{"id":117798,"date":"2023-08-18T12:08:03","date_gmt":"2023-08-18T10:08:03","guid":{"rendered":"https:\/\/www.velasolaris.com\/handbuch\/solar-loop-controller\/"},"modified":"2025-10-21T13:18:13","modified_gmt":"2025-10-21T11:18:13","slug":"solar-loop-controller","status":"publish","type":"handbuch","link":"https:\/\/www.velasolaris.com\/en\/handbuch\/polysun-designer\/controllers\/solar-loop-controller\/","title":{"rendered":"Solar Loop Controller"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\" id=\"h-solar-thermal-controller-design-and-operation-in-polysun\">Solar Thermal Controller: Design and Operation in Polysun<\/h1>\n\n\n\n<p class=\"wp-block-paragraph\">The &#8216;Solar Loop Control&#8217; page of the Polysun manual explains how to control solar circuits in <a href=\"https:\/\/www.velasolaris.com\/en\/features\/solar-thermal-systems\/\">solar thermal systems<\/a>. It details how the solar pump is controlled by temperature differences and various flow modes, such as fixed flow, specific flow and match flow. It provides a clear overview of input and output parameters, typical switching examples, and the significance of measured values and pump settings for efficient solar thermal control, and is intended for design engineers and users. The explanations cover the options necessary to optimise the solar circuit in <a href=\"https:\/\/www.velasolaris.com\/en\/products\/polysun-designer\/\">Polysun<\/a>, from configuring the measuring points to linking the control criteria logically.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-description-of-the-solar-thermal-control-system\">Description of the Solar Thermal Control System<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The solar thermal loop controller is a two-channel controller that regulates the pump in the solar-loop.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The controller regulates the status and flow rate of up to two pumps based on the temperature difference of two distinct measured values.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The controller has 2 (plus 3 optional) analogic inputs.<\/li>\n\n\n\n<li>The controller has 1 (plus 3 optional) outputs (partially digital and partially analogic).<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Block-Diagram\" style=\"font-size:30px\">Controller <strong>Block Diagram<\/strong> <\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The block diagram shows the employed measuring and controlling values.<\/p>\n\n\n\n<div class=\"wp-block-group is-nowrap is-layout-flex wp-container-core-group-is-layout-7387b849 wp-block-group-is-layout-flex\">\n<figure class=\"wp-block-image size-full is-resized\"><img decoding=\"async\" src=\"https:\/\/www.velasolaris.com\/wp-content\/uploads\/2023\/10\/image198-1.png\" alt=\"\" class=\"wp-image-71690\" style=\"width:680px;height:401px\"\/><figcaption class=\"wp-element-caption\">Figure: block diagram: measuring values of solar loop<\/figcaption><\/figure>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Controller-Input-Mask-\u201cFixed-Flow-Rate\u201c\" style=\"font-size:30px\"><strong>Controller Input Mask \u201cFixed Flow Rate\u201c<\/strong><\/h2>\n\n\n\n<div class=\"wp-block-group is-nowrap is-layout-flex wp-container-core-group-is-layout-7387b849 wp-block-group-is-layout-flex\">\n<figure class=\"wp-block-image size-large is-resized\"><img decoding=\"async\" src=\"https:\/\/www.velasolaris.com\/wp-content\/uploads\/2023\/10\/image199-1-1024x714.png\" alt=\"\" class=\"wp-image-71692\" style=\"width:815px;height:568px\"\/><figcaption class=\"wp-element-caption\">Figure: controller input mask \u201cFixed flow rate\u201c<\/figcaption><\/figure>\n<\/div>\n\n\n\n<p class=\"wp-block-paragraph\">With this setting the solar pump cuts in as soon as the collector outflow temperature is 6 degrees higher than the temperature in the tank on layer 5. The flow rate is 60 l\/h for the collector field as a whole.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Controller-Input-Mask-\u201cSpecific-Flow-Rate\u201d\" style=\"font-size:30px\"><strong>Controller Input Mask \u201cSpecific Flow Rate\u201d<\/strong><\/h2>\n\n\n\n<div class=\"wp-block-group is-nowrap is-layout-flex wp-container-core-group-is-layout-7387b849 wp-block-group-is-layout-flex\">\n<figure class=\"wp-block-image size-large is-resized\"><img decoding=\"async\" src=\"https:\/\/www.velasolaris.com\/wp-content\/uploads\/2023\/10\/image200-1-1024x717.png\" alt=\"\" class=\"wp-image-71694\" style=\"width:941px;height:659px\"\/><figcaption class=\"wp-element-caption\">Figure: controller input mask \u201cSpecific flow rate\u201c<\/figcaption><\/figure>\n<\/div>\n\n\n\n<p class=\"wp-block-paragraph\">With this setting the solar pump cuts in as soon as the collector outflow temperature is 6 degrees higher than the temperature in the tank on layer 5. The flow rate is 15 l\/h\/m2 of collector field.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Controller-Input-Mask-\u201cMatched-Flow\u201d\" style=\"font-size:30px\"><strong>Controller Input Mask \u201cMatched Flow\u201d<\/strong><\/h2>\n\n\n\n<div class=\"wp-block-group is-nowrap is-layout-flex wp-container-core-group-is-layout-7387b849 wp-block-group-is-layout-flex\">\n<figure class=\"wp-block-image size-large is-resized\"><img decoding=\"async\" src=\"https:\/\/www.velasolaris.com\/wp-content\/uploads\/2023\/10\/image201-1-1024x713.png\" alt=\"\" class=\"wp-image-71696\" style=\"width:910px;height:634px\"\/><figcaption class=\"wp-element-caption\">Figure: controller input mask \u201dMatched flow\u201c<\/figcaption><\/figure>\n<\/div>\n\n\n\n<p class=\"wp-block-paragraph\">With this setting the solar pump cuts in as soon as the collector outflow temperature is 6 degrees higher than the temperature in the tank on layer 5. The flow rate ranges between 50 and 100 l\/h for the collector field as a whole as an attempt is made to reach an output temperature of 60\u00b0C.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Input-Values\" style=\"font-size:30px\"><strong>Input Values<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Collector-Temperature-[\u00b0C]\">Collector Temperature [\u00b0C]<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The value refers to the point where the temperature of the collector is measured. Enter either the collector mean or outflow temperature.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Tank-Temperature-[\u00b0C]\">Tank Temperature [\u00b0C]<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The value refers to the point where the tank temperature is measured. Enter the relevant tank layer.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Aperture-Area-of-Collector-[m2]-(Required-in-Case-of-Specific-Flow-Rate)\">Aperture Area of Collector [m<sup>2<\/sup>] (Required in Case of Specific Flow Rate)<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The value refers to the aperture area of the selected collector. This value enables a pump to be controlled with a specific flow rate.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Inlet-Temperature-of-Collector-[\u00b0C]-(Required-in-Case-of-Matched-Flow-Operation)\">Inlet Temperature of Collector [\u00b0C] (Required in Case of Matched Flow Operation)<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The collector\u2019s inlet temperature is used to define the pump flow rate in \u201cMatched flow\u201d mode. To this end measure pipe temperature at collector\u2019s inlet.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Yield-of-Collector-Field-[W]-(Required-in-Case-of-Matched-Flow-Operation)\">Yield of Collector Field [W] (Required in Case of Matched Flow Operation)<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The yield of the collector field is used to define the pump rate in \u201dMatched flow\u201c mode. Select the relevant collector field.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Description-of-Control-Parameters\" style=\"font-size:30px\"><strong>Description of Control Parameters<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Description\">Description<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The \u201cdescription\u201c value enables the user to assign controllers any name or number. Polysun assigns a consecutive number as a standard feature as different controllers are added chronologically in the hydraulic system.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Sign-of-Output\">Sign of Output<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The term \u201cNormal\u201c means that digital output signals are controlled as intended in the switching logics. (Example: if X1&gt;X2 the output of pump 1 is positive)<br>The term \u201cInverted\u201d that output signals are multiplied -1.<br>(Example: if X1&gt;X2 the output of pump 1 is equal to zero)<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Maximum-Temperature-of-Collector-[\u00b0C]\">Maximum Temperature of Collector [\u00b0C]<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">If collector temperature X1 is higher than the entered maximum temperature the solar-loop pump cuts off.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Maximum-Temperature-of-Tank-[\u00b0C]\">Maximum Temperature of Tank [\u00b0C]<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">If tank temperature X2 is higher than the entered maximum temperature the solar-loop pump cuts off.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Cut-in-Temperature-Difference-[K]\">Cut-in Temperature Difference [K]<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">If the collector outflow temperature X1 is higher than tank temperature X2 by the entered value, the solar-loop pump cuts in.<br>(Example: if X1 &gt; X2 + value, the pump cuts in)<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Cut-off-Temperature-Difference-[K]\">Cut-off Temperature Difference [K]<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">If the collector outflow temperature X1 is lower than tank temperature X2 plus the entered value, the solar-loop pump cuts off.<br>(Example: if X1 &lt; X2 + value, the pump cuts off)<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Definition-of-Flow-Rate-Setting\">Definition of Flow Rate Setting<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Specific flow rate<br>The controller regulates the pump according to the aperture area of the collector field by means of the value entered in the \u201cSpecific Flow rate\u201d. <strong>The corresponding pumps should be set to \u201cFlow rate setting\u201c <\/strong>(Double-click on pump to adjust the required settings)<strong>.<\/strong><\/li>\n\n\n\n<li>Fixed flow rate<br>Selecting a fixed flow rate the pump is controlled by means of the value entered in the \u201dFixed flow rate\u201c field. The input value \u201cAperture area of collector\u201c has no relevance and will be hidden. <strong>The corresponding pumps should be set to \u201cFlow rate setting\u201c <\/strong>(Double-click on pump to adjust the required settings)<strong>.<\/strong><\/li>\n\n\n\n<li>Matched Flow<br>In case of \u201cmatched flow\u201c operation the flow rate of the pump will be defined by means of a preset&nbsp; flow rate range. In the process the flow rate will be set so as to allow the collector output temperature&nbsp; to be reached. <strong>The corresponding pumps should be set to \u201cFlow rate setting\u201c <\/strong>(Double-click on pump to adjust the required settings)<strong>.<\/strong><\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Definition-of-Flow-Rate-Value\">Definition of Flow Rate Value<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Specific flow rate [l\/h\/m<sup>2<\/sup>]<br>Value of the specific flow rate in [l\/h\/m<sup>2<\/sup>] aperture area of collector field.<\/li>\n\n\n\n<li>Fixed flow rate [l\/h]<br>Value of the required fixed flow rate of collector field.<\/li>\n\n\n\n<li>Matched flow:<br>Value used to define the variable flow rate: collector outflow temperature [\u00b0C]; minimum flow rate [l\/h], maximum flow rate [l\/h].<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Output-Values\" style=\"font-size:30px\"><strong>Output Values<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Status-Pump-1\">Status Pump 1<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This digital output refers to the solar-loop pump to be controlled. Select the relevant pump from the list.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Status-Pump-2-(Optional)\">Status Pump 2 (Optional)<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This digital output is activated just like the output of Status Pump 1. A second component (e.g. a further pump) may be controlled based on the same criteria as Status Pump 1. Select the relevant component from the list.<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Flow-Rate-Pump-1-(Optional)\">Flow Rate Pump 1 (Optional)<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This analogic output controls the flow rate of pump 1. Select the relevant pump from the list. (the output is active only if the option &#8220;Flow rate setting&#8221; has been selected in the field &#8220;Flow rate-controlled&#8221; for the pump to be controlled; otherwise pump settings will have priority over the analogic control outputs. Double click on the pump to change\/check the settings)<\/p>\n\n\n\n<h3 class=\"wp-block-heading has-medium-font-size\" id=\"Flow-Rate-Pump-2-(Optional)\">Flow Rate Pump 2 (Optional)<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">This analogic output performs the same function as the flow rate output of pump 1. Select the relevant pump from the list.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"Overview-of-Control-Dependencies\" style=\"font-size:30px\"><strong>Overview of Control-Dependencies<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Table: Control-dependencies of the flow rate pump<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table><tbody><tr><td>Outputs<\/td><td>Parameter<\/td><td>Tip<\/td><td>Inputs<\/td><td>Function<\/td><\/tr><tr><td rowspan=\"4\">Y1: Status Pump 1 Y1 = Y2 Y2: Status Pump 2<\/td><td rowspan=\"4\">Fixed flow rate<\/td><td rowspan=\"4\">Set pump to<br>&#8211; Flow rate setting &#8211;<\/td><td>X1: Collector temperature<\/td><td>Y1=0 if X1 &gt; maximum collector temperature [\u00b0C]<\/td><\/tr><tr><td>X2: Tank temperature<\/td><td>Y1=0 if&nbsp; X2 &gt; maximum tank temperature&nbsp; [\u00b0C]<\/td><\/tr><tr><td>X1: Collector temperature<\/td><td rowspan=\"2\">Y1=1 if&nbsp; X1 &gt; X2 + cut-in temperature difference [K]<br>Y1=0 if&nbsp; X1 &lt; X2 + cut-off temperature difference [K]<\/td><\/tr><tr><td>X2: Tank temperature<\/td><\/tr><tr><td rowspan=\"5\">Y3: Flow rate Pump 1 Y3 = Y4 Y4: Flow rate Pump 2<\/td><td rowspan=\"5\">Specific flow rate<\/td><td rowspan=\"5\">Set pump to<br>&#8211; Flow rate setting \u2013 Flow rate dependent on X3 and the value of the specific flow rate<\/td><td>X1: Collector temperature<\/td><td>Y1=0 if&nbsp; X1 &gt; maximum collector temperature [\u00b0C]<\/td><\/tr><tr><td>X2: Tank temperature<\/td><td>Y1=0 if X2 &gt; maximum tank temperature&nbsp; [\u00b0C]<\/td><\/tr><tr><td>X1: Collector temperature<\/td><td rowspan=\"3\">Y1=1 if&nbsp; X1 &gt; X2 + cut-in temperature difference [K]<br>Y1=0 if X1 &lt; X2 + cut-off temperature difference&nbsp; [K]<\/td><\/tr><tr><td>X2: Tank temperature<\/td><\/tr><tr><td>X3: Aperture area of collector<\/td><\/tr><tr><td rowspan=\"6\">Y3: Flow rate Pump 1 Y3 = Y4 Y4: Flow rate Pump 2<\/td><td rowspan=\"6\">Matched Flow<\/td><td rowspan=\"6\">Set pump to<br>&#8211; Flow rate setting \u2013 Flow rate within the entered range and adjusted to the defined collector output temperature<br><br><\/td><td>X1: Collector temperature<\/td><td>Y1=0 if X1 &gt; maximum collector temperature [\u00b0C]<\/td><\/tr><tr><td>X2: Tank temperature<\/td><td>Y1=0 if X2 &gt; maximum tank temperature&nbsp; [\u00b0C]<\/td><\/tr><tr><td>X1: Collector temperature<\/td><td rowspan=\"4\">Y1=1 if&nbsp; X1 &gt; X2 + cut-in temperature difference [K]<br>Y1=0 if X1 &lt; X2 + cut-off temperature difference&nbsp; [K]<\/td><\/tr><tr><td>X2: Tank temperature<\/td><\/tr><tr><td>X4: Collector input temperature<\/td><\/tr><tr><td>X2: Yield of collector field<\/td><\/tr><\/tbody><\/table><\/figure>\n","protected":false},"author":19748,"featured_media":0,"parent":117529,"menu_order":42,"comment_status":"closed","ping_status":"closed","template":"","class_list":["post-117798","handbuch","type-handbuch","status-publish","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v28.0 (Yoast SEO v28.0) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Solar Thermal Controller: Polysun Operation Guide<\/title>\n<meta name=\"description\" content=\"Learn how Polysun&#039;s solar thermal controller optimizes pump regulation in heat pump systems with precise input and flow rate settings.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.velasolaris.com\/en\/handbuch\/polysun-designer\/controllers\/solar-loop-controller\/\" \/>\n<meta property=\"og:locale\" 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