KT-Elektronik SOL3-3 Installation And Owner's Manual
Solar controller
SOL3-3
Installation and operating
manual
Firmware version 1.07
April 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 pushbutton ........................................................................................... 6
1.1.2 Rotary switch ................................................................................................... 7
1.2 Display .................................................................................................................... 8
1.3 Retrieving data – Information level ....................................................................... 10
1.4 Setting the system time ........................................................................................ 11
1.5 Adjust usage schedule settings ............................................................................ 12
1.6 Setting the party mode (heating circuit/auxiliary heating) ..................................... 14
1.7 Access advanced information level ...................................................................... 15
1.7.1 Setting holidays .............................................................................................. 16
1.7.2 Setting vacation times .................................................................................... 16
1.8 Operation level stucture ....................................................................................... 18
2 Commissioning ............................................................................................................ 19
2.1 Setting the system variant ID ................................................................................ 19
2.2 Activate and deactivate functions ......................................................................... 20
2.3 Edit settings .......................................................................................................... 22
2.4 Sensor calibration ................................................................................................. 23
2.5 Reset to factory default settings ........................................................................... 24
3 Manual operating mode .............................................................................................. 25
4 System variants ........................................................................................................... 26
4.1 Extending the basic system variant representations ............................................ 33
5 Solar circuit functions .................................................................................................. 35
5.1 Basic Control function ........................................................................................... 35
5.2 Storage ................................................................................................................. 37
5.3 Swimming pool ..................................................................................................... 38
5.4 Collector return flow sensor, Collector flow sensor .............................................. 39
5.5 Measurement of solar power and solar energy .................................................... 40
5.6 Rotation speed control .......................................................................................... 42
5.7 Collector overheating protection ........................................................................... 43
5.8 Collector minimum temperature ........................................................................... 44
5.9 Start up function ................................................................................................... 44
5.10 Forced pump operation (blocking protection) ..................................................... 44
5.11 Collector Antifreeze ............................................................................................ 45
5.12 Two collector arrays ........................................................................................... 45
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5.13 External heat exchanger ..................................................................................... 46
5.14 Auxiliary heating with secondary heat generator ................................................ 47
5.15 Raise return flow of external heating system ..................................................... 47
5.15.1 Main principle ............................................................................................... 48
5.15.2 Implementation ............................................................................................ 48
6 Domestic water circuit functions .................................................................................. 49
6.1 Domestic water heating in storage tank ............................................................... 49
6.2 Thermal Disinfection of the storage tank .............................................................. 49
7 System wide functions - all system variants ................................................................ 50
7.1 Automatic summer/winter switching ..................................................................... 50
7.2 Antifreeze ............................................................................................................. 50
7.3 Locking manual operating mode .......................................................................... 51
7.4 Locking the rotary switch ...................................................................................... 51
7.5 Enter a valid individual access code ..................................................................... 51
7.6 Temperature difference controller ........................................................................ 52
8 Malfunction .................................................................................................................. 53
8.1 Error list ................................................................................................................ 53
8.2 Sensor failure ....................................................................................................... 53
8.3 Temperature monitoring ....................................................................................... 54
8.4 Error status register .............................................................................................. 54
8.5 SMS delivery in case of a system failure .............................................................. 55
9 Communication .......................................................................................................... 56
9.1 Communication module KOM232PC ................................................................... 57
9.2 Communication module iCon485 ........................................................................ 57
9.3 Communication module KOM232M ..................................................................... 59
9.4 Data Modem DataMod11 .................................................................................... 60
9.5 ModBus-MBus-Gateway ...................................................................................... 61
9.6 Description of the adjustable communication settings ......................................... 61
9.7 Memory module ................................................................................................... 62
9.8 55Viewer for visualization and remote maintenance. .......................................... 63
9.9 Data Logging ....................................................................................................... 64
10 Mounting ................................................................................................................... 65
11 Electrical connection ................................................................................................. 67
11.1 Notes for wire installation ................................................................................... 67
11.2 Surge Protection Measures ................................................................................ 67
11.3 Connecting the controller .................................................................................... 67
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11.3.1 Connecting the sensors ............................................................................... 68
11.3.2 Connecting the pumps ................................................................................. 68
11.3.3 Legend for connection diagram ................................................................... 68
11.3.4 Wiring diagram ............................................................................................. 69
11.3.5 Terminal assignment for Outputs ................................................................. 70
11.3.6 Terminal assignment for inputs .................................................................... 70
12 Appendix ................................................................................................................... 71
12.1 Function block lists ............................................................................................. 71
12.2 Parameter list ..................................................................................................... 74
12.3 Resistance values .............................................................................................. 80
12.4 Technical specifications ...................................................................................... 81
12.5 Accessories ........................................................................................................ 82
12.6 Function block settings in configuration levels ................................................... 83
12.7 Abbreviations ...................................................................................................... 84
12.8 Access codes ..................................................................................................... 85
12.9 Notes .................................................................................................................. 85
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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
1.4).
1.1 Controls
The operational controls are located on the front side of the controller.
1.1.1 Rotary pushbutton
Rotary pushbutton
Turn :
Display, select settings and function blocks
Push :
confirm selection or setting
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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
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
aux. heating (2) and hot water circulation (3)
Party mode
System time:
Setting time, date and year
Configuration and settings level
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1.2 Display
During operation, the display shows the current time as well as information about the
status of the controller. The usage periods are represented by black squares below the
row of numbers. Symbols mark the operational status of the controller.
Holiday operating
mode (OM)
Vacation OM
Malfunction
Frost protection OM
2
Solar circuit
3
Auxiliary heating,
domestic water
circuit
Automatic operating
mode
Automatic operating
mode
Night-time operation
Manual operating mode Daytime Operation
Stand-by OM Manual operating mode
Collector pump CP1 Stand-by OM
Collector heat exchanger
pump, CTP
Circulation pump ZP
Storage tank pump SP1 Aux. heating NH
Collector switching
valve CUV
Collector pump CP2
Temperature
difference switch TdS
Storage switching
valve SUV
Storage pump SP2
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The following applies to the icon of the collector pump(s):
Icon or
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
The controller status can be viewed at operating mode level (Chapter 1.3 ).
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1.3 Retrieving data – Information level
In the standard rotary switch position „Information level“ one can retrieve
informations about time, date, vacation-times and holidays as well as the temperature
set-points for the connected sensors and their current temperature.
Note: Information can also be retrieved in level "manual operating mode". To do so,
select "Info", then confirm and proceed as described.
Procedure:
Select value.
The screen now displays different items one after the other, depending on the
configuration of the controller.
__:__ Current time
Flow temperature from the collector to the storage tank CVF
Return flow temperature from the collector to the storage tank CVF
Temperature at storage tank sensor SF1
Temperature at storage tank sensor SF2
Temperature at solar collector CF1
2
Temperature at solar collector CF2
Operating hours of solar circuit
Set-point/threshold and actual value comparison.
When the time is marked in the display, pressing the rotary pushbutton will
show the date.
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1.4 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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1.5 Adjust usage schedule settings
There are three separate usage schedules for
• Auxiliary heating
• Domestic water circulation
The following applies to each time program:
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. If only two time ranges are needed, the
start and end time of the third range have to be set to the same value.
The time ranges for the control circuits are adjusted by means of their identification
numbers shown in the display:
3
Auxiliary heating
3
Domestic water circulation
Setting FS* Value range
Time range/day 1–7 1–7, 1, 2, 3, 4, 5, 6, 7, for which 1–7 = daily,
1 = Monday 2 = Tuesday, ..., 7 = Sunday
Beginning of first time range 06:00 00:00 to 24:00 hours; 15 minute increments
End of first time range 22:00 00:00 to 24:00 hours; 15 minute increments
Beginning of second time range 22:15 00:00 to 24:00 hours; 15 minute increments
End of second time range 22:15 00:00 to 24:00 hours; 15 minute increments
Beginning of third time range – 00:00 to 24:00 hours; 15 minute increments
End of third time range – 00:00 to 24:00 hours; 15 minute increments
* Factory default settings valid for heating circuit
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Procedure: Turn rotary switch to position “Usage schedules”
Select circuit for which the time ranges shall be
set.
(only available circuits of the selected system
variant are offered)
Confirm selected circuit.
Display: 1–7
Select time range/day:
1–7 = daily,
1 = Monday 2 = Tuesday, ..., 7 = Sunday
Switch time range/day to edit mode:
Display: START, flashes
Change start time (15-minute increments).
Confirm start time. Display: STOP
Change stop time (15-minute increments).
Confirm stop time.
Display: START
The second time range is adjusted the same
way as the first one.
Repeat the procedure for each day to be scheduled.
Move the rotary switch back to the "Information level" position (left hand).
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3
Auxiliary heating
3
Domestic water
circulation
Note: Do not use menu 1–7 to check the scheduled time ranges. Selecting this
menu item after having adjusted the schedule will copy Monday times to all other
days of the week.
Installation and operating manual KT-Elektronik
1.6 Setting the party mode (heating circuit/auxiliary heating)
The party mode overrides the nominal operation of the controller by starting a new or
prolonging a programmed daytime mode time range for the duration of the time set for
the party mode. The party mode timer starts working once the rotary switch is moved to
the "automatic mode" position (left hand). When the timer runs out the party mode
function is reset to 00:00.
The party mode is set one after the other for each circuit with the rotary switch:
Setting FS Value range
initiate or continue nominal operation 0 h 0 to 48 h
Procedure:
Move rotary switch to the position “party mode” .
Select the circuit for which daytime mode shall be initiated or prolonged.
3
Storage tank auxiliary heating
Confirm selected circuit.
Display: shows 00:00 or remaining party timer time.
Set desired non-recurring duration.
Move the rotary switch back to the "Information level" position (left
hand).
Note:
The lapse of time of the party timer is displayed in 15 minute increments.
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1.7 Access advanced information level
After entering the access code 1999 the following informations are accessible through
the menu items as described in chapter 1.3:
•Measured values for not needed sensor inputs of current system layout
•Volume flow rate
•Performance
•Holidays (editable)
•Vacation times (editable)
•Valve positions
•Binary input switching status
•Info 2 - The following values are sequentially displayed:
Controller-ID
Memory usage, Data logging module (chapter 9.9)
Modbus client address
Operating hours of solar circuit
Volume flow rate of flow sensor in solar circuit
Current performance of solar circuit
Total gain (rate) of solar circuit
Daily gain 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.
Installation and operating manual KT-Elektronik
1.7.1 Setting holidays
On public holidays the time ranges entered for Sunday apply. The number of
programmable holidays is limited to 20.
Setting FS Level / Range
Holidays – Advanced information level / 01.01 to 31.12
Procedure:
In the advanced information level select the
menu item "holidays". Display:
Confirm selection "holidays".
Eventually select item – – – –.
Enter edit mode for holiday. flashes
Change holiday setting.
Confirm the holiday set.
To enter more holidays reselect – – – – and repeat the steps highlighted in grey.
Select End
Leave menu "holidays".
Note: Holidays can alternatively be entered in level PA5 (Chapter 2.2).
Remove holiday:
In menu "holidays" select the holiday to be deleted.
Confirm selection.
Select item – – – –.
Delete holiday.
Note: Holidays that are not assigned to a fixed date should be deleted by the
end of the year, so they are not automatically taken over into the next year.
1.7.2 Setting vacation times
During vacation times the system is set to permanent reduced operation. The number of
programmable vacation times is limited to 10.
Setting FS Level / Range
Vacation (Beginning, End) – Advanced information level / 01.01 to 31.12
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Procedure:
In the advanced information level select the
menu item "vacations". Display:
Confirm selection "vacations".
Display: START, – –.– –
Eventually select item – – – –.
Enter edit mode for vacation time. flashes
Change beginning of vacation.
Confirm setting.
Display: STOP, – –.– –
Change end of vacation.
Confirm setting. Black squares are shown below
the figures 1 to 4 at the head of the display for
the assignment of the vacation to each control
circuit.
Select control circuits for which the vacation
shall be applied.
current vacation for heating circuit Rk1
The vacation can be assigned to a single circuit
or to any combination of circuits (Rk1, domestic
water circuit).
To enter more vacation times reselect – – – – and repeat the steps highlighted in grey.
Select End
Leave menu "vacations".
Note: Vacation times can alternatively be entered in level PA5 (Chapter 2.2).
Remove vacation:
In menu "vacations" select the beginning of the vacation time to be
deleted.
Confirm selection.
Select item – – – –.
Delete vacation.
Note: Saved vacation times should be deleted by the end of the year, so they are not
automatically taken over into the next year.
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Installation and operating manual KT-Elektronik
1.8 Operation level stucture
PA3/CO3: Solar circuit
PA4/CO4: Auxiliary heating/domestic water heating
PA5/CO5: System wide
PA6/CO6: Communication
Anl: system variant ID
Fig. 2: Level structure
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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 7.5).
2.1 Setting the system variant ID
Several hydraulic system variants are available. Each variant is represented by an
identification number. The variants are illustrated in chapter 4. The available controller
functions are described in chapters 5, 6 and 7.
Editing the variant ID resets previously entered function blocks to factory default settings.
At parameter level, function block parameters and settings will be preserved. The variant
ID can be set at configuration level.
Procedure:
Switch to configuration and settings level.
Display shows 0 0 0 0
Enter a valid access code.
Confirm code.
Display: PA3
Select system variant.
Switch to edit mode.
Edit system variant ID.
Confirm ID.
Display: End
Leave configuration and settings level.
Display: 0 0 0 0
Move the rotary switch back to the "Information level" position .
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2.2 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
CO4: Domestic water circuit/auxiliary heating
CO5: System wide
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:
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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.
To configure more function blocks, repeat the steps highlighted in grey.
Select End
Leave configuration level.
Select End
Leave configuration and settings level.
Display: 0 0 0 0
Move the rotary switch back to the "Information level" position .
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2.3 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 12.2). The
functions are grouped by topic:
PA3: Solar circuit
PA4: Domestic water circuit / auxiliary heating
PA5: System wide
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
Leave configuration and settings level.
Display: 0 0 0 0
Move the rotary switch back to the "Information level" position .
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2.4 Sensor calibration
The controller is designed for connection of Pt1000-sensors. The sensor values of
resistance are listed on page 80.
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 (for all inputs) 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 according to the icons displayed on page 10.
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
Leave configuration and settings level.
Display: 0 0 0 0
Move the rotary switch back to the "Information level" position .
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2.5 Reset to factory default settings
All parameters set by means of the rotary switch as well as the parameters set in level
PA3 to 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.
KT-Elektronik SOL3-3
3 Manual operating mode
The manual operating mode allows the configuration of all outputs
(chapter 11).
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 system variant:
POS2 : Position presetting for analogue output
UP1: Operate the relay for heating circuit pump UP1
ZP: Operate the relay of the circulation pump
CP1: Operate the relay of the collector pump CP1
CP2: Operate the relay of the collector pump CP2
CU: Operate the relay of the collector switching valve CUV
SP1: Operate the relay of the storage tank pump SP1
SP2: Operate the relay of the storage tank pump SP2
NH: Operate the relay for auxiliary heating NH
SU: Operate the relay for the storage tank switching pump SUV
CTP: Operate the relay for the collector heat exchanger pump CTP
TdS: Operate the relay for the temperature difference switch TdS
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 .
The manual operating mode of the affected control circuit can be
deactivated by selecting any other operating mode.
EB_37383_SOL3-3_EN002 25
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 7.2).
Installation and operating manual KT-Elektronik
4 System variants
26 hydraulic system variants are available. They differ in the first instance in:
• Number of collector arrays,
• Number of storages,
• Switching between several collectors or storages by means of switching valves
or several pumps,
• Internal (or none) or external heat exchanger.
The following section shows 15 system variants, all other1 differ only by the presence or
absence of extensions as:
• Auxiliary heating (e.g boiler, electric cartridge heater),
• Domestic water circulation pump
The system images shown are just basic variant representations missing any kind of cutoff and safety devices or check valves for example.
System variant I I.0.0 One collector, one storage tank
1 All system variant IDs are listed at page 70 in the list of output terminal configuration.
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System variant 2 I.0.0
Two collectors (switching valve), one storage tank
System variant 3 I.0.0
Two collectors (two pumps), one storage tank
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