Ariston AST 100 Guide

SOLARcomfort
Solar Hot Water
Systems
AST 100 Solar
Controller
Installation,
Commissioning and User
Instructions
LEAVE THESE INSTRUCTIONS WITH THE
END USER
Country of Destination GB/IE

1
TABLE OF CONTENTS
1. GENERAL INFORMATION...............2
1.1 GUARANTEE ..........................................2
1.2 SYSTEM CONTENTS................................2
1.3 SYSTEM INSTRUCTION BOOKS ..................2
1.4 SOLARCOMFORT.................................3
1.5 LIFESTYLE ............................................3
1.6 HOW THE SYSTEM WORKS.......................3
2. SAFETY ...........................................4
3. TECHNICAL DATA ...........................6
3.1 COMPONENT LIST ..................................7
3.2 DIMENSIONS .........................................7
4. REGULATIONS & STANDARDS......8
4.1 WATER REGULATIONS .............................8
4.2 BUILDING REGULATIONS ..........................8
4.3 GENERAL GUIDANCE ...............................8
4.4 BRITISH & EUROPEAN STANDARDS ............9
4.5 UK REGULATIONS (WATER HEATING) ........9
4.6 UK REGULATIONS (CONSTRUCTION) .........9
4.7 EU DIRECTIVES ..................................10
4.8 OTHER PUBLICATIONS ...........................10
4.9 ELECTRICAL CONNECTION .....................10
4.10 THERMAL INSULATION ............................10
5. OPERATION & FUNCTIONS .........11
5.1 CONTROLLER LAYOUT ...........................11
5.2 CONTROLLER FUNCTIONS ......................12
5.3 MENU OPTION &VALUE DISPLAY ............12
5.4 MENU NAVIGATION ...............................12
5.5 CONTROLLER SETTINGS ........................13
5.6 SYSTEM IMAGE ....................................14
5.7 SYSTEM IMAGE ICONS ...........................14
5.8 TOOL BAR .........................................15
5.9 OPERATING MODE HND1 & HND2 ......16
5.10 CONTROLLER SETTINGS........................16
6. INSTALLATION...............................17
6.1 POSITIONING CONTROLLER....................17
6.2 WALL MOUNTING CONTROLLER ..............17
6.3 ELECTRICAL CONNECTIONS....................18
6.4 WIRING DIAGRAM STANDARD SYSTEM
ARR 1...............................................19
6.5 WIRING DIAGRAM SYSTEM WITH AUXILIARY
HEATING ARR 2 ..................................20
7. COMMISSIONING SYSTEM ..........21
7.1 INITIAL SETTING ...................................21
7.2 OPTIONS FOR STANDARD SYSTEM
ARR 1...............................................23
7.3 OPTIONS FOR SYSTEM WITH AUXILIARY HEAT
ARR 2...............................................24
7.4 INFORMATION ONLY MENU OPTIONS .........25
7.5 SETUP PARAMETERS MENU OPTIONS .......27
8. MAINTENANCE .............................32
8.1 FUSE REPLACEMENT.............................32
8.2 SENSOR FAILURE .................................32
8.3 CONTROLLER FAILURE ..........................32
8.4 FAULT FINDING ....................................32
9. USER INSTRUCTIONS .................35
9.1 CONTROLLER FUNCTIONS ......................35
9.2 MENU OPTION AND VALUE DISPLAY .........35
9.3 HOUSEHOLDER RESET OPTIONS .............35
9.4 HOW TO RESET COUNTERS ...................36
9.5 FAULT CONDITION ................................36

2
1. GENERAL
INFORMATION
This manual is an integral and essential part of the product. It should be
kept with the product.
Please read carefully the instructions and notes about SOLARcomfort
contained in this manual as they provide important information regarding
theinstallation, commissioninganduser instructionsof theAST 100 Solar
Controller and the SOLARcomfort system.
IMPORTANT
Failure to follow these instructions correctly may invalidate the
guarantee.
IMPORTANT
Solar domestic hot water heating systems must be installed to
comply with the current Building Regulations, British Standards
and any applicable local regulations refer to section 5.
The SOLARcomfort AST100 Solar Controller is guaranteed for 2 years -
see terms and conditions of guarantee on back page.
The complete SOLARcomfort solar water heating system is supplied in
the following consignments:-
1. 800201 Collector 1 per box
2. 3107024/5 Roof Fittings Kit 1cardboardtube
3. 3820011/2 System Components 1 box
4. 3820001 Tyfocor antifreeze heat transfer fluid
1 x 20l container
The following instruction booklets are supplied with a complete
SOLARcomfort solar water heating system:-
1. SOLARcomfort Solar HotWater Systems Collectors 2 & 3 Collector
Set.
Covers collector installation and plumbing connection.
Supplied in System Components box.
2. SOLARcomfort Solar Hot Water Systems Pump Group 40/60.
Covers installation, plumbingconnection, systemfilling,flushing and
commissioning.
Supplied in System Components box.
3. SolarController AST 100
Covers installation, wiring connection and User Instructions.
Supplied in System Components box.
1.1 GUARANTEE
1.2 SYSTEM CONTENTS
1.3 SYSTEM INSTRUCTION BOOKS

3
SOLARcomfort systems are highly efficient and provide cost savings on
the energy used for heating hot water wherever they are used in the UK.
However, the savings made will depend on local climate, installation
characteristics and the households use of hot water.
It is important that the SOLARcomfort system is correctly sized for the
local climate condition and the householders domestic hot water
requirements.
After installation of the SOLARcomfort system, changes to the
householders use of hot water will be beneficial. Simple changes such as
bathing in the evening instead of the morning, and putting automatic
washing machines on when free hot water is available by solar energy.
In addition the timing of the dwelling’s boiler controls must be modified to
ensure the‘hot water ON’time is set so that the water temperature in the
cylinder is at a minimum by the start of the ‘solar day’.
The solar collectors are heated by the sun’s rays. The heat generated is
storedinahotwaterstoragecylindere.g.anAristonPrimotwincoilstainless
steel cylinder. The AST 100 Solar Controller continually compares the
temperature of the water within the cylinder with the temperature of the
solarcollectors.
Wheneverthesolar collectorsarehotter thanthewater within thecylinder,
thecontroller switcheson thesystem’s circulating pump. The temperature
differential between the collectors and the cylinder is set via the AST 100
Solar Controller. The heat transfer fluid within the solar system is then
circulatedthroughthe collectors andthecylinder’sheat exchanger,heating
the cylinder in just the same way as a central heating boiler.
The cylinder typically has two coils (heat exchangers), the lower coil is
heated by the solar system, therefore solar is the primary heat source.
Theupper cylinder isheatedbyanauxiliary heatsource,typicallyacentral
heating boiler, which is used to heat water when there is insufficient heat
generated by the solar system. The Ariston Primo twin cylinder also has
twoimmersionheatersmaking itsuitablefor electriconly heating systems.
The SOLARcomfort system is a forced circulation sealed system and
therefore requires an expansion vessel and a pressure relief valve (PRV),
bothsupplied withSOLARcomfort.
Theairseparatormodulewithanintegralairventtogetherwithan automatic
air vent positioned at the highest point on the system ensures that the
sealed system remains free of air.
1.6 HOW THE SYSTEM WORKS
See fig. 1.6A
1.4 SOLARCOMFORT
1.5 LIFESTYLE

4
FIG. 1.6ASOLAR BASIC PRINCIPLES
Roof mounted collectors
(two collector system shown)
Pump group
Expansion
vessel
Solar system
low level fill
point
Ariston ITSI 210/300
twin coil cylinder
Upper coil
heated by boiler
or other heat
source
Lower coil heated by
solar energy
AST 100
Controller
Air vent
PRValve
Solar system
drain point
Temperature
Sensor S1
Temperature
Sensor S3
Temperature
Sensor S2 PRV discharge
vessel
Energy
Monitoring
Sensor S4
(option)

5
2. SAFETY WARNING
All wiring should be carried out to and comply with the current IEEWiring
Regulations.
All electrical work must comply with any relevant regulations that apply at
the time of the installation.
All electrical installation and maintenance of the AST 100 Controller must
be carried out by a competent qualified installer.
WARNING
TYFOCOR LS HeatTransfer Fluid.
Although non-toxic it should not be swallowed.
Refer to label on its container for storage and safety information.
A detailed technical specification is available from Ariston on request.
Caution
SOLARcomfort should be installed and commissioned by approved
contractors. Failure to do so may invalidate the warranty.
Caution
The controller should be positioned so that it is inaccessible to children
and cannot be tampered with.

6
3. TECHNICAL DATA CONTROLLER
Type AST100
Housing PC-ABS & PMMA
Dimensions 173 x 110 x 46
Mounting Wall (2 screws)
Operation 3 Push Buttons
Protection IP20 / DIN 40050
Environmental Temperature 0 - 40°C
FUNCTIONS
Temperature Differential Control Standard
Operating Hours Counter Standard
Energy Monitor Option
ELECTRICAL
Power Supply 210-240V
Electromechanical Relay 250V
Controller Mains Cable 1.0mm² 3 core heat resistant flex 3093y
Pump Cable (R1 and R2) 1.0mm² 3 core heat resistant flex 3093y
SENSORS
Collector Sensor S1
Cylinder lower S2
Cylinder upper S3
Energy monitor (collector return) S4

7
3.1 COMPONENT LIST
FIG. 3.1ACONTROLLER COMPONENT LIST
Listedbelow are allthe componentssuppliedwith theController.
Item Description Qty
1 Controller 1
2 Sensor- Collector 1
3 Sensor-Cylinder Upper 1
4 Sensor-Cylinder Lower 1
5 Spare Fuse -T4A 1
6 CableClips andscrews 4
7 FixingScrews 2
8 Wall Plug 2
FIG. 3.2ACONTROLLER DIMENSIONS
3.2 DIMENSIONS
47 110
11
13
173 130 155
104
==
HANGING
POINT
FIXING
POINT

8
4. REGULATIONS &
STANDARDS
SOLARcomfort hot water heating systems should be installed in
compliance with the following standards and regulations.
Water Supply (WaterFittings) Regulations 1999/ www.wras.co.uk
These regulations (bye-laws in Scotland) ensure a good supply of
wholesome water and that only approved materials, pipes and fittings are
used to convey water.
Theseare statutory documentsand take priority over all otherregulations
and recommendations. The installation of an unvented hot water storage
cylinderis classifiedas a“Controlled Service”and RegulationG3 applies.
To meet the requirements of the Regulations, installation of an unvented
system should be undertaken by a “competent installer”.
All installations of unvented hot water storage systems having a capacity
of more than 15 litres should be notified to the relevant Local Authority by
means of building notice or by the submission of full plans. It is important
to note that it is a criminal offence to install an unvented hot water storage
systemwithoutnotifyingtheLocalAuthority. Theinstallationoftheunvented
cylinder and hot water system must comply with BS 6700 and the HSE
Legionella Code of Practice.
Current guidance notes do not cover the connection of a solar thermal
circuit to an unvented storage vessel (cylinder). However, if guidance is
sought for compliance with current regulations the fundamental principle
is to provide a fail-safe means of shutting off the solar input to the heat
exchangerifthecylindertemperatureshould riseabovethesettemperature
of the cylinder’s energy cut out. (See Note 1).
As with all unvented hot water systems, notification of intention to install
should be given to your local building control.
Option A. A nonself-resettingmechanical shut-offshould be installedon
the solar primary flow to the cylinder. The mechanical shut-off should be
suitable for usewithasolar primarycircuit(i.e.high temperature andglycol
resistant). The mechanical shut-off should be integrated electrically with
thecylinder energycutout/s and ifnecessarythesolar circuittemperature
control, please refer to the solar controller manufacturer for further
information.
Option B. Where the solar controller and hydraulic system demonstrate
that by no lesser means the requirement in Option A is satisfied by other
means;certification by an approvals body is required to demonstrate that
in the event of the stored water going over temperature, the heat input to
the cylinder is isolated by physical means and is non self-resetting.
Thesesystems shouldbeclearlyidentifiedwith referencetotheapprovals
body. (See Note 2).
Note 1 : Whilst most solar cylinders use a coil type heat exchanger other
options such as external plate to plate devices, external annulars or‘tank
in tank’systems may be used but the same control options always apply.
Note 2 : Current approved bodies include the British Board of Agrèment
(BBA),WRc-NSF Limited, or KIWA.
4.1 WATER REGULATIONS
4.2 BUILDING REGULATIONS
4.3 GENERAL GUIDANCE

9
4.4 BRITISH & EUROPEAN
STANDARDS
Connection of thermal solar heating systems
EN 12976: Thermal solar heating systems and their components
(prefabricated systems).
ENV12977:Thermalsolarheatingsystem andtheircomponents(bespoke
systems).
BS5918:Latest version:Solar heating systems for domestic hot water.
Installation and equipment of DHW cylinders
BS5546:2000 Specification forinstallationofhotwater supplies fordomestic
purposes, using gas-fired appliances of rated input not exceeding 70 kW.
BS6700: 1997 Specification for design, installation, testing and
maintenance,of servicing,supplying waterfordomesticusewithinbuildings
and their curtilages.
The local water company by-laws.
Electrical connection
Current IEE wiring regulations.
Health and Safety document No 635 (Electricity atWork Regulations)
The Pressure Equipment Regulations (PED) 1999 - www.eurodyn.com
TheBuildingRegulations(L1A&B)2006andDomesticHeatingCompliance
Guide- www.communities.gov.uk
TheBuilding Regulations(P)2005 -www.communities.gov.uk
Controlof SubstancesHazardous to HealthRegulations (COSHH)1994-
www.hse.gov.uk
Further details available from:www.hse.gov.uk
Health & Safety At Work Act (HSW) 1974
Work at Height Regulations 2005.
Reportingof Injuries,Diseasesand DangerousOccurrences Regulations
(RIDDOR) 1995.
Management Health & Safety at Work Regulations (MHSWR) 1999.
Noise atWork Regulations 1989.
Construction (Health, Safety &Welfare) Regulations (CHSWA) 1996.
Electricity at Work Regulations 1989.
Construction Regulations (Head Protection) 1989.
Control of Substances Hazardous to Health Regulations (COSHH) 1994.
Construction (Design and Management) Regulations (CDM) 1994.
Personal Protective Equipment at Work Regulations 1992.
Lifting Operations and Lifting Equipment Regulations (LOLER) 1998.
Confined Spaces Regulations 1997.
Manual Handling Operations Regulations 1992.
TheWorkplace(Health,SafetyandWelfare) Regulations 1992(WHSWA).
Provision and Use ofWork Equipment Regulations (PUWER) 1998.
Healthand Safety(First Aid)Regulations 1981.
LZC - Low or zero carbon energy sources: strategic guide.
4.5 UK REGULATIONS
PARTICULARLY RELEVANT FOR
WATER HEATING EQUIPMENT
4.6 UK REGULATIONS
PARTICULARLY RELEVANT FOR
CONSTRUCTION