SOLARcomfort Solar Hot Water Systems AST 100 Solar Controller Country of Destination GB/IE Installation, Commissioning and User Instructions LEAVE THESE INSTRUCTIONS WITH THE END USER
TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6 GENERAL INFORMATION ...............2 GUARANTEE .......................................... 2 SYSTEM CONTENTS ................................ 2 SYSTEM INSTRUCTION BOOKS .................. 2 SOLARCOMFORT ................................. 3 LIFESTYLE ............................................ 3 HOW THE SYSTEM WORKS ....................... 3 2. SAFETY ........................................... 4 3. TECHNICAL DATA ...........................6 3.
1. GENERAL INFORMATION This manual is an integral and essential part of the product. It should be kept with the product. Please read carefully the instructions and notes about SOLARcomfort contained in this manual as they provide important information regarding the installation, commissioning and user instructions of the AST 100 Solar Controller and the SOLARcomfort system. IMPORTANT Failure to follow these instructions correctly may invalidate the guarantee.
1.4 SOLARCOMFORT SOLARcomfort systems are highly efficient and provide cost savings on the energy used for heating hot water wherever they are used in the UK. However, the savings made will depend on local climate, installation characteristics and the households use of hot water. It is important that the SOLARcomfort system is correctly sized for the local climate condition and the householders domestic hot water requirements. 1.
Roof mounted collectors (two collector system shown) Air vent Energy Monitoring Sensor S4 (option) Temperature Sensor S1 Ariston ITSI 210/300 twin coil cylinder AST 100 Controller PR Valve Pump group Temperature Sensor S3 Expansion vessel Upper coil heated by boiler or other heat source Temperature Sensor S2 PRV discharge vessel Solar system low level fill point Lower coil heated by solar energy FIG. 1.
2. SAFETY WARNING All wiring should be carried out to and comply with the current IEE Wiring Regulations. All electrical work must comply with any relevant regulations that apply at the time of the installation. All electrical installation and maintenance of the AST 100 Controller must be carried out by a competent qualified installer. WARNING TYFOCOR LS Heat Transfer Fluid. Although non-toxic it should not be swallowed. Refer to label on its container for storage and safety information.
3. TECHNICAL DATA CONTROLLER Type AST100 Housing PC-ABS & PMMA Dimensions 173 x 110 x 46 Mounting Wall (2 screws) Operation 3 Push Buttons Protection IP20 / DIN 40050 Environmental Temperature 0 - 40°C FUNCTIONS Temperature Differential Control Standard Operating Hours Counter Standard Energy Monitor Option ELECTRICAL Power Supply 210-240V Electromechanical Relay 250V Controller Mains Cable 1.0mm² 3 core heat resistant flex 3093y Pump Cable (R1 and R2) 1.
3.1 COMPONENT LIST Listed below are all the components supplied with the Controller. Item 1 2 3 4 5 6 7 8 Description Controller Sensor - Collector Sensor - Cylinder Upper Sensor - Cylinder Lower Spare Fuse - T4A Cable Clips and screws Fixing Screws Wall Plug Qty 1 1 1 1 1 4 2 2 FIG. 3.1A CONTROLLER COMPONENT LIST 3.2 DIMENSIONS 110 = 47 173 155 130 HANGING POINT 104 = FIXING POINT 11 13 FIG. 3.
4. REGULATIONS & STANDARDS SOLARcomfort hot water heating systems should be installed in compliance with the following standards and regulations. 4.1 WATER REGULATIONS Water Supply (Water Fittings) Regulations 1999 / www.wras.co.uk These regulations (bye-laws in Scotland) ensure a good supply of wholesome water and that only approved materials, pipes and fittings are used to convey water. 4.
4.4 BRITISH & EUROPEAN STANDARDS Connection of thermal solar heating systems EN 12976: Thermal solar heating systems and their components (prefabricated systems). ENV 12977: Thermal solar heating system and their components (bespoke systems). BS5918: Latest version: Solar heating systems for domestic hot water. Installation and equipment of DHW cylinders BS5546: 2000 Specification for installation of hot water supplies for domestic purposes, using gas-fired appliances of rated input not exceeding 70 kW.
4.7 EU DIRECTIVES Further details available from: www.europa.eu.int Construction Directive: 89/106/EEC Electromagnetic: 89/336/EEC Low voltage: 73/23/EEC Machinery Directive: 98/37/EC 4.8 OTHER PUBLICATIONS Preventing hot water scalding in bathrooms: using TMVs (IP 14/03). DTI testing of solar systems (SP300275 1-3). Review of issues related to active solar heating systems (SP300246). Active solar performance and data review (SP300270). Solar heating systems for hot water (BS 5918).
5. OPERATION & FUNCTIONS 5.1 CONTROLLER LAYOUT Display °C AST 100 Indicator light Backward button Forward button Set button Cover retaining screw Cable entry through bottom only Arr 1 (default) Typical operating display for standard system. (The cylinder can be either a twin coil or a single coil buffer type, controlled by AST 100 Controller) Arr 2 Typical operating display for system with auxiliary heat source control. (Upper coil shown only when it is controlled by AST 100 Controller R2) FIG.
5.2 CONTROLLER FUNCTIONS INDICATOR LIGHT AST 100 Indicator Light Off No power to the SOLARcomfort controller. Green Power is On - normal condition. Red/Green flashing Initialisation phase. HND1 or HND2 are set to On. Red flashing Fault condition. Indicates one of the sensors is defective or not connected. Also a sensor symbol on the display will flash rapidly indicating which sensor is causing fault - see 5.7.
The backward button indexes the options back from the ‘setup parameters’ through to the ‘infomation only’ options. From here the ‘system setup parameters’ has to be accessed again by pressing and holding the forward button at the last ‘display only’ option. °C Information only options Setup parameters COL hP Arr VERS First Last First Last BACKWARD FORWARD Press and hold BACKWARD FORWARD FIG. 5.4A MENU NAVIGATION 5.5 CONTROLLER SETTINGS To change the menu option settings:1.
There are two operating displays for SOLARcomfort, which one is shown depends on the setting for setup parameter option ‘Arr’:- 5.6 SYSTEM IMAGE Note:‘Arr’ is set on commissioning to suit the installed system and should not be changed - see 7.1. 1. Standard system for twin or single coil cylinders - Arr 1. Only bottom coil is controlled by AST 100 (R1). 2. System with auxiliary heat source control - Arr 2. Both coils are controlled by AST 100 (R1 & R2).
Solar Pump Shown in pipework to collectors. Flashes when solar pump is running (R1 On). Auxiliary Heating Pump Arr 2 only Shown in pipework to auxiliary heat source. Flashes when auxiliary pump is running (R2 On). 5.8 TOOL BAR The tool bar icons show the current system status. Icon Sta tus Indica tion On Rela y R1 ena bled - s ola r pump On On Rela y R2 ena bled - a ux.
5.9 OPERATING MODE HND1 & HND2 Solar pump icon Auxiliary heat source pump icon Arr 1 When HND1 and/or HND2 are set to On or Off the following icons will be displayed flashing HND 1 Set to Auto - Normal operation. Set to On - Relay R1 On - solar pump running - pump icon flashes. Set to Off - Relay R1 Off - solar pump not running - pump icon not flashing. HND 2 Set to Auto - Normal operation. Set to On - Relay R2 On - auxiliary heat pump running - pump icon flashes.
6. INSTALLATION The pump module and air separator modules should normally be wall mounted in close proximity to the cylinder. 6.1 POSITIONING CONTROLLER Fig. 6.1A gives a typical layout. The AST 100 Solar Controller should be positioned so that the householder has easy access with good visibility of the display. Also, consideration has to given to routing for connection to the pump module, cylinder and collector temperature sensors.
6:3 ELECTRICAL CONNECTIONS All wiring should be carried out to and comply with the current IEE Wiring Regulations. All electrical work must comply with any relevant regulations that apply at the time of the installation. All electrical installation and maintenance of SOLARcomfort must be carried out by a competent qualified installer. DO NOT drill casing for cable entry. 1. 2. 3. 4. 5. All cable sheath clamps must be correctly fitted. The conductor sheaths must be continuous into joint enclosures.
6.4 WIRING DIAGRAM STANDARD SYSTEM - Arr 1 IMPORTANT The mains supply cable must be separated from the sensor cables by a minimum of 15mm. Collector S1 Collector Sensor Arr 1 Collector S4 Energy Monitoring Sensor (option) FUSE 4A Temp. Sensor Pt1000 6 7 S4 N R2 N R1 N L 12 13 14 15 16 17 18 19 20 8 g/y blue S3 brown 5 brown 4 blue S2 blue 3 brown 2 g/y S1 g/y 1 R1 2(1)A 220-240V~ 1.0mm² 3 core heat resistant flex 3093y 1.
6.5 WIRING DIAGRAM SYSTEM WITH AUXILIARY HEATING - Arr 2 IMPORTANT The mains supply cable must be separated from the sensor cables by a minimum of 15mm. Arr 2 S1 Collector Sensor Collector Collector S4 Energy Monitoring Sensor (option) FUSE 4A Temp. Sensor Pt1000 7 S4 8 N R2 N R1 N L 12 13 14 15 16 17 18 19 20 R1 2(1)A 220-240V~ R2 2(1)A 220-240V~ brown 6 blue S3 blue 5 brown 4 brown S2 blue 3 g/y 2 g/y S1 g/y 1 1.
7. COMMISSIONING CONTROLLER 7.1 INITIAL SETTING IMPORTANT Note To change the system settings see 5.5. IMPORTANT To set up the AST 100 Controller the following conditions must exist:1. Mains lead connected to 220 - 240V fused 5 amp supply. 2. Sensor S1 connected. 3. Sensor S2 connected. 4. Sensor S3 connected. 5. Sensor S4 connected (option). On power up the controller will go through an initialisation phase during which the operating control light flashes red then green.
Arr 2 Arr 2 is used for two coil cylinders when the use of both the upper and lower coils of the cylinder are controlled by the AST 100 Controller (R1 & R2). There are two ways that this can be done:- IMPORTANT *Some boilers with integral circulating pumps are not suitable for this application - consult Ariston for further details. IMPORTANT 1. Arr 2 Auxiliary Heat Source The lower solar coil is controlled by the AST 100 Controller, i.e.
7.2 OPTIONS FOR STANDARD SYSTEM Arr 1 Quick reference only, for further details see 7.4 and 7.5 The following menu options will be available when Arr is set to 1 - see 7.1 Set ‘X’ indicates value is display only. Set ‘✓ ‘ *indicates value can be changed using set button. Set ‘reset’ *indicates value can be reset using set button.
7.3 OPTIONS FOR SYSTEM WITH AUXILIARY HEAT Arr 2 Quick reference only, for further details see 7.4 and 7.5 The following menu options will be available when Arr is set to 1 - see 7.1 Set ‘X’ indicates value is display only. Set ‘✓ ‘ *indicates value can be changed using set button. Set ‘reset’ *indicates value can be reset using set button.
7.4 INFORMATION ONLY MENU OPTIONS Note Options that display can be set to zero - for procedure see 5.5. COL # # . # °C The following menu options are display only. When power is switched on to the controller it goes through an initialisation phase and then shows the first of the ‘information only’ options (COL). The forward and backward buttons can then be used to index through the ‘information only’ options. 7.4.
Only when Arr is 2 hP2 hP2 Displays the total hours auxiliary heat source has operated as defined by relay R2 - Auxiliary pump ON time. ### Only when OHQM is On KWh ## Only when OHQM is On MWh ## 7.4.6 KWh and MWh Energy Monitoring Display Only These options are only shown when Energy Monitoring OHQM function is set to ON and a sensor S4 is connected to the collector return pipework. The heat quantity transported is determined from :1. The flow volume, as set by ‘FMAX’ 2.
7.5 SETUP PARAMETERS MENU OPTIONS Note Options that display can be set changed - for procedure see 5.5. Arr 1 Arr 2 To access the ‘setup parameters’ use the forward button to reach the last ‘information only’ option, then press and hold the forward button until the first of the ‘setup parameters’ is shown (Arr). The forward and backward through the ‘setup parameters’. buttons can then be used to index 7.5.1 Arr System Arrangement Range - Arr 1 or Arr 2 ~ Default Arr 1 Arr 1 Arr 2 FIG. 7.
S MX 4.0°K 7.5.4 S MX Maximum Cylinder Temperature Range - 0.5K to 19.5K ~ Default 4.0K S MX is the maximum temperature the cylinder is allowed to reach. In the event of the set S MX value being exceeded, further heating of the cylinder is prohibited by switching R1 Off (solar pump stopped). will be displayed. The S MX setting is overridden when, OCX is set to On and/or OREC is set to On - see 7.5.6 & 7.5.9. EM 140°C 7.5.
OCF Off Only when OCF is On CFR 4°C Note For details of filling the system with glycol see pump manual. 7.5.8 OCF & CFR Antifreeze function OCF Range - On or Off ~ Default Off CFR Range - -10°C to 10°C ~ Default 4°C CFR is only available when OCF is set to On. When OCF is set to On and the collector temperature falls below the set CFR value the solar pump will be switched ON (R1 On). This has the effect of the water from the cylinder warming the collectors to prevent freezing.
7.5.12 FMAX System Flow Rate Range - 0 to 6.0 l/min ~ Default 6.0 l/min Only when OHQM is On FMAX FMAX is only displayed when OHQM is set to On. 6.0l /min Enter the actual flow rate as set on the pump module - see fig 7.5B, also refer to Pump Manual. FIG. 7.5B FLOW RATE SETTING Only when OHQM is On MEDT 1 Only when OHQM is On Only when MEDT is 1 or 2 MED% 45% 7.5.13 MEDT Antifreeze type Range - 0 to 3 ~ Default 1 MEDT is only displayed when OHQM is set to On.
On Relay R2 On, auxiliary heat source pump running. Indicator light flashes red/green and Off flashes on display. Relay R2 Off, auxiliary heat source pump running. flashes on display - LANG En 7.5.17 LANG Language Setting Range - dE, En or It ~ Default En dE En It PROG 68.30 does not flash. set for German set for English set for Italian 7.5.18 PROG Programme Number Display only Displays the current programme number. VERS 7.5.
8. MAINTENANCE 8.1 FUSE REPLACEMENT The AST Controller has a internal fuse located under the front cover - see fig. 8.1A. If the display or Indicator lamp do not light up when power to the controller is switched On it indicates a possible fuse or power failure. A spare fuse is supplied with the controller. Fuse type SMTX T4/250V. FIG. 8.1A FUSE LOCATION 8.2 SENSOR FAILURE Symptoms of a sensor failure are:- COL 888.
Pump is overheated, but no heat transfer from collector to the cylinder; flow and return are equally warm. The collector temperature increases considerably more than the cylinder temperature, the system cannot dissipate the heat. Is there air in system? Is the solar pump operating correctly ? NO YES NO Is collector circuit dirty/ blocked? Vent the system; increase system pressure to at least static primary pressure +0.
A B Cylinders are cooled during the night. The gravitation (head) of the system may too high. Fit stronger non-return valve. Or fit electrical two way valve between the pump and the cylinder, wired with pump (R1) when pump is On valve is open. Does the solar pump run during the night? NO YES Check the controllers’ settings. Rever t to default settings. Is collector temperature higher at night than ambient? NO YES Check the non return valves in the system are working correctly.
9. USER INSTRUCTIONS IMPORTANT The AST 100 Controller will have been set by the installer to reflect the system as installed. Under no circumstances should any of the system parameters be changed by the householder. The householder may reset the hour counters and energy monitor - see 9.3. 9.1 CONTROLLER FUNCTIONS INDICATOR LIGHT Indicator Light Off No power to the SOLARcomfort Controller. Green Power is On - normal condition. Red/Green flashing Initialisation phase. HND1 or HND2 are set to On.
9.4 HOW TO RESET COUNTERS TO RESET A COUNTER 1. Press forward button to scroll through to required option. If the menu option can be changed or reset displayed. will also be AST 100 SET flashes, the value will be reset 2. Press and hold set button until to 0. 3. To confirm press set again until it stops flashing. BACKWARD FORWARD To interrupt reset procedure, do not press any button for about 5 seconds and the controller option will return to previous setting. 9.
TERMS AND CONDITIONS OF GUARANTEE The SOLARcomfort AST 100 Controller is guaranteed for 2 years. Please read these terms and conditions which are in addition to any terms and conditions detailed in this book or any registration card supplied with your appliance. SOLARcomfort solar thermal systems must only be installed and commissioned by Ariston trained and approved installers. Failure to comply with this requirement will invalidate the warranty. A charge will be made to the owner of the appliance if:1.
