Thermo Technologies USDT 2004B Manuale utente

USDT 2004

Installation and User’s Guide

Introduction

General Information 2

Installation

Collector Sensor 3

Control Box 5

Operation

Power Connection 6

Operating Display 6

Changing Factory Settings 8

Manual Operation Of Pump 9

Advance Operation 10

Frost and Overheating Protections 12

Energy Calculations 14

Troubleshooting 15

Thermo Technologies

9009 Mendenhall Place • Suite E

Columbia, Maryland 21045

Phone 410.997.0778 • Fax 410.997.0779

e-Mail i[email protected]

Revision 4.0, October 2007

Introduction

Note: The information supplied in this manual is for guidance only -no part of this may be used

for any agreement, whether express or implied, or to form any contract. Thermo Technologies

reserves the right to change specifications without prior notice.

SDT 2004 is a powerful temperature differential control unit and may be used in a wide

range of applications. The user has the choice of *two modes:

Par Mode (access code 32) –This program is USDT 2004's basic program. It uses two sensors

to control a simple solar water heating system and factory settings may be altered.

Men Mode (access code 64) -This program, initiated by the user, customizes USDT 2004 for

applications involving a BTU Meter or where a third sensor (or reference value) is required.

*NOTE: USDT 2004 may be used for several advanced applications originating inMen Mode.

USDT 2004 has the following functions:

•2 inputs for temperature sensors

•Input for flow rate input or additional temperature sensor

•BTU meter capability for constant flow rate or with a puls flow meter

•Adjustable (-4o F to 39 o F) frost protection

•Adjustable (32 o F to 299 o F) overheating protection

•Adjustable (1o F to 99 o F) temperature difference ?T

•Manual pump operation

•Digital display of all parameters

•System status and diagnostic displays

Two -Sensor Operation

At its most basic function, USDT 2004 is a two-sensor

solar hot water controller. One sensor (S1 in diagram)

monitors the collector temperature whilst the other sensor

(S2) monitors the temperature at the bottom of the

storage tank. The solar loop circulation pump runs while

the collector temperature exceeds the tank temperature

by an adjustable temperature difference diff. To avoid

overheating, the circulation pump stops if the tank

temperature (T2) reaches the adjustable high limit (TMAX)

temperature. The pump A1 runs only when the

temperature at the collector sensor location S1 is higher

than the tank temperature at location S2 by at least diff

(?T). The pump stops if diff is less than the preset value

or, when the temperature at location S2 has reached the

TMAX :A1 (ON) only when S1 > (S2 + diff) & S2 < T max

The temperature hysteresis (a lagging in the set-point) may over-ride diff to avoid pump cycling.

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:

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 on/off switch or plug.

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

well or strapping directly to piping. For the system to function correctly, it is essential that

the sensors are located and installed properly. Sensors must be well insulated in order to

prevent influence by the ambient temperature.

When used outdoors, water must not enter the immersion sleeves. Exposure to moisture (e.g.

condensation) can diffuse through the cast resin and damage the sensor.

Corrosion-resistant immersion sleeve (sensor pockets) must be used when sensors are used in

open loops or swimming pools.

l Collector sensor (red cable with protective terminal box): Push into a thermowell, (sensor

pocket), which is soldered or riveted directly to the manifold (vacuum tubes). Alternately, 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 Tank sensor (white cable): This 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 desired 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; 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 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 kept spare.

Caution:Do not overheat the tubing! Remove heat as soon as the tubing shrinks tight, as

material will continue to shrink. With a heat gun or flame source, use an even back and forth

motion all around tubing. 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).

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 or 22 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 a third temperature sensor or flow

meter input for BTU operation.

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 the 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 up to 14 AWG. All 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.

OPERATION OF

DIGITAL DISPLAY

our controller displays information one request 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 Symbolic display of sensor location, reading unit, and operation domain

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

ðPush selection key once to move to the next selection; or increase the selected

parameter by one unit while display is blinking.

ïPush selection key once to move to the previous selection; or decrease the selected

parameter by one unit while display is blinking.

òPush 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.

ñPush selection key once to accept selection (blinking stops showing the new set-point

steady) or go back to the previous selection.

*Men mode is for use with advanced applications.

Use selection keys ïð during normal system operation to display the desired parameter:

T1 xxx Collector temperature in oF

T2 xxx Tank temperature in oF

T3 xxx Reading of the third sensor; if the third sensor displays a fixed reference

temperature of 999 oF, the sensor designation can be wrong or the sensor is not

connected correctly (open circuit).

G xx Flow rate [gallon/h] –programmable by user

XX xxx Collector power in [kW] –amount of energy collector is producing

YY xxx Energy collected in [MWh]

ZZ xxx Energy collected in [kWh]

STAT Display of the system’s status. Any current problems outlined.

Example: The following windows display the temperatures of T1 (the collector), T2 (the

bottom of the tank) and T3 (3rd sensor see P.11)

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

Basic Mode (Par): Pressing the selection key ðseveral times allows you to navigate sensor

temperatures and energy output and also access (Par)mode. Push selection key òonce to enter

the program mode.

Advanced Operations: Pressing the selection key ðseveral times allows you to enter into the

advanced mode (Men). Push selection key òonce to enter the program mode.

CHANGING FACTORY SETTINGS:

Temperature differentials and manual operation of pump

Par Mode is USDT 2004's basic program; it uses two sensors to control a simple solar

water heating system. The unit is already factory set with ON/OFF pump temperatures.

However, these temperatures may be altered if required:

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. Please make sure that you are in Par mode.

RUV 3.5 –Displays the software revision number corresponding to this manual.

PR O –Inapplicable

PROGRAMMING THE TEMPERATURE RANGE

USDT 2004 is factory set at approx T2 > 161 oFPUMP OFF, T2 < 150 oFPUMP ON. Once Par

mode has been accessed, using Code 32 as illustrated above, the user may program a different

temperature range. There are two temperatures that should be entered:

Tank Overheating Protection

In Par Mode, user can customize the temperature range by using max?and max=.Use the

navigation key ^_ in Par to locate max temperatures and push selection key òonce to make

changes:

max?1Pump stops above tank temperature (T2)

max=1Pump runs again below this set point (T2)

Temperature Differential Adjustment

diff=1Pump runs when temperature difference between collector T1 (collector) and T2

(tank) exceeds this value. Factory setting is 15.1 oF. Consult your collector

manufacturer for the recommended value.

diff?1Pump stops when temperature difference between collector T1 (collector) and T2

(tank) reaches this value. Factory setting is 7.0 oF. Consult your collector

manufacturer for the recommended value.

Manual Operation of Pump

The pump can be manually turned on or off once Par mode has been accessed using Code 32:

AUTO Use the navigation key ^_ in Par to locate the pump window O AUTO.Push

selection key òonce to enter pump operation (ON or OFF). When the manual mode

has been selected, an icon (a small icon symbolizing a right hand image) appears

under the text line.

Automatic mode

Manual ON

Manual OFF

ADVANCED OPERATIONS

or 3rd sensor designation

Men Mode customizes USDT 2004 for applications in conjunction with a BTU meter, a third

sensor or reference value. If BTU capability is not required, this program may also, for

example, measure the flow rate or the temperature of the storage tank (T3, top of the tank).

Men Use the navigation key ^_ to navigate to the Men Window. Use Code 64 to access and

program Men mode.

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.

ENGL –Pre-Set to English. Spanish available in INTER.

CODES –64 for Men Mode.

SENSOR : USDT 2004 accepts two different sensor types or a reference value. Press the

Advance key ïð briefly until SENSOR appears in centerline and press the key ò. Ensure the

reference value readsKTY sensor, all factory supplied sensors are KTY type:

SDT 2004 is extremely powerful. All factory settings can be changed to meet the

unique requirements of other applications. All advanced operations have their origin in

Men Mode where USDT 2004’s parameters may be altered depending on the

application.

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