Lochinvar Solar Differential Control Installation Manual

SL-DC-I-O Rev A

Solar Differential Control

Installation and Operation

Manual

 WARNING:

This manual must only be used by a qualified heating installer/service technician. Read all instructions, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Contents

HAZARD DEFINITIONS .................................................... 2

1. INTRODUCTION

Application and Safety Instructions ................................... 3

Main Characteristics ........................................................... 4

Technical Characteristics ................................................... 4

Display ............................................................................. 5-6

2. SERVICE

Language ........................................................................... 7

Time and Date .................................................................... 7

Systems 1-8 .................................................................... 8-9

Extra ................................................................................ 10

Thermostat Function ................................................. 10

Cooling Function ....................................................... 10

Diffcontrol Function ................................................... 11

Antistagnation Function ............................................ 11

External sensor ............................................................... 12

Protection Function .................................................... 12-13

Maximum Temperature............................................. 12

Cooling/ Recooling ................................................... 13

Overheat/ Freeze Protection .................................... 13

Sensor Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Impulse Flow Meter .................................................. 14

GDS1 ........................................................................ 14

GDS2 ........................................................................ 15

Energy Measurement ...................................................... 15

Warm sensor ........................................................... 15

Cold sensor ............................................................. 16

Flow 2 ...................................................................... 16

Pump P1/ Pump P2 ........................................................ 17

Glycol and Glycol Mix...................................................... 18

Factory Setting ................................................................ 18

Reset operation time ....................................................... 18

Time graph temperature .................................................. 19

Time graph operation ...................................................... 19

Calibration Sensors ......................................................... 19

Priority Tank .................................................................... 19

P1 // P2 function in system 5 .......................................... 19

3. SETTINGS MENU

Maximum Temperature tank 1 ........................................ 20

dTMaximum tank 1 .......................................................... 20

dTMinimum tank 1 ........................................................... 20

dTMaximum return .......................................................... 20

dTFs ................................................................................ 20

dTMinimum tank 1 ........................................................... 20

Minimum rev pump .......................................................... 20

Minimum Temperature collector ...................................... 21

Maximum Temperature tank 2 ........................................ 21

dTMaximum tank 2 .......................................................... 21

dTMinimum tank 2 ........................................................... 21

Delay P2 .......................................................................... 21

Extra Functions ........................................................... 22-23

Thermostat Function ................................................. 22

Start 2 Hysteresis ..................................................... 22

Cooling Function ....................................................... 22

Cooling Hysteresis .................................................... 22

Differential Control Function ..................................... 23

Maximum cold tank ................................................... 23

Minimum warm tank ................................................. 23

Antistagnation Function ............................................. 23

Start/ Stop/ Output Option ........................................ 23

4. OPERATION MENU

Automatic and OFF operation ......................................... 24

Manual Testing ................................................................ 24

Operation Hours Menu ............................................... 24-25

Data logger “SD card” ......................................... 25-28

5. TEMPERATURES MENU .......................................... 29

6. SPECIAL FUNCTIONS.............................................. 30

Dimmer ..................................................................... 30

Security ..................................................................... 30

Others ............................................................................... 30

Notes ................................................................................ 31

Revision Notes ................................................. Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

1 Introduction

SL-DC lnstallation and Operation Manual

 WARNING

Before starting work the installer should carefully read this Installation & Operation Manual, and make sure all instructions contained there in are understood and observed.

The Solar controller should be mounted, operated and maintained by trained personnel only. Personnel in the course of training are only allowed to handle the product under the supervision of an experienced fitter.

All instructions in this Installation & Operation manual should be observed when working with the controller. Any other application shall not comply with the regulations. The manufacturer shall not be liable in case of incompetent use of the control. Any modifications and amendments are not allowed for safety reasons.

Application Safety Instructions

■ The Solar controller is intended for Solar heating systems. The temperature of the water in the tank is controlled by the temperature difference “dt” between solar collector and tank.

■ The controller is normally used in conjunction with a pumping station which includes a circulation pump and a safety valve.

 WARNING

Before starting work disconnect power supply! All installation and

wiring work related to the controller must be carried out only when de-energized. The appliance should be connected and commissioned by qualified personnel only. Make sure to adhere to valid safety regulations.

■ The controllers have been designed for use in dry environments. For example, they are used in residential rooms, office spaces and industrial facilities.

■ Verify that the installation complies with existing regulations before operation to ensure proper use of the installation.

CAUTION

 WARNING

The controllers are neither splashnor drip-proof. Therefore, they must be mounted in a dry place.

Do not interchange the connections of the sensors and the 120V connections under any circumstances! Interchanging these connections may result in life endangering electrical hazards or the destruction of the appliance and the connected sensors and other appliances.

1 Introduction

Main Characteristics

SL-DC Installation & Operation Manual

■ Large graphic display with backlight

■ Easy to use interface (4 keys with scroll menu)

■ Several languages available

■ Energy measuring with SD card interface to save the

recordable statistics (Temperatures, Power, Energy, Time operation) and Parameters

■ Graphic view for temperature, power, energy, operating time and temperature

■ 8 working systems with several extra functions possible

■ 5 inputs for temperature sensors (PT1000 type)

■ 1 logical input for impulse flow meter input

(for energy measurement)

Technical Characteristics

Table 1A Technical characteristics

Operating Temperature

Electrical Protection

Installation Category

Pollution Degree

Fusible

Power Supply

Maximum Power Consumption

(with all outputs activated)

Outputs:

P1 (Main pump with standard or PWM speed regulation) P2 (Pump with standard or PWM speed regulation, Booster

pump, valve)

P3 (Extra, Additional heat, cooling . . . )

Inputs:

T1 (Collector 1)

T2 (Tank 1)

T3 (Extra sensor)

T4 (Extra sensor, Tank2, Collector2)

T5 (Collector return)

■ 2 analog inputs for VFS / VPS sensor inputs (flow, pressure and temperature sensor)

■ 2 pump outputs (standard PWM) with pump exercise function

■ 1 extra output (to control additional heat, cooling system, differential control or anti-stagnation function )

■ Automatic, OFF or Manual test mode

■ Sensor auto checks (short circuit and breaks)

■ Collector type choice (tube or panel)

■ Collector protection (freeze or overheat)

■ Permanent memory storage

32°F - 122°F

IP20

Max T5AH250VAC

120 VAC 60Hz

4.2A (~ 504W)

Triac 1A 120 VAC.

Triac 1A 120 VAC

Relay 2A 120 VAC

PT 1000 type PT 1000 type PT 1000 type PT 1000 type PT 1000 type

T6 (Flow meter)

GDS1 (Flow meter)

GDS2 (Pressure sensor)

Sensors delivered with the product:

2 Collectors

1 Tank 1 Extra

Software Version

Impulse type (low voltage 5V)

Analog type

(VFS)

Analog type

(VPS)

PT 1000 (1.5M 356°F)

PT 1000 (3M 221°F) PT 1000 (3M 221°F)

Displayed during the initial start-up

Version xxxxxx

1 Introduction (continued)

Display

SL-DC Installation & Operation Manual

Figure 1-1 Display, keys

1: Simplified drawing of the installation.

- The logos of pumps turn when they are activated.

- The filled triangles on the valve logo indicate the circulation direction.

2: Solar system is working.

3: SD card storage is active.

4: Temperature of different sensors, Pumps speed indications, Power and Energy quantity stored.

1 2 3

T1_ _ _°F T2_ _ _°F

T3_ _ _°F T4_ _ _°F

P1_ _ _ %

_ _ _ BTU/h

_ _ _ BTU

A. Keypad description:

Figure 1-2 Keypad

Navigation key up or plus key

(+)

Navigation key down or minus key

Navigation key right

Navigation key left

(►)

(◄)

(-)

1 Introduction

Main Menu Display

Figure 1-3 Main menu

SL-DC Installation & Operation Manual

Information

Services Settings Operation

Operation h

Temperatures

Press (►) to enter the navigation menu. (The title of the active menu is high lighted in black on the top of the display. When you enter the navigation menu you can choose another submenu by moving the selection cursor with the keys (+) or (-), then you can enter this submenu with ( ►). From all menus you can press (◄) to return to the previous menu.

NOTICE

IMPORTANT

To prevent mistakes after installation, all critical parameters (system and Extra function) are not accessible after 4 hours power on. If you want to modify these parameters, you must unplug and plug in the controller. No settings are lost when unplugging, or after a power failure.

After 4 hours you can still change all the other parameters to optimize your system.

Not all submenus, selection, or options discussed in this manual are available on all systems. The figures are representative of what the screen on the control will look like when the described procedures are followed.

SL-DC Installation & Operation Manual

2 Service

Languages

With (+) or (-) select the line “ENGLISH” and press ( ►) to highlight the line. Now that you can change the language with (+) or (-), there are several choices: English, German, Dutch, Spanish, French, Italian, Portuguese, and Hungarian.

Figure 2-1 Language screen

Service---- --- -

English

Time and date US version yes System Extra off

External sensor no

Protection func.

Figure 2-2 Time and Date

---

Time 6:41

Month 12

With (+) or (- ) select the line TIME and DATE and press ( ►) to enter the submenu Time and Date.

Now you can select the date and time line with (+) or (- ), then press ( ►) to highlight the value which must

be adjusted.

NOTE: If power supply is lost, the hours will be saved for 24 hours. After this time the clock will need to be readjusted.

Time and Date

--- -

20 yaD

1002 raeY

Figure 2-3 U.S. version

Service---- --- -

English Time and date US version yes System Extra off

External sensor no

Protection func.

YES: °F, 12H am/pm, GPM, BTU and BTUh NO: °C, 24H, Liter, KW and KWh

On this menu you can choose the displayed units.

2 Service

SL-DC Installation & Operation Manual

Systems

When the line is selected, press ( ►) to enter the submenu. You have the choice between 8 systems with the possibility to add different functions.

System 1

This is a basic system, with 1 tank, 1 pump, 1 collector array and 2 sensors. With this system you can add extra functions with 1 or 2 sensors (Booster pump, Thermostat, Cooling, Antistagnation or Diffcontrol function).

Figure 2-4 System 1

The loading of the tank is authorized by the control if the temperature difference “dt” between the collector (T1) and the tank (T2) is greater than the value programmed for “dt”.

System 2

This is a system with 2 tanks, 1 pump, 1 valve, 1 collector array and 3 sensors. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation).

T1 _ _ _°F T2 _ _ _°F

P1 _ _ _ %

System

System 3

This is a system with 2 tanks, 2 pumps, 1 collector array and 3 sensors. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation).

Figure 2-6 System 3

T1 _ _ _°F T2 _ _ _°F T4 _ _ _°F

P1 _ _ _ % P2 _ _ _ %

P2P1

T2 T4

System

The loading of the tanks is authorized by the control if the temperature difference “dt” between the collector (T1) and the tanks (T2, T4) is greater than the value programmed for “dt”. You can choose different possibilities for the priority of the tank loading. See chapter “Priority Tank” for more information.

System 4

This is a system with 1 tank, 1 pump, 1 valve, 2 collector arrays with 2 different cardinal directions (East/ West) and 3 sensors. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation).

Figure 2-7 System 4

Figure 2-5 System 2

T1 _ _ _°F T2 _ _ _°F T4 _ _ _°F

P1 _ _ _ %

T2 T4

System

The loading of the tanks is authorized if the temperature difference “dt” between the collector (T1) and the tanks (T2, T4) is greater than the value programmed for “dt”. You can choose different possibilities for the priority of the tank loading. See chapter “Priority Tank” for more information.

T1 _ _ _°F T2 _ _ _°F

T4 _ _ _°F

P1 _ _ _ %

System

The loading of the tanks is authorized by the control if the temperature difference “dt” between the collectors (T1, T4) and the tank (T2) is greater than the value programmed for “dt”. The valve direction of P2 is routed to the warmer collector.

2 Service (continued)

SL-DC Installation & Operation Manual

System 5

This is a system with 1 tank, 2 pumps, 2 collector arrays with 2 different cardinal directions (East/ West) and 3 sensors. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation).

Figure 2-8 System 5

T1 T4

T1 _ _ _°F T2 _ _ _°F T4 _ _ _°F

P1 _ _ _ %

P1 P2

P2 _ _ _ %

System

The loading of the tank (T2) is authorized by the control if the temperature difference “dt” between the collectors (T1, T4) and the tank is greater than the value programmed for “dt”. The tank will be loaded with the warmer collector (T1, T4) if parameter “P1 II P2 = no” (default setting).

The tank can be loaded from both collector fields at the same time, if parameter “P1 II P2 = yes”. See chapter “Protection Function”.

System 6

This is a system with 1 collector array, 1 solar tank, 1 pump, 1 valve and 4 sensors. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation.)

System 7

This is a system with 1 collector array, 1 solar tank, 2 pumps and 1 external heat exchanger. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation and Diffcontrol function).

Figure 2-10 System 7

T1 _ _ _°F T2 _ _ _°F

P1 _ _ _ % P2 _ _ _ %

The loading of the tank is authorized by the control if the temperature difference “dt” between the collector (T1) and the tank (T2) is greater than the value programmed for “dt”. You can choose a time delay for the start up of the pump between the heat exchanger and the tank. Default value is 1 minute to give the heat exchanger time to heat up. See section “P2 delay”.

System

System 8

This is a system with 1 tank, 2 pumps, 1 collector array, 3 sensors and 1 external heat exchanger. With this system you can add an extra function with 1 sensor (Thermostat, Cooling, Antistagnation.)

Figure 2-11 System 8

Figure 2-9 System 6

T1 _ _ _°F T2 _ _ _°F T3 _ _ _°F T4 _ _ _°F

P1 _ _ _ %

System

The loading of the tank (T2) is authorized by the control if the temperature difference “dt” between the collectors (T1) and the tank (T2) is greater than the value programmed for “dt”. If the “dt” between tank (T3) and the space heating return (T4) is sufficient, the space heating return will be preheated through tank 1. This saves energy at the external heating source.

T1 _ _ _°F T2 _ _ _°F T4 _ _ _°F

P1 _ _ _ %

P1 starts if the temperature difference “dt” between the collector (T1) and tank (T2) is sufficient.

The loading of the tank with P2 is authorized by the control if the temperature difference “dt” between the heat exchanger (T4) and the tank (T2) is greater than the value programmed for “dt”.

The operation of the P1 & P2 pumps is independent.

P2 _ _ _ %

System

2 Service

SL-DC Installation & Operation Manual

Extras

When the line is selected, press ( ►) to highlight the line. You have the choice between 4 extra functions . The choices are not the same with all systems, see the specific system details for available extras.

Figure 2-12 Extras menu

Service---- --- -

English Time and date System

Extra off

External sensor no Protection func. Sensor options

Thermostat Function

This function is generally used to control an additional heat source to load up your primary solar tank in case solar energy is lacking. (See the Extra Function section.)

Cooling Function

The cooling function is generally used for cooling down the primary solar tank at time of high solar radiation. With this function you could dissipate excess energy to another heat zone. (Swimming pool or other basins for example, as illustrated in FIG. 2-14 below.) ( See Extra Function section.)

Figure 2-14 Function used to warm basin

Extra Function used to control the pump to warm up another basin.

Suggestions:

- Pump controls for Fuel or Gas burner. . .

- Electrical element inside the solar tank. (Important: in this case you must connect a relay for switching the output.) (See FIG. 2-13 below.)

Figure 2-13 Extra function and external burner

Extra Function to control the pump coupled with an external burner.

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