KT-Elektronik SOL3-7 Installation And Operating Manual

Solar controller
SOL3-7
Installation and operating manual
Firmware version 1.07 June 2011
Installation and operating manual KT-Elektronik
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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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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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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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 controller SOL3-7 it equipped with a graphical display. The display allows it to visualize the current system scheme with all relevant sensor informations as welll as state informations of pumps and valves 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 normal rotary switch position ,„Information level“, the system scheme, time, date as well as relevant temperatures measured by the connected sensors and state informations of pumps and valves of the selected hydraulc schema.
By turning and pushing the rotary pushbutton it is possible to show time, date, temperature, and query the values of connected sensors and their setpoints.
Procedure:
Select value: In the display appears, depending on system configuration, successively the different data points, which are described by an acronym:
Sample displays 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 flow sensor of heating circuit VF
SF1: 52.9°C Temperature at storage tank sensorr SF1
CF1: 27.3°C Temperature at collector sensor CF1
coll 12 h Operating hours of solar circiut
trend show Graphical presentation of logged system data
Setpoint or limit value compared to the displayed value.
Pushing the rotary pushbutton in the clock display shows the date and year.
Additional values can be displayed in the optional, advanced level of information (Kapitel
1.10).
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Display area
Installation and operating manual KT-Elektronik

1.5 Setting the system time

The current time and date must be set immediately after the commision and after a power failure of more than 24 hours. In this case, the system time on the clock 01/01/2000 10:00 preset and is displayed inverted (white on black) .
Procedure:
Set rotary switch to time
Display: System scheme and time(inverted)
Edit time
Confirm time
Display: System scheme and year (inverted)
Edit year
Confirm year Jahreszahl übernehmen.
Display: System scheme and year (inverted) Format: day.month
Edite date
Confirm date
Display: System scheme and time (inverted)
Set rotary switch to Information level
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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 graphicaly shown, name of times-of-use is displayed inverted.
Select times-of-use to view
heating circuit
hot water circulation
auxilary heating
Confirm times-of-use to modify
Display: Selection 'Monday to Sunday' (inverted)
Select day of week (inverted):
Monday to Sunday
Monday to Friday
Saturday to Sunday
single day
Confirm day of week (interval)
Display: 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 selection of the day of week starts again. Repeat these steps for the daily input in the same order.
Set rotary switch to Information level
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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
Display: weekly schedule (name of times-of-use is displayed inverted.)
Select times-of-use
heating circuit
auxilary heating
Confirm times-of-use
Display: Current Party timer (inverted)
Edit desired duration of time-of-use The party time is displayed across days.
Confirm Party timer
Display: weekly schedule (name of times-of-use is displayed inverted.)
Set rotary switch to Information level
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Note: The lapse of time of the party timer is displayed in 15 minute increments.
Installation and operating manual KT-Elektronik

1.8 Setting holidays

On public holidays the times-of-use entered for Sunday apply. The number of programm­able holidays is limited to 20. Once programmed the holidays are valid every year.
Procedure:
Set rotary switch to configuration and settings level
Display: Settings menue (LCD contrast selected)
Select item 'PA5'
Confirm selection
Select item 'PA5.01'
Confirm selection
Display: date of holiday or placeholder
Select date of holiday or placeholder
Confirm date or placeholder to modify
Display: Date of holiday (inverted)
Edit date of holiday (day.month) or erase the date by select placeholder '--.--' (01.01 to 31.12)
Confirm input
Display: Modified date or placeholder (edit further holidays)
Set rotary switch to Information level
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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 level
Display: Settings menue (LCD contrast selected)
Select item 'PA5'
Confirm selection
Select item 'PA5.02'
Confirm selection
Display: vacation time or placeholder
Select vacation time or placeholder
Confirm vacation time or placeholder to modify
Display: Vacation time (inverted)
Edit vacation time by set first and last day of vacation period (day.month) or erase the date by select placeholder '--.--' (01.01 to 31.12)
Confirm input
Display: Modified date or placeholder (edit further vacation time)
Set rotary switch to Information level
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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 level
Display: Settings menue (LCD contrast selected)
Select item 'PA1' (respectively 'PA3')
Confirm selection
Set access code (key number) 1999
Confirm access code (key number) 1999
Display: Settings menue ('PA1' selected)
Set rotary switch to Information level
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Note: Re-entering the access code 1999 hides the advanced informations.
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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Usage of the trend show
Set rotary switch to Information level
Display: System scheme
Select 'trend show'
Confirm Selection 'trend show'
Display: Trend show settings
Select item Confirm selection to modify the item
Select 'end' Confirm selection 'end' Display: Trend show
Move focus to show values of records
Set focus to the middle of the display area (readjust time domain)
Moving the focus to the right or left edge
Leave trend show
Display: System scheme
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Installation and operating manual KT-Elektronik

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 8.5).

2.1 Set language

The device SOL3-7 will delivered with german language as factory default language. It is possible to use other languages.
Procedure:
Set rotary switch to configuration and settings level
Display: Settings menue (LCD contrast selected- Language German as default)
Select 'Anzeigesprache' in Settings menue
Confirm selection
Display: Current languages (inverted)
Select your prefered language
Confirm language
Display:
Settings menue in the chosen language
Set rotary switch to Information level
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2.2 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:
Set rotary switch to configuration and settings level
Display: Settings menue (LCD contrast selected)
Select 'syst.var.id' in Settings menue (system code number)
Confirm selection
Display: Access code (Key number)
Set valid key number (chapter13.9)
Confirm key number
Display: System scheme
(system code number inverted)
Select system scheme
Confirm system
Display: Settings menue (Item 'syst.var.id' selected)
Set rotary switch to Information level
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Installation and operating manual KT-Elektronik

2.3 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 13.1.
The functions are grouped by topic:
CO1: Heating circuit CO3: Solar circuit CO4: Domestic water circuit/auxiliary heating CO5: System wide CO6: Modbus-Communication
Function block parameters
Some functions that can be configured via function blocks require additional parameters. This function block parameter will queried to edit or to confirm in the line of the function block after function block is activated or deactivated.
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Procedure:
Set rotary switch to configuration and settings level
Display: Settings menue (LCD contrast selected)
Select 'CO3' in Settings menue
Confirm selection
Display: Access code (Key number)
Set valid key number (chapter13.9)
Confirm key number
Display: Configuration menue 'CO3'
Select funktion to activate or deactivate function (1/0)
Confirm selection
Display: 'F01 Forced pump op. 0'
(Function block value inverted)
Activate or deactivate function (1/0)
Selektion bestätigen
Anzeige: Configuration menue 'CO3'
Set rotary switch to Information level
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2.4 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 13.2). The functions are grouped by topic:
PA1: Heating circuit PA3: Solar circuit PA4: Domestic water circuit / auxiliary heating PA5: System wide PA6: Modbus Communication
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Procedure:
Set rotary switch to configuration and settings level
Display: Settings menue (LCD contrast selected)
Select 'PA3' in Settings menue
Confirm selection
Display: Access code (Key number)
Set valid key number (chapter13.9)
Confirm key number
Display: Settings menue 'PA3'
Select setting
Confirm setting to modify
Display: Setting menue 'PA3' (Value inverted)
Edit setting
Confirm setting
Display: Setting menue 'PA3 (Line 'PA3.01' selected)
Set rotary switch to Information level
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2.5 Sensor calibration

The controller is designed for connection of Pt1000-sensors. The sensor values of resistance are listed on page 100.
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:
Select the function block according to chapter 2.3 CO5.F20 "Sensor calibrat" and activate or confirm the function block set.
As a function block parameter are viewed with turning the rotary pushbutton all in the chosen hydraulic system used temperature sensor inputs. If the rotary pushbutton is pushed, the displayed value is inverted for input.
By turning the rotary pushbutten edit the reference value as an actual temperature of a thermometer directly at the measuring point and confirm by pressing the rotary pushbutton.
Proceed in this manner to be aligned with each temperature sensor input.
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2.6 Reset to factory default settings

All parameters set by means of the rotary switch as well as the parameters set in level PA1 to PA5 can be reset to factory default settings, except the maximum flow temperature and return flow temperature thresholds in level PA1.
Procedure:
Set rotary switch to configuration and settings level
Display: Settings menue (LCD contrast selected)
Select item 'PA1' (respectively 'PA3')
Confirm selection
Set access code (key number) 1991
Confirm access code (key number) 1991
Display: Settings menue ('PA1' selected)
Set rotary switch to Information level
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Note: The error message "Error 2" will be generated while resetting to the factory default settings. It will be removed automatically shortly after midnight.
Installation and operating manual KT-Elektronik

3 Manual operating mode

The manual operating mode allows the configuration of all outputs (chapter 12).
Procedure:
Set rotary switch to manual mode
Display: System scheme and 'Collector 1'
Select switching output or valve
Confirm selected output
Display: System scheme and current state of collector pump 1 (inverted)
Edit state of output
Confirm state of output
Display: System scheme and 'Collector 1'
Set rotary switch to Information level
The manual operating mode of the affected control circuit can be deactivated by selecting any other operating mode.
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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 can not be guaranteed (Chapter 8.2).
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