KT-Elektronik SOL3-1 User manual

Solar controller
SOL3-1
Installation and operating
manual
Firmware version 1.0x,
November 2008

Installation and operating manual KT-Elektronik
Warranty
We permanently enhance our products, therefore we reserve the right to make changes
to our products at any time and without prior notice.
We take no responsibility for the accuracy or completeness of this manual. No liability
can be accepted for the use of our products for a buyer specific purpose. Buyer claims,
especially claims for damages including lost profits or other financial losses are
excluded. This does not apply if the damage caused by intent or gross negligence. In
case of negligent violations of major contractual obligations, our liability is limited to the
foreseeable damage
Security advices
Only qualified personnel that is familiar with installation and
commissioning of this product is allowed to mount the device and put it
into operation. Appropriate shipping and storage are assumed.
The product is designated for use in heavy current equipment.
Installation and maintenance have to be performed according to the
corresponding safety regulations.
2EB_37381_SOL3-1_EN 2

SOL3-1
Table of contents
1 Operation ..................................................................................................................... 5
1.1 Controls ................................................................................................................. 5
1.1.1 Control Button and selector switch ................................................................. 5
1.1.2 Rotary switch .................................................................................................. 6
1.2 Operating modes ................................................................................................... 7
1.3 Display ................................................................................................................... 7
1.4 Retrieving data - Information level ......................................................................... 8
1.5 Setting the system time ......................................................................................... 9
1.6 Access advanced information level ..................................................................... 10
1.7 Prescribe temperature set-points ........................................................................ 11
1.8 Operation level stucture ....................................................................................... 12
2 Commissioning ........................................................................................................... 12
2.1 Activate and deactivate functions ........................................................................ 13
2.2 Edit settings ......................................................................................................... 14
2.3 Sensor calibration ................................................................................................ 15
2.4 Reset to Factory default settings ......................................................................... 16
3 Manual operating mode ............................................................................................. 17
4 Solar circuit functions ................................................................................................. 18
4.1 System diagram ................................................................................................... 18
4.1.1 Basic control functions .................................................................................. 18
4.1.2 Limiting the storage temperature .................................................................. 20
4.1.3 Overheating protection .................................................................................. 20
4.1.4 Collector minimum temperature .................................................................... 21
4.1.5 Start up function ............................................................................................ 21
4.1.6 Forced pump operation (anti-locked) ............................................................ 22
4.1.7 Collector Antifreeze ....................................................................................... 22
5 System wide functions ............................................................................................... 23
5.1 Automatic summer/winter switching .................................................................... 23
5.2 Locking manual operating mode ......................................................................... 23
5.3 Locking the rotary switch ..................................................................................... 23
5.4 Enter a valid individual access code .................................................................... 24
6 Malfunction ................................................................................................................. 25
6.1 Error list ............................................................................................................... 25
6.2 Sensor failure ...................................................................................................... 25
6.3 Temperature monitoring ...................................................................................... 26
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Installation and operating manual KT-Elektronik
6.4 Error status register ............................................................................................. 26
6.5 SMS delivery in case of a system failure ............................................................. 27
7 Communication .......................................................................................................... 28
7.1 Communication module KOM232PC ................................................................... 29
7.2 Communication module iCon485 ........................................................................ 29
7.3 Communication module KOM232M ..................................................................... 31
7.4 Data Modem DataMod11 .................................................................................... 32
7.5 ModBus-MBus-Gateway ...................................................................................... 33
7.6 Description of the adjustable communication settings ......................................... 33
7.7 Memory module ................................................................................................... 34
7.8 55Viewer for visualization and remote maintenance. .......................................... 35
7.9 Data Logging ....................................................................................................... 36
8 Mounting .................................................................................................................... 37
9 Electrical connection .................................................................................................. 39
9.1 Wiring diagram .................................................................................................... 40
10 Appendix .................................................................................................................. 41
10.1 Function block lists ............................................................................................ 41
10.2 Parameter lists ................................................................................................... 42
10.3 Resistance values ............................................................................................. 46
10.4 Technical specifications ..................................................................................... 47
10.5 Accessories ....................................................................................................... 48
10.6 Customer data ................................................................................................... 48
10.7 Important abbreviations ..................................................................................... 51
10.8 Access codes .................................................................................................... 51
10.9 Notes ................................................................................................................. 51
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SOL3-1
1 Operation
The controller is factory-provided with standard temperature settings and timing
programs and therefore ready for use.
The current date and time have to be set at initial operation of the controller
(Chapter 1.5).
1.1 Controls
The operational controls are located on the front side of the controller.
1.1.1 Control Button and selector switch
Control button
Turn :
Display, select settings and function blocks
Push :
confirm selection or setting
EB_37381_SOL3-1_EN 2 5

Installation and operating manual KT-Elektronik
1.1.2 Rotary switch
The rotary switch is used to select the operating mode on the left hand and the basic
settings of the controller on the right hand.
Rotary switch – operating mode
Information level, display operating behaviour
of system.
Turning off the control functions
(Controller remains in operation)
Manual operating mode: manual pump control
Rotary switch – Settings
Solar-Turn-on threshold
Solar-Turn-off threshold
Usage schedules1for heating and hot water
Party mode1
System time:
Setting time, date and year
Configuration and settings level
1 not available for SOL3-1
6EB_37381_SOL3-1_EN 2

SOL3-1
1.2 Operating modes
Normal operating mode off
Normal operating mode is always off, only pump blocking protection and equipment anti-
freeze is ensured (if activated).
Manual operating mode
Manual pump operation (chapter 3).
1.3 Display
During operation, the display shows the current time as well as informations about the
status of the controller. Symbols mark the operational status of the controller.
Current time display
Malfunction
Antifreeze
Solar circuit
Manual operating mode
Stand-by OM
Collector pump CP
The controller status can be viewed at operating mode level (Chapter 1.4).
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Installation and operating manual KT-Elektronik
The following applies to the icon of the collector pump:
Symbol Description
Icon off Pump off
Icon flashes briefly Condition to turn on the pump is met but the pump is still off because of the minimum idle
time.
Icon is on but disappears for a
short time in intervals
Condition to turn off the pump is met but the
pump is still running because of the minimum
running time.
Icon on Pump is running
1.4 Retrieving data - Information level
In the standard rotary switch position „Information level“ one can retrieve
informations about time, date, as well as the temperature set-points for the connected
sensors and their current temperature.
Procedure:
Select value.
The screen now displays different items one after the other, depending on the
configuration of the controller.
__:__ Current time
Collector temperature CF
Temperature at storage sensor SF
Display the operating hours of solar circuit
Set-point/threshold and actual value comparison.
When the time is marked in the display, pressing the control button will show
the date.
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Note: Information can also be retrieved in level "manual operating mode". To do so,
select "Info", then confirm and proceed as described.

SOL3-1
1.5 Setting the system time
System time and date have to be set during first start-up and after each loss of power
with a duration of more than 24 hours. This is indicated by a blinking time display.
Procedure:
Turn rotary switch to the position
“system time” (right hand).
Display: shows current time setting
Change the time setting.
Confirm the time set.
Display: shows current year setting
Change the year setting.
Confirm the year set.
Display: show current date setting (day.month)
Change date setting.
Confirm the date set.
Display: shows current time setting
Move the rotary switch back to the "Information
level" position (left hand).
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Installation and operating manual KT-Elektronik
1.6 Access advanced information level
After entering the access code 1999 the following informations are accessible through
the menu items as described in chapter 1.4:
•Binary input switching status
•Info 2 - The following values are sequentially displayed:
Controller-ID
Memory usage, Data logging module (chapter 7.9)
Modbus client address
-
-
Operating hours of solar circuit
Start of solar circuit
Access advanced operation level:
Switch to configuration and settings level.
Display shows 0 0 0 0
Enter access code 1999.
Confirm code. Display shows 0 0 0 0
Move the rotary switch back to the "Information level" position (left
hand).
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Note:
Re-entering the access code 1999 hides the advanced informations.

SOL3-1
1.7 Prescribe temperature set-points
The solar circuit of the controller can be programmed with turn-on and turn-off
thresholds.
The turn-on threshold determines how much the temperature of the collector
(at least) has to be higher than the storage temperature in order to allow to turn on the
pump.
The turn-off threshold determines how much the temperature of the collector
(at least) has to be higher than the storage temperature in order to keep the pump
running once it has been turned on.
Switch position
Setting FS Value range
Turn-on threshold 8 K 1 to 50 K
Switch position
Setting FS Value range
Turn-off threshold 4 K 1 to 50 K
Procedure: Move rotary switch to the position turn-on threshold or turn-off threshold.
Change temperature.
Move the rotary switch back to the "Information level" position (left
hand).
EB_37381_SOL3-1_EN 2 11
Note:
The turn-on threshold must always be higher than the turn-off threshold, otherwise
the pump is never turned on.

Installation and operating manual KT-Elektronik
1.8 Operation level stucture
PA3/CO3: Solar circuit
PA5/ O5: general
PA6/ O6: ommunication
Anl: system variant ID
2 Commissioning
The configuration procedures and parametrization described in this chapter can only be
performed by entering a valid controller access code.
The access code provided by the factory for first time use can be found in the appendix.
To avoid an unauthorized use, it is recommended to cut out or black out the code.
Additionally the standard code can be replaced by an individual one (Chapter 5.4).
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Information level
Figure 1: Level structure

SOL3-1
2.1 Activate and deactivate functions
Each function can be activated within its related function block. The sequence of
numbers shown at the head of the display (0 to 24) represent the function block
numbers. When accessing the configuration level, a black square is displayed right hand
below active function block numbers. The function blocks are described in chapter 12.1.
The functions are grouped by topic:
CO3: Solar circuit
CO5: General
CO6: Modbus-Communication
Procedure: Switch to configuration and settings level.
Display shows 0 0 0 0
Enter a valid access code.
Confirm code.
Display: PA3
Select configuration level.
Access configuration level.
Select function block.
Activated function blocks are marked with "- 1".
Deactivated function blocks are marked with “- 0”.
Switch to edit mode.
F__ flashes
Activate function block.
Display: F__ - 1
An active function block can be identified by a black square that is
displayed right hand below the function block number at the head of the
display.
else:
Deactivate function block.
Display: F__ - 0
Confirm setting.
As long as the function block is not closed, other function block parameters
can be set.
Procedure:
Edit and confirm settings.
Eventually, the next function block parameter is displayed.
Once all settings are confirmed, the function block will be left.
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Installation and operating manual KT-Elektronik
To configure more function blocks, repeat the steps highlighted in grey.
Select End
Leave configuration level.
Select End
Return to Information level .
2.2 Edit settings
Depending on the current system variant ID and active functions, not all parameters
listed in the parameter list in the Appendix will be accessible (–> Chapter ). The functions
are grouped by topic: PA3: Solar circuit
PA5: General
PA6: Modbus-Communication
Procedure: Switch to configuration and settings level.
Display shows 0 0 0 0
Enter a valid access code.
Confirm code.
Display: PA3
Select settings level.
Access settings level.
Select parameter.
Switch to edit mode.
Edit parameter
Confirm parameter.
To set more parameters repeat the steps highlighted in grey.
Select End
Leave settings level.
Select End
Return to Information level .
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SOL3-1
2.3 Sensor calibration
The controller is designed for connection of Pt1000-sensors. The sensor values of
resistance are listed on page 46.
If the temperature values displayed by the controller do not match the real temperatures,
the measured values of the connected sensors can be adjusted. The temperature value
displayed has to be replaced by the value measured directly at the measuring point
(reference value). The adjustment has to be activated in CO5, function block F20. A
wrong adjustment can be deleted by setting - 0 in F20.
Procedure: Switch to configuration and settings level. Display shows 0 0 0 0
Enter a valid access code.
Confirm code. Display: PA3
Select configuration level CO5.
Access configuration level CO5.
Select function block F20.
Switch to edit mode.
Select sensor icon:
Temperature at solar collector CF
Temperature at storage sensor SF
Display measured value. Value flashes.
Correct value.
The current temperature measured with a thermometer directly at the
measuring point has to be entered (reference value).
Confirm adjusted value.
To calibrate other sensors repeat procedure.
Select End
Leave configuration level.
Select End
Return to Information level .
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Installation and operating manual KT-Elektronik
2.4 Reset to Factory default settings
All parameters set by means of the rotary switch as well as the parameters set in level
PA3 and PA5 can be reset to factory default settings,
Procedure: Switch to configuration and settings level.
Enter access code 1991.
Confirm code.
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Note: The error message "Err 2" will be generated while resetting to the factory
default settings. It will be removed automatically shortly after midnight.

SOL3-1
3 Manual operating mode
The manual operating mode allows the configuration of all outputs (Chapter 9).
Manual operating mode is set with the turn switch for the requested circuit:
Procedure: Move rotary switch to position “Manual operating mode”.
Select menu item in compliance with the control circuit:
CP1: Operate the collector pump CP1
Confirm selection. Display flashes.
Change the position, switching state of the pump and other units.
Confirm editing.
The changed values remain as long as the manual operating mode stays
active.
Move the rotary switch back to the "Information level" position (left
hand).
The manual operating mode of the affected control circuit can be
deactivated by selecting any other operating mode.
EB_37381_SOL3-1_EN 2 17
Note:
Just by moving the rotary switch to the position “manual operating mode”,
the outputs of the controller are not affected. Only the specific change of
position respectively switching status will influence them.
In manual operating mode the antifreeze function cannot be guaranteed
(Chapter 4.1.7).

Installation and operating manual KT-Elektronik
4 Solar circuit functions
4.1 System diagram
The solar controller SOL3-1 is used to control solar thermal systems with one collector
array and one storage tank.
4.1.1 Basic control functions
The controller monitors the collector temperature (sensor CF) as well as the storage
temperature (sensor SF) and turns the collector pump (CP) on once enough solar
energy is available to heat up the storage tank.
The temperature chart shows how regulation works under consideration of the
parameters:
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Figure 2: System diagram

SOL3-1
A) The collector temperature exceeds the storage temperature by more than the
turn-on threshold (8 K). The collector pump is turned on.
B) The collector temperature dropped below the turn-off threshold (SF + 4 K). The
collector pump is turned off.
C) The collector temperature exceeds the turn-on threshold again. The pump is
turned on as soon as the minimum idle time elapses.
D) The collector temperature dropped and falls below the turn-off threshold again
(SF + 4 K). The collector pump is turned off.
E) The collector temperature exceeds the storage temperature by more than the
turn-on gap (8 K). The collector pump is turned on.
F) The collector temperature quickly dropped below the turn-off threshold again.
The pump remains running as long as the minimum running time has not
elapsed.
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Figure 3: temperature chart

Installation and operating manual KT-Elektronik
Parameters for the basic function:
Setting FS Parameter level / Value range
Turn-on threshold 8 K Direct input
Turn-off threshold 4 K Direct input
Pump minimum run time 60 s PA3 / 0 to 1800 s
Pump minimum idle time 180 s PA3 / 0 to 1800 s
4.1.2 Limiting the storage temperature
The storage is only charged until the maximum allowed temperature is reached. Using
factory default settings, charging the storage already ends at 60°C. Falling below 58°C
would initiate a new charging cycle. If the water is leaded to extraction points directly,
there is a scalding danger at higher temperatures. If using additional components – such
as mixer taps – and therefore is no risk, higher storage temperatures can and should be
allowed.
Setting FS Parameter level / Value range
Maximum storage temperature
(turn-off condition) 60 °C PA3 / 50°to 160 °C
Maximum storage temperature
(turn-on condition) 58 °C PA3 / 50°to 160 °C
4.1.3 Overheating protection
If the collector temperature exceed this maximum value (default factory setting 130°C), it
is assumed that steam is already in the system, and therefore no circulation takes place
any more. The collector pump is turned off in this case until the temperature dropped to
a lower value (default factory setting 110°C).
Setting FS Parameter level / Value range
Maximum collector temperature
(turn-off condition) 130 °C PA3 / 90°to 160 °C
Maximum collector temperature
(turn-on condition) 110 °C PA3 / 90°to 160 °C
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