Adrian Bretsch ba6622bed7 Initial commit: ThermIQ ASP1 documentation

All Markdown documentation files for the ThermIQ smart hybrid heating system.
PDFs excluded via .gitignore — generated on demand.

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

2026-05-08 12:30:03 +02:00

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ThermIQ — Schaltschrank (Electrical Cabinet) ASP1

Adrian is responsible for the Schaltschrank design and build. This document tracks decisions, component list, wiring notes, and open items.

Cabinet Designation: ASP1

First installation: Walda, Germany.

AC Power Distribution

Grid 230V/400V
    └── Q0: FI/LS (RCD + MCB) — main protection
            └── 230 V AC busbar
                    ├── LS Miner 1 → K10 (contactor) → Miner 1 (2x Schuko)
                    ├── LS Miner 2 → K11 (contactor) → Miner 2 (2x Schuko)
                    ├── LS Pumpen → P3, P4, P5 (Wilo Stratos PICO plus)
                    ├── LS Ventile → Relay block K3-K6 → RV1, RV2 (Belimo CQ230A)
                    ├── LS RK → K2 → Rückkühler fan
                    └── LS PSU → 24 V DC PSU

24 V DC Distribution

24 V DC PSU
    ├── RevolutionPi (Core + DIO + AIO)
    ├── Safety relay (coil supply + input circuit)
    ├── Relay coils: K2, K3, K4, K5, K6, K7
    └── Fuses per branch

Relay / Contactor Summary

ID	Type	Coil	Load	Function
K2	Relay	24 V DC	230 V AC	Rückkühler fan
K3	Relay	24 V DC	230 V AC	RV1 AUF
K4	Relay	24 V DC	230 V AC	RV1 ZU
K5	Relay	24 V DC	230 V AC	RV2 AUF
K6	Relay	24 V DC	230 V AC	RV2 ZU
K7	Relay	24 V DC	potential-free	Heat pump EVU I1
K10	Contactor	safety output	230 V AC	Miner 1 power
K11	Contactor	safety output	230 V AC	Miner 2 power

RevolutionPi I/O Mapping

Digital Outputs (DO)

DO	Function	Load
DO_K2	Rückkühler fan relay	K2 coil
DO_K3	RV1 AUF	K3 coil
DO_K4	RV1 ZU	K4 coil
DO_K5	RV2 AUF	K5 coil
DO_K6	RV2 ZU	K6 coil
DO_EVU_SPERRE	Heat pump block	K7 coil

Digital Inputs (DI)

DI	Signal	Source
DI_SAFETY_OK	Safety relay output	Safety relay
DI_K10_FB	K10 feedback	K10 Hilfskontakt
DI_K11_FB	K11 feedback	K11 Hilfskontakt
DI_RK_FAULT	Rückkühler fault	Optional

Analog Outputs (AO)

AO	Function	Range	Target
AO1	P3 setpoint	0–10 V	Wilo PICO BMS module
AO2	P4 setpoint	0–10 V	Wilo PICO BMS module
AO3	P5 setpoint	0–10 V	Wilo PICO BMS module

Analog Inputs (AI)

AI	Signal	Range	Notes
AI1	Temperature Pufferspeicher	(TBD)	4-20 mA or 0-10 V
AI2	Temperature Warmwasser	(TBD)

Wiring Notes

0–10 V pump cables: use shielded cable, shield connected to PE at cabinet end only
Safety circuit: NC contacts in series for E-Stop, FLOW OK, TEMP MAX
Contactor feedback: Hilfskontakt (NC) in series in safety relay feedback loop
EVU relay K7: potential-free — verify no voltage is applied to Buderus I1
Miner Schuko: both plugs of each miner routed through its contactor
PE: all metal enclosures to PE

Commissioning Checklist

Verify Q0 FI/LS trips correctly
Verify safety relay trips on E-Stop 1
Verify safety relay trips on E-Stop 2
Verify safety relay trips on FLOW OK open
Verify safety relay trips on TEMP MAX open
Verify K10 and K11 de-energize on safety trip
Verify K7 does not inject voltage into Buderus I1
Verify RevPi AO1-AO3 reach correct voltages (0, 5, 10 V)
Verify P3, P4, P5 respond to 0-10 V setpoint
Verify RV1 opens/closes via K3/K4
Verify RV2 opens/closes via K5/K6
Test miner power-up via gRPC API
Verify Deye RS485 data readable from RPi

Open Items / Decisions Pending

Exact current ratings for Miner 1/2 Schuko circuits (S19J ~3200 W = ~14 A each)
Confirm Pufferspeicher / Warmwasserspeicher sensor types (PT1000 / 4-20mA)
Confirm RevPi AIO module exact model (AIO hat or separate module)
Decide if Hand/0/Auto switches needed on valve circuit
Confirm Rückkühler motor protection (motor starter vs. MCB)
Smart meter integration protocol
Battery connection to Deye (type, capacity)

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