Operation Instruction

SP116

1. General information 11.1 About this manual 11.2 Safety regulations 11.3 Liability waiver 11.4 Symbols used . 12. Product information 22.1 System description 22.2 Single-pipeline solar control system: SP 116············ . 32.2.1 Components 32.2.2 Installation description·· 32.2.3 Technical data 4

2.3 Display symbols· .. ··.. ·······.. ·.. ··············· .. ·············· .. ·············· .. ···.. ·············· .. ·43. Functions and operation 5

3.1 Setting week and time················································································ 53.2 Time-controlled auxiliary heating 53.3 Time-controlled circulation function .. ···· 63.4 Temperature difference circulation function······· . .. 63.5 Switching on/ off auxiliary heating manually·· . .. 73.6 Forbid/Permit using auxiliary heating ········73.7 Frost protection 73.8 Storage tank overheating protection. . 73.9 High temperature protection of solar system 83.10 Holiday function 83.11 Anti-legionella protection 83.12 Collector emergency cut-off. . 83.13 Memory function· 93.14 Reset Function 93.15 Manual operations 94. Error messages··············· ······.. ····· ·.. ·····.. ·.. ·.. ········································ 9

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User's Manual SPI16

1 General information

1.1 About this manual

This manual describes the installation, function and operation of an integrated solar control system,which is suitable for split pressurized solar heating system, Before installing and operating the device,please read the following information carefully,

1.2 Safety regulations

• Installation, commissioning and maintenance of the device may only be performed by professionalpersonal.

• All operations that require opening the device are only to be conducted cleared from the powersupply, All safety regulations for working on the power supply are valid,

• The device must not be installed in rooms where easily inflammable material (e.g. gas or oil)mixtures are present or may occur.

• Before connecting the system, make sure that the energy supply matches the specifications ofthe device, Protect the solar control system against overloading and short+circuiting.

• All devices connected to the solar control system must conform to the technical specifications ofthe device.

• As soon as it becomes evident that safe operation is no longer possible, please immediately take thedevice out of operation.

• Without lightning rod, please don't use this device during a thunderstorm

1.3 Liability waiver

• Improper installation or operation can cause damages to material and persons. The manufacturercannot monitor the compliance with these instructions or the circumstances and methods used forinstallation, operation, utilization and maintenance of this controller. Damage by mishandling orimproper installation on costumer site is immediately leading to warranty exclusion.

• As faults can never be excluded, we don't offer a guarantee for the completeness of the drawingsand texts of this manual, they only represent some examples. They can only be used on own risk.No liability is assumed for incorrect, incomplete or false information and the resultingdamages.

• The manufacturer preserves the right to put changes to product, technical date or installation andoperation instructions without prior notice.

1.4 Symbols used

..&. Dan.~er: Failure to observe these instructions can lead to injury of persons or safety risks .

.&. Attention: Failure to observe these instructions can result in damage to the product orenvironment.

o Note: Useful information and instructions.

l' Operation steps: Indication of operation steps.

User's Manual SPI16

2 Product information

2.1 System description

The solar collector pump (P 1) is activated as soon as the temperature difference between the collectorarray (Tl) and the storage tank (T2) is reached. If the temperature difference between the collectorarray (Tl) and storage tank (T2) drops below the switch-off temperature difference, or the storage tank(T3) reaches the maximum storage temperature, the solar pump (pI) will be switched off.T3 is.used to measure the temperature of the top part of storage tank. If the turning-on condition forauxiliary heating is filled, the auxiliary heating will be activated.

1 collector array --- 1 storage tank

T 1: Temperature sensor for collector arrayT2: Temperature sensor in bottom part of storage tankT3: Temperature sensor in top part of storage tankPI: Solar collector pumpP2: Solar circulation pump

&. Danger: If there is only one temperature sensor in water storage tank (usually in bottompart T2), it is possible, that the auxiliary heating function will not be activated or

deactivated at a right time, because the water temperature in top part of the tank (T3) cannot bemeasured. In this case, if you still want to use auxiliary heating function, control program willautomatically take the signal from bottom temperature sensor (T2) instead of (T3). However, waterin top part of tank might often be overheated. It may cause damages to material and persons. So it ishighly recommended not to use auxiliary heating in such a case.

o Note: To lock this function, please press "System setting" button until the signalappears on the screen (see details in 3.6 Forbid/Permit using auxiliary heating).

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User's Manual

2.2 Single-pipeline solar control system: SPl16

2.2.1 Components

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-- - ------ ---2

1 Operating screen 2 Pump speed regulation 3 Security valve5 Filling and flushing connector4 Manometer 6 WILOpump

7 Expansion vessel connector 8 Output connector 9 Input connector

2.2.2 Installation description

SP 116 should be installed in return flow of the solar circuit, as indicated above. Please seedetailed installation instruction in attached manual.

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User's Manual SPI16

2.2.3 Technical data

Rated voltage AC 220V (optional: ACll ~V)

Externality size 380mm*215mm* 135 mm

Weight 11 kg/carton

Max. own consumption ~3W

Range of temperature measuring NTC: O~I99·C; PTlOOO: O~199·C

Accuracy of temperature measuring 1·C

Power of pumps (solar collector pump PI<600W

and circulation pump P2)

Power of auxiliary hea ting ~3000W (optional: ~6000W)

System working pressure 8 bar

Safety valve response pressure 6 bar

Ambient temperature -20~60·C

Input signalsTl~T3 (solar collector; top part of water tank; bottom

part of water tank)

Output signals3 (auxiliary heating; solar collector pump; solar

circulation pump)

2.3 Display symbols

8 Weekday. 7days of week can be set (e.g. Week 1 means "Monday") ..e) Time. Setting hours and minutes.

@ Time-controlled auxiliary heating. Setting three heating time periods.

a::::3 Time-controlled hot water circulation. Setting three time periods.

e Tank temperature. As turning-on/off temperature value for auxiliary heating.

~ Frost protection signal.

~ Overheating protection for storage tank.

f22 High temperature protection for solar collector.

m Holiday function signal.

[ill] Switch on/off auxiliary heating manually.

~ Forbid/permit using auxiliary heating.

~ Reset signal.<5D Temperature display.E3

mmLlM Flow rate display.

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User's Manual SPI16

3 Functions and operation

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&. Danger: Before connecting the power supply, make sure that the water tank, solarcollector, solar control system and all temperature sensors are good connected!

o Note: For safety, auxiliary heating is locked at delivery state. The single "[&\]" displayson the screen. If you want to use this function, please see operation: 3.6 Forbid/Permitusing auxiliary heating.

3.2 Time-controlled auxiliary heating

Solar control system can be combined with electric boiler or gas/oil boiler. The system is supportedwith a default program which can be customized to meet your individual needs. You can create a timerprogram with up to three time periods to heat the water~'~to a desired value. During the threepreset time periods, auxiliary heating starts working, when the water temperature in top part ofstorage tank (T3) is below preset turning-on temperature, and it stops working, when T3 exceeds therequired temperature.

o Note: Default setting: the first time period: 4: 00 turning-on, 5:00 turning-off; thetime section: 10:00 -10:00; the third time section: 17:00 turning-on, 22:00 turning-off.

l' Press "System Setting" button until the signal "®"l' appears. ~--------------..

Press "+" "-" button to set the start time of the firsttime period. Press "+" to adjust hours, press "-"button to adjust minutes.

l' Press "Gonfirm" button to save the settings, press"Cancel" button to cancel the settings.

l' Immediately after setting the first time period, the displayenters into the operating menu of next time period.

l' Perform like above steps, the other two time periods canbe set.

3.1 Setting week and time

After power supply is switched on, please firstly set the weekof the system.

l' Press "System Setting" button until the signal "8"displays on the screen,

l' Press "+" "-" button to set weekday. (range: 0-6, e. g.1 means "Monday")

l' Press "Confirm" button to save the setting; press "Cancel"button to cancel the setting.

l' Press "System Setting" button again until "0" displayson the screen.

l' Pres"+" button to set hour, press" -" button to set minute.Press "Confirm" button to save the setting; press

l' "Cancel" button to cancel the setting.

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(l,,-,'----'------cTNote: If you want to shut off one of the three time periods, you can set a same value for bothstart time and end time, e. g., you can set both the start and end time of second time periodat 10: 00 am.

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User's Manual SPI16

3.3 Time-controlled circulation function

This function needs an extra circulation pump (P2). You can set up a timer program with up tothree time periods. This pump can be triggered at times when hot water will be needed.

o. Note: Within the preset three time periods, pump P2 always stops for 15 minutes afteroperating for 3 minutes.

o Note: Default setting: the first time period: 6: 00 turning-on, 8:00 turning-off; the secondtime period: 10: 0 0 ~ 10: 00; the third time period: 19: 00 turning-on, 21 :00 turning-off.

Three time periods should be set within one day (24 hours) .

l' Press "System Setting" , until "(E3 " displays on the screen.l' Press "+" "-" button to adjust the start time and end ,------------------.

time of first time period. Press "+" button to adjust Q) 05: OOON E3

hours, press "-" button to adjust minutes.l' Press "Confirm" button to confirm the setting, press (l'"

"Cancel" button to cancel this setting. er, uu

l' Immediately after setting the first time period, the display'------1

enters into the operating menu of next time period. '-- .....J

l' Perform like above steps, the other two time periods canbe set.

o Note: If you want to shut off one of the three time periods, you can set a same value for bothstart time and end time, e. g., you can set both the start and end time of second time periodat 10:00 am.

3.4 Temperature difference circulation function

The solar control program works on the principle of temperature difference circulation. Solar pump PIis triggered, as soon as the preset temperature difference between collector and tank is reached.

l' Press "System Setting" button, until " •• " displays onl' Press "+" «:» button to adjust storage tank temperature. ,-----------------.,.

Default value: 60'C, setting range: 45~75'C.l' Press "Confirm" button to save the setting. Press "Cancel"

button to cancel this function.l' At the same time the menu shows "I O'C " , the default

value of switch-on temperature difference.l' Press "+" '. "-" button to adjust it. Setting range:

the screen.

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5~20'C.l' Press "Confirm" button to save the setting. Press "Cancel" button to cancel this function.l' Then the menu shows "5'C", the default value of switch-off temperature difference.l' Press "+" «:» button to adjust it, adjustable range: 2~12'C.l' Press "Confirm" button to confirm the setting. Press "Cancel" button to cancel the function.

o Note: Between 60~70'C scale can form more easily, we usually set the water tanktemperature at 60'C.

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3.5 Switching on/ off auxiliary heating manually

If you want to use hot water immediately, but the watertemperature doesn't reach the desired value, you canswitch onloff the auxiliary heating manually.

If Press "confirm" button, until "[ill)" displays onthe screen to switch on auxiliary heating manually.

If Press "Cancel" button to switch off auxiliary heatingmanually.

3.6 Forbid/Permit using auxiliary heating

If Press "System Setting" button, until ,,[~ 1" displayson the screen.

If Press "Confirm" button to save the setting and forbidauxiliary heating.

If Press "System Setting" button until" [~l " displays onthe screen.

If Press "Cancel" button to cancel the setting and permitauxiliary heating.

o Note: When forbid auxiliary heating, customer can't switch onloff auxiliary heatingmanually and time-controlled auxiliary heating function is also automatically deactivated.

3.7 Frost protection

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In winter, when the temperature of collector drops below the preprogrammed startingtemperature of frost protection (default value 5°C), solar pump PI starts working. Whencollector temperature exceeds the switch-off temperature of frost protection, pump P I stopsworking and the system exits frost protection.

If Press "System Setting", until '~" displays on thescreen.

If Press "+" "-" button to adjust the temperature offrost protection. Setting range: 3·C -I DOC.

If Press "Confirm" button to confirm the setting, press"Cancel" button to deacti vate th is function.

3.8 Storage tank overheating protection

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To :tern]and

To avoid overheating of water storage tank, system is supported with an overheating protectionfunction. When the temperature of tank (T3) is higher than the maximum tank temperature,even the condition of temperature difference circulation is reached, solar pump is stillforbidden to operate

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3.1

Wh,heabe :

User's Manual SPI16

l' Press "System Setting" button, until [fiJ displays onthe screen.

l' Press "+" "-" button to adjust the maximum tank

temperature. Default value: 80·C, setting range: 60·C-90·C.

l' Press "Confirm" button to confirm the setting, press"Cancel" button to quit the function.

3.9 High temperature protection of solar system

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When collector temperature reaches 11S·C, and meanwhile the storage tank doesn't reach themax. tank temperature, the high temperature protection function of solar system will be activated.

l' Press "Confirm" button to confirm the setting, press"Cancel" button to quit this function.

3.10 Holiday function

o

If you intend to be absent for an extended period (holiday), or hot water is not required for anextended period, you can activate the holiday function. This function is activated nightly (22:00-6: 00) to re-cool the storage tank and to prevent high thermal loads of the solar system due tocompletely heated storage tank.

l' Press "System Setting" , until ~ displays on thescreen.

l' Press "+" « :» button to adju st the maximum collector ..;jItemperature. Default value: l1S·C, adjustable range:lOO·C-130·C.

l' Press "System Setting", until "[BQ]" displays on thescreen, it indicates that the function is active.

l' Press "Confirm" button to confirm this setting. Press"Cancel" button to deactivate this function.

o Note: When using holiday function, system will lockauxiliary heating automatically.

3.11 Anti-legionella protection

To safeguard t,he water hygiene, solar system will monitor the storage tank temperature. If thetemperature never reaches 70 in every 7 days, auxiliary heating will be activated automaticallyand heats the tank water to 70·C.

3.12 Collector emergency cut-off

When the temperature of collector reaches or exceeds 120·C, in order to prevent evaporation ofheat medium liquid and protect other components of solar system, solar circulation pump willbe stopped compulsively, until the temperature of collector gets lower.

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User's Manual SPII6 User' !

3.13 Memory function No,

6

In case of power failure, solar control system is able to remain the preset parameters unchanged.

3.15 Manual operations

Customers can monitor the flow rate any time by viewing the signal "mm LlM" on main operatingmenu. And when there are no other operations and it returns to main menu, they can alsoactivate some functions by pressing different buttons directly.

3.14 Reset Function

If necessary, all the settings (except time setting) can be resetto the factory settings.

If Press "System Setting" button, until "~" displayson the screen.

If Press "Confirm" button, all of parameters will bereset to factory settings.

If Press "Confirm" button 2 second to switch on/offsolar collector pump (Pl) manually.

If Press "Cancel" button 2 second to switch on/off solarhot water circulation pump (P2) manually.

If Press "+" - button repeatedly to check thetemperature values in different part of solar system.

4 Error messages

2

3

4

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.&. Danger: Never try to repair the solar control system yourself! Consult a specialist in case of anerror. o

The following table explains the error messages and corresponding handling indication. Most of the"- problems can be found in the list below.

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User's Manual SPI16

No. Familiar problem Possible reason Solution

I Pump works but no flow rate displays.There is probably too much air Replenish heat medium liquid

in the pipeline. and exhaust the air.

Storage tank reaches max. When tank temperature drops,

2System has temperature difference but tank temperature. pump starts working.

pump doesn't work. Solar collector reaches its When collector temperature

max. temperature. drops, pump starts working.

Auxiliary heating is forbidden. Activate it manually.3 A uxiliary heating doesn't work. Temperature sensor has broken Check sensor connection and

circuit or short circuit. make the wiring again.

Auxiliary heating still operates Anti-Iegionella function starts4 It's normal.

at 23:00. up.

There is air leakage in solarCheck the pipeline and

5 System pressure drops. exhaustsystem.

the air.

Pump works but system doesn't haveFrost protection function is A fter collector temperature

6 temperatnre difference, meanwhileactivated,~signal blinks.

auxiliary heating function starts up.rises, pump stops working.

The solar control system SP 116 shows error messages III tbe main operating menu if there is aproblem with temperature sensor.

Error message meaning Possible cause Error rectification

Tbere is broken circuit Sensor wiring interrupted, not Check resistance value,<FF"C>

with sensor connections. connected or short circuit. replace sensor if necessary.

There is a short circuit Sensor wiring interrupted, not Check resistance value,<FEoC>

with sensor connections. connected or short circuit. replace sensor if necessary.

o Note: A potentially defective sensor can be checked using an ohmmeter. To do this, the sensormust be disconnected. Its resistance value can be compared with the figures below, small

PT 1000 resistance value

NTC 10K B=3950 resistance value

1°C 10 110 20 130 40 150 60 70 80 90 100 110 120

In I 33620 i 20174 12535 I 8037 5301 I 3588 2486 1759 1270 933 697 529 407

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Install:

1 SBefoexecpraYcons

A1 0

Installation Instruction

SP116

1 Safety·········· .

2 Components .

3 Input and output signals· 2 2 (]

4 System demonstration with model SP 116 2

5 Installation······································································································ 2

5.1 Mounting······· 2

5.2 Filling the system·······························································.··························· 4

5.3 Electrical wiring·················.··········.············.············.············.········.······ ... ·.. ··· 5

6 Commissioning.······························.··········.·.······.·.·.··········.········.····.·.·············· 6

7 Replacing the pump 7

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Installation instruction SP1l6

1 Safety

Before installing the device, please read this manual carefully. Please note that the installation must beexecuted according to relevant technical rules. The installation must also be adapted to the conditionsprovided by the customer. Damages by improper using or incorrect modification of installation andconstruction on costumer site are immediately leading to warranty exclusion.

&. Attention: This manual is for trained personals only!

o Note: As faults can never be excluded, we don't offer a guarantee for the completeness of thedrawings and texts of this manual, they only represent some examples.

2 Components

8

---- ---------2

3 -------4-------S--------- _.------------J

7·-----------

9

No Components Function description1 Operating screen (LCD) Display operating menu.

2 Pump speed regulation Three speed levels available, offers different flow rate_

3 Security valve Protect the system against over-pressure.

4 Manometer Display system pressure (Max. 10 bar, normal workingpressure is approx. 2 bar)

5Filling and flushing Through this connector medium can be pumped into solarconnector system

6 Circulation pump WILO Star RS 15/6 (11 OV or 220V)

7Expansion vessel Connect expansion vessel. Expansion vessel balances theconnector system pressure.

8 Return flowCopper material, left side. Max. working temperature 150 "C,screw thread 1/2' (DN 15) as standard

9 Input and output signals Temperature sensors, power cord and other outputs.

Installation instruction SP1l6 Installa

3 Input and output signals

L----------------------6

3.1 Single-pipeline solar control system: SP116

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1 Tl connector 4 P2 circulation pump connector2 T2 connector 5 Power plug connector

3 T3 connector 6 Auxiliary heating connector

4 System demonstration with model SP116

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5 Installation

5.1 Mounting

+ Open the package carton and take out the solar control system carefully.• Determine the mounting position of the solar control system, considering the mounting

place for expansion vessel. See picture 1.

+Ir

2

Insiallation instruction SP1l6

Picture 1

• Drill the holes for dowels, put the dowels into the holes, fixed the solar control system onthe wall using fastening screws. The solar control system must be vertically installed. Seepicture 2.

Picture 2

• Use two wrenches to connect the pipes. See picture 3.

Picture 3

i• Install an automatic exhaust valve next to the interface of solar collector. See picture 4.

3

Installation instruction SP1l6 Installa

Picture 4

5.3 I

• Irse

• Connect filling connector (5) with a separate pump.• Install a 3-way ball valve beside the solar control system for draining (drain valve). And open

ball valve. See picture 5. Until there has medium overflow from ball valve, please closedthe ball valve. (There is already a non-return valve installed inside the solar control systembetween filling and drain valve.)

Picture 5

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• After above steps, connect an expansion vessel to expansion vessel connector(7). See picture6.

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5.2 Filling the system

• Connect a separate pump to the fill valve with pressure hose.• Open the filling and drain valve, fill the system with the separate pump. Heat mediu liquid (usually

use water-glycol mixture as heat medium, 50% glycol and 50% water) will be pumped into thesystem until it overflows through the ball valve (drain valve)

• Close the drain valve and continue to fill the system with medium liquid until the system pressureis not lower than 2 bar (the system pressure can be read from the manometer).

• Close the filling connector and switch off the pump. • 1

4

Installation instruction

5.3 Electrical wiring

• Insert the temperature sensors into storage tank (T2, T3) and solar collector (TO. Connect thesesensors to the solar control system SPl16 correspondingly. See picture 7.

1

iiiilii•• SPll6Picture 7

• Connect auxiliary heating wire if available. Cable (coffee) for the "L" , cable (blue) for"N" line, cable (yellow-green) for the ground wire.

Picture 8

• To connect external circulation pumps or any electromagnetic valves, firstly loose the aviationsocket and dismount it as indicated below. Connect the wire to aviation socket, number I connects

"N" wire (blue co lor}, number 2 connects ground wire (yellow-green color), number 3connects "L" wire (red color). Reassemble the aviation socket and connect it to the solarcontrol system .

Picture 9

••

• Tighten all joints and screw connections. Then plug the power supply into a socket.

5

Installation instruction SP1l6 Installai

6 Commissi~oning.c

se

• Switch on the power of solar control system.• Press "Confirm" button 2 seconds (in main operating menu) to activate the solar collector

pump (PI) manually and let the system circulate for a moment. See picture 10

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Picture 10

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• Observe the flow rate of solar control system which displays on LCD screen. If the flow rateis not regular, it indicates that there must be air still in the system. Open the air vent valveseveral times to relief the air.

Picture 11

• When the flow rate becomes regular, observe the system pressure from manometer. If thepressure is lower than 2 bar, refill the system with heat medium liquid to increase thepressure.

• Op

Picture 12

6

installation instruction SP1l6

• Carry out a pressure test of all system jornts again for leaks. The solar system must be ventedseveral times after some operating hours.

• Refill the system if necessary.• Remove the separate pump for filling after commissioning.• If there is auxiliary heating wire connected, press "Confirm" button until "rrrn" signal

displays on screen. it means switch on auxiliary heating manually. Then customer can useauxiliary heating function.

7 Replacing the pump

The integrated solar collector pump could be replaced if it gets broken.• Disconnect the power supply of solar control system. Loose the screw and open the metal cover.

Picture 13

• Remove the front half of the insulation material from system.

• Open the terminal box, disconnect the power supply connection.

Picture 15

7

Installation instruction SPl16

+ Loose the screws and open the WILO pump.

Picture 16

+ Replace the old one with new WILO pump.

Picture 17

+ Fasten the WILO pump screws.

Picture 18

+ Connect the power supply again and close the terminal box.

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Picture 19

8

Installation instruction SP1l6

• Attach the front half of the foam cover.

Picture 20

• Attach the metal cover and fasten the screws again.

•.

Picture 21

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