KT-Elektronik SOL3-7 User manual

Solar controller
SOL3-7
Installation and operating
manual
Firmware version 1.07
June 2011

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 and put into operation
the device. 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.
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Table of contents
1 Operation .......................................................................................................................... 6
1.1 Controls ...................................................................................................................... 6
1.1.1 Rotary switch ....................................................................................................... 7
1.1.2 Rotary pushbutton .............................................................................................. 7
1.2 Operating .................................................................................................................. 8
1.3 Display ...................................................................................................................... 8
1.3.1 System scheme ................................................................................................... 9
1.3.2 Operating Mode ................................................................................................ 10
1.4 Retrieving data – Information level .......................................................................... 11
1.5 Setting the system time ............................................................................................ 12
1.6 Adjust usage schedule settings ............................................................................... 13
1.7 Setting the party mode (heating circuit/auxiliary heating) ........................................ 15
1.8 Setting holidays ........................................................................................................ 16
1.9 Setting vacation times .............................................................................................. 17
1.10 Access advanced information level ........................................................................ 18
1.11 Trend show – Data logging .................................................................................... 20
2 Commissioning ............................................................................................................... 22
2.1 Set language ........................................................................................................... 22
2.2 Setting the system variant ID ................................................................................... 23
2.3 Activate and deactivate functions ............................................................................ 24
2.4 Edit settings ............................................................................................................. 26
2.5 Sensor calibration .................................................................................................... 28
2.6 Reset to factory default settings ............................................................................... 29
3 Manual operating mode .................................................................................................. 30
4 System variants .............................................................................................................. 31
4.1 Extending the basic system variant representations ................................................ 40
5 Solar circuit functions ..................................................................................................... 43
5.1 Basic Control function .............................................................................................. 43
5.2 Storage .................................................................................................................... 45
5.3 Swimming pool ......................................................................................................... 46
5.4 Collector return flow sensor, Collector flow sensor .................................................. 47
5.5 Measurement of solar power and solar energy ........................................................ 48
5.6 Rotation speed control ............................................................................................. 49
5.7 Collector overheating protection .............................................................................. 50
5.8 Collector minimum temperature ............................................................................... 51
5.9 Start up function ....................................................................................................... 51
5.10 Forced pump operation (blocking protection) ........................................................ 51
5.11 Collector Antifreeze ................................................................................................ 52
5.12 Two collector arrays ............................................................................................... 52
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5.13 External heat exchanger ........................................................................................ 53
5.14 Auxiliary heating with secondary heat generator ................................................... 53
6 Heating circuit functions ................................................................................................. 55
6.1 Prescribing the room temperature set-points ........................................................... 55
6.2 Weather-compensated control ................................................................................. 55
6.2.1 Gradient characteristic ..................................................................................... 55
6.2.2 4-point characteristic ......................................................................................... 57
6.3 3-point control .......................................................................................................... 59
6.4 Two-point control ..................................................................................................... 59
6.5 Underfloor heating/screed drying ............................................................................. 60
6.6 Deactivation depending on the outdoor temperature ............................................... 61
6.6.1 OT deactivation temperature for daytime operating mode ................................ 61
6.6.2 OT deactivation temperature for night-time operating mode ............................. 61
6.6.3 OT activation temperature for daytime operating mode .................................... 61
6.6.4 Summer operating mode (OM) .......................................................................... 62
6.7 Delayed outside temperature compensation ........................................................... 62
6.8 Remote operation .................................................................................................... 63
6.9 Optimization ............................................................................................................. 63
6.10 Raise return flow of external heating system ........................................................ 64
6.10.1 Main principle .................................................................................................. 64
6.10.2 Implementation ................................................................................................ 65
7 Domestic water circuit functions ..................................................................................... 66
7.1 Domestic water heating in storage tank ................................................................... 66
7.2 Thermal Disinfection of the storage tank ................................................................. 66
8 System wide functions - all system variants ................................................................... 67
8.1 Automatic summer/winter switching ......................................................................... 67
8.2 Antifreeze ................................................................................................................. 67
8.3 Locking manual operating mode .............................................................................. 68
8.4 Locking the rotary switch ......................................................................................... 68
8.5 Enter a valid individual access code ........................................................................ 68
8.6 Temperature difference controller ............................................................................ 69
9 Malfunction ..................................................................................................................... 70
9.1 Error list .................................................................................................................... 70
9.2 Sensor failure ........................................................................................................... 70
9.3 Temperature monitoring ........................................................................................... 71
9.4 Error status register ................................................................................................. 71
9.5 SMS delivery in case of a system failure ................................................................. 72
10 Communication ............................................................................................................ 73
10.1 Communication module KOM232PC .................................................................... 74
10.2 Communication module iCon485 .......................................................................... 74
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10.3 Communication module KOM232M ...................................................................... 76
10.4 Data Modem DataMod11 ...................................................................................... 77
10.5 ModBus-MBus-Gateway ....................................................................................... 78
10.6 USB communication cable USB-L3 ...................................................................... 79
10.7 Modbus-TCP-Gateway ......................................................................................... 80
10.8 Description of the adjustable communication settings .......................................... 80
10.9 Memory module .................................................................................................... 81
10.10 55Viewer for visualization and remote maintenance. ......................................... 82
10.11 Data Logging ....................................................................................................... 83
11 Mounting ....................................................................................................................... 84
12 Electrical connection ..................................................................................................... 86
12.1 Notes for wire installation ....................................................................................... 86
12.2 Surge Protection Measures ................................................................................... 86
12.3 Connecting the controller ....................................................................................... 86
12.3.1 Connecting the sensors ................................................................................... 87
12.3.2 Connecting the pumps .................................................................................... 87
12.3.3 Legend for connection diagram ....................................................................... 87
12.3.4 Wiring diagram ................................................................................................ 88
12.3.5 Terminal assignment for Outputs .................................................................... 89
12.3.6 Terminal assignment for inputs ....................................................................... 92
13 Appendix ....................................................................................................................... 93
13.1 Function block lists ................................................................................................. 93
13.2 Parameter list ......................................................................................................... 97
13.3 Resistance values ................................................................................................ 100
13.4 Technical specifications ....................................................................................... 101
13.5 Accessories .......................................................................................................... 102
13.6 Function block settings in configuration levels ..................................................... 103
13.7 Einstellungen in den Parameterebenen .............................................................. 104
13.8 Abbreviations ....................................................................................................... 106
13.9 Access codes ....................................................................................................... 107
13.10 Notes .................................................................................................................. 108
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Installation and operating manual KT-Elektronik
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.
The user is guided by means of rotary switches and pressing the control button described
below control levels.
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Bedienknopf
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KT-Elektronik SOL3-7
1.1.1 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
Control on, display informations about
operating behaviour of unit (standard position)
Turning off the control functions
(Controller remains in operation)
Manual operating mode:
manual switching of pumps and valves,
position presetting in percent
Rotary switch – Settings
Solar-Turn-on threshold
Solar-Turn-off threshold
Scheduled time ranges and operating modes for
heating circuit (1), aux. heating (2) and hot water
circulation (3)
Party mode
System time:
Setting time, date and year
Configuration and settings level
1.1.2 Rotary pushbutton
The rotary pushbutton is an integral part of the intuitive operating concept, with only one
button.
Turn :
Display, select settings and function blocks
Push :
confirm selection or setting
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Installation and operating manual KT-Elektronik
1.2 Operating
The operation of the device SOL3-7follows a continuous uniform display and operating
philosophy.
Values and display texts are shown in black characters with no background. Elements for
direct input or selection are shown with white characters on black background. Choice
elements in rows oriented menus are shown with black characters on a gray background.
With the help of the rotary switch, a control level is set. The rotary pushbutton is used to
select and adjust.
1.3 Display
The contro er SOL3-7 it equipped with a graphica disp ay. The disp ay a ows it to
visua ize the current system scheme with a re evant sensor informations as we as state
informations of pumps and va ves for a quick overview of the operating condition of the
system.
Example of display in the information level:
For the use of the device the user is facilitated in operating levels for display and input of
operating parameters with clear text menus and explanatory texts.
Example of display in the setting level:
Example of display for checking and modifying of times-of-use (weekly schedule):
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1.3.1 System scheme
With the on the display shown system scheme, the relevant sensor information, the
operating mode of the control circuits and state information of pumps and valves for a
quick overview of the operating condition can be visualized.
Among the symbols used in the system scheme are the following:
Element Symbol Meaning
Pump Pump is in operation
Pump is not in operation
Switching
valve Switching valve is showen with filled triangles
Valve
Valve is not in operation
Valve 'CLOSE' is in operation
Valve 'OPEN' is in operation
Auxilary
heating
Auxilary heating is not in operation
Auxilary heating is in operation
Collector
pump
A temporarily shown sun above a collector represents an
operating state indication of the pump belonging to the
collector.
Condition for the activation of the pump is not met and the
pump is not operating.
Condition for the activation of the pump is met and the pump
is operating.
The condition for switching off the pump is met, but pump is
due to the minimum ON time still in operation.
Condition for switching on the pump is met, but pump is due
to the minimum OFF time yet in operation.
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Installation and operating manual KT-Elektronik
1.3.2 Operating Mode
The operation of the heating circuit, hot water circulation and auxilary heating can be
affected depending on time and day of week. There are two different set-points for night
and day exist. A usage schedule determines when to operate in day-time operating mode
or night-time operating mode. It is possible to deactivate schedules (without deleting them)
and to specify manually to operate permanently in day-time or night-time operating mode.
Icons on the display indicate the current operating mode for each function of the controller:
Daytime operating mode (nominal operation)
Values are permanently adjusted to meet the set-points entered for nominal operating
mode regardless of scheduled time ranges or summer operating mode settings.
Night-time operating mode (reduced operation)
Values are permanently adjusted to meet the set-points entered for reduced operation
regardless of scheduled time ranges.
Normal operating mode off
Normal operating mode is deactivated regardless of the scheduled time ranges. Only
equipment anti-freeze is ensured (if activated).
Automatic operating mode
The controller automatically switches between both modes depending on the time.
Manual operating mode
Manual control of valves and pumps (Chapter 3).
The operating modes of heating circuit, hot water
circulation and auxilary heating are in the system scheme,
context-sensitive arranged and allow capture at a glance
the current function of the system part.
Operating mode Symbol Symbol Time phase
Standby Nominal operation
(Day mode)
Automatic mode Reduced operation
(Night mode)
Manual mode
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1.4 Retrieving data – Information level
At the norma rotary switch position ,„Information eve “, the system scheme, time, date
as we as re evant temperatures measured by the connected sensors and state
informations of pumps and va ves of the se ected hydrau c schema.
By turning and pushing the rotary pushbutton it is possib e to show time, date, temperature,
and query the va ues of connected sensors and their setpoints.
Procedure:
Se ect va ue:
In the disp ay appears, depending on system configuration, successive y the
different data points, which are described by an acronym:
Samp e disp ays Meaning
So: 14:57 Time
AF: -5.3°C Outdoor temperature AF
RF: 20.4°C Room temperature RF
VF: 34.1°C Temperature at f ow sensor of heating circuit VF
SF1: 52.9°C Temperature at storage tank sensorr SF1
CF1: 27.3°C Temperature at co ector sensor CF1
co 12 h Operating hours of so ar circiut
trend show Graphica presentation of ogged system data
Setpoint or imit va ue compared to the disp ayed va ue.
Pushing the rotary pushbutton in the c ock disp ay shows the date and year.
Additional values can be displayed in the optional, advanced level of information (Kapitel
1.10).
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Installation and operating manual KT-Elektronik
1.5 Setting the system time
The current time and date must be set immediate y after the commision and after a power
fai ure of more than 24 hours. In this case, the system time on the c ock 01/01/2000 10:00
preset and is disp ayed inverted (white on b ack) .
Procedure:
Set rotary switch to time
Disp ay: System scheme and time(inverted)
Edit time
Confirm time
Disp ay: System scheme and year (inverted)
Edit year
Confirm year Jahreszah übernehmen.
Disp ay: System scheme and year (inverted)
Format: day.month
Edite date
Confirm date
Disp ay: System scheme and time (inverted)
Set rotary switch to Information eve
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1.6 Adjust usage schedule settings
There are three separate usage schedules for
•Heating circuit
•Auxiliary heating
•Domestic water circulation
For systems that do not contain the functional groups mentioned, this chapter has no
meaning, the display and input of times-of-use is not offered by the SOL3-7.
The following applies to each usage schedule:
For each day of the week, three time ranges can be programmed. If only one time range is
needed, the start and end time of the second range have to be set to the same value. The
third range will then not be shown any more.
A usage schedule is presented as a weekly schedule. For each day there is shown every
interval (time-to-use) for nominal operation (day) by a gray bar chart. A black bar indicates
a time in addition to the party program set-operation (chapter 1.7).
To check the set times of use should the group of days (Monday to Sunday, Monday to
Friday, Saturday and Sunday) are not used. If this menu, even after adjustment of
schedule settings opened, the times-of-use of Monday will transfered to all other days of
week.
Factory defaults
Times Mo Tue Wed Thu Fr Sa Su
Heating circuit 06:00 – 22:00
Auxiliary heating - - : - - – - - : - -
Domestic water circulation 00:00 – 24:00
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Installation and operating manual KT-Elektronik
Procedure:
Set rotary switch to times-of-use
Times-of-use for heating circiut is graphica y
shown, name of times-of-use is disp ayed
inverted.
Se ect times-of-use to view
•heating circuit
•hot water circu ation
•auxi ary heating
Confirm times-of-use to modify
Disp ay:
Se ection 'Monday to Sunday' (inverted)
Select day of week (inverted):
•Monday to Sunday
•Monday to Friday
•Saturday to Sunday
•sing e day
Confirm day of week (interva )
Disp ay: Start and stop time for day of week
Edit start time (inverted):
•15 minute increment
•00:00 to 24:00
•- - : - - deaktivated
Confirm Start or stop time
Anzeige: next start or stop time
After confirming the maximum 6 times the
se ection of the day of week starts again.
Repeat these steps for the dai y input in the
same order.
Set rotary switch to Information eve
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1.7 Setting the party mode (heating circuit/auxiliary heating)
Using the Party mode function, the controller continues or activates the nominal operating
mode (day) during the time when the party timer is active, regardless of the programmed
times-of-use. The activation of the party mode (count down) starts with turning the rotary
switch to any operating mode position (e.g.information level). When the party timer has
elapsed, the party mode timer is reset to 00:00 and the controller continue working as
programmed times-of-use.
Setting FS Value range
initiate or continue nominal operation 0 h 0 to 48 h
Procedure:
Set rotary switch to party mode
Disp ay: week y schedu e
(name of times-of-use is disp ayed inverted.)
Se ect times-of-use
•heating circuit
•auxi ary heating
Confirm times-of-use
Disp ay: Current Party timer (inverted)
Edit desired duration of time-of-use
The party time is disp ayed across days.
Confirm Party timer
Disp ay: week y schedu e
(name of times-of-use is disp ayed inverted.)
Set rotary switch to Information eve
Note:
The lapse of time of the party timer is displayed in 15 minute increments.
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Installation and operating manual KT-Elektronik
1.8 Setting holidays
On public holidays the times-of-use entered for Sunday apply. The number of programm-
able holidays is limited to 20. Once programmed the holidays are valid every year.
Procedure:
Set rotary switch to configuration and settings
eve
Disp ay: Settings menue (LCD contrast se ected)
Se ect item 'PA5'
Confirm se ection
Se ect item 'PA5.01'
Confirm se ection
Disp ay: date of ho iday or p aceho der
Se ect date of ho iday or p aceho der
Confirm date or p aceho der to modify
Disp ay: Date of ho iday (inverted)
Edit date of ho iday (day.month) or erase the date
by se ect p aceho der '--.--' (01.01 to 31.12)
Confirm input
Disp ay: Modified date or p aceho der
(edit further ho idays)
Set rotary switch to Information eve
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1.9 Setting vacation times
During vacation times the system is set to permanent reduced operation. The number of
programmable vacation times is limited to 10.
Procedure:
Set rotary switch to configuration and settings
eve
Disp ay: Settings menue (LCD contrast se ected)
Se ect item 'PA5'
Confirm se ection
Se ect item 'PA5.02'
Confirm se ection
Disp ay: vacation time or p aceho der
Se ect vacation time or p aceho der
Confirm vacation time or p aceho der to modify
Disp ay: Vacation time (inverted)
Edit vacation time by set first and ast day of
vacation period (day.month) or erase the date by
se ect p aceho der '--.--' (01.01 to 31.12)
Confirm input
Disp ay: Modified date or p aceho der
(edit further vacation time)
Set rotary switch to Information eve
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Installation and operating manual KT-Elektronik
1.10 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:
•Measured values for not needed sensor inputs of current system layout
•Valve positions
•Binary input switching status
•Modem state
•Data of M-Bus meters
•Info II - The following values are sequentially displayed:
ID Controller ID
Logg Memory usage of data logging-module (Kapitel 10.11)
MBAd Station address
Koll Operating hours of solar circuit
V' Volume flow rate of flow sensor in solar circui
Pakt Current performance of solar circuit
Wtot Total gain (rate) of solar circuit
WTag Daily gain of solar circuit
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Provide advanced information level:
Set rotary switch to configuration and settings
eve
Disp ay: Settings menue (LCD contrast
se ected)
Se ect item 'PA1' (respective y 'PA3')
Confirm se ection
Set access code (key number) 1999
Confirm access code (key number) 1999
Disp ay: Settings menue ('PA1' se ected)
Set rotary switch to Information eve
Note:
Re-entering the access code 1999 hides the advanced informations.
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Installation and operating manual KT-Elektronik
1.11 Trend show – Data logging
The device SOL3-7 is equipped with an internal memory capacity. Every minute the
controller saves data into this memory, in order to analyze in retrospect the operation of the
device without use of additional tools.
The internal backup includes:
•Sensor readings
•States of the switching outputs
•Error Status Register and archive
•Access to controller settings
•user-defined data points
The trend display shows a graph of up to 3 selectable data points with exactly 160 values.
The display area is determined based on the variable minimum and maximum values in the
range of 160 displayed records.
One record will be selected through a focus (vertical line in the display area). The recording
time stamp below the center and the values in plain text on the left side of the display area
are displayed.
With the control button, the displayed time range can be changed and adjusted to the
middle of the display area.
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