CALEFFI 257260A Manual Download Page 20 | Manualshive

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© Caleffi 11236_iSolar_Plus.mon

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20

9 10

VBus

S1

S2

S3

R1

R2

System layout 6

The controller calculates the temperature differences
between collector sensor S1 and tank sensors S2 and S3. If
the differences are larger than or identical to the adjusted
switch-on temperature differences (DT1O / DT2O), the
solar pumps will be operated by relay 1 and / or relay 2,
and the respective tank will be loaded until the switch-off
temperature differences (DT1F / DT2F) or the maximum

Arr 6

Tank 1

Tank 2

S4

Display Channels
Channel

Description

Terminal

Page

COL

x

Temperature collector

S1

37

TST1

x

Temperature tank 1 bottom

S2

37

TST2

x

Temperature tank 2 bottom

S3

37

S4

x

Temperature sensor 4

S4

37

n1 %

x

Pump speed R1

R1

38

n2 %

x

Pump speed R2

R2

38

h P1

x

Operating hours R1

R1

38

h P2

x

Operating hours R2

R2

38

TIME

x

Time

-

34

tank temperatures (S1MX / S2MX) are reached. The priority
logic causes priority loading of the selected tank (PRIO), if
possible. Loading both tanks simultaneously is possible as
well (PRIO = 0).
Sensor S4 can optionally be connected for measurement
purposes or used as reference sensor for the tank emer-
gency shutdown option (OSEM).

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Summary of Contents for 257260A

Page 1: ...u for buying this product Read this manual carefully to get the best perfomance from this unit Please keep this manual carefully Mounting Connection Application examples Operation Troubleshooting 49011111 49011111 ISOLAR PLUS ...

Page 2: ... change Errors excepted Please pay attention to the following safety advice in order to avoid danger and damage to people and property Instructions Attention should be paid to Valid national and local standards and regulations Respective valid standards and directives Equipment to be installed and used in accordance with the rules of the National Electrical Code NEC or with Canadian Electrical Cod...

Page 3: ...al data Housing plastic PC ABS and PMMA Protection type IP 20 EN 60529 Ambient temp 32 104 F 0 40 C Size 6 8 4 3 1 9 172 110 46 mm Mounting wall mounting mounting into patch panels is possible Display System screen for system visualization 16 segment display 7 seg ment display 8 symbols for system status and operating control lamp Operation by 3 push buttons at the front of the housing Functions D...

Page 4: ... Î Î Complete wiring connections in accordance with termi nal allocations see chap 1 2 Electrical connection Î Î Place the cover back onto the housing Î Î Fasten the cover by means of the cross head screw 1 Installation VBus 1 2 S1 S2 S3 3 4 5 6 L N R1 N R2 N 20 19 18 17 16 15 S4 7 8 14 13 12 T4A VBus 9 10 CU 72091163 01 1 1 A 1 100 240 V 1 A 100 240 V R1 R2 100 240V 50 60 Hz Temp Sensor Pt1000 IP...

Page 5: ...n external power switch last step The supply voltage must be 100 240 V 50 60 Hz Flexible cables must be attached to the housing with the enclosed strain relief and the corresponding screws The controller is equipped with two semiconductor re lays to which loads such as pumps valves etc can be connected Relay 1 18 conductor R1 17 neutral conductor N 13 ground conductor Relay 2 16 conductor R2 15 ne...

Page 6: ...active 37 STAB x ODB stabilization in progress 37 COL x Temperature collector S1 37 TST x Temperature tank S2 37 S3 x Temperature sensor 3 S3 37 TSTT x Temperatur tank at the top S3 37 S4 x Temperature sensor 4 S4 37 TR x Temperature return sensor S4 37 n x Pump speed R1 R1 38 hP x Operating hours R1 R1 38 hP1 x Operating hours R1 if OBST is activated R1 38 hP2 x Operating hours R2 if OBST is acti...

Page 7: ...ifference 40 0 Ra 20 0 K 41 DTCF x Cooling switch off temperature difference 30 0 Ra 15 0 K 41 OSTC x Option tank cooling OFF 42 OHOL x Option holiday cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN x Option minimum limitation OFF 42 CMN x Minimum collector temperature 50 F 10 C 42 OCF x Option antifreeze OFF 42 CFR x Antifreeze temperature 40 0 F 4 0 C 42 O TC x Option tube co...

Page 8: ...37 FLL x ODB filling time active 37 STAB x ODB stabilization in progress 37 COL x Temperature collector S1 37 TST1 x Temperature tank 1 bottom S2 37 TSTT x Temperature tank 1 at the top S3 37 TST2 x Temperature tank 2 bottom S4 37 n1 x Pump speed R1 R1 38 n2 x Pump speed R2 R2 38 h P1 x Operating hours R1 R1 38 h P2 x Operating hours R2 R2 38 TIME x Time 34 Heat exchange from tank 1 to tank 2 will...

Page 9: ...on antifreeze OFF 42 CFR x Antifreeze temperature 40 0 F 4 0 C 42 O TC x Option tube collector OFF 44 TCST x OTC starting time 07 00 44 TCEN x OTC ending time 19 00 44 TCRU x OTC runtime 30 s 44 TCIN x OTC standstill interval 30 min 44 DT3O s Switch on temperature difference 3 12 0 Ra 6 0 K 10 DT3F s Switch off temperature difference 3 8 0 Ra 4 0 K 10 DT3S s Nominal temperature difference 3 20 0 R...

Page 10: ... K RIS3 Rise Adjustment range 2 40 Ra 1 20 K in steps of 2 Ra 1 K Factory setting 4 Ra 2 K Pump speed control A relative minimum pump speed can be allocated to the output R2 via the adjustment channel n2MN n2MN Pump speed control Adjustment range 30 100 in steps of 5 Factory setting 30 Note When loads which are not speed controlled e g valves are used the value must be set to 100 in order to deact...

Page 11: ...m temperature limitation uses sensor 4 as reference sensor The maximum temperature limitation function provides a maximum tem perature setting usually to reduce scald risk in a storage tank If MX3O is exceeded relay 2 is switched off until the temperature at sensor 4 falls below MX3F The minimum temperature limitation uses sensor 3 as reference sensor The minimum temperature limitation function pr...

Page 12: ...OL x Temperature collector S1 37 TSTB x Temperature tank 1 bottom S2 37 TSTT x Temperature tank 1 at the top S3 37 TDIS s Thermal disinfection temperature S3 37 S4 x Temperature sensor 4 S4 37 TR x Temperature return sensor S4 37 n1 x Pump speed R1 R1 38 h P1 x Operating hours R1 R1 38 h P2 x Operating hours R2 R2 38 kWh x Heat quantity kWh 38 MWh x Heat quantity MWh 38 CDIS s Countdown of monitor...

Page 13: ...g time 19 00 44 TCRU x OTC runtime 30 s 44 TCIN x OTC standstill interval 30 min 44 OHQM x Option energy metering OFF 44 FMAX x Maximum flow 6 0 l 44 MEDT x Antifreeze type 1 44 MED x Antifreeze concentration 45 44 AH O s Switch on temp for thermostat 1 110 F 40 C 14 AH F s Switch off temp for thermostat 1 120 F 45 C 14 t1 O s Switch on time 1 thermostat 00 00 14 t1 F s Switch off time 1 thermosta...

Page 14: ... 95 0 C in steps of 1 0 F 0 5 C Factory setting 120 0 F 45 0 C t1 O t2 O t3 O Thermostat switch on time Adjustment range 00 00 23 45 Factory setting 00 00 t1 F t2 F t3 F Thermostat switch off time Adjustment range 00 00 23 45 Factory setting 00 00 In order to block the thermostat function for a certain period there are three time frames t1 t3 If the function should be active between 6 00 and 9 00 ...

Page 15: ...n temperature TDIS is continuously exceeded for the entire heating period DDIS S3 is used as the reference sensor and displayed as TSTT PDIS Monitoring period Adjustment range 0 30 0 24 h dd hh Factory setting 01 00 This function is used for protecting the upper tank zone against Legionella by activating the backup heating Reference sensor for the thermal disinfection is S3 Î Î To activate the fun...

Page 16: ...annels Channel Description Terminal Page COL x Temperature collector S1 37 TSTB x Temperature tank 1 bottom S2 37 TSTT x Temperature tank 1 at the top S3 37 S4 x Temperature sensor 4 S4 37 TR x Temperature return sensor S4 37 n x Pump speed relay R1 38 hP1 x Operating hours R1 R1 38 hP2 x Operating hours R2 R2 38 kWh x Heat quantity kWh 38 MWh x Heat quantity MWh 38 TIME x Time 34 tures S1MX S2MX ...

Page 17: ...0 K 41 DTCF x Cooling switch off temperature difference 30 0 Ra 15 0 K 41 OSTC x Option tank cooling OFF 42 OHOL x Option holiday cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN x Option minimum limitation OFF 42 CMN x Minimum collector temperature 50 F 10 C 42 OCF x Option antifreeze OFF 42 CFR x Antifreeze temperature 40 0 F 4 0 C 42 PRIO x Priority 2 43 tLB x Break time 2 mi...

Page 18: ...k 1 Tank 2 Display Channels Channel Description Terminal Page COL x Temperature collector S1 37 TST1 x Temperature tank 1 bottom S2 37 TST2 x Temperature tank 2 bottom S3 37 S4 x Temperature sensor 4 S4 37 TR x Temperature return sensor S4 37 n x Pump speed relay R1 38 hP1 x Operating hours R1 R1 38 hP2 x Operating hours R2 R2 38 kWh x Heat quantity kWh 38 MWh x Heat quantity MWh 38 TIME x Time 34...

Page 19: ...ture 230 F 110 C 41 OSYC x Option system cooling OFF 41 DTCO x Cooling switch on temperature difference 40 0 Ra 20 0 K 41 DTCF x Cooling switch off temperature difference 30 0 Ra 15 0 K 41 OSTC x Option tank cooling OFF 42 OHOL x Option holiday cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN x Option minimum limitation OFF 42 CMN x Minimum collector temperature 50 F 10 C 42 OCF...

Page 20: ...m Arr 6 Tank 1 Tank 2 S4 Display Channels Channel Description Terminal Page COL x Temperature collector S1 37 TST1 x Temperature tank 1 bottom S2 37 TST2 x Temperature tank 2 bottom S3 37 S4 x Temperature sensor 4 S4 37 n1 x Pump speed R1 R1 38 n2 x Pump speed R2 R2 38 h P1 x Operating hours R1 R1 38 h P2 x Operating hours R2 R2 38 TIME x Time 34 tank temperatures S1MX S2MX are reached The priorit...

Page 21: ...270 F 130 C 40 OCC x Option collector cooling OFF 41 CMX x Maximum collector temperature 230 F 110 C 41 OSYC x Option system cooling OFF 41 DTCO x Cooling switch on temperature difference 40 0 Ra 20 0 K 41 DTCF x Cooling switch off temperature difference 30 0 Ra 15 0 K 41 OSTC x Option tank cooling OFF 42 OHOL x Option holiday cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN x O...

Page 22: ...tch off R1 R2 S1 S2 S3 Arr 7 Display Channels Channel Description Terminal Page COL1 x Temperature collector 1 S1 37 TST x Temperature tank S2 37 COL2 x Temperature collector 2 S3 37 S4 x Temperature sensor 4 S4 37 TSTT x Temperature store at the top S4 37 n1 x Pump speed R1 R1 38 n2 x Pump speed R2 R2 38 h P1 x Operating hours R1 R1 38 h P2 x Operating hours R2 R2 38 TIME x Time 34 temperature di...

Page 23: ...41 OSYC x Option system cooling OFF 41 DTCO x Cooling switch on temperature difference 40 0 Ra 20 0 K 41 DTCF x Cooling switch off temperature difference 30 0 Ra 15 0 K 41 OSTC x Option tank cooling OFF 42 OHOL x Option holiday cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN1 x Option minimum limitation collector 1 OFF 42 CMN1 x Minimum temperature collector 1 50 F 10 C 42 OCN2...

Page 24: ...L x ODB filling time active 37 STAB x ODB stabilization in progress 37 COL x Temperature collector S1 37 TSTB x Temperature tank 1 bottom S2 37 TSTT x Temperature tank 1 at the top S3 37 TSFB x Temperature solid fuel boiler S4 37 n1 x Pump speed R1 R1 38 n2 x Pump speed R2 R2 38 h P1 x Operating hours R1 R1 38 h P2 x Operating hours R2 R2 38 TIME x Time 34 A solid fuel boiler will be operated by r...

Page 25: ...ay cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN x Option minimum limitation OFF 42 CMN x Minimum collector temperature 50 F 10 C 42 OCF x Option antifreeze OFF 42 CFR x Antifreeze temperature 40 0 F 4 0 C 42 O TC x Option tube collector OFF 44 TCST x OTC starting time 07 00 44 TCEN x OTC ending time 19 00 44 TCRU x OTC runtime 30 s 44 TCIN x OTC standstill interval 30 min 44...

Page 26: ...se Adjustment range 2 40 Ra 1 20 K in steps of 2 Ra 1 K Factory setting 4 Ra 2 K Pump speed control A relative minimum pump speed can be allocated to the output R2 via the adjustment channel n2MN n2MN Pump speed control Adjustment range 30 100 in steps of 5 Factory setting 30 Note When loads which are not speed controlled e g valves are used the value must be set to 100 in order to deactivate pump...

Page 27: ...r The maximum temperature limitation function provides a maximum tem perature setting usually to reduce scald risk in a storage tank If MX3O is exceeded relay 2 is switched off until the sensor falls below MX3F TIn Arr 8 this func tion uses sensor 3 as reference sensor The minimum temperature limitation uses sensor 4 as reference sensor The minimum temperature limitation function provides a minimu...

Page 28: ...NIT x ODB initialization active 37 FLL x ODB filling time active 37 STAB x ODB stabilization in progress 37 COL x Temperature collector S1 37 TSTB x Temperature tank 1 bottom S2 37 TSTT x Temperature tank 1 at the top S3 37 TRET x Temperature heating circuit S4 38 n x Pump speed relay R1 38 hP1 x Operating hours R1 R1 38 hP2 x Operating hours R2 R2 38 TIME x Time 34 A heating circuit return prehea...

Page 29: ...Cooling switch on temperature difference 40 0 Ra 20 0 K 41 DTCF x Cooling switch off temperature difference 30 0 Ra 15 0 K 41 OSTC x Option tank cooling OFF 42 OHOL x Option holiday cooling OFF 42 THOL x Holiday cooling temperature 110 F 40 C 42 OCN x Option minimum limitation OFF 42 CMN x Minimum collector temperature 50 F 10 C 42 OCF x Option antifreeze OFF 42 CFR x Antifreeze temperature 40 0 F...

Page 30: ...L x Temperature collector S1 37 TST x Temperature tank S2 37 S3 x Temperature sensor 3 S3 37 TSTT x Temperature tank at the top S3 37 S4 x Temperature sensor 4 S4 37 TR x Temperature return sensor S4 37 n x Pump speed relay R1 30 h P1 x Operating hours R1 R1 38 h P2 x Operating hours R2 R2 38 kWh x Heat quantity kWh 38 MWh x Heat quantity MWh 38 TIME x Time 34 will be operated by relay 2 in order ...

Page 31: ...0 EM x Emergency temperature collector 270 F 130 C 40 CMX s Maximum collector temperature 230 F 110 C 41 OCN x Option minimum limitation OFF 42 CMN x Minimum collector temperature 50 F 10 C 42 OCF x Option antifreeze OFF 42 CFR x Antifreeze temperature 40 0 F 4 0 C 42 O TC x Option tube collector OFF 44 TCST x OTC starting time 07 00 44 TCEN x OTC ending time 19 00 44 TCRU x OTC runtime 30 s 44 TC...

Page 32: ...peration only the display channels are shown Î Î Scroll through the display channels by pressing buttons 1 and 2 Accessing the adjustment channels Î Î Scroll down in the display menu and press button 1 for approx two seconds after you have reached the last display item When an adjustment value is shown on the display is indicated to the right of the channel name Î Î Press button 3 in order to acce...

Page 33: ...ching position is shown Heating circuit Tanks 1 and 2 with heat exchanger Backup heating with burner symbol Temperature sensor System screen system screen green everything OK red green flashing initialization phase red flashing manual operation sensor fault sensor symbol is flashing quickly 2 3 Flashing codes LED flashing codes System screen flashing codes Collectors with collector sensor backup h...

Page 34: ...Save the adjustment by pressing button 3 again The symbol stops flashing Î Î Press button 1 or 2 to switch to the next or previous channel 1 2 3 OK The three push buttons of the BS Plus controller The commissioning menu consists of the following 6 channels 1 Language Î Î Adjust the desired menu language in this channel dE German En English Fr French LANG Language selection Selection dE En Fr Facto...

Page 35: ...e been made in the other channels will be lost Therefore changing the system layout is always followed by a security enquiry Only confirm the security enquiry if you are sure that you wish to change the system layout selection Security enquiry Î Î To confirm the security enquiry press button 3 Arr 9 solar system layout with heating circuit return preheating Arr 10 standard solar system layout with...

Page 36: ...F 1 C Factory setting 140 F 60 C Note The controller is also equipped with a non adjustable emergency shutdown function which will shut the system down if the tank reaches 200 F 95 C 6 Minimum pump speed Î Î Adjust a minimum speed for the pump nMN n1MN n2MN Pump speed control Adjustment range 30 100 in steps of 5 Factory setting 30 Note If loads which are not speed controlled e g valves are used t...

Page 37: ...l function S3 temperature sensor 3 S4 temperature sensor 4 S3 S4 Sensor temperatures Display range 40 500 F 40 260 C Indication of other temperatures Indicates the current temperature of the corresponding sensor TSFB temperature solid fuel boiler TRET temperature heating return preheating TR temperature return TSFB TRET TR Other mea sured tempe ratures Display range 40 500 F 40 260 C Note S3 and S...

Page 38: ... both values The accumulated heat quantity can be set back to 0 As soon as one of the display channels of the heat quantity is selected the symbol is permanently shown on the display Î Î Press button 3 for about two seconds in order to access the RESET mode of the counter The display symbol will flash and the heat quantity value will be set to 0 Î Î Confirm the reset with button 3 in order to fini...

Page 39: ...pump is activated at full speed for 10 seconds Then the speed is reduced to the minimum pump speed value factory setting 30 If the temperature difference reaches the adjusted nominal temperature difference the pump speed increases by one step 10 If the difference increases by the adjustable rise value the pump speed increases by 10 respectively until the maximum pump speed of 100 is reached The re...

Page 40: ... is set for the collector temperature limitation While the collector is in emergency shutdown flashing is shown on the display EM EM1 EM2 Collector temperature limitation Adjustment range 170 390 F 80 200 C in steps of 2 F 1 C Factory setting 270 F 130 C Note If the drainback option ODB is activated the adjustment range of EM is changed to 170 250 F 80 120 C The factory setting in that case is 200...

Page 41: ...mperature S MX S1MX and the switch on tempera ture difference DTCO is reached the solar system remains activated Solar loading is continued until either the tank temperature reaches 200 F 95 C emergency shutdown of the tank the temperature difference falls below the ad justed value DTCF or the collector emergency shutdown temperature EM is reached If the system cooling function is active and flash...

Page 42: ...w 40 F 5 C in order to protect the tank from frost damage CFR CFR1 CFR2 Antifreeze temperature Adjustment range 40 0 50 0 F 40 0 10 0 C in steps of 1 F 0 5 C Factory setting 40 0 F 4 0 C Tank cooling function When the tank cooling function is activated the controller aims to cool down the tank during the night in order to prepare it for solar loading on the following day If the adjusted maximum ta...

Page 43: ...e If the priority is set to Su 1 or Su 2 solar loading of the subordinate tank will be aborted at once if the temperature in the priority tank tank 1 for Su 1 tank 2 for Su 2 falls below the adjusted maximum temperature If in that case the temperature difference between the priority tank and the collector is not sufficiently high solar loading will be stopped completely DTSE Spread temperature dif...

Page 44: ...switched off In system layout 7 Arr 7 both collectors are operated independently from each other by means of this function If the tank is being loaded by one collector the other one is nevertheless operated after the adjusted standstill time Energy metering OHQM Energy metering Adjustment range OFF ON Factory setting OFF If OHQM is activated the heat quantity gained can be calcu lated and displaye...

Page 45: ... drainback option ODB is activated the pump will operate at 100 speed for the adjusted filling time tFLL in order to fill the system with fluid from the holding tank After tFLL pump speed will go down to the adjusted minimum pump speed nMn The switch off conditions will then be ignored for the stabilization time tSTB in order to avoid the system from shutting down prematurely If the function is ac...

Page 46: ...tion is not possible in manual mode Reset By using the reset function all adjustments will be set back to the factory settings Î Î To initiate a reset press button 3 Any previous adjustments will be lost Therefore initi ating the reset function is always followed by a security enquiry Only confirm the security enquiry if you are sure that you wish to reset all adjustments to the factory settings R...

Page 47: ...display channel 88 8 888 8 Cable broken Check cable Short circuit Check cable Disconnected Pt1000 temperature sen sors can be checked with an ohmmeter In the following table the resistance values with the corresponding temperatures are shown Operating control lamp off Check the power supply Is it disconnected no The fuse of the controller could be blown It can be replaced after the front cover has...

Page 48: ...ger blocked yes no Clean it Heat exchanger too small yes Replace with correctly sized one no Plausibility control of the option tube collec tor special function Change Ton and Toff correspondingly Switch on temperature difference Ton to large no yes Non ideal position of the coll ector sensor e g flatscrew sensor instead of sensor in sensor wells no Pump is overheated but no heat transfer from the...

Page 49: ...the pump start up in manual operation yes There is no current check fuses replace them and check power supply The adjusted temperature difference for starting the pump is to high choose a value which makes more sense no Is the pump current enabled by the control ler yes Is the pump stuck Turn the pump shaft using a screwdriver now pas sable Pump is defective re place it Are the controller fuses o ...

Page 50: ...ers with VBus It is used for visualizing data issued by the controller collector temperature storage temperature and energy yield of the solar thermal system The use of high efficient LEDs and filter glass assures a high optical brilliance and good readability even in poor visibility conditions and from a larger distance An additional power supply is not required Large Display GA3 The Large Displa...

Page 51: ...ion of the ServiceCenter software is included VBus PWM interface adaptor TheVBus PWM interface adaptor is used for the speed control of a pump via a PWM or 0 10V signal Via theVBus the adaptor receives information from the controller about the necessary pump speed The speed is converted into a PWM or direct voltage signal and put out to the corresponding terminals AM1 Alarm module The AM1 alarm mo...

Page 52: ...EFFI NORTH AMERICA Inc Important notice The texts and drawings in this manual are correct to the best of our knowledge As faults can never be excluded please note Your own calculations and plans under con sider ation of the current standards should only be basis for your projects We do not offer a guarantee for the completeness of the drawings and texts of this manual they only represent some exam...

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