USDT 2004
Installation and User’s Guide
Introduction
General Information
2
Installation
Collector Sensor
3
3
5
6
6
Control Box
Power Connection
Display Window
Operation
Basic Operation (Factory Setting for Only Two Sensors)
Manual Operation Mode
7
8
Three Sensor Operation
9
Sensor Selection
11
12
Alarm Functions and Diagnostics
Energy Calculations
Troubleshooting
13
14
ã Thermo Technologies
5560 Sterrett Place • Suite 115
Columbia, Maryland 21044
Phone 410.997.0778 • Fax 410.997.0779
e-Mail [email protected]
Revision 7, November 2005
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION
Note: This installation procedure is for guidance only, and the installer should verify its
suitability. Make sure that the solar system is physically installed, manually tested, and ready for
controlled operation.
he following safety precautions are strongly recommended:
T
1. Before attempting to install and operate the unit read this instruction manual carefully.
2. Only suitably qualified personnel should carry out installation and required maintenance.
3. It is recommended that the unit be connected to the power supply via an isolating switch of 6
amp.
4. WARNING: When the unit is connected to the 115-volt power supply and the cover is
opened, high voltage circuits will be exposed.
When installing the unit, all required
connections should be completed and the cover attached to the controller box before turning
the power on. Ensure that all connections are secure. If any maintenance work is required
isolate the unit from the power supply before removing the cover. Never leave the unit
unattended if the cover has been removed and the power supply is connected.
5. Do not exceed unit ratings of 3.15 amps (1/6 HP or 245 Watts pump).
6. It is advisable to route power cables away from sensor cables.
ensor installation: Temperature sensors may be installed in fluid lines by mounting in a
tee or strapping it to the piping directly. For the system to function correctly, it is essential
that the sensors are located and installed properly. They MUST be pushed completely
into the optional sensor pockets (Thermowell is not supplied). Sensors must be well insulated in
order to prevent them from being influenced by the ambient temperature.
When used outdoors, water must not enter the immersion sleeves (lasting impedance change).
Exposure to moisture (e.g. condensation) can diffuse through the cast resin and damage the
sensor. In this event, heating at approx. 195 °F for one hour may reverse the damage.
When sensors are used in open loops or swimming pools, corrosion-resistant immersion sleeve,
(sensor pockets), must be used.
l
Collector sensor (red cable with protective terminal box): Either push into a thermowell,
(sensor pocket), which is soldered or riveted directly to the manifold (vacuum tubes). Alternately,
3
Download from Www.Somanuals.com. All Manuals Search And Download.
strap the sensor to the collector outlet pipe or the absorber (flat plate collectors) that projects from
the collector housing. Ideally, house the collector sensor (encased in a suitable sensor pocket)
into a T-piece on the collector return outlet. Protect the sensor cable from UV and moisture.
l
Return (tank) sensor (white cable): The sensor required for the solar loop return is installed
in the lower part of the storage tank. If there is no provision for this tank sensor, push the sensor
beneath the insulation – keeping it close to the inner tank wall at the desire tank location.
For external heat exchangers, the tank sensor should be installed with an immersion sleeve in the
return leg (cold side) of the heat exchanger. In tanks with integrated heat exchangers, the sensor
pocket should be fitted at the exchanger's return to the collector.
l
Pool sensor installation: Place a heat conductive T-piece on the suction line directly at the
pool outlet and screw in the sensor with an immersion sleeve (check corrosion resistance of the
material used). Alternately, attach the sensor with clips or adhesive tape, using the appropriate
thermal insulation to guard against environmental influences.
l
Sensor cable extension: Sensor cables (22/4 AWG telephone cable, you need only two
wires of 4) can be extended up to 150 ft. A connection between the sensor and extension can be
established as follows:
Cut the supplied heat-shrinkable tubing to desired length (about ½ ”). Slide tubing over one end of
wire to be sliced (after removing enough outer insulation to accept the tubing). Splice the wire
and slide tubing over the splice. Heat gently all around until tubing shrinks tight.
Slide larger tubing (about ¾ “) over the entire completed splice. Heat gently all around until tubing
shrinks tight. This connection can then be drawn gently into the pipe work. Only two of the wires
are required for the sensor cable; the other two wires are spare wires.
Caution: Do not overheat the tubing! Remove heat as soon as the tubing shrinks tight, as
material will continue to shrink. With flame source, use even back and forth motion all around
tubing. A heat gun may be used, if available. Let tubing cool for maximum strength.
ontroller unit installation: For viewing comfort, the controller unit should be positioned
at eye level. For optimum longevity, avoid extremes of temperature in the placement of
electronic equipment. In addition, avoid heavy electrical loads, switches or contactors as these
may cause electrical and electromagnetic interference with the unit (when switched on or off).
4
Download from Www.Somanuals.com. All Manuals Search And Download.
Undo the screw at the top of the housing. The control electronics are mounted on the enclosure
cover. The controller enclosure can be screwed to the wall with cable entry grommets pointed
downwards. Use the supplied plastic bridges to secure power and sensor cables.
Base of the unit to be mounted at eye-level and wired as shown above
Caution: Controller wiring should only be done when the unit is not energized. It is possible to
damage the control unit if it is assembled under voltage. Miniaturized terminal blocks are used for
making wiring connections. The wire is held in place within the terminal with screw that provides
excellent contact without damage to the wire.
Sensor Cable Connection: Use up to an 18 AWG stranded wire to connect the sensor cables to
the unit. The S1 terminal should be connected to the collector sensor (higher temperature); the
S2 terminal is designated for the tank sensor (lower temperature). And the S3 terminal is
reserved for the advanced usage of the unit such as third temperature sensor (in program mode
1) or flow meter input for BTU operation in advanced programming mode.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
ower Connections: A small blade screwdriver may be used to fasten miniaturized
terminal block screws while the corresponding wire is inserted.
NOTE 1: Always disconnect the controller from power supply before opening the housing.
NOTE 2: The controller should be properly grounded. Flexible wires, 18/3 AWG
(gauge/conductor) simplify connection to the terminals. The power terminal block will
accommodate wire sizes to 14 AWG. All other connections should be secured and adequately
tightened, as loose power connections will over-heat, and may cause fire.
NOTE 3: It is important that the specified output loads (245 Watts) are not exceeded. Where
these loads expect to exceed, external relays must be used. It is good practice to install a switch
to disconnect the controller and pump from power. Always keep power cables away from sensor
cables and other low voltage signal cables.
NOTE 4: To protect against lightning damage, the system must be grounded according local
regulation. Sensor failures due to the weather or electrostatic are mostly due to poor grounding.
our controller displays requested information one at a time. The unit display window
has three lines to inform you about the system's status, unit of displayed parameter
and its value.
Upper Line Display
Center Line Display Sensor ID and its reading in normal mode (user interface window)
Lower Line Display Set-point indicator that illuminates only during programming mode
Symbolic display of sensor location, reading unit, and operation domain
ð
ï
ò
Push selection key once to move to the next selection; or increase the selected
parameter by one unit.
Push selection key once to move to the previous selection; or decrease the selected
parameter by one unit.
Push selection key once to enter the advanced (Par or *Men) mode. Once in selected
mode, press one more time to select the parameter in that mode. Selected parameter
blinks allowing the user to modify it. You can modify the selected parameter while the
middle window blinks by pressing the ïor ðkey.
ñ
Push selection key once to accept selection (blinking stops showing the new set-point
steady) or go back to the previous selection.
* Menmode is for use in advanced applications only. See P.9.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Use selection keys ïðduring normal system operation to display the desired parameter:
o
T1 xxx
T2 xxx
T3 xxx
Collector temperature in F
Tank temperature in F
o
Reading of the third sensor; if the third sensor is not used it displays a fixed
reference temperature of 250oF
Collector power in [kW]
Energy collected in [MWh]
Energy collected in [kWh]
XX xxx
YY xxx
ZZ xxx
GAL xx
Flow rate [gallon/h]
Operation Mode – Example: Following chart displays system temperatures
At the upper text line, the icon for the text is always displayed. Program symbol is displayed
during the setting of parameters at the lower text line. In addition, an arrow icon > is displayed
while pump is running.
Program Mode - Pressing the selection key ðseveral times allows you to enter into the
program mode (Par). Push selection key òonce to enter the program mode.
Basic Operation (Factory Setting for Only Two Sensors)
PROGRAM 0: (basic 2-sensor program)
Par
Using the navigation key ^_ allows you to select the desired parameter while you are in
the program mode. Press the selection key òonce to select the parameter in the
window. Selected parameter blinks allowing you to modify it. You can modify the
selected parameter while the middle window blinks by pressing the ïor ðkey. The
unit accepts the new value by pressing the ñkey once. To avoid unintentional set-point
changes, the user must enter the access code “32” to manipulate factory settings.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
RUV X.X – This display shows the software revision number.
NR O – This is PROGRAM 0 which indicates simple operation of unit as a Universal Solar
Differential Temperature (USDT) controller. Change this value to 1 (NR 1) for activation of the
third sensor or pulse flow meter input (PROGRAM 1).
Hysteresis Bandwidth
User can program hysteresis (temperature range for output control) by using max? and max=.
For
max?1
Pump stops above tank temperature (T2)
max=1
Pump runs again below this set point (T2)
Delta T Adjustment
diff=1
Pump runs when temperature difference between collector T1 (collector) and T2
(tank) exceeds this value. Factory setting is 15 oF. Consult your collector
manufacturer for the recommended value.
diff?1
Pump stops when temperature difference between collector T1 (collector) and T2
(tank) reaches this value. Factory setting is 7 oF. Consult your collector
manufacturer for the recommended value.
Manual Operation Mode
AUTO
The above display indicates that the unit is working in automatic mode. The
pump starts at a temperature difference of 15 oF and runs as long as ? T is
above 7 oF. The B symbol appears in upper display line next to the collector
8
Download from Www.Somanuals.com. All Manuals Search And Download.
symbol while the pump is running. User can switch to manual mode by pressing
òkey. By pressing ðkey while centerline blinks, a hand symbol Gin lower line
shows manual operation. Pressing ðone more time lets you turn the pump ON or
OFF. By pressing ñkey you change the pump operation.
Advanced Operation (Setting for Three Sensors and Flow Rate Input)
To change the factory setting of two sensors you need to advance to the Men domain using
access code “64”:
Navigation of advanced features of the unit and selection of parameters is the same as before by
using ïòñðkeys:
Advancing – Press the Advance key ïð briefly to advance to the next selection or to
increase/decrease the set point of the selected parameter. Hold it down for fast change.
Acceptance – Press Set-Up key òonce to select the parameter. Press ñkey to accept the
selection or the set point.
Three-Temperature Sensor Setting (PROGRAM 1):
USDT 2004 accepts two different sensor types or a reference value. Press the
Advance key ïðbriefly until SENSOR appears in centerline and press the key ò.
Select S3 sensor and change the 250 reference value to read KTY sensor:
Note: Tank over heating protection in program mode 1 (NR 1) controls the pump
operation based on temperature reading by T2 and T3 sensor readings.
Selection:
S3
Designation:
KTY Thermistor sensor (2000 O at 25 C)
Sensor 3 (tank) selection
o
Accept this setting by pressing ñkey. If you wish to change set points for pump
operation, follow instruction explained in Basic Operation section (these changes
are made in Par domain).
max?1
Pump stops above tank temperature (T2)
max=1
Pump runs again below this set point (T2)
max?2
Pump stops above tank temperature (T3)
9
Download from Www.Somanuals.com. All Manuals Search And Download.
max=2
Pump runs again below this set point (T3)
Energy calculation mode (PROGRAM 1):
USDT 2004 computes the energy production as a function of the temperature
differential and fluid volume. In addition, the system anti-freeze (Glycol) percentage
should be entered as it affects the thermal conductivity and heat transfer rate.
Press the Advance key ïðbriefly until BTU appears in centerline and press the
key ò. Designate sensor inputs for example T1 as collector inlet and T2 as
collector outlet temperature. F SEN can be connected to a flow meter or be a
constant number in a closed loop solar system.
BTU
Energy calculation mode
S IN
Sensor port selection for inlet temperature (1, 2, 3, --)
S OUT
F SEN
outlet temperature (1, 2, 3, --)
Sensor port selection for flow rate (1, 2, 3, --)
Energy calculation will be initiated only after temperature sensor ports are
designated. Flow rate can be either a constant number to be entered by user, or
from a flow meter input. To activate the energy calculation without using the flow
meter's impulse input, a dash (-) must be selected for F SEN channel followed by
the constant flow rate in gph (gallon per hour) unit.
LLP
GAL
Flow meter rate impulse number in liter per pulse, if flow meter is
used
Constant flow rate in gph instead of flow meter reading in (--)
sensor mode
GLYCOL
CLEAR
DIF
Anti-freeze percentage
Sets the BTU meter's counter to zero
Sensor calibration
The output of USDT 2004 unit is kW for system power and kWh or MWh for
collected energy.
dvanced Mode – USDT 2004 is extremely powerful. It can be used in wide range of applications
such as a BTU meter, a boiler fuel optimizer, a swimming pool temperature differential
controller, a greenhouse temperature regulator, an air handler, and more. Factory
settings are exclusively for solar water heating systems in the USA market. However, all its
parameters can be changed to meet the unique requirements of other applications. The user may
use access code "64" to modify the USDT 2004 program mode and its parameters.
Men
This mode is for advanced applications
The factory setting will be retrieved by pressing and holding òkey during powering of the
unit. A “RESTOR” displays for three seconds while factory settings are restored.
Selection of different sensor types, energy collection calculation parameters, system protection
and optimization can be can be modified in advanced (Men Domain) mode.
Mode
Operation
SENSOR
SGUARD
Selects sensor type
Protects system from overheating and frost
10
Download from Www.Somanuals.com. All Manuals Search And Download.
START
ALARM
BTU
Starts pump at pre-set insolation (solar radiation intensity)
Enables/Disables protection functions
Energy calculation and setting
ensor Designation – USDT 2004 accepts two different sensor types or a reference
value . User can program a constant reference temperature instead of a sensor output.
The factory-preset sensor is the thermistor (KTY 10) type. The KTY 10 tank sensor,
white wire, should be used in a conditioned environment and will not be permanently damaged up
to 360 F.
o
Selection:
S1
S2
S3
Sensor 1 (collector outlet) selection
Sensor 2 (collector inlet) selection
Sensor 3 (tank) selection
Designation:
o
PT
PT 1000 sensor (1000 O at 0 C, not available in US market)
o
KTY
250
- 4
Thermistor sensor (2000 O at 25 C)
250 oF reference temperature
- 4 oF reference temperature
Sensor wires can receive electromagnetic pulses, which can result in a wrong temperature
reading. The USDT 2004 reads sensor values every 50 ms. It can bundle several readings and
process their average.
AV 1 Sensor 1 average
AV 2 Sensor 2 average
AV 3 Sensor 3 average
The numbers of samples can be programmed from 4 to 20. The impedance characteristics of
sensors temperature dependencies are represented in the following table:
T
0
10
20
25
30
40
50
60
70
80
90
100°C
R(KTY) 1630 1772 1922 2000 2080 2245 2417 2597 2785 2980 3182
3392 W
rost and overheating protections - Pump operation can be manipulated by the user in
both collector stagnation and frost conditions. The set-up is possible in System Guard,
SGUARD, domain.
Overheating protection – The Circulation pump may not be powerful enough to circulate the
heat transfer fluid in the solar loop with air pockets. User can program the pump to stop at a
desired maximum collector temperature, shown by ? symbol, to protect the pump. The USDT
2004 will take over the normal operation after the temperature decreases to an acceptable
o
working temperature, shown as =. This feature is disabled at 299 F set point.
Frost Protection – Frost protection in the sun-belt region is provided by circulating water in the
solar loop when freezing conditions exist. Regardless of the temperature difference ? T, the
11
Download from Www.Somanuals.com. All Manuals Search And Download.
circulation pump runs when the collector temperature is below a programmable minimum
temperature, shown by = symbol. The pump stops as soon as the temperature in the solar loop
reaches a safe region programmed by the ? symbol. This feature is also disabled at the factory
by entering - 4 oF.
min= Pump runs below this temperature
min? Pump stops above this temperature
tart functions - The Circulation pump can be programmed to start on low insolation
level. The Start function feature is useful when heat transferred to the collector sensor is
not fast enough for early start; especially when the collectors are flat mounted.
The enabled start function runs the pump at a given solar radiation or programmed temperature
difference. The feature is disabled at the factory.
START
ENABL
DISAB
Start function screen
Enable start function
Disable start function
If this feature is selected, following parameters must be adjusted for proper operation:
SENS
Pyranometer port designation (radiation monitoring sensor port)
1
2
3
--
Sensor 1
Sensor 2
Sensor 3
Manual input in next step
INS
CIRC
INT
Radiation threshold in W/m2
Pump runtime in seconds
Maximum interval time in second
Number of flushes
FLU
The following example activates the circulation pump at 200 W/m2 and runs it for 15 seconds. If
rT condition is met within the time period, the pump stays on.
INS
20
CIRC 15
larm functions - User can enable the alarm function of the USDT 2004 in the ALARM
screen. Status of sensors and circulation pump can be viewed if alarm function is active.
A
A ON
A OFF
Alarm function enable
Alarm function disable
The status of the system can be monitored in the Stat Mode only if the corresponding feature is
active. The following example shows a system condition with a circulation problem:
OT OFF
OT OK
Overheating feature disable
No overheating
1 SHORT
2 SHORT
1 OPEN
Short circuit in sensor 1 wiring
Short circuit in sensor 2 wiring
Disconnection in sensor 1 wiring
12
Download from Www.Somanuals.com. All Manuals Search And Download.
2 OPEN
OK
NO CIRC
OK CIRC
CLEAR
Disconnection in sensor 2 wiring
System operates normal
o
r T is more than 108 F in last 30 minutes
Pump is running
Clears NO CIRC display after correction
nergy calculation - Energy gain is calculated by obtaining the temperature increase of
heat transfer fluid across the solar collector. The amount of fluid flow through the
collector is registered by an in-line flow meter. USDT 2004 computes the energy production as a
function of the temperature differential and fluid volume. In addition, the system anti-freeze
(Glycol) percentage should be entered as it affects the thermal conductivity and heat transfer
rate.
BTU
Energy calculation mode
S IN
S OUT
Sensor port selection for inlet temperature (1, 2, 3, --)
outlet temperature (1, 2, 3, --)
F SEN
Sensor port selection for flow rate (1, 2, 3, --)
Energy calculation will be initiated only after temperature sensor ports are designated. Flow rate
can be either a constant number to be entered by user, or from a flow meter input. To activate the
energy calculation without using the flow meter's impulse input, a dash (-) must be selected for F
SEN channel followed by the constant flow rate in gph (gallon per hour) unit.
LLP
GAL
GLYCOL
CLEAR
DIF
Flow meter rate impulse number in liter per pulse, if flow meter is used
Constant flow rate in gph instead of flow meter reading in (--) sensor mode
Anti-freeze percentage
Sets the BTU meter's counter to zero
Sensor calibration
The output of USDT 2004 unit is kW for system power and kWh or MWh for collected energy.
The energy calculation dependents on flow meter accuracy, the temperature sensors class, and
their locations. The flow meter is a mechanical device and its accuracy fluctuates over time.
Therefore, the user should calibrate the flow meter and incorporate temperature sensor tolerance.
The supplied Thermistor sensor has an accuracy of ± 2 oF. DIF represents the temperature
difference between two sensors. User can increase the accuracy of reading by adjusting the DIF
parameter. The energy calculation becomes accurate at temperature range that this reading
adjustment is made.
13
Download from Www.Somanuals.com. All Manuals Search And Download.
roubleshooting
T
In general, all of the settings in the menus Par and Men and the terminal should first be checked
if there is a malfunction.
Malfunction, but "realistic" temperature values:
·
·
Check program number.
Check the switch-on and switch-off thresholds and the set differential temperatures. Have
the thermostat and differential thresholds already been reached?
·
·
Were the settings in the submenus (Men) changed?
Can the pump (output) be switched on and off in manual mode? If a forced pump “ON”
and “OFF” lead to the appropriate reaction at the output, the unit is certainly in order.
·
·
Are all of the sensors connected with the right terminals? Heat up the sensor using a
cigarette lighter and watch the display.
Did you change the reference temperature 250 (three sensor operation) to KTY?
Incorrect display of temperature(s):
·
·
·
Displayed values such as -999 if a sensor short-circuits
or 999 if there is an interruption do not necessarily mean a material or terminal error.
Are the right sensor types (KTY or PT1000) selected in the menu Men under SENSOR?
The factory settings set all inputs to KTY.
The sensor can also be checked without a measuring instrument by connecting the presumed
defective sensor to a terminal that works and checking the display. The resistance measured by
an ohmmeter should have the following value depending on the temperature:
T
0
10
20
25
30
40
50
60
70
80
90
100°C
R(KTY) 1630 1772 1922 2000 2080 2245 2417 2597 2785 2980 3182
3392 W
The settings of the parameters and menu functions ex works can be restored any time by
pressing the down arrow (enter) while powering the controller. The sign that appears for three
seconds on the display is RESTOR for load factory settings.
If the system is not in operation while connected to the power supply, the 3.15A quick-blowing
fuse that protects the control system and the output should be checked and exchanged if
necessary.
As the programs are constantly being improved, there may be a difference in the sensor, pumps,
and program descriptions. Only the enclosed manual (identical serial number) applies for the
equipment supplied. The program version for the manual must correspond to the equipment
version.
If the control system is found to be malfunctioning despite the checks described above, please
contact your retailer or Thermo Technologies directly. The cause of the error can only be
determined if the settings of the unit is known. The schematic diagram of the system in question
is a great help to isolate the potential problem.
14
Download from Www.Somanuals.com. All Manuals Search And Download.
|