SOLCAL. 1 digital regulator. 257 series CONTENTS INSTALLATION AND COMMISSIONING MANUAL. Function

Transcription

1 EN SOLCAL 1 digital regulator Copyright 2013 Caleffi 257 series INSTALLATION AND COMMISSIONING MANUAL CONTENTS Function 1 Technical data Dimensions Wiring diagram 3 Functional characteristics 4 Application diagrams 5 Function The analogic digital regulator for solar thermal circuits is designed to allow simple and intuitive management procedures. The regulator, which features a high level of functional efficiency, is characterised by its application flexibility and ease of use by means of analogic selectors. The display provides real time information concerning the operating status of system devices, namely pumps and valves, any probe alarms, etc. and system temperatures. There are 11 possible application programs available to meet the needs of virtually all solar thermal systems. 1

2 WARNINGS The following instructions must be read and understood before installation, commissioning and maintenance of the regulator. The safety symbol is used in this manual to draw attention to the respective safety instructions. The meaning of this symbol is as follows: CAUTION! YOUR SAFETY IS INVOLVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN INJURY. - The digital regulator must be installed by a licensed installer in accordance with national regulations and/or relevant local requirements. - If the digital regulator is not installed, commissioned and maintained correctly in accordance with the instructions in this manual, then it might not work properly and may endanger the user. CAUTION: Risk of electric shock. The rear panel is live. Cut off the electric supply before carrying out any work. Failure to follow these instructions may result in personal injury or damage to property. LEAVE THIS MANUAL AS A REFERENCE GUIDE FOR THE USER Solar collector overtemperature safety logic On reaching the water storage set-point temperature, the solar pump will stop. If the collector temperature reaches 120 C the solar pump restarts; the pump is stopped or restarted to manage the collector temperature, with hysteresis of C with respect to the 120 C re-start temperature. The water storage can be loaded up to a maximum temperature of 90 C. When this temperature is reached the solar pump stops; if the solar collector temperature continues to rise, at 140 C the pump is stopped definitively and will restart only at 120 C C (105 C). 2

3 Technical data and installation Regulator Voltage: 230 V (~), ±10%, 50 Hz Power consumption: 4 VA Output contacts: 1 relay. 250 V (ac) with one switch-over contact 8 (2) A max. 1 relay. 250 V (ac) with two switch-over contacts total 9 A max. Protection class: II Protection class: IP 40 Ambient temperature: 0 40 C Humidity class: class F to DIN EN Interface: serial (RS 232 with special minidin cable Type 9636/9636USB) Pt1000 probes Code Colour grey 3 m cable LIYY, 2 x 0,5 mm², T max. 100 C Code Colour red 3 m cable SIHF, 2 x 0,5 mm², T max. 180 C Pt1000 probes resistance table CAUTION C W C W Fit the probe with the red coloured silicone sheath (T max. 180 C) on the solar collector. Probes connection The cable connecting the probes to the regulator must be installed in a dedicated raceway. If the connection cable shares the raceway with other power cables, an earthed shielded cable must be used. Any alteration of the regulator wiring could result in electrical disturbance. A reset is required (i.e. switching the regulator power supply off for a few seconds and then on again) whenever work is carried out on the wiring. The cables can be extended to 100 m using a cable with cross section of 1 mm 2. Dimensions ø 6, B B SOLCAL 1 OFF ON TEST B A C A C A Code A 136 B 90 C 80 Mass (kg) 0,88 Code Code A B L (m) / / Wiring diagram 1 collector probe 2 collector probe and bottom water storage probe common 3 bottom water storage probe 4 third probe 5 third probe 13 neutral 14 live 15 relay 1 line 16 relay 1 neutral 17 relay 2 open 18 relay 2 neutral 19 relay 2 close N N N N L I 3

4 Functional characteristics Installation The solar regulator can be used for 11 different solar thermal system s, which can be selected by means of 4 dip switches located in the rear panel. The regulator has 2 relay outputs, one of which for the solar pump and one for a second pump or a 3-contact diverter valve. The analogic selectors on the front panel can be used to set 6 different storage, collector, or switch-over temperature parameters. The display shows a dynamic synoptic panel, with illuminated LCD representing the selected system diagram, the temperature readings and the current operations. If the selector relative to the function, located alongside it, is moved to change the relative values, the change appears on the display and approximately 10 seconds after the last movement the display reverts to the system diagram. Pressing the button with the manual symbol serves to switch the system off or on, or to activate the test function (all connected outputs are switched on). The LEDs show the operating status. Description of controls SOLCAL OFF ON TEST ) LED 1: operating error or probe fault (red) 2) LED 2: solar collector circuit pump running 3) LED 3: second relay output active 4) LED 4: off, regulator disabled 5) LED 5: on, regulator enabled 6) LED 6: active relays test 7) Level one for water storage setting temperature control, in the second level depending on the program selected (see systems) 8) Min. and max. Δt control 9) Control of minimum solar collector start-up temperatures and minimum operating time 10) Function button Parameter management and set-up Button Pressing the button once briefly causes the display to illuminate; pressing the button again with the display on serves to select the required operating status OFF - ON or Test. The commands become operational after approximately two seconds. If the button is pressed for longer than 2 seconds all the temperature settings appear cyclically on the display. As the values are displayed, they can be edited by means of the relative selectors on the front panel, in accordance with individual design requirements and the selected system. Indication and editing of nominal values The three front panel selectors can be used to set three nominal values at level 1 and a further three values at level 2. To reach level 2 press button for 2 seconds. The control selector must be rotated while keeping button pressed. If a potentiometer is rotated, the set value appears on the display for 4 seconds, after which the screen returns to the default level with the synoptic diagram. Display The regulator display shows the position and temperatures of the probes in real time and the operating status of the devices of the selected system, namely pumps and valves. If a probe is not recognized, when the system is switched on symbol X will appear accompanied by information indicating the cause for non-recognition. Probe fault or open connecting cable, symbol displayed. Probe short circuit, symbol displayed. If one of the probes required for the function is in error status, the system will be disabled and the red LED will flash. If an optional probe is faulty or disconnected the system will continue to operate. The display illumination will remain on for approximately 30 seconds after a control element is operated. Systems selection ON The system is selected by means of the dip switches located on the rear panel of the regulator. Safety OFF ON TEST 10 5 s To avoid accidental modification of the parameters entered by means of the selectors, approximately 20 minutes after the last time they are moved an automatic lock function is activated. If it becomes necessary to re-parametrize the regulator the lock function must be disabled by pressing function button (10) for 5 seconds. 4

5 Diagram 1 Solar heating system with 1 water storage Diagram 1 solar collector probe, bottom water storage probe and read-only top water storage probe Relay 1 = solar pump contact Relay 2 = inoperative Relay 3 = inoperative On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the water storage T set-point, the solar pump will stop. The top water storage probe is utilised exclusively to display the temperature. level 1: water storage T set-point C 60 C 60 C level 2: inoperative level 1: ΔT set-point for solar pump ON level 2: ΔT set-point for solar pump OFF level 1: solar collector T min for ΔT verification start level 2: time for which solar pump remains OFF 5 25K 6K 6K 3 23K 3K 3K C 25 C 25 C 2 20 min 5 min 5 min 5

6 Diagram 2 Solar heating system with 1 water storage and swimming pool Diagram 2 solar collector probe, bottom water storage probe, swimming pool probe Relay 1 = solar pump contact Relay 2 = three-way diverter valve contact to storage Relay 3 = three-way diverter valve contact to swimming pool On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the bottom water storage T set-point, the fluid is diverted by the three-way valve to the swimming pool exchanging circuit. The probe on the swimming pool is responsible for preventing an excess temperature rise; as soon as the swimming pool temperature set-point is passed, the solar pump is stopped. level 1: water storage T set-point C 60 C 60 C level 2: swimming pool T set-point C 29 C level 1: solar collector Tmin for ΔT verification start C 25 C 25 C 6

7 Diagram 3 Solar heating system with 1 water storage and with boiler integration Diagram 3 solar collector probe, bottom water storage probe, top water storage probe Relay 1 = solar pump contact Relay 2 = integration pump contact On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the water storage T set-point, the solar pump will stop. The top water storage probe is used to manage the temperature integration pump at the programmed set-point, with a differential of +0-5 C with respect to the programmed set-point. level 1: water storage T set-point C 60 C 60 C level 2: integration T set-point C 55 C level 1: solar collector T min for ΔT verification start C 25 C 25 C 7

8 Diagram 4 Solar heating system with 2 water storages Diagram 4 solar collector probe, bottom water storage 1 probe, bottom water storage 2 probe Relay 1 = solar pump contact Relay 2 = second water storage pump contact On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the water storage 1 T set-point, the solar pump will stop. On reaching the minimum temperature for water storage 1 load change (can be set with a minimal difference with respect to the storage 1 set-point of at least -5K), the water storage 2 pump will start. This latter pump will stop when the temperature in water storage 2 reaches a difference of approximately 2K with respect to water storage 1. level 1: water storage one T set-point C 60 C 60 C level 2: water storage 1 load change T set-point C 55 C level 1: solar collector Tmin for ΔT verification start C 25 C 25 C 8

9 Diagram 5 Heat exchange system Diagram 5 Number of probes utilised 2: water storage 1 bottom probe, water storage 2 bottom probe Relay 1 = inoperative Relay 2 = pump contact for exchange between water storages On reaching Tmin for water storage 1 loading change, the water storage 2 pump starts. This latter pump will stop when the temperature in water storage 2 reaches a difference of approximately 2K with respect to water storage 1. level 1: water storage loading change T set-point C 60 C 55 C 9

10 Diagram 6 Solar heating system with heating circuit return temperature increase M Diagram 6 solar collector probe, bottom water storage 1 probe, heating return probe Relay 1 = solar pump contact Relay 2 = heating return to water storage diverter valve contact Relay 3 = heating return to boiler diverter valve contact On reaching the solar collector Tmin, the ΔT (collector - bottom storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the water storage T set-point, the solar pump will stop. The set-point temperature at which you wish to make the exchange is correlated with the temperature accumulated in the water storage (which must be more than 5K higher than the return temperature from the heating circuit), if the circuit return temperature is lower, the valve diverts towards the storage. This latter diverts back to the boiler when the return temperature reaches a difference of approximately -3K with respect to the water storage temperature. level 1: water storage 1 T set-point C 60 C 60 C level 2: Heating return circuit exchanging T set-point C 20 C level 1: solar collector Tmin for ΔT verification start C 25 C 25 C 10

11 Diagram 7 System for integration to water storage with alternative energy sources M Diagram 7 Number of probes utilised 2: bottom storage probe and heating return probe Relay 2 = heating return to water storage diverter valve contact Relay 3 = heating return to boiler diverter valve contact The water storage accumulates energy, for example from a heat pump. The set-point temperature at which you wish to make the exchange is correlated with the temperature accumulated in the water storage (which must be more than 5K higher than the return temperature from the heating circuit), if the circuit return temperature is lower, the valve diverts towards the water storage. This latter diverts back to the boiler when the return temperature reaches a difference of approximately -3K with respect to the water storage temperature. level 1: three-way valve diversion T set-point C 60 C 20 C (recommended) 11

12 Diagram 8 Solar heating system and loading of stratification water storage M Diagram 8 solar collector probe, top water storage probe, bottom water storage probe Relay 1 = solar pump contact Relay 2 = top storage loading exchange diverter valve contact Relay 3 = bottom storage loading exchange diverter valve contact On reaching the solar collector Tmin, the ΔT is checked (collector - top water storage, when the high part is satisfied, water storage T set-point, the same procedure is repeated for the bottom part of the water storage); if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the minimum exchange temperature in the top part of the water storage, the diverter valve diverts to heat the bottom part of the water storage. The valve diverts back to the top part of the water storage when the temperature of the top part of the storage reaches a difference of approximately -5K with respect to the storage set-point. level 1: water storage T set-point C 60 C 60 C Inoperative level 1: solar collector T min for ΔT verification start C 25 C 25 C 12

13 Diagram 9 Solar heating system with overheating dissipation M Diagram 9 solar collector probe, bottom water storage probe, top water storage probe Relay 1 = solar pump contact Relay 2 = three-way diverter valve contact to storage Relay 3 = three-way diverter valve contact to dissipation On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the water storage T set-point with a differential of +0-5 C, the solar pump stops and the fluid is diverted to the dissipation circuit by the three way valve; if the solar collector temperature rises above 120 C the solar pump restarts to dissipate the energy in the circuit, with hysteresis of +0-15K. The valve diverts back to the water storage when the storage temperature reaches a difference of approximately -2K with respect to the set-point. The top water storage probe is read-only. level 1: water storage T set-point C 60 C 60 C Inoperative level 1: solar collector T min for ΔT verification start C 25 C 25 C 13

14 Diagram 10 Solar heating system with 2 collectors East/West Diagram 10 East solar collector probe, West solar collector probe (optional probe code Tmax 180 C), bottom water storage probe Relay 1 = East solar pump contact Relay 2 = West solar pump contact On reaching Tmin of the East or West solar collector, or both collectors, the ΔT (collector - bottom storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. level 1: water storage T set-point C 60 C 60 C Inoperative level 1: solar collector T min for ΔT verification start C 25 C 25 C 14

15 Diagram 11 Solar heating system with 2 water storages and three-way control valve 1 2 TM T Diagram 11 solar collector probe, water storage one 1 probe, water storage two probe Relay 1 = solar pump Relay 2 = water storage loading exchange diverter valve On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. on reaching the water storage 1 set-point temperature the diverter valve diverts to water storage 2. The valve diverts back to water storage 1 when the temperature of water storage 2 reaches the programmed set-point. On reaching the temperature set-point of the water storages, the solar pump will stop. level 1: water storage 1 T set-point C 60 C 60 C level 2: water storage 2 T set-point C 60 C 60 C level 1: solar collector T min for ΔT verification start C 25 C 25 C 15

16 Diagram 11 B (variant of diagram 4) Solar heating system with 2 water storages with priority on the first one and three-way control valve Diagram shown on the display Functional diagram 11 B 1 2 TM T Diagram 11 B solar collector probe, water storage 1 probe, water storage 2 probe Relay 1 = solar pump Relay 2 = water storage loading exchange diverter valve On reaching the solar collector Tmin, the ΔT (collector - bottom water storage) is checked; if it is higher than the ON set-point the solar pump will start; the solar pump continues to run for a minimum time of one minute and it stops if ΔT is lower than the OFF set-point ΔT. On reaching the water storage 1 set-point temperature the diverter valve diverts to water storage 2. The valve diverts back to water storage 1 when the temperature of water storage 2 falls below the programmed set-point. On reaching the temperature set-point of the water storages, the solar pump will stop. To use hydraulic diagram 11 B, set the dip switches as per diagram 4 and follow the relative wiring diagram. Potentiometer Levels and parameters description Setting range Factory level 1: water storage 1 T set-point C 60 C 60 C level 2: water storage 2 T set-point C 60 C 55 C level 1: solar collector T min for ΔT verification start C 25 C 25 C 16