPLAY TEMPERATURE SET FROST PUMPSTATE
SELECT INCREASE / DECREASE PROTECTION INDICATOR
KEY SWITCHES TEMPERATURE
ADJUST KEY
(HIDDEN)
3.1.1 DISPLAY SELECT INDICATORS:
(WITH SELECT INDICATOR FLASHING)
KEYPAD LOCK ENABLED KEYPAD LOCK DISABLED
(DISPLAY MODE) (PROGRAMMING MODE)
:Collector temperature display Minimum collector temp. set point (TC)
:Tank temperature display Tank or Auxiliary set point (TT)
:Actual Delta T temperature Delta T temperature set.

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3.1.2 TEMPERATURE DISPLAY:
The display is used to show the corresponding information for each Display
Select Indicator.
3.1.3 TEMPERATURE SET INCREASE / DECREASE SWITCHES:
The keys are used to decrease or increase any of the system set
points. These keys have an auto repeat facility: press and hold in order to
advance quickly. Please note that the unit must be in programming mode
before any set points can be adjusted.
3.1.4 DISPLAY SELECTOR SWITCH:
Pressing the key will advance the display selector lamp to the next option.
This allows you to view a system temperature or set point depending on the
mode of the unit.
3.2 PRINCIPLE OF OPERATION
3.2.1 PUMP OPERATION:
In the simplest form the solar system needs two sensors. One is positioned
at the collector (manifold) usually on the roof, which is called the Collector
Sensor .The second is positioned such that it measures the temperature
of the water returning to the collector, after the system has extracted the heat
from it. This is called the Return Sensor .
Two conditions must be satisfied before the pump will run:
1As the sun shines on the collector, the collector sensor picks up the rise
in temperature, while the return sensor remains at the existing
temperature. The difference between these two temperatures is referred to
as Delta T ( ). For example, when is set to 4, the collector temperature
must rise at least 4°C above the return temperature before the pump
will operate, but only when condition 2 is also satisfied.
2The collector temperature must be above the minimum collector
temperature set point TC (for example 40°C), before the pump will operate to
optimise the use of the solar collector.
3.2.2 AUXILIARY OPERATION:
In the normal mode of operation, the SMT 100 provides the facility, which
allows the solar controller to either operate an auxiliary heater for boosting
the temperature, or to divert surplus heat to another circuit. This function is
totally independent in its operation to the solar pump control described above,
and has its own separate sensor , and an output relay marked “AUX.”.
The thermostat set point is called TT.
When temperature is below TT set point, C is connected to contact 1.
When temperature rises above TT set point, C is connected to contact 2.

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3.2.3 FROST PROTECTION:
As a safety feature for the protection of your solar heating equipment, the
SMT 100 provides frost protection facilities. If the collector sensor
measures a temperature below –15°C, (–15°C default), it activates the pump
to circulate water through the system. This will prevent freezing, thereby
avoiding permanent damage. The minimum permitted temperature is called
TF. To adjust TF, see section 3.3.7.
3.2.4 STORAGE TANK LIMIT TEMPERATURE:
The SMT 100 has a useful feature to allow maximum temperature from solar
to be limited inside the storage tank (cylinder). The controller can switch off
the circulation pump if the stored temperature reaches TS (90°C default).
This value may be set from 60°C to 90°C, (see section 3.3.7). This value
should NOT be set below 90°C unless for special applications.
NOTE: Stagnation could damage automatic air vent and open pressure relief
valve, if fitted close to the collector.
3.3 PROGRAMMING THE SMT 100
3.3.1 DISPLAYING THE COLLECTOR TEMPERATURE
When the unit is switched on, it goes through an initialisation routine that
lasts about 3 seconds and ends with two bleeps. The default display select is
the collector temperature. The Display select indicator will be constantly ON
(NOT flashing) to inform you that the “keypad lock” is engaged and the SMT
100 unit is in DISPLAY MODE. A full stop will also appear on the display to
inform the user of a “key lock”. Pressing the selector key will advance the
display selector lamp to the next option. To advance quickly, hold the key
for an auto-repeat facility.
3.3.2 DISPLAYING THE TANK TEMPERATURE
To view the Tank temperature, press the key until the selector lamp is
illuminated.
3.3.3 DISPLAYINGTHEACTUAL TEMPERATURE
To view the Actual temperature, press the key until the selector lamp is
illuminated. Please note that this displays the Collector Temperature minus
the Return Temperature. (Coll Temp - Ret Temp).
3.3.4 SETTING THE MINUMUM COLLECTOR TEMPERATURE
Before setting TC, TT or the SMT100 unit must be in PROGRAMMING
MODE. This is achieved by pressing and holding the key for eight
seconds. This will cause the display selector lamp to flash indicating that the
keypad lock is OFF and the unit is in PROGRAMMING MODE. Press the
key until the selector lamp is illuminated, then press the or keys to
set therequired minimum collector temperature TC (we recommend minimum
+30°C,maximum +45°C).
3.3.5 SETTING THE TANK OR AUXILIARY TEMPERATURE
Press the key until the selector lamp is illuminated, then press the
or keys to set the required Tank temperature TT (minimum 0°C, maximum
+90°C).

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3.3.6 SETTING THE TEMPERATURE
Press the key until the selector lamp is illuminated, then press the
or keys to set the Delta T (minimum 4°C, maximum +20°C).
3.3.7 Setting the Frost Protection temperature / Storage Tank Limit Temperature
Note that the unit must be in PROGRAMMING MODE, (keypad lock disabled)
in order to change both values.
1To adjust TF, first make sure that the display select indicator is at . Now
press the hidden TF adjust key (see section 3.1 diagram for location of key)
and the current TF value will be displayed, (-30°C to +3°C).
2Use the keys to adjust this value.
3Press the key to exit and accept the new value.
4Press the hidden TF adjust key a second time. The tank safety temperature
will be displayed (+60°C to +90°C).
5Use the keys to adjust this value.
6Press the key to exit and accept the new value.
The unit can then be brought out of PROGRAMMING MODE pressing and
holding the select key for eight seconds. The display selector lamp will cease
to flash as the unit is now in DISPLAY MODE.
3.4 ADDITIONAL FEATURES
3.4.1 MAXIMUM AND MINIMUM RECORD TEMPERATURES
The maximum and minimum Collector and Tank temperatures may be
displayed by pressing and holding the key for 3 seconds. Ensure that the
or selector lamp is selected. The display will show the maximum
temperature reached since the unit was reset. This may be reset to the
present Collector or Tank temperature by pressing the key whilst viewing
the maximum recorded temperature (while the key is pressed). To view
the maximum ever recorded temperature, continue to press the key for a
further 8 seconds after the maximum temperature has been read (an “F”
indicates that a sensor fault or temperature above 100°C has occurred in the
unit’s history).
The minimum Collector and Tank temperatures may be displayed in the same
manner only using the key. To reset proceed as above.
The hysteresis has been increased to ±2°C.
The pump will switch off if the Tank temperature reaches 90°C and back on
again when the tank temperature drops to 86°C. As before, the pump will run
if the Collector sensor registers a temperature above 99°C, until the Tank
reaches 90°C. The tank safety temperature has priority over all other
settings.

3.4.2 MANUALPUMPOVERRIDE
The Pump can be manually switched ON at any time by pressing both the
keys together. On release of the keys, the pump will switch to itss
previous state. Note that the unit must be in DISPLAY mode for this function
to work.
3.4.3 KEYPADLOCK
It is possible to lock the keypad so that the set values may not be accidentally
changed. To lock the keypad, press and hold the key for eight seconds.
The bleeper will then sound and the “Display Select Indicator” will stop
flashing, showing that the present settings are fixed and protected, and a full
stop will appear in the display. To unlock the keypad, press the key for
eight seconds and the “Display select Indicator” will start flashing. Note that
the keypad lock must be engaged in order to view the Collector, Tank and
Actual temperatures.
3.4.4 SENSORFAULT
In the case of a Tank sensor fault, the auxiliary relay will switch OFF; i.e. C
connected to 2. In the case of a Collector sensor fault the pump relay will
divert to manually on. In the case of a Return sensor fault the pump relay will
divert to manually on.
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SECTION 4 - FAULT FINDING
Problem: Nothing happens when the unit is powered-up.
Cause / Remedy: One of the fuses could be blown - check and replace if
necessary (refer to specifications for values). If the fuse blows
again, contact the agent where the unit was purchased.
Problem: The temperature display is fluctuating.
Cause / Remedy: One of the sensor connections may be loose. Tighten
connections and re-route cables if necessary.
Problem: Unable to set any of the parameters: Keypad will not operate.
Cause / Remedy: The keypad Lock is on - see ‘Keypad Lock’ section 3.5.2.
Problem: One of the sensors is reading “F”.
Cause / Remedy: One of the sensors is either faulty or not properly connected or
is reading a temperature above 100°C. The sensor, which is
causing the problem, will show “F” on the display when
selected. Check that all connections / couplers are secure. If
the fault persists, replace the sensor.
Problem: The “T” light is flashing even when the keypad lock is engaged.
Cause/Remedy: This is not a fault. This is an indication that the temperature of
the collector is below the anti-frost set point (-15°C), and the
pump should be on.

SECTION 5 SPECIFICATIONS
ELECTRICAL:
SupplyVoltage: 120 AC Single Phase
Ambient Temperature: 0°C to +40°C
Fuses: 2 x 1 A 20mm Quick Blow
RelayOutputs: Pump Relay: 3A single pole
Aux. Relay: 3A single pole changeover
MECHANICAL:
Dimensions: SMT 100 Unit: Width: 165mm
Height: 100mm
Depth: 85mm
Sensor: diameter: 7.3mm (8.5mm
for heat shrink)
Weight: SMT 100 Unit: 0.96Kg
Box Material: Plastic
SENSORS:
Type: SXTM PT 100 Platinum Film
Compensation: 3 wire compensated
PARTS LIST
SMT 100 Unit C0132
SX PT100 Sensor Assembly: 25m Collector A0741
SX PT100 Sensor Assembly: 10m Collector A7143
SX PT100 Sensor Assembly: 5m Tank A0742
SX PT100 Sensor Assembly: 5m Return A7141
SX PT100 Sensor Assembly: 0.5m Return A0740
SX Sensor Extender 10m A6911
SX Sensor Extender 20m A6921
SX Sensor Extender 50m A6951
External relay 16A C0328
CE
This product has been tested to the EU EMC 89/336/EEC directive according to the
Manufacturers report, which is available upon request.
This product is in conformance with the Low Voltage Directive 73/23/EEC.
Thermomax certifies that this datalogging and / or control device has been
manufactured to an ISO 9002 Quality System.
Thermomax undertakes to repair or replace the device, if same is shown to be
defective in its manufacture and / or components, but Thermomax shall not be
responsible for any other financial or economic loss (or any indirect loss) which may
be incurred by the buyer / customer or others in the use of the device.
Any claim for repair or replacement must be made not later than 15 months after the
date of manufacture.
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