ACV Solar Unit 200 Installation, Operation, Functions And Options, Troubleshooting
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ACV Solar Unit 200 Installation, Operation, Functions And Options, Troubleshooting

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Solar Unit 200
Solar controller
Manual for the
specialised craftsman
Installation
Operation
Functions and options
Troubleshooting
Thank you for buying this product.
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Please read this manual carefully to get the best performance from this unit.
Manual
Please keep this manual carefully.

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  • Page 1 Solar Unit 200 Solar controller Manual for the specialised craftsman Installation Operation Functions and options Troubleshooting Thank you for buying this product. Please read this manual carefully to get the best performance from this unit. Manual Please keep this manual carefully.
  • Page 2 Safety advice Information about the product Please pay attention to the following safety advice in order to avoid danger and Proper usage damage to people and property. The solar controller is designed for electronically controlling standard solar thermal Danger of electric shock: systems in compliance with the technical data specified in this manual.
  • Page 3 Disposal • Dispose of the packaging in an environmentally sound manner. • At the end of its working life, the product must not be disposed of as urban waste. Old appliances must be disposed of by an authorised body in an environmentally sound manner.

  • Page 4: Table Of Contents

    Solar controller Solar Unit 200 The Solar Unit 200 has been especially developed for the speed control of high- efficiency pumps in standard solar and heating systems. It is equipped with two PWM outputs and an additional input for a VFD Grundfos Direct Sensor that enables a precise heat quantity measurement.

  • Page 5: Overview

    Overview • Especially designed for the speed control of high-efficiency pumps Technical data • 1 input for a VFD Grundfos Direct Sensor Inputs: 4 Pt1000 temperature sensors, 1 VFD Grundfos Direct Sensor • System-Monitoring-Display Outputs: 2 semiconductor relays, 2 PWM outputs •...

  • Page 6: Installation

    Installation Mounting WARNING! Electric shock! display Upon opening the housing, live parts are exposed! Î Always disconnect the device from power supply before opening the housing! cover buttons Note Strong electromagnetic fields can impair the function of the device. Î Make sure the device as well as the system are not exposed to strong electromagnetic fields.

  • Page 7: Electrical Connection

    Electrical connection Fuse WARNING! Electric shock! 100 – 240 V~ Upon opening the housing, live parts are exposed! 50 – 60 Hz IP 20 Î Always disconnect the device from power supply be- PWM 1/2 fore opening the housing! Seriennummer 1 (1) A 240 V~ 1 (1) A 240 V~ Temp.

  • Page 8: Vfd Grundfos Direct Sensor

    VFD Grundfos Direct Sensor™ Data communication / Bus The controller is equipped with 1 input for a digital VFD Grundfos Direct Sensor™ The controller is equipped with the VBus for data transfer and energy supply ® for measuring the flow rate and the temperature. Connection is made at the VFD to external modules.

  • Page 9: System Overview

    System overview Standard solar system (page 10) Solar system with heat exchange Solar system with backup heating Solar system with store loading in (page 13) layers (page 24) (page 19) Solar system with 2 stores and valve Solar system with 2 stores and pump Solar system with east-/west collectors Solar system with backup heating by logic (page 30)

  • Page 10: Systems

    Systems Arrangement 1: Standard solar system The controller calculates the temperature difference between collector sensor S1 Sensors S3 and S4 can optionally be connected. S3 can optionally be used as the and store sensor S2. If the difference is larger than or identical to the adjusted reference sensor for the store emergency shutdown option (OSEM).
  • Page 11 Display channels Channel Description Connection terminal Page INIT ODB initialisation active ODB filling time active STAB ODB stabilisation in progress Temperature collector Temperature store Temperature sensor 3 TSTT Temperature store top Temperature sensor 4 Temperature flow sensor S1 / S4 / VFD Temperature return sensor S4 / VFD Temperature Grundfos Direct Sensor™...
  • Page 12 Adjustment channels Channel Description Factory setting Page DTCO Switch-on temperature difference cooling 20.0 K [40.0 °Ra] DTCF Switch-off temperature difference cooling 15.0 K [30.0 °Ra] OSTC Store cooling option OHOL Holiday cooling option THOL Holiday cooling temperature 40 °C [110 °F] Collector minimum limitation option Collector minimum temperature 10 °C [50 °F]...
  • Page 13 Arrangement 2: Solar system with heat exchange The controller calculates the temperature difference between collector sensor S1 switch-on temperature difference (DT3O), until the adjusted minimum (MN3O) and store sensor S2. If the difference is larger than or identical to the adjusted and maximum (MX3O) temperature thresholds of the respective store are reached.
  • Page 14 Display channels Channel Description Connection terminal Page INIT ODB initialisation active ODB filling time active STAB ODB stabilisation in progress Temperature collector TST1 Temperature store 1 base TSTT Temperature store 1 top TST2 Temperature store 2 base Temperature flow sensor Temperature return sensor Temperature Grundfos Direct Sensor™...
  • Page 15 Adjustment channels Channel Description Factory setting Page OSTC Store cooling option OHOL Holiday cooling option THOL Holiday cooling temperature 40 °C [110 °F] Collector minimum limitation option Collector minimum temperature 10 °C [50 °F] Antifreeze option Antifreeze temperature 4.0 °C [40.0 °F] Tube collector option TCST OTC starting time...
  • Page 16 System-specific functions Speed control The following adjustments are used for the specific functions in system 2. ∆T control for the heat exchange between 2 stores DT3S Set temperature difference Adjustment range: 1.5 … 30.0 K [3.0 … 60.0 °Ra] DT3O Factory setting: 10.0 K [20.0 °Ra] Switch-on temperature difference Note...
  • Page 17 n2MN PUM2 Minimum speed R2 Pump control type R2 Adjustment range: (10) 30 … 100 % Selection: OnOF, PULS, PSOL, PHEA Factory setting: 30 % Factory setting: OnOF With this parameter, the pump control type can be adjusted. The following types A relative minimum pump speed can be allocated to the output R2 via the adjust- can be selected: ment channel n2MN.
  • Page 18 Maximum temperature limitation heat exchange Minimum temperature limitation heat exchange MX3O / MX3F MN3O / MN3F Maximum temperature limitation Minimum temperature limitation Adjustment range: 0.0 … 95.0 °C [30.0 … 200.0 °F] Adjustment range: 0.0 … 90.0 °C [30.0 … 190.0 °F] Factory setting: Factory setting (only if Arr = 2): MX3O: 60.0 °C [140.0 °F]...
  • Page 19 Arrangement 3: Solar system with backup heating The controller calculates the temperature difference between collector sensor S1 ture (AH O) is reached. This function can optionally be combined with up to three and store sensor S2. If the difference is larger than or identical to the adjusted adjustable time frames.
  • Page 20 Display channels Channel Description Connection terminal Page INIT ODB initialisation active ODB filling time active STAB ODB stabilisation in progress Temperature collector TSTB Temperature store 1 base TSTT Temperature store 1 top TDIS Thermal disinfection temperature (thermal disinfection) Temperature sensor 4 Temperature flow sensor S1 / S4 / VFD Temperature return sensor...
  • Page 21 Adjustment channels Channel Description Factory setting Page Collector minimum limitation option Collector minimum temperature 10 °C [50 °F] Antifreeze option Antifreeze temperature 4.0 °C [40.0 °F] Tube collector option TCST OTC starting time 07:00 TCEN OTC ending time 19:00 TCRU OTC runtime 30 s TCIN...
  • Page 22 System-specific functions The following adjustments are used for the specific functions in system 3. The chan- nels described are not available in any other systems. Thermostat function Backup heating Use of surplus energy t1 O, t2 O, t3 O Thermostat switch-on time Adjustment range: 00:00 …...
  • Page 23 Thermal disinfection of the upper DHW zone This function helps to contain the spread of Legionella in DHW stores by system- atically activating the backup heating. For thermal disinfection, the temperature at the reference sensor will be moni- tored. Protection is ensured when, during the monitoring period, the disinfection temperature is continuously exceeded for the entire disinfection period.
  • Page 24 Arrangement 4: Solar system with store loading in layers The controller calculates the temperature difference between collector sensor S1 temperature (S1MX / S2MX) is reached. The priority logic causes priority loading and store sensors S2 and S3. If the difference is larger than or identical to the cor- of the upper store zone, if possible.
  • Page 25 Display channels Channel Description Connection terminal Page Temperature collector TSTB Temperature store 1 base TSTT Temperature store 1 top Temperature sensor 4 Temperature flow sensor S1 / S4 / VFD Temperature return sensor S4 / VFD Temperature Grundfos Direct Sensor™ Flow rate Grundfos Direct Sensor™...
  • Page 26 Adjustment channels Channel Description Factory setting Page OSTC Store cooling option OHOL Holiday cooling option THOL Holiday cooling temperature 40 °C [110 °F] Collector minimum limitation option Collector minimum temperature 10 °C [50 °F] Antifreeze option Antifreeze temperature 4.0 °C [40.0 °F] PRIO Priority Loading break (store sequence control)
  • Page 27 Arrangement 5: Solar system with 2 stores and valve logic temperature (S1MX / S2MX) is reached. The priority logic causes priority loading of The controller calculates the temperature difference between collector sensor S1 and store sensors S2 and S3. If the difference is larger than or identical to the store 1.
  • Page 28 Display channels Channel Description Connection terminal Page Temperature collector TST1 Temperature store 1 base TST2 Temperature store 2 base Temperature sensor 4 Temperature flow sensor S1 / S4 / VFD Temperature return sensor S4 / VFD Temperature Grundfos Direct Sensor™ Flow rate Grundfos Direct Sensor™...
  • Page 29 Adjustment channels Channel Description Factory setting Page OHOL Holiday cooling option THOL Holiday cooling temperature 40 °C [110 °F] Collector minimum limitation option Collector minimum temperature 10 °C [50 °F] Antifreeze option Antifreeze temperature 4.0 °C [40.0 °F] PRIO Priority Loading break (store sequence control) 2 min tRUN...
  • Page 30 Arrangement 6: Solar system with 2 stores and pump logic priority loading of the store selected in the PRIO channel, if possible. If PRIO = 0, The controller calculates the temperature difference between collector sensor S1 and store sensors S2 and S3. If the difference is larger than or identical to the corre- both stores will be loaded simultaneously.
  • Page 31 Display channels Channel Description Connection terminal Page Temperature collector TST1 Temperature store 1 base TST2 Temperature store 2 base Temperature sensor 4 TSTT Temperature store top Temperature flow sensor S4 / VFD Temperature return sensor S4 / VFD Temperature Grundfos Direct Sensor™ Flow rate Grundfos Direct Sensor™...
  • Page 32 Adjustment channels Channel Description Factory setting Page Collector emergency temperature 130 °C [270 °F] Collector cooling option Maximum collector temperature 110 °C [230 °F] OSYC System cooling option DTCO Switch-on temperature difference cooling 20.0 K [40.0 °Ra] DTCF Switch-off temperature difference cooling 15.0 K [30.0 °Ra] OSTC Store cooling option...
  • Page 33 Arrangement 7: Solar system with east-/west collectors and 1 store The controller calculates the temperature difference between collector sensors Sensor S4 can optionally be used as the reference sensor for the store emergency S1 and S3 and store sensor S2. If the differences are larger than or identical to the shutdown option (OSEM).
  • Page 34 Display channels Channel Description Connection terminal Page COL1 Temperature collector 1 Temperature store COL2 Temperature collector 2 Temperature sensor 4 TSTT Temperature store top Temperature flow sensor S4 / VFD Temperature return sensor S4 / VFD Temperature Grundfos Direct Sensor™ Flow rate Grundfos Direct Sensor™...
  • Page 35 Adjustment channels Channel Description Factory setting Page CMX2 Maximum collector temperature 2 110 °C [230 °F] OSYC System cooling option DTCO Switch-on temperature difference cooling 20.0 K [40.0 °Ra] DTCF Switch-off temperature difference cooling 15.0 K [30.0 °Ra] OSTC Store cooling option OHOL Holiday cooling option THOL...
  • Page 36 Arrangement 8: Solar system with backup heating by solid fuel boiler The controller calculates the temperature difference between collector sensor S1 perature difference (DT3O), until the adjusted minimum (MN3O) and maximum and store sensor S2. If the difference is larger than or identical to the adjusted (MX3O) temperature thresholds of the solid fuel boiler and the store are reached.
  • Page 37 Display channels Channel Description Connection terminal Page INIT ODB initialisation active ODB filling time active STAB ODB stabilisation in progress Temperature collector TSTB Temperature store 1 base TSTT Temperature store 1 top TSFB Temperature solid fuel boiler Temperature flow sensor Temperature return sensor Temperature Grundfos Direct Sensor™...
  • Page 38 Adjustment channels Channel Description Factory setting Page OSTC Store cooling option OHOL Holiday cooling option THOL Holiday cooling temperature 40 °C [110 °F] Collector minimum limitation option Collector minimum temperature 10 °C [50 °F] Antifreeze option Antifreeze temperature 4.0 °C [40.0 °F] Tube collector option TCST OTC starting time...
  • Page 39 System-specific functions Speed control The following adjustments are used for the specific functions in system 8. ∆T control for the backup heating by a solid fuel boiler DT3S Set temperature difference Adjustment range: 1.5 … 30.0 K [3.0 … 60.0 °Ra] DT3O Factory setting: 10.0 K [20.0 °Ra] Switch-on temperature difference...
  • Page 40 PUM2 n2MN Pump control type R2 Minimum speed R2 Selection: OnOF, PULS, PSOL, PHEA Adjustment range: (10) 30 … 100 Factory setting: OnOF Factory setting: 30 With this parameter, the pump control type can be adjusted. The following types A relative minimum pump speed can be allocated to the output R2 via the adjust- can be selected: ment channel n2MN.
  • Page 41 Minimum temperature limitation solid fuel boiler Maximum temperature limitation solid fuel boiler MN3O / MN3F MX3O / MX3F Minimum temperature limitation Maximum temperature limitation Adjustment range: 0.0 … 90.0 °C [30.0 … 190.0 °F] Adjustment range: 0.0 … 95.0 °C [30.0 … 200.0 °F] Factory setting (only if Arr = 8): Factory setting: MN3O: 60.0 °C [140.0 °F]...
  • Page 42 Arrangement 9: Solar system with heating-circuit return preheating Heating-circuit return preheating will be activated by relay 2, if the temperature dif- The controller calculates the temperature difference between collector sensor S1 and store sensor S2. If the difference is larger than or identical to the adjusted ference between sensors S3 and S4 is larger or identical to the adjusted switch-on temperature difference (DT3O).
  • Page 43 Display channels Channel Description Connection terminal Page INIT ODB initialisation active ODB filling time active STAB ODB stabilisation in progress Temperature collector TSTB Temperature store 1 base TSTT Temperature store 1 top Temperature flow sensor Temperature return sensor Temperature Grundfos Direct Sensor™ Flow rate Grundfos Direct Sensor™...
  • Page 44 Adjustment channels Channel Description Factory setting Page OSTC Store cooling option OHOL Holiday cooling option THOL Holiday cooling temperature 40 °C [110 °F] Collector minimum limitation option Collector minimum temperature 10 °C [50 °F] Antifreeze option Antifreeze temperature 4.0 °C [40.0 °F] Tube collector option TCST OTC starting time...
  • Page 45 Arrangement 10: Standard solar system with heat dump The controller calculates the temperature difference between collector sensor S1 sink. For safety reasons, excess heat dump will only take place as long as the store and store sensor S2. If the difference is larger than or identical to the adjusted temperature is below the non-adjustable shutdown temperature of 95 °C [200 °F].
  • Page 46 Display channels Channel Description Connection terminal Page Temperature collector Temperature store Temperature sensor 3 TSTT Temperature store top Temperature sensor 4 Temperature flow sensor S1 / S4 / VFD Temperature return sensor S4 / VFD Temperature Grundfos Direct Sensor™ Flow rate Grundfos Direct Sensor™ Speed relay R1 h P1 Operating hours R1...
  • Page 47 Adjustment channels Channel Description Factory setting Page TCRU OTC runtime 30 s TCIN OTC standstill interval 30 min Grundfos Direct Sensor™ OHQM Heat quantity measurement option VFD allocation FMAX Maximum flow rate 6.0 l/min MEDT Antifreeze type MED% Antifreeze concentration (only if MEDT = propylene or ethylene glycol) 45 % MAN1 Manual mode R1...

  • Page 48: Operation And Function

    Operation and function System-Monitoring-Display Buttons System-Monitoring-Display ê forwards (+) Ⓢ (selection / The System-Monitoring-Display consists of 3 blocks: channel display, tool bar and adjustment mode) system screen. backwards (-) Channel display The controller is operated via the 3 buttons below the display. Button 1 (+) is used for scrolling forwards through the menu and increasing adjustment values.

  • Page 49: Flashing Codes

    System screen Permanently Flashing Status indications: shown The system selected is indicated in the System-Monitoring-Display. It consists of several system component symbols which are – depending on the current status of Relay 1 active ⓵ the system – either flashing, permanently shown or not indicated. ⓶...

  • Page 50: Commissioning

    Commissioning Commissioning forwards (+) 1. Language Î Adjust the desired menu language. Ⓢ (selection / LANG adjustment mode) Language selection Selection: dE, En, Fr, ES, It 2 backwards (-) Factory setting: dE Î Connect the device to the mains The controller runs an initialisation phase. 2.
  • Page 51 Commissioning Commissioning Only confirm the security enquiry if you are 7. Minimum speed sure that you wish to change the system selec- Î Adjust the minimum speed for the corresponding tion. pump. Security enquiry: nMN, n1MN, n2MN Î In order to confirm the security enquiry, press Minimum speed button 3.

  • Page 52: Channel Overview

    Commissioning Channel overview Display channels Confirmation Note Completing the commissioning menu The display and adjustment channels as well as the adjustment ranges de- After the last channel of the commissioning menu has pend on the system selected, the functions and options as well as on the been adjusted and confirmed, the controller asks for system components connected to the controller.
  • Page 53 Display of collector temperatures Display of sensors 3, 4 and VFD COL, COL1, COL2 S3, S4, VFD Collector temperature Sensor temperatures Display range: -40 … +260 °C [-40 … +500 °F] Display range: -40 … +260 °C [-40 … +500 °F] VFD: 0 …...
  • Page 54 Display of flow rate In order to access the reset mode of the counter, press button 3 for approx. 2 s. Ⓢ starts flashing and the heat quantity value will be set back to zero. In order to finish the reset process, press button 3. In order to interrupt the reset process, do not press any button for about 5 s.

  • Page 55: Adjustment Channels

    Adjustment channels System selection TIME Indicates the current clock time. In order to adjust the hours, press button 3 for approx. 2 s. Set the hours by pressing buttons 1 and 2. System selection. In order to adjust the minutes, press button 3. Adjustment range: 1 …...
  • Page 56 ∆T control Speed control DT O / DT1O / DT2O / DT3O DT S / DT1S / DT2S / DT3S RIS / RIS1 / RIS2 / RIS3 Switch-on temperature difference Set temperature difference Rise Adjustment range: 1.0 … 20.0 K [2.0 … 40.0 °Ra] Adjustment range: Adjustment range: Factory setting: 6.0 K [12.0 °Ra]...
  • Page 57 Maximum speed PUM1 / PUM2 nMX, n1MX, n2MX Pump control type Maximum speed Selection: OnOF, PULS, PSOL, PHEA Adjustment range: (10) 30 … 100 % Factory setting: PSOL Factory setting: 100 % With this parameter, the pump control type can be adjusted. The following types In the adjustment channel n1(2)MX a relative maximum speed for connected can be selected: pumps can be allocated to the outputs R1 and R2.
  • Page 58 Store emergency shutdown Cooling functions In the following the 3 cooling functions – collector cooling, system cooling and store cooling – are described in detail. The following notes are valid for all three cooling functions: Note OSEM The cooling functions will not become active as long as solar loading is Store emergency shutdown option possible.
  • Page 59 System cooling Store cooling OSYC OSTC DTCO OHOL System cooling option Store cooling option Holiday cooling option Switch-on temperature difference Adjustment range: OFF / ON Adjustment range: OFF / ON Adjustment range: Adjustment range: OFF / ON Factory setting: OFF 1.0 …...
  • Page 60 Collector minimum limitation Note Since this function uses the limited heat quantity of the store, the anti- freeze function should only be used in regions with few days of tempera- tures around the freezing point. The antifreeze function will be suppressed if the store temperature falls below +5 °C [+40 °F] in order to protect the store from frost damage.
  • Page 61 Store sequence control will be activated when PRIO is set to SE 1, SE 2, 1 or 2. If priority PRIO 0 is adjusted and the switch-on conditions for both stores are ful- If the priority store cannot be loaded, the subordinate store will be checked. If use- filled, the stores are loaded in parallel (Arr 6) or in progressive loading (Arr 4, 5) ful heat can be added to the subordinate store, it will be loaded for the circulation respectively, beginning with the store with the lowest temperature.
  • Page 62 Heat quantity measurement TCEN TCRU Tube collector function ending time Tube collector function runtime OHQM Adjustment range: 00:00 … 23:45 Adjustment range: 5 … 500 s Heat quantity measurement option Factory setting: 19:00 Factory setting: 30 s Adjustment range: OFF / ON Factory setting: OFF If OHQM is activated, the heat quantity gained can be calculated and displayed.
  • Page 63 Heat quantity measurement with a VFD Grundfos Direct Sensor™ Heat quantity measurement with a VFD Grundfos Direct Sensor™ is possible in all system layouts. In order to use a VFD Grundfos Direct Sensor™ for heat quantity measurement, proceed as follows: MEDT MED% Register the VFD Grundfos Direct Sensor™...
  • Page 64 Filling time tFLL Drainback option Filling time Adjustment range: OFF / ON Adjustment range: 1.0 … 30.0 min Factory setting: OFF Factory setting: 5.0 min Note The parameter tFLL is used for adjusting the filling time. During this period, the If the drainback option is activated, the cooling functions and the antifreeze pump runs at 100 % speed.
  • Page 65 Unit Operating mode UNIT MAN1 / MAN2 Temperature unit selection Operating mode Selection: °F, °C Adjustment range: OFF, Auto, On Factory setting: °C Factory setting: Auto In this adjustment channel, the display unit for temperatures and temperature differ- For control and service work, the operating mode of the relays can be manually ences can be selected.

  • Page 66: Troubleshooting

    Troubleshooting If a malfunction occurs, the display symbols will indicate an error code: WARNING! Electric shock! Upon opening the housing, live parts are exposed! The symbol☍ is indicated on the display and the symbol ⚠ is flashing. Î Always disconnect the device from power supply before opening the housing! Sensor fault.
  • Page 67 Pump is overheated, but no heat transfer from the collector to the store, flow Pump starts up very late. and return have the same temperature; perhaps also bubbling in the lines. Air or gas bubbles in the system? Switch-on temperature difference Vent the system;...
  • Page 68 Stores cool down at night Check the non-return valve in warm Further pumps which are connect- Collector circuit pump runs during water circulation - o.k. ed to the solar store must also be the night? checked. Check controller Clean or replace it. The gravitation circulation in the Collector temperature at night is circulation line is too strong;...

  • Page 69: Index

    Index Antifreeze function ......................60 Operating mode ........................ 65 Backup heating ........................22 Priority logic ........................60 Booster function ....................... 64 Return preheating ......................53 Collector cooling ......................58 Collector emergency shutdown ..................58 Speed control ........................56 Commissioning ........................50 Spreaded loading .......................
  • Page 70 Software License Information (Firmware Version 3.00) Copyright 2020 (c) Raspberry Pi (Trading) Ltd. THIS SOFTWARE IS PROVIDED BY THE COPYRIGHT HOLDERS AND CON- TRIBUTORS "AS IS" AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLU- Redistribution and use in source and binary forms, with or without modification, DING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHAN- are permitted provided that the following conditions are met: TABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED.
  • Page 72 ACV International Distributed by: Oude Vijverweg 6 B-1653 - Dworp - Belgium © All contents of this document are protected by copyright.

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