Solar Controller SUNGO SL

OPEATING INSTUCTIONS, Version SW03/3.00/ HW3.0 Solar Controller SUNGO SL Wagner& Co Figure Solar Controller SUNGO SL. The benefits at a glance Large illuminated display to indicate temperature, balance values and system status with clearly visible symbols for easy readability. Easy and safe operation via four buttons for vertical and horizontal scrolling through the menus. Extensive diagnostics for monitoring system functions, eg. sensor cutoff and monitoring of temperature difference T too high Integrated security functions such as collector cooling, storage tank cooling, system protection and vacuum tube collector function. Solar charging of and tank systems Choice of thermostat function or return temperature increase Balance/reset values 5 temperature inputs PT000 output, speed-controlled The sensor T5 (solar return) and an external volume measuring device provide energy measurements in kwh. NEW now also SECUSOL system ready! Contents. Technical Description.... General Safety Guidelines... 4. Installer s Qualifications... 4. Operating equirements... 4.3 Installation and Operating Information... 4 3. Installation.... 4 3. Installation of the Housing... 4 3. Connecting Wires... 5 4. Operation... 6 4. Display and Buttons... 6 4. Information Menu... 8 4.3 Settings Menu.... 9 4.4 Manual Operation Menu...0 4.5 Special Functions Menu...0 4.6 Service System Messages... 4.7 Service Sensor Control... 5. Application Examples... 5. Standard Single Tank System... 5. Standard Dual Tank System... 5.3 SECUSOL System... Solar Thermal / Solar Circuit EN-SUNGO-SL-BA-0804-P300

. Technical Description Solar Controller SUNGO SL Material Dimensions (LxHxWinmm) 00% recyclable ABS-housing for wall mounting 73x38x5 Protection type IP40 according to VDE 0470 ate of radio interference N according to VDE 0875 Operating voltage Diameter of cable max. for 30 V connections Temperature sensor / Temperature range Sensor load Test voltage Switching voltage Output parameters of switches Internal mains protection Operating temperature (internal) / storage temperature Weight 30 Volt AC; 50 Hz; -0% to +5%.5 mm² unifilar or finely stranded Pt000; 000 W at 0 C; ange: -30 C to +5 C The cable of the sensor must be installed with no tension. The sensor must not be loaded mechanically when the temperature of the collector is more than 60 C. 4 kv min according to VDE 063 30 Volt AC A / ca. 30 VA for cos ϕ = 0.7-.0 for each output Microfuse 5x0mm; A/T 0 to +50 C / -0 to +65 C ca. 360 g Solar Charging The solar circuit pump is switched on and off by means of a temperature difference control. The sensors T (collector) und T (tank, bottom) are required as control elements. The on/off conditions and the temperature limitation can be variably set in the settings menu. Note: The temperature limitation always affects sensor T (tank, bottom). Speed Control The solar circuit pump can be controlled via speed control (in this case impulse packet control). This means that individual sine half-waves in the alternate current are switched on or off depending on the temperature difference. Therefore the speed can be altered within a range of 30-00% which results in longer system run times. The minimum speed can be custom set. Sensor T3 (tank, top) Sensor T3 (tank, top) has different functions. By default it is the measuring sensor for the top of the tank. In that case it has no switch function and is not monitored by the diagnostics system. With the return temperature increase function activated it functions as a hot sensor (source). With the thermostat heating with additional sensor function activated it functions as an additional sensor. In both cases this sensor is used in the hotareaofthetankandaffectsswitchingoutputa. If used in this way the sensor function is monitored as normal by the diagnostics system. Balance Values In addition to the actual values of the sensors T (collector) and T (tank, bottom) the display also shows balance values which represent the smallest and biggest temperature values for each sensor. After reset the actual temperature value is displayed. Manual Operation Allows switching inputs and outputs on or off manually. On exiting the manual operation menu, the software returns to automatic operation. The manual operation menu can be used for a maximum of 8 hours.after that the software automatically switches back to automatic operation and to the information menu. Manual Lag Function In order to check the temperature values in the information menu even when the outputs are set manually, a time lag has to be selected in the manual lag function in the manual operation menu. On exiting the manual operation menu, this time span passes once and then is set back to zero. In this mode a blinking symbol for the manual operation is shown in the information menu. Collector Cooling The tank is loaded up to the preset temperature limitation which affects sensor T (tank, bottom). If the preset temperature limitation is exceeded output A (solar circuit pump) switches off. If the temperature of T (collector) then rises above the selectable standard value of 0 C the solar circuit pump is switched on in order to cool the collector. It switches off again when the temperature at the collector sensor has decreased by 0 K. This type of intermittent operation of the solar circuit pump means that the collector is never or only rarely in an idle state. If the preset tank temperature limitation is exceeded by 5 K the collector cooling function is suppressed. The system shuts down completely. Storage Tank Cooling Storage Tank Cooling means that if necessary the tank temperature can be reduced down to a preset lowest switching off value (setting for vacations). When the collector cooling function is activated storage tank cooling will also become active. In order for storage tank cooling to become active the following 3 conditions must be met:. Temperature T (tank, bottom) must be higher than or equal to the preset tank temperature limitation plus K.. Temperature T (tank, bottom) must be higher than the preset switching off value for storage tank cooling. 3. Temperature T (collector) must be lower than temperature T (tank, bottom) minus 0 K. In order for storage tank cooling to switch off one of the following conditions must be met:. Temperature T (tank, bottom) is lower than the switching off value for storage tank cooling.. Temperature T (collector) must be higher than temperature T (tank, bottom) minus K. EN-SUNGO-SL-BA-0804-P300

Vacuum Tube Collector Function The vacuum tube collector function allows operation of the solar heating system even if sensor T (collector) is installed in the connecting pipe of the collector. If the temperature increase at sensor T exceeds the preset switching on value for the collector temperature increase (standard: K) the solar circuit pump is switched on for the duration of a preset lag time (standard: 5 s). During this time the switching on difference and the solar charge between sensor T (collector) and sensor T (tank, bottom) has to be activated, otherwise the solar circuit pump will switch off again. The rise in temperature at sensor T (collector) is measured again immediately after the last runtime of the pump. System Messages The system messages for interrupted or shorted-out sensors are represented by symbols on the display. For better recognition of the system messages the display illumination switches on and off every second as long as the error prevails and no key entry is made. Triac The Triac is an electronic on/off switch for the 30 V outputs of the SUNGO Controller. Function: A triac switch consists of diodes which can be switched anti-parallel (= antiparallel thyristors). The thyristors switch through the positive or negative sine halfwave as long as a switching on difference exists. The triac switch switches off when the temperature falls below the switching-off difference. System Protection In order to protect the system components (solar circuit pump, or 3 way valves etc.) in the solar heating circuit from extremely high temperatures the solar charge is stopped completely if a temperature limit at the collector sensor is exceeded, even if this was permitted on account of a temperature difference between sensor T (collector) and sensor T (tank, bottom). The standard temperature value for activating the system protection function is 35 C. However, this value can be variably set within a range of 5 to 00 C. T4 is higher than the switch-on level plus the switch-off difference. With the heating option an additional sensor T3 can be activated. If this is the case A is only switched on if temperature T3 is higher than the switching on level plus the switching off difference plus the additional difference for T3. With the cooling option activated output A switches on if the current temperature T4 falls below the preset switch level. Output A switches off if the current temperature T4 is lower than the switch level minus the switching off difference. There are 3 independent time windows available for the thermostat. If no time window is activated time window has to be set to 0:00 and 3:59. eturn Flow Boost This is a freely adjustable temperature difference for simple heating support which leads the heating return-flow T4 (drain) to the heating boiler, either directly or via the solar tank, depending on the preset temperature difference to the tank sensor T3 (source),by switching the 3 way valve on output A. Note: In addition to the switching phase (black) on output A, the switching head also requires a constant phase (brown). SECUSOL Function The solar heating system is operated on a drain back principle. This means if the solar circuit pump is not activated there is no solar fluid in the collectors and risers. See SECUSOL instructions for further details. Measuring the Yield For measurements of the solar yield in kwh. The heat yield is measured with a volume measuring device, an additional sensor T5 (return) and the existing sensor T (collector). Dual tank operation The SUNGO SL is capable of controlling a dual tank system by using output A for switching between tanks with the help of a 3 way valve. Change the menu item 0 to0 in order to control a dual tank system. Note: If the dual tank option is selected menu item 0 can no longer be activated. Preference The SUNGO SL always uses tank as a preference for the dual tank option. This cannot be changed. Thermostat The thermostat function for switching on can be set at a range between 0 to 30 C with a variable difference between to 40 K for switching off. Choose between the options heating and cooling. With the heating option activated output A switches on if the current temperature T4 falls below the preset switching on level. Output A switches off if the current temperature EN-SUNGO-SL-BA-0804-P300 3

. General Safety Guidelines The following safety advice is designed to protect you from dangers that can arise from improper handling of devices, whether intentional or otherwise. A distinction is made between general advice presented here and specific advice presented throughout the guidelines. DANGE for danger to the person Improper electrical installation of the device can lead to potentially fatal electric shocks as well as other health hazards. CAUTION for danger to property This symbol indicates dangers that can result in damage to the components or the function of the control. NOTE for additional information This symbol indicates practical advice and tricks of the trade which will be useful for installing and operating the control.. Installer s Qualifications Setting up and commissioning of the SUNGO SL must be carried out by a qualified installer. All national and local safety regulations need to be complied with. Please note that in case of a complaint the guarantee is only valid if correct commissioning has been certified in a commissioning report.. Operating equirements Application Controlling solar thermal systems through the selection of applicable control patterns and additional functions to adapt the control for the required operation of the hydraulic system. The control must only be operated in dry rooms. The control can be integrated into the solar circulation unit or mounted on the wall. Limitations of use If used in a non-solar thermal application the functionality of the control has to be checked before commissioning. If in doubt contact the control service of Wagner & Co. If these operating requirements are not observed any claims under the warranty will not be accepted..3 Installation and Operating Information Any installation and wiring work has to be carried out in an idle state as during operation the voltage on the outside of the triacs is 30 V. Mains power must be connected to the control from outside the solar station via an external ON/OFF Switch. This is also required to activate the special functions menu through switching the mains power ON/OFF. Operating temperatures above 50 C are not permitted for the control. LCD display panels are designed in such a way that a specific reading position is required. When installing the control, be careful to place the display so that it is at eye level or slightly higher. This way you can ensure optimal display contrast. The base of the control is divided into a safety low voltage section and a 30 V section by a crosspiece. Make sure that you do not confuse these sections during the installation process. The default operating mode is the automatic mode. Manual operation is used only for functional testing of the different hydraulic components (pump, /3 way valve). In this operating mode maximum temperatures or sensor functions are not monitored. Do not operate the system if the control,the wiring or the connected 30 V mains are visibly damaged. The control is fitted with a mains microfuse. Collectors and hydraulic pipework can get extremely hot during sunny periods. There is a risk of scalding when fitting the collector temperature sensor. 3. Installation 3. Installation of the case Opening the case No tools are required to open the control case. The lid folds over on top of the lower half. You can dislodge and lift up the lid by pulling gently on the side clips. When fully opened the lid will not move so that you can take care of mounting and wiring comfortably. Wall mounting Use the supplied drilling template to drill the fixing holes for the controller. Mount the control to the wall. Do not overtighten the screws to avoid damage to the lower part of the housing. 4 EN-SUNGO-SL-BA-0804-P300

Installation in the Solar Circulation Unit With the screws mount the SUNGO SL on the wall holder of the solar circulation unit. Break out the cable feeds which are located on the base housing next to the crosspiece. Strip the 30 V cables in a way that the insulated single cables start directly at the feed to the base housing. Hold cable clamps steady when screwing tight in order to minimise pressure on the circuit board. There is a danger of the terminals to be torn off! Finally connect to mains power. When the control is switched on the voltage on the triacs housing is 30 V AC. 3. Connecting Wires Layout of the SUNGO SL Connections All electrical connections are made to the circuit board at the bottom of the control. The sensor connections (safety low voltage) are located on the right hand side and the 30 V mains connections and the switching outputs A and A on the left hand side. General connection rules If flexible wires are used and the control is wall mounted, a strain relief must be fixed within or outside of the control. In this case you must crimp the wire ends. If required PG9 screws can be fixed at the feed-throughs in case of wall mounting. 30 V mains connection Mains power is connected from outside the control via an ON/OFF Switch. This switch is not required if mains power is with a protective plug to a socket. The control is suitable for mains operation at approx. 30 V/50 Hz. All earth wires are connected to the PE terminals. The neutral terminals (N) are connected electrically. Switching output A is a 30 V normally open contact which is activated via speed-control. Switching output A is purely a normally open contact. Connecting the temperature sensors The wires of the temperature sensors can be extended: Up to 5 m length, x 0.5 mm² cable can be used, beyond 5 m and up to 50 m x 0.75 mm² is necessary. Shielded cables should be used for long connections to the collector. Do not connect the shielding at the sensor end, just trim and isolate. The polarity of the temperature sensors is irrelevant and they can be connected either way. The sensor wires must be installed separately from 30 V mains cables. Lightning Protector Module The SUNGO SL is fitted with spike protection on all sensor terminals. Generally, further protection of the tank sensors is not required. Sensor T (collector) should be fitted with the sensor connection box SP with an overvoltage protection. ControllerIC Plug for Display FUSE 5X0 Triac PE-PE A A L Trafo T T T3 T4 T5 M M M M M T7 M PE-PE N N N Potential Earth Switching output Solar circuit pump Mains L Collector sensor, T Tank sensor, bottom, T Tank sensor, top / Additional thermostat sensor / return flow boost (source) Thermostat / return flow boost (sink), T4 Heat meter (yield), return flow sensor, T5 Volume flow meter, T7 Figure SUNGO SL circuit board components. EN-SUNGO-SL-BA-0804-P300 5

4. Operation 4. Display and Buttons Settings menu Information menu Manual operation menu Special functions menu Temperature difference Numerical display for temp. or sensor errors Collector temperature Symbol for reset value Tank temp., bottom Pump ON/ Pump OFF Output A Output A dt min max start stop 88888 KWh C % x! ok? Balance or start / stop values Units Tank temp., top/ thermostat additional sensor Temperature thermostat/ return flow boost (sink) Time slot thermostat Tank temp., mid section/ return flow boost (source) Confirm and save symbol System error 6 EN-SUNGO-SL-BA-0804-P300

Horizontal operating level Vertical operating level Settings menu as an example Switching off diff. T3 - T4, return temperature increase Switching on diff. T3 - T4, return temperature increase Min temp. level, return temperature increase Temp. limitation, return temperature increase Stop time window 3, thermostat Start time window 3, thermostat Stop time window, thermostat Start time window, xx thermostat Stop time window, thermostat Start time window, thermostat dt min dt max T min T max stop start stop start stop start 3 3 I I 4 4 T max dt max dt min T min dt d min d max T start dt dt Temperature limitation tank, bottom Switching on difference T - T, solar Switching off difference T - T, solar Min. temp. source Design temp. diff. speed control, solar Min. speed, solar circuit pump Max. speed solar circuit pump (SECUSOL) Charge time solar heating system (SECUSOL) Current time Switching on temperature, thermostat Switching off temperature, thermostat Difference additional sensor T3, thermostat Set values Activate value Increase value Decrease value Activate save function Save value EN-SUNGO-SL-BA-0804-P300 7

4. Information Menu Information menu Menu item Description Display min max min max h h min max h h Collector temperature; Current value C Collector temperature; Balance; minimum, resettable C Collector temperature; Balance; maximum, resettable C Tank temperature, bottom; Current value C Tank temperature, bottom; Balance; minimum, resettable C Tank temperature, bottom; Balance; maximum, resettable C Tank temperature, top; Current value C Operating hours, total; Balance h operating hours since last reset; Balance, display, resettable h Tank temperature or, bottom; (if tank system is selected) Tank temperature or, bottom; (if tank system is selected) Tank temperature or, bottom; (if tank system is selected) Operating hours tank or, total; (if tank system is selected) operating hours tank or since last reset; (if tank system is selected) Current value Balance; minimum, resettable Balance; maximum, resettable Balance Balance; display, resettable C C C h h kwh Thermostat or return temperature increase (drain); Current value C Heat counter, return; (flow value corresponds to collector temperature) Current value Heat counter, total yield; Balance kwh C kwh heat counter since last reset; Balance, display, resettable kwh Heat counter tank or, total; Balance kwh kwh heat counter, tank or kwh since last reset; Balance, display, resettable kwh Pump symbol idle: Operating symbol Temperature difference (collector, tank) is smaller than required to activate the solar circuit pump. The solar circuit pump is off. otating pump symbol: Temperature difference (collector, tank) is sufficient to activate the solar circuit pump. The solar circuit pump is running. Operating symbol 8 EN-SUNGO-SL-BA-0804-P300

4.3 Settings Menu Settings menu Menu item Description ange Default setting T max dt max dt min T min T max dt max dt min dt d min d max T start Temperature limitation tank, bottom 5 90 C 85 C Switching on difference between collector and tank 3 40 K 5 K Switching off difference between collector and tank 35 K 3 K Min. temp. above which the switching difference is analyzed 5 90 C 0 C Temperature limitation tank or, bottom 5 90 C 85 C Switching on difference between collector and tank or 3 40 K 0 K Switching off difference between collector and tank or 35 K 3 K Design temperature difference the speed control adjusts to 50 K 0 K Minimum speed of the solar circuit pump 0% increments Maximum speed of the solar circuit pump Only with SECUSOL! Charge time (s) of the solar heating system with speed 00%; in 0 s increments Only with SECUSOL! 30 00% 30% 30 00% 00% 0 360 s 60 s Set current time (keep button pressed for faster run-through) 0:00-3:59 0:00 dt dt Switching on temperature thermostat 0 30 C 30 C Switching off difference thermostat 40K 5K Additional sensor difference for tank, top, can be selected in heating function. 3 0K 0K start stop start stop start stop I I 3 3 Start time slot, thermostat 0:00-3:59 0:00 Stop time slot, thermostat 0:00-3:59 3:59 Start time slot, thermostat 0:00-3:59 0:00 Stop time slot, thermostat 0:00-3:59 0:00 Start time slot 3, thermostat 0:00-3:59 0:00 Stop time slot 3, thermostat 0:00-3:59 0:00 T max T min dt max dt min Temperature limitation return temperature increase 5 90 C 85 C Minimum temperature from which the switching on difference is read 5 90 C 0 C Switching on difference return temperature increase between temperature measure location T3 and T4 3 40K 4K Switching off difference return temperature increase between temperature measure location T3 and T4 35K K Only available if heating or cooling thermostat is used. Only available if return temperature increase is used. EN-SUNGO-SL-BA-0804-P300 9

4.4 Manual Operation Menu Manual operation menu Menu item Description ange Default setting Off = 0/On = Switching the solar circuit pump on or off manually (A) Off = 0/On = Switching output A on or off manually (LA or thermostat) 0 0 0 0 T stop Activation of manual operation lag time in automatic mode 0 600 min 0 min 4.5 Special Functions Menu During the first minute after switching on the control activate the special functions menu by selecting it so that parameters can be altered.the menu stays active for minute after exiting it. On exiting the menu the parameters can only be viewed but not changed again.place the control in the idle position once again if you need to alter any functions. Special functions menu Menu item Application Description ange Default setting 0 System choice 0 : Standard single tank system 0 : Standard dual tank system 0 3: SECUSOL system (see SECUSOL instructions for further info) 3 System Protection Off = 0/On = Activation of system protection. Cannot be activated with SECUSOL! 0or System protection start temperature 5 00 C 35 C 3 Collector Cooling Off = 0/On = Activation of collector cooling. Cannot be activated with SECUSOL! 0or 4 Collector cooling start temperature 00 50 C 0 C 5 Storage tank Cooling Off = 0/On = Activation of tank cooling. Only possible with collector cooling. Cannot be activated with SECUSOL! 0or 0 6 Switching off temperature 30 90 C 60 C 7 Off = 0/On = Activation of yield measurement 0or 0 8 9 Measuring the Yield Frost protection type 8-: DC0 for standard systems 8-: DC40 for vacuum tube collectors (ready mix) Glycol fraction in %. 0% = No Glycol (pure water) 00% = Pure Glycol (no water) Note: Glycol fraction for solar circuit can only be selected with DC0! or 0 00% 40% 0 Function selection 0 0: Additional functions off 0 : Thermostat, heating 0 : Thermostat, heating with additional sensor T3 (tank, top) 0 3: Thermostat, cooling 0 4: return temperature increase 0 4 0 Off = 0/On = 0or 0 Activation of vacuum tube collector function Vacuum Tube collector function un time of solar circuit pump from reaching the switching on value 60 s 5 s 3 Switching on value for temperature increase at sensor T (collector).0 5.0 K.0 K The special functions menus should only be edited by expert personnel. Incorrect settings may adversely affect the solar heating system. 0 EN-SUNGO-SL-BA-0804-P300

4.6 Service System Messages System information with display Display Description emedy C C! Blinking! Blinking! Blinking System messages All system messages are displayed with a blinking caution symbol. In case of sensor errors the sensor in question is also marked with short circuit or interruption symbol. Interruption The sensor on the display or the pipe is interrupted. Short circuit There is a short circuit on the sensor on the display, the cable or the output on the control. Test the resistance value of the sensors and compare with the tables. Check all connections to the sensor.! Blinking dt too high A value of 0 K is added to the switch-on difference between T and T. The message is displayed if after 30 minutes the total difference has not been reduced. Check wiring to the pump Check system for air and vent if required Check sensors and sensor wiring, replace sensors if required 4.7 Service Sensor Control esistance values for Pt000 sensors in relation to the temperature -0 C 0 C 0 C 0 C 30 C 40 C 50 C 60 C 70 C 80 C 90 C 00 C 0 C 96 Ω 000 Ω 039 Ω 078 Ω 7 Ω 55 Ω 94 Ω 3 Ω 7 Ω 309 Ω 347 Ω 385 Ω 43 Ω The working condition of the sensor can be checked with this table and an Ohm meter. 5. Application examples 5. Standard Single Tank System P: Solar circuit pump P: Heating circuit pump P3: Tank charging pump Vr: Switch-over valve for return temperature increase Collector field T: Collector sensor T: Tank sensor, bottom T3: Tank sensor, middle T4: Sensor heating return-flow T3 T A T4 A T T Version TEMO Combi Cylinder Hot water Cold water Heating circuit TEMO Ttw T3 P3 P P T A Vr B AB Oil or gas boiler CICO T4 Measuring the yield Collector field T T5 D Solar return-flow Figure 4 Standard single tank system controlled by SUNGO SL. EN-SUNGO-SL-BA-0804-P300

5. Standard Dual Tank System P: Solar circuit pump P: Heating circuit pump P3: Tank charging pump Vu: Switch-over valve, tank charging Collector field T: Collector sensor T: Tank sensor, bottom T3: Tank sensor, top T4: Tank sensor, bottom T3 T T4 A A T Heating circuit P P ECOplus CICO Oil or gas boiler P3 A AB Measuring the yield M B V Collector field T D T5 Solar return-flow Hot water Cold water Figure 5 Standard dual tank system controlled by SUNGO SL. 5.3 SECUSOL System T: Collector sensor T: Tank sensor, bottom T3: Tank sensor, top (optional) Collector field (EUO C) P: Solar circuit pump P: Heating circuit pump P3: Tank charging pump Ttw: Hot water sensor (heating control) BWM: Thermostatic mixing valve T3 T A T T Heating circuit Ta Ttw P T3 SECUSOL T Oil or gas boiler P3 P Measuring the yield Collector field T T5 Hot water BWM D Solar return-flow Cold water Figure 6 SECUSOL system controlled by SUNGO SL. Subject to modifications, errors excepted. Wagner & Co, 008 www.wagner-solar.com WAGNE & CO Zimmermannstraße D-3509 Cölbe/Marburg +49 64 80 07-0 Fax 80 07-