Prozeda primos 200 SR Installation And Operating Instructions Manual
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Prozeda primos 200 SR Installation And Operating Instructions Manual

Controller unit for solar thermal systems
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Controller unit for solar thermal systems
primos 200 SR
Installation and operating instructions
English version of original German installation and operating instructions
Version: 1.0
February 2012

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Summary of Contents for Prozeda primos 200 SR

  • Page 1 Controller unit for solar thermal systems primos 200 SR Installation and operating instructions English version of original German installation and operating instructions Version: 1.0 February 2012...
  • Page 2 • These installation and operating instructions will hereinafter be designated as "Instructions". • The primos 200 SR controller will hereinafter be designated as "Controller". • The thermal solar power plant will hereinafter be designated as "Solar power plant".
  • Page 3 This manual is designed to help you use the controller properly, safely and economically. Target group This manual is addressed to all persons who carry out any of the following tasks: • Installing the controller • Connecting the controller • Putting the controller into operation •...
  • Page 4 Style conventions used in the text Specific style conventions are assigned to different elements in the manual. This makes it easy to recognise the type of text concerned: Standard text, "Menu", "Menu item", "Button designations", • lists and  actions. Notes accompanied by this symbol contain information about how to operate the controller economically.

  • Page 5: Table Of Contents

    Table of contents Safety ........................7 1.1 Proper use .............................. 7 1.2 Basic safety information ........................7 Description of the controller ................... 9 2.1 Overview ..............................9 Installing the controller ..................10 3.1 Removing the terminal cover ......................11 3.2 Fastening the controller ........................12 Connecting the controller ..................
  • Page 6 10 Measuring energy output ..................40 10.1 Flow indicator............................40 10.2 Setting the energy output measurements................. 41 11 Restore factory settings ..................41 12 Faults ........................42 12.1 Faults with fault message ........................ 42 12.2 Faults without fault message ......................44 13 Technical data ......................

  • Page 7: Safety

    Safety 1 Safety This chapter contains information on: • the proper use of the controller and • the safe use of the controller. Read this chapter through carefully before you install, connect or operate the controller. 1.1 Proper use The controller is used for monitoring and controlling a solar thermal system. Appropriate use of the controller includes the following requirements: •...
  • Page 8 Safety Preventing risks of fatal injury from electric shocks • Make sure that all regulations applicable at the point of use are complied with. • Always make sure that the controller is disconnected from the power supply before carrying out any work on it. •...

  • Page 9: Description Of The Controller

    Description of the controller • When in "manual mode", the system must only ever be operated for a short time and only for test purposes. • Install sensor lines separately from 230 V lines. • Use only sensor connection boxes supplied by the manufacturer. 2 Description of the controller The controller is used for monitoring and controlling a solar thermal system.

  • Page 10: Installing The Controller

    Installing the controller 3 Installing the controller DANGER Risk of fatal injuries due to explosions or fire.  Never use the controller in areas where there is a risk of explosion.  Install the controller on a non-flammable subsurface. DANGER Risk of fatal electric shock when working on the opened controller.

  • Page 11: Removing The Terminal Cover

    Installing the controller 3.1 Removing the terminal cover  Undo the locking screw (1).  To remove the terminal cover (2), pull it off as shown here.

  • Page 12: Fastening The Controller

    Installing the controller 3.2 Fastening the controller If you wish to lead cables and lines through the back of the controller, you need to do this before you fasten it. ATTENTION Risk of damage to the controller housing due to screws tightened too firmly.

  • Page 13: Connecting The Controller

    Connecting the controller 4 Connecting the controller DANGER Risk of fatal electric shock when working on the opened controller.  Make sure that the controller is disconnected from the mains voltage before removing the terminal cover.  Make sure that the power supply has been secured to prevent it from being switched on again.
  • Page 14 Connecting the controller The following illustration shows the elements of the controller that are important for connection: Pos. Description Terminals for extra-low voltage area Fuse Terminals for 230 V area Terminals for protective conductor Cut-out apertures for cable feedthrough at the back Screw clamps for securing the cables Cut-out apertures for cable feedthrough on the underside ...

  • Page 15: Connecting The Controller To The Power Supply

    Connecting the controller 4.2 Connecting the controller to the power supply When making the mains connection, you must ensure that the mains supply can be disconnected at any time. If you make a permanent mains connection, proceed as follows:  Install a switch outside the controller. If you make the mains connection complete with cable and earthing pin plug, proceed as follows: ...

  • Page 16: Assignment Of The Terminals To The System Components

    Connecting the controller 4.4 Assignment of the terminals to the system components The connections in the following table are options that may be used in all hydraulic layouts: Terminal S3 + S3 Temperature sensor for the collector return for the "Energy output measurement"...
  • Page 17 Connecting the controller Terminal assignment for hydraulic layout 110.00 Terminal R1 + N + PE Solar circuit pump, 230 V connection S1 + S1 Temperature sensor for collector S2 + S2 Temperature sensor for storage tank...
  • Page 18 Connecting the controller Terminal assignment for hydraulic layout 000.00 In layout 000.00 you can use the output R1 as a multi-function controller. Terminal R1 + N + PE Multi-function controller on switching output R1 S1 + S1 Option: "Cooling", "Heating" or "Temperature difference controller" functions S2 + S2 Option: "Cooling", "Heating"...

  • Page 19: Operating The Controller

    Operating the controller 5 Operating the controller This chapter provides you with an overview of the controller's display elements and operating elements. This is followed by explanations of all the basic actions. 5.1 Description of the display elements The main menu is located in the top part of the display. It is comprised of the following menus: Main menu Symbol...
  • Page 20 Operating the controller When you have selected a menu, the applicable menu symbol (1) will be displayed. The bottom section of the screen displays the value (3) complete with a corresponding addition (2) and a measurement value symbol (7). Below these, status information and messages may be displayed (4–6), depending on the specific menu item.

  • Page 21: Using The Operating Buttons

    Operating the controller 5.2 Using the operating buttons The operating buttons allow you to navigate in the menus and make changes to values. The following table explains the functions of the operating buttons: Operating Function buttons Display the previous menu item. Increase the displayed value.

  • Page 22: Displaying And Changing The Values In The Menus

    Displaying and changing the values in the menus Changing values  To activate the displayed menu item, select The value flashes.  To increase the value, select  To reduce the value, select  To cancel the entry, select The value stops flashing. The value that is currently set will be displayed. ...
  • Page 23 Displaying and changing the values in the menus "Info" menu Example Symbol Description Reset 75 °C Current temperature of collector – Min. 12 °C Minimum temperature of collector × Max. 105 °C Maximum temperature of collector × 52 °C Current temperature of storage tank –...

  • Page 24: Displaying And Changing Values In The "Program" Menu

    Displaying and changing the values in the menus To reset a value, proceed as follows:  Select The OK symbol will be displayed.  Press to confirm. The value will be reset. 6.2 Displaying and changing values in the "Program" menu The "Program"...
  • Page 25 Displaying and changing the values in the menus "Program" menu Value Symbol Description Range Factory Current setting setting Min 40 °C Target temperature for the 15–85 °C 40 °C collector Only if "Target temperature" has been selected as the charging principle in the "Basic settings"...
  • Page 26 Displaying and changing the values in the menus "Program" menu Value Symbol Description Range Factory Current setting setting Start 00:00 Time window 1 (2, 3): Start 00:00– 00:00 1 (2, 3) When the start time for 23:59 the first time window has been defined, define the other time intervals in time windows 2 and 3...

  • Page 27: Controlling Switching Outputs In The "Manual Mode" Menu

    Displaying and changing the values in the menus 6.3 Controlling switching outputs in the "Manual mode" menu The "Manual mode" menu allows the controller's switching outputs to be turned on and off for test purposes. To enable the controller to run in automatic mode again, you have to exit manual mode after completion of setting tasks.
  • Page 28 Displaying and changing the values in the menus In editing mode you can display and make changes to values in this menu. If editing mode is activated, the menu symbol is displayed in the form of an "unlocked" symbol. Only specialist personnel are permitted to activate editing mode.
  • Page 29 Displaying and changing the values in the menus "Basic settings" menu Position Symbol Description Range Factory Current setting setting P: 7: Pump runtime "Drain-back" 15–360 s 180 s function P: 8: "Recooling" function 0–1 0 = Off 1 = On Only if the "Collector protection"...
  • Page 30 Displaying and changing the values in the menus "Basic settings" menu Position Symbol Description Range Factory Current setting setting P: 18: "Anti-freeze protection" 0–1 function 0 = Off 1 = On P: 19: "Anti-freeze protection" 1–3 function: Selection of the sensor P: 20: "Anti-freeze protection"...
  • Page 31 Displaying and changing the values in the menus * Position 16: Glycol types Selection Meaning Selection Meaning Anro Tyfocor L5.5 Ilexan E, Glythermin Dowcal 10 Antifrogen L Dowcal 20 Antifrogen N Dowcal N Ilexan E Tyfocor LS Ilexan P – –...

  • Page 32: Setting The Control Functions

    Setting the control functions 7 Setting the control functions The general control functions allow you to configure the settings for the charging of the storage tanks. You can set the following control functions: • Charging principle • Pump control • "Tube collector" function 7.1 Setting the charging principle In order to optimise the energy output, you can choose from the following charging principles:...
  • Page 33 Setting the control functions The "Basic settings" menu allows you to set the following parameters: • P:33: Pump control on switching output R1 In order to keep the storage tank temperature as constant as possible, the solar circuit pumps can be controlled by means of speed control. You can set the minimum pump output with speed control between 30 % and 100 %.
  • Page 34 Setting the control functions Controlling HE pumps with PWM signals In the case of the pump control system with PWM signal, the controller sends a PWM signal (pulse width modulation signal) at the terminal HE1. The PWM signal can be sent normally (not inverted) or inverted.

  • Page 35: Setting The "Tube Collector" Functions

    Setting multi-function controllers (MFC) 7.3 Setting the "Tube collector" functions If the solar power system is equipped with tube collectors, you have to activate this function. The control type is selected in the menu "Basic settings" with the following value: •...

  • Page 36: Setting The "Heating" Function

    Setting multi-function controllers (MFC) The "Program" menu allows you to set the following parameters: • Switch-on temperature of the "Heating“ and "Cooling" functions • Hysteresis of the "Heating" and "Cooling" functions • Time window 1 (2, 3): Start • Time window 1 (2, 3): Stop 8.2 Setting the "Heating"...

  • Page 37: Setting Protective Functions

    Setting protective functions The "Program" menu allows you to set the following parameters: • Maximum temperature Tmax of the sink for the "Temperaturedifference controller" function • Minimum temperature Tmin of the source for the "Temperaturedifference controller" function • Switch-on difference dTmax for the "Temperaturedifference controller" function •...

  • Page 38: Storage Tank Protection" Function

    Setting protective functions 9.2 "Storage tank protection" function If a hydraulic layout with two storage tanks is used, the "Storage tank protection" function will be automatically active and cannot be changed. This function protects the storage tanks against overheating caused by faulty wiring or any other possible faults.

  • Page 39: Setting The "Drain-Back" Function

    Setting protective functions The "Basic settings" menu allows you to set the following parameters: • P:5: "Collector protection" function • P:6: Collector protection temperature • P:8: "Recooling" function • P:9: Temperature to which the storage tank is recooled 9.5 Setting the "Drain-back" function The "Drain-back"...

  • Page 40: Setting The "Anti-Freeze Protection" Function

    Measuring energy output 9.6 Setting the "Anti-freeze protection" function The "Anti-freeze protection" function can be activated only if the "Drain-back" function has been deactivated. This function protects the solar power system against the heat transfer fluid freezing. If the temperature falls below the preset temperature, the solar circuit pump switches on. If the preset temperature is exceeded, the solar circuit pump switches off.

  • Page 41: Setting The Energy Output Measurements

    Restore factory settings 10.2 Setting the energy output measurements The "Basic settings" menu allows you to set the following parameters: • P:12: Measurement principle for energy output measurement • P:15: Flow rate for the "Flow indicator" measurement principle • P:16: Energy output measurement: Glycol type •...

  • Page 42: Faults

    Faults 12 Faults ATTENTION Risk of damage to the system if faults are remedied incorrectly.  Make sure that faults are only ever remedied by specialist personnel. There are two categories of system faults: • Faults that are detected by the controller and trigger a fault message •...
  • Page 43 Faults The table below shows the faults with fault messages: Fault message Possible cause Action A sensor line is interrupted. Make sure that the sensor lines are intact. A sensor is faulty. Check the sensor resistance. If necessary, replace the Flashing sensor.

  • Page 44: Faults Without Fault Message

    Faults 12.2 Faults without fault message The table below shows the faults without fault messages: Fault Possible cause Action No indication on the display. There is no mains voltage. Switch on the controller or connect the controller to the mains voltage. Make sure that the main fuse for the mains connection is switched on.
  • Page 45 Faults Fault Possible cause Action The pump symbol rotates The connection to the pump Make sure that the cable without the pump actually has been interrupted. connection to the pump is running. intact. The pump has seized up. Make sure that the pump is running.

  • Page 46: Technical Data

    Technical data 13 Technical data Autonomous electronic temperature difference controller, continuous operation Housing material 100% recyclable ABS housing Dimensions L x W x D in mm 176 × 162 × 44 Protection class IP30 according to DIN 40050, EN 60529 Operating voltage AC 230 voltage, 50 Hz, –10 to +15% Power consumption...

  • Page 47: Resistance Table

    Resistance table 14 Resistance table With reference to the table below, check the functioning of the temperature sensors usinga resistance meter: Temperature in °C / Resistance in ohms –10 °C 0 °C 10 °C 20 °C 40 °C 60 °C 80 °C 100 °C 960 Ω...
  • Page 48 These instructions were prepared by a technical documentation office certified by DocCert-System. Address of manufacturer Prozeda GmbH In der Büg 5 D-91330 Eggolsheim Telephone: +49(0)9191/6166-0 Telefax: +49(0)9191/ 6166-22 Email: kontakt@prozeda.de www.prozeda.de 1334B TB003 10B E...

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