Caleffi solar ISolar 3 Bedienungsanleitung

Thanks for buying this product.

Read this manual carefully to get the best perfomance from this unit.

Mounting

Connection

Handling

Fault localization

Examples

manual

49005100

*49005100*

Contents

Imprint .................................................................................2

Security devices...................................................................2

Technichal data and function survey .................................3

1. Installation .............................................................4

1.1 Mounting.................................................................................. 4

1.2 Electrical wiring...................................................................... 4

1.2.1 Standard solar system........................................................... 5

1.2.2 Solar system and after-heating............................................ 5

2. Operation and function ........................................6

2.1 Adjustment buttons .............................................................. 6

2.2 System monitoring display ................................................... 6

2.2.1 Channel indication................................................................. 6

2.2.2 Tool bar.................................................................................... 6

2.2.3 System screen......................................................................... 7

2.3 Blinkcodes ............................................................................... 7

2.3.1 System-Screen Blinkcodes ................................................... 7

2.3.2 Blinking codes......................................................................... 7

3. Commissioning......................................................8

4. Control parameter and indication channels ......8

4.1 Channel overview.................................................................. 8

4.1.1-6 Indication channels ................................................................ 9

4.1.7-18 Adjustment channels...........................................................10

5. Tips for fault localization....................................13

5.1 Miscellaneous........................................................................ 14

6. Accessory .............................................................16

Reprinting / copying

This mounting- and operation manual including all parts is

copyrighted.Another use outside the copyright requires

the approval of CALEFFI NORTH AMERICA, Inc..This

especially applies for copies, translations, micro ﬁlms and

the storage into electronic systems.

Editor: CALEFFI NORTH AMERICA, Inc.

Important notice:

We took a lot of care over the texts and drawings of this

manual and to the best of our knowledge and consent.As

faults can never be excluded, please note:

Your own calculations and plans under consideration of

the current norms and DIN-directions should only be

basis for your projects.We don´t offer a guarantee for the

completeness of the drawings and texts of this manual

- they only represent some examples.They can only be

used on own risk. No liability is assumed for incorrect,

incomplete or false information and the resulting damages.

Errors an technical changes excepted.

Safety regulations:

Please read the following information carefully before

installing and operating the controller. In this way damage to

the solar system by wrong installation will be avoided.Please

observe that the mounting is adapted to the characteristics

of the building, that the local regulations are respected and

is conform with the technical rules.

CU 72060171 01

UL 60730-1A:2002

CSA E60730.1:2002

3 |





• system-monitoring-display

• upto4temperaturesensors

Pt1000

• heatbalancing

• functioncontrol

• user-friendlyoperationby

simple handling

• solaroperatinghourscounter

and thermostat function optio-

nally

Scope of delivery:

1 x ISOLAR 3

1 x accessory bag

1 x spare fuse T4A

2 x screws and dowels

4 x strain relief and screws

Additionally enclosed in the full kit:

1 x sensor FKP6

2 x sensor FRP6

Technical data

Housing:

plastic, PC-ABS and PMMA

Protection type: IP 20 / DIN 40050

Environmental temp.: 32 ... 104 °F

Size: 172 x 110 x 46 mm

Mounting: wall mounting, mounting

into patch-panels is possible

Display: System screen for sys-

tems visualisation, 16-segment display,

7-segment display,8 symbols for system

status and operating control lamp

Operation: by 3 pushbuttons in the

front of the housing

Functions: Temperature differential

controller with optional add-on system

funtcions. Function control according,

operating hours counter for solar

pump, tube collector special function,

as well as heat quantity balancing.

Inputs: for 4 temperature sensors

Pt1000

Outputs: 2 electromechanical relay

Bus: VBus®

Power supply:

115 V~

Total power supply:

2 (1) A 115V~

Mode of operation:

Typ 1.b

Breaking capacity per relay:

electromechanical relay:

2 (1) A 115V~

display

pushbutton

can fuse 4A

cable conduits with strain

relief

cover

1.1 Mounting

The unit must only be located internally. It is not suitable

for installation in hazardous locations and should not be

sited near to any electromagnetic ﬁeld.The controller must

additionally be equipped with an all-polar gap of at least 3 mm

or with a gap according to the valid installaton regulations,

e.g. LS-switches or fuses. Please pay attention to a separate

laying of the cable lines and installation of ac power supply.

1. Unscrew the cross-recessed screw of the cover and

remove it from the housing.

2. Mark the upper fastening point on the wall and premount

the enclosed dowel and screw.

3. Hang up the housing at the upper fastening point and mark

the lower fastening point on the underground (hole pitch

130 mm), afterwards put the lower dowel.

4. Fasten the housing at the underground.

1. Installation Warning!

Switch-off power supply before

opening the housing.

1.2 Electrical wiring The power supply to the controller must only be made by

an external power supply switch (last step of installation!)

and the line voltage must be 115 Volt (50...60 Hz). Flexible

lines are to be ﬁxed at the housing by enclosed strain relief

supports and screws.

Depending on the version the controller is equipped with

2 relays to which the consumers e.g. pumps, valves etc.

can be connected:

• Relay 1

18 = conductor R1

17 = neutral conductor N

13 = ground clamp

• Relay 2

16 = conductor R2

15 = neutral conductor N

14 = ground clamp

The temperature sensors (S1 up to S4) will be connected

to the following terminals independently of the polarity:

1 / 2 = Sensor 1 (e.g. Sensor collector 1)

3 / 4 = Sensor 2 (e.g. Sensor tank 1)

5 / 6 = Sensor 3 (e.g. Sensor TSPO)

7 / 8 = Sensor 4 (e.g. Sensor TRL)

The power supply is effected to the clamps:

19 = neutral conductor N

20 = conductor L

12 = ground clamp

hanging

ﬁxation

Electrostatic discharge can lead to damages of elec-

tronic components!

Dangerous voltage on contact!

net clamps

fuse

consumer clamps

Sensor clamps earthing clamps

VBus®

The controller comes with aVBus®for data communication

and energy supply of external modules. The connection

is effected with optional polarity at the clamps marked

with„VBus®“.Via this data Bus you can install one or more

VBus®modules, e.g.:

• heat quant. measurement module WMZ-M1

• large display GA3

• Data logger, DL1

• Data teleindication, DFA2

Additionaly, the controller can be connected to the PC with

the help of a RS-COM adapter. With the ServiceCenter

Software (RCS) the controller parameters can be changed,

measurements can be read out, processed and visualised.

The software enables an easy function control and adjust-

ment of the system.

5 |

S4 / TRF

1.2.1 Allocation of clamps for system 1 Standard solar system with 1 tank, 1 pump and 3 sen-

sors. The sensor S4 / TRF can optionally be used for heat

quantity balancing.

Arr 1

R1 S3

S4 / TRF

Solars ystem and after-heating with 1 tank, 3 sensors

and after-heating.The sensor S4 /TRF can optionally be used

for heat quantity balancing.

Arr 2

1.2.2 Allocation of clamps for system 2

Symbol Speciﬁcation

S1 collector sensor

S2 tank sensor below

S3 tank sensor at the top

S4 / TRF sensor for heat quantity

balancing (optionally)

R1 solar pump

R2 pump for heat exchange

Symbol Speciﬁcation

S1 Collector sensor

S2 Tank sensor below

S3 Tank sensor at the top

(optionally)

S4 / TRF Sensor for heat quantity

measurement (optionally)

R1 Solar pump

backwards forward

SET

(selection / adjustment mode)

The system monitoring display consists of 3 blocks: indica-

tion of the channel, tool bar and system screen (active

system scheme).

The indication channel consists of two lines.The upper

line is an alphanumeric 16-segment indication in which mainly

the channel names / menu items are shown. In the lower

7-segment indication,the channel values and the adjustment

parameters are indicated.

Temperatures and temperature differences are indicated in

°F / °C or Ra / K.

2.2.1 Channel indication

only channel indication

2.2.2 Tool bar

The additional symbols of the tool bar indicate the current

system status.

only tool bar

2. Operation and function

2.1 Pushbuttons for adjustment

The controller is operated by 3 pushbuttons below the

display. The forward-key (1) is used for scrolling forward

through the indication menu or to increase the adjustment

values. The backwards-key (2) is accordingly used for the

reverse function.

For adjustment of last indication channel, keep button 1

pressed for 2 seconds.If an adjustment value is shown on

the display, SEt is indicated. In this case you can press the

key „Set“ (3) in order to change into input mode.

Select a channel by keys 1 and 2

Shortly press key 3, so that „SEt“ ﬂashes

Adjust the value by keys 1 and 2

Shortly press key 3, so that „SEt“ permanently appears,

the adjusted value is now saved.

2.2 System monitoring display





Complete Monitoring-Display

Symbol standard ﬂashing

relay 1 active

relay 2 active

maximum tank limitation

active / maximum tank

temperature exceeded

collector cooling function or

reccoling function active

antifreeze- function activated collector minimum limitation

or antifreeze function active

collector security shutdown or

tank securtiy shutdown active

+ sensor defect

+ manual operation active

an adjustment channel is

changed SET-mode

7 |

The system screen (active system scheme) shows the

schemes selected on the controller. It consists of several

system component symbols, which are - depending on the

current status of the system - either ﬂashing, permanently

shown or hidden.

Sensor

Collector 1

Pumps

Additional symbol for

operation of the burner

Tank

Tank heat exchanger Tank 2 or after-heating (with

additional symbol)

Sensor tank top

Collectors

with collector sensor

Pump

3-way-valves

The ﬂow direction or the current bre-

aking capacity are always shown.

Heating circuit

Tank 1 and 2

with heat exchanger

After-heating

with burner symbol

Temperature sensor

2.2.3 System screen

only system screen

Constantly green: everything all right

Red/green blinking: initialisation phase

manual operation

Red blinking: sensor defect

(sensor symbol is quickly blinking)

2.3 Blinking codes

2.3.2 LED blinking codes

2.3.1 System screen blinking codes

•Pumps are blinking during starting phase

•Sensors are blinking if the respective sensor-indication

channel is selected.

•Sensors are quickly blinking in case of sensor defect.

•Burner symbol is blinking if after-heating is activated.

3. Commissioning

On commissioning you have to adjust primarily the matching system

System survey:

Arr 1 : standard solar system

Arr 2 : solar system with after-heating

backwards forward

SET

(Selection / Adjustment mode)

Operation cont-

rol lamp

Arr 1 Arr 2

1.Ac power supply must be activated.The controller passes

an initialisation phase in which the operating control lamp

ﬂashes red and green.After having ﬁnished the initialisation,

the controller is in automatic operation with factory set-

tings.The preadjusted system scheme is Arr 1.

2. - select Arr

- change into -mode (see 2.1)

- select the system scheme by Arr-characteristics

- adjustment is saved by pressing button

Now the controller is ready for operation and should enable

an optimum operation of the solar system by the factory

settings made.

4. Controller parameter and indication channels

4.1 Channel-overview

Legend:

Corresponding channel is available.

Corresponding channel is available if the appropriate option

is activated.



Corresponding channel is only available if the option heat

quantity measurement is activated (OWMZ).

MEDT

The channel antifreeze content (MED%) is only shown if a

medium other than water orTyfocor LS / G-LS (MEDT

0 or 3) is used.The adjustment is only appropriate when

using other types of antifreeze.



Corresponding channel is only available if the option heat

quantity measurement is deactivated (OWMZ).

Please note:

S3 and S4 are only indicated if sensors are connected.

channel Arr speciﬁcation page

1 2*

COL x x Temperature collector 1 9

TST x Temperature tank 1 9

TSTL x Temperature tank 1 below 9

TSTU x Temperature tank 1 above 9

S3 x Temperature sensor 3 9

TRF   Temperature return sensor 9

S4   Temperature sensor 4 9

h P1 x Operating hours relay 1 9

h P2 x Operating hours relay 2 9

kWh   Heat quantity kWh 10

MWh   Heat quantity MWh 10

Arr 1-2 System 8

DT O x x Switch-on temperature difference 10

DT F x x Switch-off temperature difference 10

S MX x x Maximum temperature tank 1 10

EM x x emergency temperature collector 1 10

channel Arr speciﬁcation page

1 2*

OCX x x Option collector cooling collector 1 11

CMX x* x* Maximum temperature collector 1 11

OCN x x Option minimum limitation collector1 11

CMN x* x* Minimun temperature collector 1 11

OCF x x Option antifreeze collector 1 11

CFR x* x* Antifreeze temperature collector 1 11

OREC x x Option reccoling 11

O TC x x Option tube collector 12

AH O x Switch-on temp. for thermostat 1 12

AH F x Switch-off temp. for thermostat 1 12

OHQM x x Option WMZ 12

FMAX   Maximum ﬂow 12

MEDT   Antifreeze type 10

MED% MEDT MEDT Antifreeze content 10

HND1 x x Manual operation relay 1 12

HND2 x x Manual operation relay 2 12

LANG x x Language 12

UNIT x x Change over °FAH / °CEL 12

PROG XX.XX Program number

VERS X.XX Version number

9 |

4.1.1 Indicataion of collector temperatures

4.1.2 Indication of tank temperatures

4.1.3 Indication of sensor 3 and sensor 4

4.1.4 Indication of other temperatures

4.1.5 Operating hours counter

Shows the current collector temperature.

•COL : collector temperature (1-collector-system)

COL:

Collector temperature

display range: -40 ...+482 °F

Shows the current tank temperature.

•TST : tank temperature (1-tank-system)

TST:

Tank temperatures

Display range: -40 ...+482 °F

Shows the current temperature of the corresponding addi-

tional sensor (without control function).

•S3 : temperature sensor 3

•S4 : temperature sensor 4

Please note:

S3 and S4 are only indicated if the temperature sensors

are connected (shown).

S3, S4:

Sensor temperatures

Display range: -40 ...+482 °F

Shows the current temperature of the sensor.

•TRF : temperature return ﬂow

TRF:

other measured

temperatures

Display range: -40 ...+482 °F

h P1, h P2:

Operating hours counter

Display channel

The operating hours counter adds up the solar operating

hours of the respective relay (h P). Full hours are shown

on the display.

The operating hours added up can be reset. As soon as

one operating hours channel is selected, the symbol in

permanently shown on the display.The button SET (3) must

pressed for approx. 2 seconds in order to get back into

the RESET-mode of the counter.The display-symbol is

ﬂashing and the operating hours will be set to 0.In order to

ﬁnish the RESET-procedure, the button must be pressed

in order to conﬁrm.

In order to interrupt the RESET-procedure, no button

should be pressed for about 5 seconds.The controller re-

turns automatically into the indicaton mode.

4.1.6 Heat quantity balancing

OHQM:Heat quantity balan-

cing

Adjustment range: OFF...ON

Factory setting: OFF

A heat quantity balancing is possible for all systems in

conjunction with a ﬂowmeter.You just have to activate the

option heat quantity balancing in the channel OHQM.

The volume ﬂow readable at the ﬂowmeter (l/min) must

be adjusted in the channel FMAX. Antifreeze type and

concentration of the heat transfer medium are indicated on

the channels MEDT and MED%.

FMAX:

Volume ﬂow in l/min

Adjustment range 0 ... 20

in steps of 0,1

Factory setting 6,0

|10

4.1.7 ∆T-regulation

Type of antifreeze:

0 : water

1 : propylene glycol

2 : ethylene glycol

3 : Tyfocor® LS / G-LS

kWh/MWh:Heat quantity

in kWh / MWh

Display channel

MEDT: Type of antifreeze

Adjustment range 0 ... 3

Factory setting 1

MED%: Concentration of

antifreeze in (Vol-) %

MED% is blinded out by

MEDT 0 and 3.

Adjustment range 20 ... 70

Factory setting 45

The heat quantity transported is measured by the indication

of the volume ﬂow and the reference sensor of feed ﬂow

S1 and return ﬂow S4. It is shown in kWh-parts in the in-

dication channel kWh and in MWh-parts in the indication

channel MWh. The sum of both channels form the total

heat output.

The heat quantity added up can be reset. As soon as one

of the display channels of the heat quantity is selected, the

symbol is permanently shown on the display.The button

SET (3) must be pressed for approx. 2 seconds in order to

get back into the RESET-mode of the counter.The display-

symbol is ﬂashing and the value for heat quantity will be

set to 0. In order to ﬁnish the RESET-procedure, the button

must be pressed for conﬁrmation.

In order to interrupt the RESET-procedure, no button

should be pressed for about 5 seconds.The controller re-

turns automatically into indication mode.

Please note: Switch-on temperature difference DO must

be at least 2 °Ra higher than the switch-off temperature-

difference DF.

DT O:

Switch-on temperature

Adjustment range

2,0 ... 40,0 °Ra

Factory setting 12.0

DT F:

Switch-off temperature diff.

Adjustment range

1,0 ... 38 °Ra

Factory setting 8.0 °Ra

Primarily the controller works in the same way as a standard

differential controller. If the switch-on difference (DT O)

is reached, the pump is activated. If the adjusted switch-off

temperature is underrun (DT F), the controller switches-

off.

4.1.8 Maximum tank temperature

If the adjusted maximum temperature is exceeded,a further

loading of the tank is stopped so that a damaging overheating

can be avoided. If the maximum tank temperature is

exceeded, on the display is shown and .

Please note: The controller is equipped with a security-

switch-off of the tank, which avoids a further loading of the

tank if 203 °F are reached at the tank.

S MX:

Maximum tank temp.

Adjustment range

40 ... 205 °F

Factory setting 140 °F

4.1.9 Limit collector temperature

Collector emergency shutdown

If the adjusted collector limit temperature (EM) is exceeded,

the solar pump (R1/R2) is deactivated in order to avoid a

damaging overheating of the solar components (collector

emergency shutdown). The limit temperature is set to

285 °F but it can be changed within the adjustment range of

230 ... 400 °F. In the display is shown (ﬂashing).

EM:

Limit collector temperature

Adjustment range

230 ... 400 °F,

Factory setting 285 °F

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