FRO­NIUS Ohmpilot User manual

Fronius Ohmpilot Operating Instructions
/ Battery Charging Systems / Welding Technology / Solar Electronics
Accessories
EN
FIND YOUR
OPERATING MANUALS
www.fronius.com/ohmpilot-manuals
FIND YOUR
OPERATING MANUALS
42,0410,2141,EN 001-14062017

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EN
Dear Reader,
We would like to thank you for the trust you have placed in us and congratulate you on
purchasing this high-quality Fronius product. These instructions will help you to familiar-
ise yourself with the product. By reading the instructions carefully, you will learn about
the diverse possibilities offered by your Fronius product. Only by doing so will you be
able to make the best possible use of its benets.
Please also observe the safety rules and thereby ensure a higher level of safety at the
location where the product is being used. Careful handling of your product will support its
quality and reliability over its long service life. These are key prerequisites for outstand-
ing results.
NOTE! Indicates a risk of awed results and possible damage to the equip-
ment.
IMPORTANT! Indicates usage tips and other particularly useful information. It is not a
signal word for a harmful or dangerous situation.
If you see any of the symbols depicted in the "Safety Rules" section, special care is
required.
Introduction
Explanation of
Safety Symbols DANGER! Indicates an imminent danger. If not avoided, death or serious
injury will result.
WARNING! Indicates a possibly dangerous situation. If not avoided, death or
serious injury may result.
CAUTION! Indicates a possibly harmful situation. If not avoided, minor injury
and/or damage to property may result.

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EN
Contents
Safety Rules .................................................................................................................................................... 7
General Remarks ........................................................................................................................................ 7
Environmental Conditions ........................................................................................................................... 7
Choice of Location....................................................................................................................................... 8
Explanation of Symbols - Installation Position............................................................................................. 9
Choice of Location - General Remarks ..................................................................................................... 10
Qualied Personnel................................................................................................................................... 11
EMC Measures.......................................................................................................................................... 11
Final Disposal............................................................................................................................................ 11
Data Back-Up............................................................................................................................................ 11
Copyright................................................................................................................................................... 11
General Remarks ........................................................................................................................................... 12
Utilisation in Accordance with "Intended Purpose".................................................................................... 12
Warning Notices on the Device ................................................................................................................ 14
Wall Mounting................................................................................................................................................. 15
Safety ........................................................................................................................................................ 15
Selecting Wall Plugs and Screws.............................................................................................................. 15
Recommended Screws ............................................................................................................................. 15
Installation Instructions.............................................................................................................................. 15
Fronius Smart Meter....................................................................................................................................... 16
Integrating the Fronius Smart Meter.......................................................................................................... 16
Indications/Controls on the Device................................................................................................................. 17
Selection of Heater......................................................................................................................................... 18
1-Phase Heater ......................................................................................................................................... 18
3-Phase Heater ......................................................................................................................................... 18
Example for Calculation of Charging Time................................................................................................ 18
Wiring Diagram............................................................................................................................................... 19
Stripping Lengths ...................................................................................................................................... 20
Electrical Connection................................................................................................................................. 20
Opening the Ohmpilot ............................................................................................................................... 20
Application Example 1: 1-Phase Heating Element up to 3 kW....................................................................... 21
Application Example 2: 3-Phase Heating Element 900 W up to 9 kW ........................................................... 23
Application Example 3: 1-Phase Heating Element up to 3 kW with Heat Pump Control................................ 25
Application Example 4: 1-Phase Heating Element up to 3 kW and External Source (e.g. gas-red heating) 28
Application Example 5: Two Heating Elements - 3-Phase and 1-Phase........................................................ 31
Application Example 6: Two 3-Phase Heating Elements up to 9 kW ............................................................. 34
Establishing the Data Connection .................................................................................................................. 37
Possible Communication Channels........................................................................................................... 37
Establishing a Connection via Modbus RTU............................................................................................. 38
Establishing a Connection via LAN ........................................................................................................... 39
Establishing a Connection via WLAN........................................................................................................ 40
Status Indication on Web Interface ................................................................................................................ 42
Optional Settings ............................................................................................................................................ 43
Manual Setting HEATER 1 ........................................................................................................................ 43
Activating Legionella Prevention ............................................................................................................... 43
Adapting the Day Curve ............................................................................................................................ 44
Temperature Limitation.............................................................................................................................. 44
Error List......................................................................................................................................................... 45
Technical Data................................................................................................................................................ 30
Input Data.................................................................................................................................................. 47
Interfaces................................................................................................................................................... 47
Output Data............................................................................................................................................... 47
General Data............................................................................................................................................. 47
Warranty Terms and Conditions, Disposal ..................................................................................................... 48
Fronius Manufacturer's Warranty .............................................................................................................. 48
Final Disposal............................................................................................................................................ 48
Applicable Standards and Guidelines ....................................................................................................... 48
Fronius Worldwide

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EN
The device has been manufactured in accordance with the state of the art
and the recognised safety rules. However, incorrect operation or misuse may
result in:
- Injury or death to the operator or third parties
- Damage to the device and other property of the operator
- Inefcient operation of the device
All persons involved in commissioning, maintaining and servicing the device
must:
- Be suitably qualied
- Have knowledge of and experience in dealing with electrical installations
- Read and follow these operating instructions carefully
The operating instructions must be kept at the location where the device is
being used at all times. In addition to the operating instructions, the generally
applicable and local regulations on accident prevention and environmental
protection must be observed.
All safety and danger notices on the device:
- Must be in a legible state
- Must not be damaged
- Must not be removed
- Must not be covered, pasted or painted over
The heatsink can reach high temperatures.
Only operate the device when all protection devices are fully functional. If the
protection devices are not fully functional, this may result in:
- Injury or death to the operator or third parties
- Damage to the device and other property of the operator
- Inefcient operation of the device
Any safety devices that are not functioning properly must be repaired by a
suitably qualied technician before the device is switched on.
Never bypass or disable protection devices.
For the location of the safety and danger notices on the device, refer to the
"General Remarks" section in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise
safety.
This is for your personal safety!
Operating or storing the device outside the specied area is regarded as not
complying with the intended purpose. The manufacturer shall not be liable for
any damage or loss resulting from this.
For exact information on permitted environmental conditions, please refer to
the "Technical Data" in the operating instructions.
Environmental
Conditions
Safety Rules
General Remarks

8
Choice of
Location
The Ohmpilot is suitable for installation indoors.
Do not install the Ohmpilot outdoors.
The Ohmpilot corresponds to protection class IP 54 and is protected
against spray water from all sides.
In order to keep warming of the Ohmpilot to a minimum, do not expose
it to direct sunlight. Install the Ohmpilot in a protected position. The
Ohmpilot must only be installed and operated at an ambient tempera-
ture of 0-40°C.
IMPORTANT!The Ohmpilot must not be installed or used at altitudes
above 2000 m.
Do not install the Ohmpilot in:
- Areas where ammonia, corrosive vapours, acids or salts are present
(e.g. fertiliser stores, ventilation openings from cattle sheds, chemical
plants, tanneries, etc.)
Do not install the Ohmpilot in:
- Places where there is an increased risk of damage from farm ani-
mals (horses, cattle, sheep, pigs, etc.)
- Stables or adjoining areas
- Storage areas for hay, straw, chaff, animal feed, fertilisers, etc.
In principle, the Ohmpilot is designed to be dust-tight. However, in areas
with high dust accumulation, the cooling surfaces may collect dust
and this may impair the thermal performance. In such cases, regular
cleaning is required. Consequently, we do not recommend installing the
Ohmpilot in places and environments with strong dust formation.
Do not install the Ohmpilot in:
- Greenhouses
- Storage or processing areas for fruit, vegetables or winegrowing
products
- Places used to prepare grain, green fodder or animal feeds

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EN
Explanation of
Symbols -
Installation
Position
The Ohmpilot is designed to be installed vertically on a vertical wall.
Do not install the Ohmpilot horizontally.
Do not install the Ohmpilot on a sloping surface.
Do not install the Ohmpilot on a sloping surface with its connection
sockets facing upwards.
Do not install the Ohmpilot at an angle on a vertical wall.
Do not install the Ohmpilot horizontally on a vertical wall.
Do not install the Ohmpilot such its connection sockets are facing
upwards.

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Do not install the Ohmpilot such that it overhangs with its connection
sockets facing upwards.
Do not install the Ohmpilot such that it overhangs with its connection
sockets facing downwards.
The following criteria should be taken into account when choosing a location for the
Ohmpilot:
Install only on a solid surface.
If the Ohmpilot is installed in an enclosed space, then forced-air ventilation must be pro-
vided to ensure adequate heat dissipation.
IMPORTANT! The maximum cable length from the output of the Ohmpilot to the load
(heating element) must not exceed 5 m.
Max. ambient temperatures:
0 °C / +40 °C
Relative humidity:
0 - 99%
The direction of air ow within the
Ohmpilot is from the bottom to the top
Do not install the Ohmpilot on the ceiling.
Choice of
Location -
General Remarks

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EN
The information on servicing contained in these operating instructions is
only intended for qualied personnel. An electric shock can be fatal. Do not
carry out any activities other than those listed in the documentation. This also
applies even if you are qualied to do so.
All cables and leads must be secure, undamaged, insulated and adequately
dimensioned. Arrange for loose connections, burnt, damaged or undersized
cables and leads to be repaired by an authorised specialist company imme-
diately.
Maintenance and repair work must only be carried out by an authorised spe-
cialist company.
With parts sourced from third parties, it is not guaranteed that they have
been constructed and manufactured in accordance with the specications
and so as to comply with the safety requirements. Only use original spare
parts (also applies to standard parts).
Do not carry out any modications, alterations, etc. to the device without the
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
In certain cases, even though a device complies with the standard limit val-
ues for emissions, it may affect the application area for which it was designed
(e.g. when there is sensitive equipment at the same location, or if the site
where the device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to
rectify the situation.
In accordance with European Directive 2002/96/EC on waste electrical and
electronic equipment and its implementation in national law, used electrical
devices must be collected separately and recycled in an environmentally
responsible manner. Ensure that you return your used device to your dealer
or obtain information regarding a local, authorised collection and disposal
system. Failure to comply with this EU Directive may result in a negative
impact on the environment and your health!
The user is responsible for the data back-up of any changes made from the
factory settings. The manufacturer shall not be liable in the event that per-
sonal settings are deleted.
Copyright of these operating instructions remains with the manufacturer.
Text and images correspond to the technical level at the time of going to
press. We reserve the right to make changes. The content of the operating
instructions shall not give rise to any claims on the part of the purchaser. We
are grateful for any suggestions for improvement and notices of errors in the
operating instructions.
Qualied
Personnel
EMC Measures
Disposal
Data Back-Up
Copyright

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With its "24 hours of sun" vision, Fronius is aiming to offer its customers solutions for
generating, storing, distributing and using energy in an intelligent and cost efcient man-
ner. The use of surplus energy for hot water preparation constitutes a simple option, with
low investment costs, for storing electricity in the form of heat and using it at a time of the
customer’s choosing.
The Fronius Ohmpilot, which carries out precisely this task, is therefore an ideal addition
to the Fronius product portfolio in the area of energy management and a further step
towards "24 hours of sun".
The solution as a whole consists of the following components:
• Fronius Symo / Galvo / Eco or Primo inverter (from Fronius Datamanager 2.0
software version 3.8.1-x onwards)
• Fronius Smart Meter
• Fronius Ohmpilot
• Resistive loads (e.g. boiler with heating element)
NOTE! With the Fronius Datamanager Box 2.0, it is also possible to use any
other generation source (CHP unit, non-Fronius inverter, etc.). However, as the
gures for power produced and consumption are not available for these
options, they cannot be displayed in Solarweb.
The Ohmpilot is a separate device that can control the surplus power from the photovol-
taic system in a continuously variable manner, using pulse width modulation, for a phase
between 0 and 100% (or 0 and 3 kW). Moreover, the Ohmpilot has two additional outputs
for switching further phases. As a result, heating elements with an output of between 300
W and 9 kW can be controlled in a continuously variable manner:
A heating element with up to 3 kW output can be controlled in a continuously variable
manner using one phase.
In the case of a heating element with 9 kW output, the surplus power of 0 - 3 kW is
controlled in a continuously variable manner in phase 1. If more power is available, the
Ohmpilot activates phase 2 in addition and phase 1 can again control the surplus in a
continuously variable manner between 3 - 6 kW. If the available power is greater than 6
kW, the Ohmpilot adds phase 3 and phase 1 again controls the surplus between 6 and 9
kW in a continuously variable manner.
General Remarks
Proper Use /
Intended Purpose

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EN
Other resistive loads such as infrared heaters, towel dryers, etc. can also be controlled.
IMPORTANT! In hard water areas, calcication of the heating element may occur, par-
ticularly if the target temperatures are set to over 60 °C. We recommend a yearly inspec-
tion. To execute this, dismantle the heating element from the storage tank and remove
the limescale. Do not scratch the surface of the heating element (formation of corrosion).
Power range
0 - 3 kW
3 - 6 kW
6 - 9 kW
Phase 1
0 - 3 kW contin-
uously variable
Phase 2
-
3 kW xed
3 kW xed
Phase 3
-
-
3 kW xed
WARNING! No electronic thermostats may be used in the loads. The use of
electronic thermostats will lead to destruction of the Ohmpilot and/or the load.
Mechanical temperature switches must be used.
WARNING! Only purely resistive loads may be connected. Connecting an
incorrect load (e.g. fan heater) will lead to destruction of the load.
0 - 3 kW contin-
uously variable
0 - 3 kW contin-
uously variable

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Warning notices and safety symbols are located on the left-hand side of the Ohmpilot.
These warning notices and safety symbols must not be removed or painted over. The
notices and symbols warn of incorrect operation that could result in serious injury and
damage to property.
Risk of serious injury and property damage from
incorrect operation
Dangerous electrical voltage
Wait for the capacitors to discharge.
Hot surface
Do not use the functions described here until you have fully read and under-
stood the following documents:
- These operating instructions
- All the operating instructions for the system components of the photo-
voltaic system, especially the safety rules
Warning Notices
on the Device
Safety symbols:
Text on the warning notices:
WARNING!
An electric shock can be fatal. Before opening the device, ensure that the input and out-
put sides are de-energised. Wait for the capacitors to discharge (15 seconds).
WARNING!
The device must not be covered and nothing may be hung over the device or the cables.

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EN
Wall Mounting
NOTE! The IP 54 protection class only applies if the cover is rmly screwed to
the back.
IMPORTANT! Depending on the surface, different types of xings are required for
mounting the Ohmpilot. The xings are therefore not included in the scope of supply for
the Ohmpilot. The tter is personally responsible for selecting the correct xings. The
Ohmpilot must be mounted with four screws. Ensure that the screws are tight and that
the wall is stable. .
To install the Ohmpilot, the manufacturer recommends the use of steel screws with a
diameter of 4 - 6 mm.
Safety
Selecting Wall
Plugs and
Screws
Recommended
Screws
Installation
Instructions
CAUTION! Risk of damage to the Ohmpilot due to dirt or water on the termi-
nals and in the electronics. When drilling, ensure that the terminals and elec-
tronics do not become dirty or wet.
1 2
3 4
max. 3Nm

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How to connect the Fronius Smart Meter to the Fronius Datamanager 2.0:
Fronius Smart Meter
A Fronius Smart Meter is required for operation of the Ohmpilot, so that the surplus
energy can be measured. For integration of the Fronius Smart Meter, an inverter with
Datamanager 2.0 and software version V3.8.1-x or higher and/or a Datamanager Box
(from software version 3.8.1-x) is necessary. It must be congured on the Datamanager
whether the Fronius Smart Meter is installed at the feed-in point or in the consumption
branch. The setting must be implemented on the webpage under the "Meter" tab for the
Datamanager.
Further information on the Datamanager can be found in the "Fronius Datamanager 2.0"
Operating Instructions
(1a) Meter position at feed-in point
The power and energy fed in are measured. Consumption is determined based on
these values and the system data.
(1b) Meter position in consumption branch
The power and energy consumed are measured directly. The power and energy
fed in are determined based on these values and the system data.
Integrating the
Fronius Smart
Meter
(1a)
(1a)
(1b)
(1)
(1b)
Fronius Smart Meter
INPUT
L1
L2
L3
N
OUTPUT
RS 485 DT/PE
Rx / x GND
1A B C D 3 4 6 7 9 11
LOAD
XXX
X
X
X
+T
-
Fronius
Datamanager
2.0
120 Ω
ON
- D+ D-

17
EN
Indications/Controls on the Device
1x WPS
2x ACCESS POINT
3x BOOST
WPS (Wi-Fi Protected Setup) is opened
for 2 minutes or until successful pairing
with the router. By pressing the WPS
button the router, the WLAN password is
transmitted to the Ohmpilot.
WLAN access point is activated for 30
minutes so that settings can be implement-
ed on the Ohmpilot via the Fronius Solar
web app.
Boost mode - dimmer level is activated for
4 hours at 100%, L2 and L3 are switched
through. This may result in electricity being
sourced from the grid.
Ohmpilot is returned to standard operating
mode, boost mode, access point or WPS
are deactivated.
No power supply to the
Ohmpilot
The faster the ashing frequency, the
greater the heat output. At 0 W heat output
the LED ashes slowly, at full output it
ashes quickly.
The output from the heating element is
measured and it is detected whether a
1-phase or 3-phase heating element is
connected.
Target temperature undercut or legionella
prevention system active (full heat output).
No connection
WPS (Wi-Fi Protected Setup) open
WLAN access point open
Connection with network
No error
No connection to the inverter
Temperature measurement faulty
Heating element faulty
Ohmpilot faulty
Target temperature not reached
Press 1x
Press 2x
Press 3x
Press
again
Unlit
Flashing green
Flashing green 2x
Steady green
Heater indication
Green LED
Unlit
Flashing blue 1x
Flashing blue 2x
Steady blue
Connection indica-
tion LAN / WLAN
Blue LED
Unlit
Flashing red 1x
Flashing red 2x
Flashing red 3x
Flashing red 4x
Flashing red 5x
Error indication
Red LED
A detailed description of the error is provided in Solar Web.

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Selection of Heater
- 0.3 to 3 kW
- Purely resistive load (no electronic temperature limiters, fans, etc.)
- 0.9 to 9 kW
- Equal load distribution on all 3 phases (e.g. 3 x 3 kW)
- If a mechanical temperature switch is being used, it must switch all 3 phases
simultaneously.
- Purely resistive load (no electronic temperature limiters, fans, etc.)
- Neutral conductor must be implemented (this can generally also be retrotted)
NOTE! A mechanical temperature switch simplies commissioning and use. If
no mechanical temperature switch is available, a temperature sensor can also
be connected to the Ohmpilot in order to limit the maximum temperature. (See
"Temperature limitation")
500-litre boiler, heater can be tted at the very bottom of the boiler, temperature spread
45 - 60 °C = 15 °C; 4.5 kW heater
Possible stored energy = 0.5 m³ x 1.16 kWh x 15 °C = 8.7 kWh
If the heater is fully activated, heating up takes approximately 2 hours (8.7 kWh / 4.5 kW)
NOTE! So that optimal use can be made of the surplus power and the hot wa-
ter is reheated quickly, the heater output should be adapted to the output of the
photovoltaic system, e.g. 5 kWp => 4.5 kW heater.
1-Phase
Heater:
3-Phase
Heater:
Example for
Calculation of
Charging Time:

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EN
Wiring Diagram
NC W NO OUT N
L1 L2 L2L3 N N L3 N
LAN
RS485
PT1000
D+ D- -
R2 R3
G B R
1 2 3
4
5 7
8910 11 12
6
7
1Green LED
Connection terminal for PT1000
Temperature sensor
Spring balancer 0.2 - 1.5 mm2
8
2Blue LED
INPUT - grid supply 1x 230 V or 3x 230 V
Spring balancer 1.5 - 1.5 mm2
3Red LED
4Button
5Ethernet RJ45, at least CAT5,
screened
6Modbus RTU (default address 40)
Spring balancer 0.2 - 1.5 mm2
max. 1000 m, screened and twisted
9OUTPUT - L2 heating element
Spring balancer 1.5 - 2.5 mm2
10 OUTPUT - L3 heating element
Spring balancer 1.5 - 2.5 mm2
11 Multifunctional relay output
(see application examples)
variable max. 13 A resistive load
Spring balancer 1.5 - 2.5 mm2
WARNING! If signal cables are connected,
the individual wires must be bound togeth-
er with a cable tie directly upstream of the
terminal. This prevents any wire making
contact with dangerous voltages if it works
loose.
12 OUTPUT - heating element continuously
adjustable up to 3 kW
NOTE! Phase and neutral conductors
must not be mixed up. Residual cur-
rent-operated circuit breaker is triggered.

20
Stripping length of terminals on power
stage set (L1, L2, etc.)
10 mm
8 mm
Stripping length of terminals on control
board (D+, D-, - and PT1000)
Stripping
Lengths
Electrical
Connection
Opening the
Ohmpilot
IMPORTANT! Electrical connection work may only be carried out by a specialist.
IMPORTANT! The ground conductor connection must be perfectly installed and reliably
connected.
IMPORTANT! The Ohmpilot must be equipped with an overvoltage protection device of
maximum B16 A and a residual-current circuit breaker on the grid side.
IMPORTANT! On the output side, it must be ensured that only purely resistive loads are
connected.
IMPORTANT! The maximum cable length from the output of the Ohmpilot to the load
(heating element) must not exceed 5 m on EMC grounds.
IMPORTANT! The Ohmpilot must be protected against overvoltage from the grid.
IMPORTANT! When connecting a heating element, check the grounding of the boiler/
buffer and/or the heating system and, when setting the temperature on the heating ele-
ment, observe the maximum permitted inlet water and hot water temperature.
IMPORTANT! The RS485 conductor should be designed as a data cable in order to
prevent any mix-up with the grid conductor when connecting.
WARNING! An electric shock can be fatal. Danger from residual voltage in
capacitors. Wait for the capacitors to discharge. The discharge time is 15
seconds.
WARNING! An inadequate ground conductor connection can cause serious
injury or property damage.
WARNING! Risk of burns from the heatsink when open.