Weishaupt WRSol 1.0 User manual

Solar controller WRSol 1.0 83258202 - 1/2008
Installation and operating instructions
manual

2
Conformity Certification to ISO/IEC Guide 22
4800000001
Manufacturer: Max Weishaupt GmbH
Address: Max-Weishaupt-Straße
D-88475 Schwendi
Product: Solar controller
WRSol 1.0
WRSol 2.0
The product described above conforms to:
Document No. DIN EN 60730-1, -2-9
DIN EN 61000-6-1, -6-3
In accordance with the directives
LVD 2006 / 95 / EC
EMC 2004 / 108 / EC
this product is labelled as follows
Schwendi, 09.07.2008
ppa. ppa.
Dr. Lück Denkinger

3
Contents 1 Safety instructions 5
2 About the Weishaupt solar controller WRSol 1.0 6
2.1 What does the solar controller do 6
2.2 What you have to observe 6
3 Installation and connection 7
3.1 Included in delivery 7
3.2 Wall mounted installation 7
3.3 Commissioning 8
3.4 Electrical connection 9
4 Hydraulic variations 11
4.1 Variation 1 11
4.2 Variation 12 11
4.3 Variation 15 12
4.4 Variation 20 12
4.5 Variation 48 13
5 Operation 14
5.1 Display and operating elements 14
5.2 Navigation / menu structure (change hydraulic variation) 14
5.3 Where do I find what… 15
5.4 Display 18
6 Parameters 20
6.1 Select type of operation 20
6.2 Select temperature and values 21
6.3 Change settings 23
6.4 Test outputs 28
6.5 Select options 29
6.6 Display faults 30
6.7 Language selection 30
7 Functions 31
7.1 Collector protection 31
7.2 Energy management via the MFA output 32
7.3 Fault transmission 32
7.4 Pump standby protection 33
7.5 Reference value of pump speed control
in conjunction with collectors 33
7.6Pump control in conjunction with a solid fuel boiler 34
7.7 Solid fuel boiler functions 35
7.8Manual operation 36
7.9Calculation of energy yield 36
7.10 Start aid function 36
1
2
3
4
5
6
7

4
8 What to do if…? 37
8.1 Fault messages (fault display) 37
8.2 Displays 38
8.3 Cause and rectification of faults 38
9 Technical data 39
9.1 Electrical data 39
9.2 Permissible ambient conditions 39
9.3 Dimensions 39
9.4 Temperature sensor data 40
9.4.1 Sensor characteristics 41
Appendix 42
Check list 42
Commissioning log of adjustable parameters
‘Change settings’ (please complete) 43
Commissioning log of adjustable parameters
‘Options’ (please complete) 44
8
9
A

5
1Safety instructions 1
Your information pack
•You are holding the operating instructions of the solar
controller.
Please read these operating instructions carefully. They
will help you to fully utilise all functions of the solar
controller and to operate your solar installation to its
optimum.
•These instructions should be kept with the solar
controller.
Explanation of notes and symbols
This symbol is used to mark instructions,
which, if not followed, could result in death or
serious injury.
This symbol is used to mark instructions,
which, if not followed, could result in damage
to, or the destruction of the equipment and
environmental damage.
Permissible application
The controller is an electronic unit intended for use with
hydraulic switching in accordance with manufacturer
specifications.
Any other application is not permitted.
Dangers when using the equipment
Weishaupt products are manufactured in accordance with
the relevant existing standards and guidelines and the
recognised safety laws. However, improper use of the
equipment could endanger life of the user or a third party,
or result in damage to the plant.
To avoid unnecessary danger, the Weishaupt solar
controller (WRSol) should only be used
•for its intended purpose
•in a technically safe, fault free condition
•in compliance with all the information in the
installation and operating instructions
Faults, which could affect the safe operation, should be
rectified immediately.
Personnel training
Only competent personnel may work on the appliance.
Competent personnel according to this operating manual
are persons who are familiar with the installation,
mounting, setting and commissioning of the product and
have the necessary qualifications such as:-
•Training, instruction or authorisation to switch electrical
circuits and electrical devices on and off, to earth them
and to mark them in accordance with the safety
standards.
Informal safety measures
• Observe all information given in the operating
instructions.
• Also observe the instructions given in the installation
and operating instructions of the collectors.
•In addition to the installation and operating instructions,
local codes of practice should also be adhered to.
Special attention should be paid to the relevant
installation and safety guidelines given.
•All safety and danger notices should be kept in a
legible condition.
•Ask the installer to instruct you in the use of the solar
controller.
Electrical safety
•Before starting work - isolate plant and protect against
reactivation, check voltage is isolated, the unit is
earthed, and protected from adjacent equipment that
might still be under voltage!
•Work on the electrical supply should be carried out by
a qualified electrician.
•Electrical components should be checked during
servicing. Loose connections and heat damaged
cables should be dealt with immediately.
•Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed.
A second person should be present to switch off the
mains supply in an emergency.
Alterations to the construction of the equipment
•No alterations to the equipment are to be made without
the approval of the manufacturer.
All conversions require written confirmation from
Max Weishaupt GmbH.
•Any parts not in perfect working order should be
replaced immediately.
•No additional components may be fitted, which have
not been tested for use with the equipment.
•Use only -weishaupt- replacement and connection
parts.
Settings
•Only settings as stipulated in these operating
instructions are permissible. Incorrect settings can
damage the solar system.
Guarantee and liability
Weishaupt will not accept liability or meet any guarantee
claims for personal injury or damage to property arising as
a result of one or more of the causes below:
•Failure to use the equipment as intended.
•Improper assembly, commissioning, operating or
servicing of the equipment.
•Failure to follow the information in the installation and
operating instructions.
•Alterations made to the construction of the equipment.
•Fitting additional components not tested or approved
for use with the equipment.
•Alterations made to the equipment.
•Improperly executed repairs.
•Acts of God.
•Damage caused by continued use despite the
occurrence of a fault.
•Use of non-original -weishaupt- spare parts.
DANGER
ATTENTION

6
About the Weishaupt solar controller WRSol 1.0
2
The Weishaupt solar controller (WRSol ) allows
easy control of your solar system.
Some characteristics of the WRSol:
•Easy interrogation of information about the solar
system.
•Temperature setpoint defaults for DHW
and frost protection.
•Easy reset to previously set values or to factory
settings.
•Recording possible with WRSol recording software.
•Speed controlled solar and/or solid fuel boiler pump.
The WRSol can be used as differential controller for:
•Solar DHW storage tank
•Solar calorifier
•Return temperature maintenance
•Swimming pool
•Solid fuel
Easy operation
Three levels are available to you:
•The standard display, in which up to three selected
values can be displayed.
•The selection menu level, for the selection of one of
seven menus from where the sub-menu level can be
accessed.
•The sub-menu level, where settings for additional
solar, return temperature increase, swimming pool and
solid fuel functions can be set.
2.1 What does the solar controller do
If programmed correctly, the controller, in conjunction with
the relevant hydraulic switching, will ensure that the
solar energy available is used correctly and that the need
for additional heat exchangers is largely avoided.
General operation of the system is possible once the
available hydraulic variation (system type) has been
entered. The parameters, control and safety function
relevant for the system type selected are preset
automatically. This allow immediate operation.
With the potential free contact (MFA output terminals 5
and 6) a fault can be reset, and a burner interlock
(exchanger interlock) or a request (exchanger release) can
be initiated.
Note: On system variations 15 and 20 the potential
free contact (MFA output) acts only as fault
output.
Setting on Multi funct. output :
9 or 10.
2.2 What you have to observe
Do not switch off the controller
Switching off the controller can damage the
solar system, if the system is filled with water.
(Frost protection no longer guaranteed).
The controller should only be shut down for
the duration of service and repair work.
Note: These operating instructions are valid only for
solar controller type WRSol 1.0
(see name plate).
ATTENTION

7
3Installation and connection 3
3.2 Wall mounted installation
127,5mm
180,5mm
3.1 Included in delivery
Included in delivery are:
•Controller WRSol 1.0
•Mounting parts for wall mounting
•Traction relief clamps incl. screws
•Collector sensors STF 225
(4 m, blue cable, -w- No. 660 229)
•Immersion sensor STF 222.2
(2.5 m, grey cable, -w- No. 660 228)
•Operating instructions WRSol 1.0
Note:
Screw in the top screw only so far that it is still possible to
hook in the controller.
Note: The sensors supplied are designed as
immersion sensors.
If site conditions require contact sensors,
these can be ordered under order
No. 660 302.
Contact sensors cannot be used as collector
sensors.

8
3
3.3 Commissioning
The WRSol 1.0 is constructed in such a way, that the
function of the controller and the type of setting
parameters can be set by selecting the relevant hydraulic
variation.
Only the selection menus and setting parameters required
for the hydraulic variation selected will then be displayed.
All other parameters are blanked out.
Procedure:
1. Select hydraulic variation required.
➭Ch. 4
2. Carry out electrical connection in accordance with
the hydraulic variation selected.
➭Ch. 3.4
3. Program the controller, if necessary, start with
language selection.
➭Ch. 6.7
4. The the hydraulic variation selected under item one in
the controller.
➭Ch. 6.3
5. Activate overheat protection (recommendation).
➭Ch. 6.5
6. Select all temperatures and values and check their
plausibility.
➭Ch. 6.2
7. Test and check all outputs in type of operation Manual
(the pump start of the solar pumps is not possible
above collector temperatures of 130°C, not even in
manual operation).
➭Ch. 6.4; Ch. 7.8
8. The controller is reset to type of operation Auto.
➭Ch. 6.1
9. Complete commissioning log in appendix.
10. Show customer the operation and functions of the
controller.

9
3
3.4 Electrical connection
Terminal rail left (sensor) Terminal rail right (outputs / voltage supply)
Connection
➭Remove terminal rail cover.
➭Connect
•sensor lines,
•MFA output,
•pump or change-over valve,
•voltage supply
according to the hydraulic variation installed
(Ch. 4).
➭Secure all connected cables with the traction reliefs
supplied.
➭Apply voltage, if fault message appears check sensor
connection, if necessary adjust hydraulic variation.
➭Refit terminal rail cover once the relevant cable cut-outs
have been opened, use screws (traction relief)
supplied.
Improper installation or repair attempts can
cause life-threatening conditions through
electric shock. The installation must only be
carried out by an electrician with the relevant
qualifications.
The unit and accessories must not be opened.
Repairs must only be carried out by the
manufacturer.
Voltage surge protection
The sensors connected do not require voltage surge
protection.
The flow and return of the solar system must be earthed.
DANGER

10
3
Wiring diagram WRSol 1.0
1NL
N N PE PE
L
(–) (+)
ϑ
ϑ
L N PE
230V 1/N/PE 50Hz
M
1~
WRSol 1.0
F1
3,15A
X2 X1
TKO/
TFK/
TPO
4 3 2 1
6 5
6 5
MFA
TSU/
TSB/
TPU/
THR
PS/
PFK/
VRA
1
F10
16A
S1
eBus
Legend
TFK Temperature sensor solid fuel boiler
(STF 225 -w- 660 229)
THR Temperature sensor heating circuit return
(STF 222.2 -w- 660 228)
TKO Temperature sensor collector
(STF 225 -w- 660 229)
TPO Temperature sensor calorifier top
(STF 225 -w- 660 229)
TPU Temperature sensor calorifier bottom
(STF 222.2 -w- 660 228)
TSB Temperature sensor swimming pool
(STF 222.2 -w- 660 228)
TSU Temperature sensor storage tank top
(STF 222.2 -w- 660 228)
F1 Internal unit fuse 3.15A slow
F10 Pre-fusing max. 16A
S1 Emergency switch
PS Pump solar
PFK Pump solid fuel boiler
VRA Valve return temperature increase
MFA Multi-function output (potential free)
Note: The output 1 (PS, PFK and VRA) must have a
max. loading of 1 amp. Circuits with higher
voltage consumption must be driven by
auxiliary relay.
If an auxiliary relay or valve for return
temperature increase is connected to
output 1 (PS, PFK and VRA), parameter
PS Speed Minimum must be set to 100%.
Additionally, an RFI Suppressor circuit must
be connected parallel to terminal 1/N
(-w- 701 890).
The internal unit fuse (F1) protects only the
outputs. The controller cannot be
de-energised via F1.
Protective earthing (Null
Potential Difference) to
local regulations
Cable grey Cable blue
Input and output assignment of individual hydraulic variations
Hydraulic variation Sensor terminals Outputs
1/2 3/4 5/6 1/N 2 3 4 5/6
1eBUSTKOTSUPS–––MFA
12 eBUS TKO TPU PS – – – MFA
15 eBUS TPO THR VRA – – – MFA
20 eBUS TKO TSB PS – – – MFA
48 eBUS TFK TPU PFK – – – MFA

11
4Hydraulic variations 4
4.1 Variation 1
4.2 Variation 12
X1:
1
N
5
6
TSU
PS
TKO
X2:
1
2
3
4
5
6
eBus
MFA
TSU
TKO
PS
X1:
1
N
5
6
TPU
PS
TKO
X2:
1
2
3
4
5
6
eBus
MFA
TKO
TPU
PS
Storage tank with collector and
back-up heating influence
The WRSol 1.0 determines the temperature differential
between the collector sensor (TKO) and the reference
sensor (TSU).
As soon as the temperature differential is greater than the
value set ( SSttoorraaggeeDDiiffff..OOnn), the solar pump is
switched on and the tank is topped up, until the switch off
condition ( SSttoorraaggeeDDiiffff..OOffff) or the maximum
temperature of the storage tank has been reached.
Depending on the average pump speed and the minimum
storage tank temperature, the external heat exchanger can
be blocked via the potential free Multi-funct. Output
(MFA).
In addition an 18 hour block can be activated.
Possible settings MFA output:
0, 1, 2, 7, 8, 9, 10, 11, 12
Calorifier tank with collector and
back-up heating influence
The WRSol 1.0 determines the temperature differential
between the collector sensor (TKO) and the reference
sensor (TPU).
As soon as the temperature differential is greater than the
value set ( CCaalloorriiffiieerrDDiiffff..OOnn), the solar pump is
switched on and the tank is topped up, until the switch off
condition ( CCaalloorriiffiieerrDDiiffff..OOffff) or the maximum
temperature of the storage tank has been reached.
Depending on the average pump speed and the minimum
storage tank temperature, the external heat exchanger can
be blocked via the potential free Multi-funct. Output
(MFA).
Possible settings MFA output:
0, 5, 6, 7, 8, 9, 10, 11, 12
The following hydraulic variations are
simplified schematic drawings, therefore
not all components (gravity break, flow
meter etc.) are included in the drawing.
ATTENTION

12
4
4.4 Variation 20
X1:
1
N
5
6
TSB
PS
TKO
X2:
1
2
3
4
5
6
eBus
PS
MFA
TKO
TSB
PS
Swimming pool with collector and heat exchanger
The WRSol 1.0 determines the temperature differential
between the collector sensor (TKO) and the reference
sensor (TSB).
As soon as the temperature differential is greater than the
value set ( SSwwiimmmmiinnggppoooollDDiiffff..OOnn), the solar pump
is switched on and the swimming pool is topped up by the
heat exchanger, until the switch off condition
( SSwwiimmmmiinnggppoooollDDiiffff..OOffff) or the swimming pool
setpoint temperature has been reached.
When connecting both pumps to connection
( PS ) please observe that both pumps
together must not consume more than 1 A
voltage, otherwise an auxiliary relay must be
installed and the minimum load of the solar
pump must be set to 100%
( PPSSSSppeeeeddMMiinniimmuumm).
Possible settings MFA output:
0, 9, 10
ATTENTION
4.3 Variation 15
TPO
M
M
THR
VRA
VRA
X2:
1
2
3
4
5
6
eBus
TPO
THR
X1:
1
N
L
5
6
MFA
AB
BA
Return temperature increase
The WRSol 1.0 determines the temperature differential
between the calorifier sensor (TPO) and the return flow
sensor (THR).
As soon as the temperature differential is greater than the
value set ( RReettuurrnnfflloowwDDiiffff..OOnn), the three way valve
(VRA) is activated (AB–B) and the available energy from
the calorifier is utilised.
If the temperature differential ( RReettuurrnnfflloowwDDiiffff..OOffff)
falls below the value set, the three way valve (VRA) is
de-energised.
Possible settings MFA output:
0, 9, 10, 11, 12
Note: An RFI suppressor must be
connected parallel to terminal 1/N
on the 3 way change-over valve.
-w- Best.-No. 701 890

13
4
4.5 Variation 48
X1:
1
N
5
6
TPU
PFK
X2:
1
2
3
4
5
6
eBus
TV
TFK
MFA
TPU
TFK
PFK
T
Storage tank supply by solid fuel burner
The WRSol 1.0 compares the solid fuel boiler temperature
(TKF) with the reference sensor (TPU).
If the temperature differential determined is greater than
the value set ( SSoolliiddffuueell..DDiiffff..OOnn) the pump is
switched on, if the default minimum temperature ( SSoolliidd
ffuueell..TTeemmpp..MMiinniimmuumm) is achieved at the same time.
Once the switch off condition SSoolliiddffuueell..DDiiffff..OOffff
has been reached, the pump is switched off.
If the solid fuel boiler temperature (TFK) exceeds the
CCaalloorriiffiieerrTTeemmpp..sseettppooiinnttand if the calorifier
temperature is greater than CCaalloorriiffiieerrTTeemmpp..
sseettppooiinnttminus DDiiffff..CCaalloorriiffiieerrMMiinniimmuumm,
an interlock or a release signal is generated on the
potential free Multi-funct. output MFA.
Possible settings MFA output:
0, 5, 6, 7, 8, 9, 10, 11, 12

14
Operation
5
5.1 Display and operating elements
Enter button
Pressing this button confirms entries and changes.
Dial knob
Escape button
Return to the main display. This key is used to exit settings.
Any unsaved entries will be lost. Return by one level at a
time.
Reset
By pressing the Reset button, the processor is re-started
with the previously set values.
It is not possible to start the factory presettings.
Factory presettings can only be reset under Select
options with Set factory presettings.
LCD display
eBus plug socket
Standard display
Selection menu
Sub menu
Display
faults
Sprache
language
idioma
Select
type of
operation
Select
temperature
and values
Change
settings
Hydraulic
variation
1
Collect
temp.
Minimum
20°C
PS
Speed
Minimum
40%
Multi
funct.
output
7
TKO 67°C
TSU 49°C
PS 100%
BA Auto
esc
Hydraulic
variation
12
Save
changes
esc
return without
saving Change
value
5.2 Navigation / Menu structure (change hydraulic variation)
esc

15
5
5.3 Where do I find what…
TKO 67°C
TSU 49°C
PS 100%
BA Auto
Standard display
Select
type of
operation
esc
esc
Auto
Manual
Off
Select
temp. and
values
Collect. temp. act. value
Solid f. temp. act. value
Tank bottom act. value
Calorif. bottom act. val.
Swim pool temp. act. val.
Calorif. top act. value
Heat cr. return act. val.
Collect. temp. maximum
Rating current collect.
Part yield collect.
Part yield delete
Total yield collector
Average rating PS
Operating hours PS
Version
By pressing the key in the standard menu the
following selection menus can be accessed.
By pressing the key you can return to the base menu.
esc
esc
Selection menu Sub menu

16
5
Change
settings
Hydraulic variations
Collect. temp. minimum
PS speed minimum
Volume flow
Heat capacity
Frost protection
Tank diff. ON
Calorifier diff. ON
Swim pool diff. ON
Return diff. ON
Tank diff. OFF
Calorifier diff. OFF
Swim pool diff. OFF
Swim pool Control Diff.
Return diff. OFF
Tank temp. minimum
Diff. calorifier minimum
Tank temp. setpoint
Calorifier temp. setpoint
Swim pool temp. setpoint
Swim pool temp. maximum
Tank temp. maximum
Tank Control Diff.
Calorifier temp. maximum
Calorifier Control Diff.
Solid fuel temp. minimum
Solid fuel temp. gradient
Solid fuel diff. ON
Solid fuel diff. OFF
PSolidf. speed minimum
Collect. temp. gradient
Multi funct. output
esc

17
5
Select
options
Collector protection
Start optim. collector
Swim pool loading
Set factory setting
Display
faults
Fault codes
Delete fault codes
Sprache
language
idioma
deutsch
english
espagnol
Check
or accept
output
SolarPump PS
Solid fuel pump
Heating return increase
Multi funct. output
esc
esc
esc
esc
Note: Only those parameters, switch
conditions and values are shown, which are
required for the hydraulic variation
selected. Only these can be selected.
Note
This parameter has to
be reselected when
changing variation.

18
5
BBAAAAuuttoo
5.4 Display
Standard value
The standard display is recognised by its 4 lines with a
dotted line in the centre of the display.
In the first three lines of the display, three temperatures,
values or switch conditions of the outputs are displayed.
The fourth line contains the operation selection switch. If
the operation selection switch is set to manual, an arrow
flashes to the right and left of BBAAMMaannuuaall, to indicate an
incorrect operating condition.
If another display has been set, the controller automatically
returns to the standard display after a time out of eight
minutes.
Operator defined standard display
The standard display can be set with certain values from
the selection groups SSeelleecctttteemmpp..++vvaalluueessand
TTeessttoorrttaakkeeoovveerroouuttppuuttss.
New values are entered on line three of the display and the
display is pushed up by one line. The value in the first line
is therefore lost.
Changing the standard display
TKO 67°C
TSU 49°C
PS 100%
BA Auto
Select
temp. +
values
Current
rating
ColleCt
1.2kW
Take over
current
rating
Yes
Current
rating
Collect
1.2kW
Select
temp. +
values
esc
TSU 49°C
PS 100%
Q1.2kW
BA Auto
esc
Standard display Selection menu Sub menu
Standard display
TTKKOO6677°°CC
TTSSUU4499°°CC
PPSS110000%%
BBAAAAuuttoo
Line 1-3 Display for
temperatures, values
or switch conditions
Display of type of
operation
If an error message is present, line BBAAAAuuttooflashes
alternating with EErrrr.
Error message
TTKKOO------°°CC
TTSSUU4499°°CC
PPSS110000%%
EErrrrDisplay of type of
operation
Note: The error code can be viewed in Ch. 6.6.

19
5
Selection menu
A selection menu only has text and no dotted line. The sub
menu is reached by pressing the , pressing means
exit, any changes not saved are lost.
Sub menu
A sub menu has a dotted line in the centre of the display.
By pressing the the selected parameter for taking over
into the standard display can be selected, or made
adjustable. The adjustable value flashes.
The change has to be confirmed by pressing the key
to save the new value. If the key is pressed the
previous value is re-entered.
esc
esc
Sub menu
Collect.
temp.
minimum
20°C
Collect.
temp.
minimum
20°C
Selection menu
Select
temp. +
values
Display does not show standard display
If the display shows the display to the right when voltage is
applied, the display is not started correctly. Pressing the
reset key re-initialises the display and the standard display
is shown.
If the standard display does not appear after repeated
initialisation the controller should be replaced.
Display not initialised
Standard display
TKO 67°C
TSU 49°C
PS 100%
BA Auto
Resetting the display
The display and all parameter are reset to the factory
settings by activating the factory presettings in menu
Select options.

20
Parameters
6
Use:
The function of the solar controller can be stipulated using
selection menu point SSeelleeccttttyyppeeooffooppeerraattiioonn.
AAuuttoo
Automatic operation to the criteria set. From an energy
point of view the best type of operation.
MMaannuuaall
Use for hydraulic commissioning and adjustment
of the solar system.
Output 1 is driven with 100%.
In manual operation,all outputs can be switched on and
off, or the speed control can be matched in 10 % steps
using Test oorrttaakkeeoovveerroouuttppuuttss.
OOffff
The system is now switched off in accordance with the
software. The controller continues to carry voltage.
Interrupt the voltage supply to the controller prior to
carrying out service or repair work.
No frost protection
In types of operation MMaannuuaalland OOffffthe
frost protection function is not longer active.
6.1 Select type of operation
ATTENTION
Select
type of
operation
esc
Auto
Manual
Off