Sunny Scout BASIC fs Installation & Service Manual

Installation & Service manual

Sunny Scout BASIC fs

Micro-processor controller for solar thermal systems

Explanation of graphic symbols used in the manual

Attention!

Symbol advise possible dangers and errors

Attention 230V~ voltage!

Symbol displays the danger of high voltages.

Information tabs

Please read carefully!

Operational information / characteristic features

Other Information or procedure

Testing / checking

Table of content

1 Application / characteristics and features

1.1 Description and application

1.2 Controller characteristics

2 Safety instructions

3 Controller installation

3.1 Opening the controller

3.2 Wall installation

3.3 Electrical connection - overview

3.4 Sensors connection

4 Operation / Display

4.1 Display graphics

4.2 Button function

5 Operating menus

5.1 "Info" Menu

5.2 "Programming" Menu

5.3 "Manual operation" Menu

5.4 "Basic adjustment" Menu

6 System diagram

Controller functions

7.1 General controller functions

7.1.2 Pump speed modulation

7.2 Protection functions

7.2.1 Collector protection

7.2.2 Re-cooling (Holiday function)

7.2.3 System protection

7.2.4 Anti-freeze protection

8 System monitoring

8.1 Sensor monitoring

8.2 Flow monitoring

9 Failure repair

9.1 Failures with an error messages

9.2 Failures without error messages

10 Technical data

11 Resistance table PT1000

12 Terms of guarantee

13 Declaration of conformity

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1 Application / characteristics and features

1.1 Description and application

The Sunny Scout BASIC fs controllers are powerful microprocessor appliances for the accurate control of solar systems. They are suitable for most types of south facing solar thermal systems

These solar controllers are for use in either residential, business or industrial premises and should be mounted in dry spaces.

The installer should ensure that the controller meets all necessary regulations and is suitable for the application prior to installation.

1.2 Controller characteristics

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The SOLAREG II generation of controllers is equipped with the following features:

◼ Intuitive menu-conducted operation with graphic symbols and four operating keys

Temperature differential regulation - digitally adjustable values

Operating hour meter for storage tank charging

Pump speed modulation & manual switch control of solar circulation pump

Continual system monitoring with error and failure display through symbols

All adjusted values are stored even in the case of any longer mains voltagebreakdown.

◼ Various protective functions, such as system protection, collector protection, recooling and flow monitoring

◼ Large wiring space

Available accessories:

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Temperature sensor PT1000

Sensor connection box

Immersion sleeves

2 Safety instructions

◼ Disconnect all appliances from the mains operating voltage completely before any installation or wiring work is commenced. Ensure that mains voltage is not connected into the ‘low voltage terminals’ (see page 10). Destruction and extremely dangerous voltages will occur in the controller, connected sensors and other system components if this is NOT complied with.

◼ Solar systems can absorb extremely high temperatures. There is a danger and risk of burning! Be careful during the installation of all temperature sensors!

◼ Mount the solar controller in a position to ensure that inadmissible operating temperatures (>50°C) are not experienced e.g. through other sources of heat.For safety the system can remain in a ‘manual only’ state for testing purposes. In this operating mode maximum temperatures or sensor functions are not monitored.

If any damage is seen in/on the controller, wiring cable or connected pumps and valves the system must not be started.

All installation and wiring work must only be carried out on the controller when the device is disconnected from the power supply.

The Sunny Scout BASIC fs must only be connected and commissioned by qualified personnel. In doing so, the applicable safety regulations must be observed.

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The controller MUST be installed only in dry, non explosive locations. Installation should NOT be made onto combustible materials.

3 Controller installation

3.1 Opening the controller

Prior to opening the device, make sure to disconnect the power supply and ensure that it cannot be switched back on again.

The top cover is held in place by two catches on the base which can be unlocked by pulling apart the sides of the top cover (see the picture).

Hinge open the top cover upwards until it is latched into position.

You can now freely install and wire the controller.

Prior to powering up the controller ensure that the top cover is securely latched back into place

3.2 Wall installation

The device is mounted on the marked points. A drilling template is provided with the device. Insert the "Quick Info" card provided with the device into the pocket provided on the back of the device. The "Quick Info" card provides the user with an overview of the functions to facilitate rapid device operation.

3.3 Electrical connection - overview

For 230V~ connections please note the following points:

◼ I The mains supply voltage to the controller should be provided by a switched

FCU with a 3 amp rated fuse.

◼ Controllers are intended use with 230V~ /50Hz mains. All pumps and valves should be similarly rated.

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All earthed wires must be connected to terminals marked with PE.

Neutral terminals (N) are electrically connected and are not switched!

The switching output (A1) is 230V~ closer. If potential-free contacts are needed, appropriate accessories are available.

3.4 Sensors connection

The SOLAREG II BASIC controllers work with precise platinum-temperature sensors type PT1000. 2 sensors are required, the third sensor is optional.

Installation / cabling of the temperature sensors:

◼ Mount the sensors into the collector and storage tank. Ensure proper heat transfer and use heat-conducting paste if necessary.

◼ Cross-sections for cable extensions:

- up to 15m 2 x 0.5mm

2 ,

- up to 50m 2 x 0.75mm

2 .

If shielded - the shield must be connected to the earth (PE)

◼ Connect the temperature sensors according the systems design and functionality required. Polarity may be ignored as they will operate when fitted into either pole of the terminal.

◼ Temperature sensor cables MUST be run separately from 230V~wires.

◼ It is recommended that the external collector sensor can be additionally protected by a ‘Collector Sensor Protection Box’ which will protect the system from over-voltage caused by a lightning strike.

4 Operation / Display

4.1 Display graphics

During actual operation, the symbols appear in differing parts of the menu dependant upon the functionality that is being set or programmed.

Display symbols

All symbols which may appear on the graphic display:

◂ Active menu dTmin max start stop F

%

◂ Measured values, e.g.: 59.6C°.

◂ Measuring points assignment ok?

◂ Status indication

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4.2 Button function

The Sunny Scout BASIC fs controller is operated by means of the 4 buttons. Use of these allows:

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◼ recall of all display values carry out controller function adjustments

Graphic symbols seen on the display lead you simply through the operating menu structure and show clearly the current menu points, display values or parameters.

The operating buttons have the following functions:

Button Function

“Scroll up"

„+“

"Scroll left"

"Exit"

"Break-off"

"Enter"

"Scroll down"

"-"

"Scroll right"

"Choice"

"Confirmation"

Description

◼ Menu rolls upwards

Value change: increase of the indicated value by 1, if held down the values rise constantly

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Main menu scroll left

Exit menu

Exit menu point

Break-off value change without storing

◼ Call up of main menu, menu rolls downwards

◼ Value change: decrease of the indicated value by 1, if held down the values fall constantly

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Main menu scroll right

Choosing one menu point

Confirmation of value change to save amendment

The symbols appear in differing parts of the menu dependant upon the functionality that is being set or programmed

5 Operating menus

5.1 "Info" Menu

In this mode all measuring values and operating states are shown:

52 °C min

40°C max

67 °C

60 °C

Indication e.g.

75 °C min

12 °C max

105 °C

1234 h

Meaning

Indication of current collector temperature

Indication of minimum collector temperature can be “reset” to current temperature

Indication of maximum collector temperature can be “reset” to current temperature

Indication of current temperature within the storage tank

Indication of minimum storage tank temperature. Can be “reset” to current temperature

Indication of maximum storage tank temperature. Can be “reset” to current temperature

Indication of current temperature - S3

Operating hours for charging storage tank

Can be “reset” to 0 h

Reset possible

No

Yes

Yes

No

Yes

Yes

No

Yes

5.2 "Programming" Menu

All changeable parameters can be checked in this menu and, if necessary, altered.

Factory programmed default values are set which, as a rule, guarantee problem free function of the system.

Indication e.g.

max

65 °C dT max

7K dT min

3K min

100 12

Meaning

Value range

Typical adjustment

Storage tank:

Permissible maximum temperature

Storage tank: switchon difference

Storage tank: switchoff difference

Adjustment of minimum pump speed modulation

100% = rotational speed regulation off

15 –95°C

3 –40K

2 –35K

65°C

7K

3K

30% – 100% 100%

Current adjustment

5.3 "Manual operation" Menu

Automatic operation is switched off during manual operation. The outputs can be manually switched on and off for servicing and testing purposes.

Once the menu has been exited or after 8 hours, automatic operation is reactivated.

Display Meaning Value range

Manual switching “on / off” output A1 (solar circulation pump)

0 = Off

1 = On

Adjustments and changes within this menu MUST be carried out only by a specialist installer or competent staff.

Incorrect settings will effect the function of the controller and solar system..

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Adjustments and changes within this menu MUST be carried out only by a specialist installer or competent staff.

Incorrect settings will effect the function of the controller and solar system..

5.4 "Basic adjustment" Menu

The hydraulic diagrams and additional functions are displayed in the Basic Setup menu. Adjustments MUST be carried out only by a specialist installer or competent staff. Settings may only be adjusted in the menu: a) within one minute after switching on the controller or b) after simultaneously pressing the buttons:

Current adjustment

Display

Line Value

0

1

2

3

Meaning

0

120 °C

0

40°C

Collector protection function: switching on or off

Collector protection function: activation temp.

Re-cooling function

(only if the collector protection is on)

Temperature to which the storage tank is re-cooled after activating the collector protection function

4 0 Anti-freeze function

5 3

Anti-freeze function

Start temperature

0 = Off

1 = On

0 = Off

110 –150°C 120°C

0 = Off

1 = On

30 –90°C

0 = Off

1 = On

0 = Off

40°C

0

-20°C ... +7°C 3°C

6 System diagram

1 collector array, 1 storage tank

S1

A1

S3

S2

PE

L

N

A1

N

Fuse

230V connections

L Live from mains supply

N Neutral from mains and outputs

A1 Live switch output 1 (solar circuit pump)

Sensor connections

S1

S2

Temp.-sensor collector

Temp.-sensor storage tank

S3 General temperature point

S3

S2

S1

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Controller functions

7.1 General controller functions

The storage tank is charged through the pump on output A1 up to its adjusted maximum temperature as long as the collector temperature is higher by a pre-set temperature than the storage tank temperature. Monitoring and protection functions ensure safe operation.

7.1.2 Pump speed modulation

The output A1 can be operated either in switch mode or can be set to operate with a modulated pump speed.

„Programming“ menu

Indication min

100

Meaning Value range Typical adjustment

Adjustment of minimum pump speed modulation

100% = rotational speed regulation off

30% – 100% 100%

Adjustments and changes within this menu MUST be carried out only by a specialist installer or competent staff.

Incorrect settings will effect the function of the controller and solar system..

7.2 Protection functions

The controller is equipped with the following protective functions.

7.2.1 Collector protection

If the storage tank is charged to the maximum temperature and the collector temperature exceeds the adjusted collector protection temperature, the solar circuit pump is turned on. The solar circuit pump is switched off once the collector temperature is 10K below the adjusted value.

In this case, the storage tank is charged up to 95°C regardless of it’s adjusted maximum temperature.

7.2.2 Re-cooling (Holiday function)

The collector protection function is only effective if the storage tank temperature is below the temperature limit (95°). Therefore, during the holiday period, for example, the storage tank is discharged at night to the adjusted recooling temperature.

"Basic adjustment" menu

Indication Meaning

Line Value

0

1

2

3

0

120°C

0

40°C

Collector protection function: switching on or off

Collector protection function: activation temp.

Re-cooling function

(only if the collector protection is on)

Temperature to which the storage tank is re-cooled after activating the collector protection function

Value range Factory set-up

0 = Off

1 = On

0 = Off

110 –150°C 120°C

0 = Off

1 = On

0 = Off

30 –90°C 40°C

7.2.3 System protection

If the collector temperature exceeds the collector protection temperature (see

7.2.2) by 10K, the solar circuit pump is turned off to protect the system components. As soon as the temperature falls below this value the system is started again.

This function comes into effect no matter if the collector protection is activated or not.

7.2.4 Anti-freeze protection

This function must be activated if the water or glycol mixture can freeze.

If the temperature at the anti-freeze sensor (S1) drops below the set value, the solar circuit pump is activated and heats the solar circuit using the heat exchanger in the storage tank.

"Basic Setup" menu

Display Meaning

Line Value

4

5

0

3

Switches on or off the anti-freeze function

Temperature at which the anti-freeze function is activated

Value range Factory setting

0 = Off

1 = On

0

-20°C – +7°C 3°C

Settings and changes in this menu must only be carried out by a specialised technician. Incorrect settings can damage or adversely affect the function of the solar power system.

8 System monitoring

In the case of an error the flashing symbol is shown.

8.1 Sensor monitoring

The sensors necessary for the control functions and their connecting cables are monitored to show breaks or short circuits. If a faulty sensor or installation is recorded by the software, the symbol is shown . By scrolling up and down you can quickly find the error source.

8.2 Flow monitoring

The controller checks the flow rate when the pump is switched on. If after 15 minutes no flow is recorded an error message will be shown. The error message is automatically reset after fault correcting.

This message, however, does not switch off the pump.

"Basic adjustment" Menu

Indication

+

Meaning

A fault with the fluid circulation within the solar system

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9 Failure repair

There are two different categories of system failures to be found:

◼ failures which can be recognised and indicated by the controller itself by displaying an error

◼ failures which cannot be recognised by the controller

9.1 Failures with an error messages

Error representation on display

Possible reasons

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Sensor cable broken

Sensor defect

Flashing

Flashing

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Short circuit in sensor cable

Sensor defect

Measures

Check the cable

Check sensor resistance if necessary replace the sensor

Check the cable

Circulation error:

No flow detected

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Flashing

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Error in pump connection

Pump defect

Air in the system

Sensor cable broken

Sensor defect

Check sensor resistance and replace sensor if necessary

Check the wiring

Replace pump

Bleed the system

Check the cable

Check sensor resistance and replace sensor if necessary

9.2 Failures without error messages

If the system doesn’t work but there is no error message on the display of the controller follow the schedule in the table below.

Possible reasons Measures Error presentation

No display function

◼ 230V mains not connected or broken

◼ Internal fuse blown

Switch on or connect the controller

Check the fuse of the power supply circuit

Check the fuse, replace it if necessary, use type 2A/T

Check the 230V~ components for shortcircuits

Contact the supplier

Exit menu "Hand".

Controller does not operate the system

"Pump" symbol rotates, but pump does not work

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Controller is defective

Controller is in manual operation

Switch-on condition is not present.

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Pump connection faulty

Pump is seized or blocked.

No voltage on the output.

Wait until switch-on condition is reached.

Check the cable to pump

Bleed the pump

Contact the supplier.

Temperature display shows large variances in a short time interval

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Sensor cables are installed too close to the 230V~ cable

Sensor cable extentions used without shielding

Controller is defective

Separate sensor cables from the power supply or shield sensor cables

Shield sensor cables

Contact the supplier

Having checked the issues listed but the system is still not working please contact the supplier or manufacturer for specialist advice.

Failures that affect the

230V~ power supply must only be must be remedied only by a competent and trained electrician.

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The right is reserved to change these specifications for technical purposes

10 Technical data

Housing

Material

Dimensions L x W x D in mm,

Weight

System of protection

Electrical values

Operating voltage

Interference grade

Max. conductor cross-section

230V~connections

Temperature sensor

Measuring range

Testing voltage

Switching voltage

Capability per one switching output

Fuse protection

Miscellaneous

Operating temperature

Storing temperature

Humidity

100% recyclable ABS-housing for wall installation

175 x 134 x 56; approx 360 g

IP20 according to DIN 40050, EN 60529

AC 230~ Volt, 50Hz, -10 ...+15%

N according to VDE 0875

2.5 mm² fine-strand/single-wire

PT1000 , 1 kΩ at 0°C

-30°C ... +250°C

4 kV 1 min according to EN 60730, IEC 60664

230V~

1A / approx. 230VA for cos φ = 0,7-1,0

Fine-wire fuse 5 x 20mm, 2A/T

(2 amperes, slow)

0 ... 50°C

-10 ... +65°C max. 60 %

11 Resistance table PT1000

Correct function of temperature sensors can be checked by using the following temperature resistance table in conjunction with suitable resistance measuring equipment:

Temperature in °C

-30

-20

-10

0

10

20

30

40

50

Resistance in Ohm

882

921

960

1000

1039

1077

1116

1155

1194

Temperature in °C

60

70

80

90

100

120

140

200

Resistance in Ohm

1232

1271

1309

1347

1385

1461

1535

1758

12 Terms of guarantee

The Sunny Scout BASIC fs controllers are carefully manufactured and tested as part of their production. Should any failures occur, check first for any operational, adjustment or system errors, as part of this investigation the solar pump and temperature sensor connections must also be checked.

PROZEDA GmbH provides a guarantee according to the following terms for 24 months commencing from the date of purchase.

a) The guarantee is only effective in the event of an existing material defect of the purchased goods. If the defect is due to an operating error, exceeding the permissible technical values, incorrect wiring, unauthorised technical changes made within the controller by the customer or other company other than the controller manufacturer then the guarantee will be void..

b) To claim under the guarantee notification in writing is required which describes the defect in detail, a copy of the customer´s invoice showing date of purchase must also be supplied. The manufacturers agents reserve the absolute right under the guarantee to either repair, replace or deliver a functioning spare part to correct the defect.

The maximum repair period is 1 month with effect from receipt of the controller by the manufacturers agents.

If two repair attempts fail then the customer has the right to the claim delivery of a functioning spare part. In the case of delivery of a spare part a new guarantee meeting these terms comes into effect.

c) Any further warranty (exchange, price reduction) is excluded. The guarantee is not transferable.

In the case of defects within the guarantee period....in the first instance contact the controller supplier or system installer. In the case of any return you must enclose a written description of the error or defect, together with details of the controllers programmed functionality and wiring details to allow a full and accurate assessment to take place.

13 Declaration of conformity

We, Prozeda GmbH, hereby declare in sole responsibility that the product Sunny

Scout BASIC fs Type 1316 complies with the following directives:

• Electromagnetic compatibility (2004/108/EC )

• Electrical equipment designed for use within certain voltage limits (2006/95/EC)

• CE marking (93/68/EEC).

Standards that were used:

• DIN EN 60730-1

• DIN EN 61326-1

• DIN EN 61326-2-2.

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Operating manual for Sunny Scout BASIC fs 1316BED100-10B-E, 02/2012