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Sorel XTDC Manual

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Read carefully before installation, commissioning and operation
Solar controller XTDC
Installation and operating instructions
A. - Safety instructions 3
A.1. - EC declaration of conformity 3
A.2. - General instructions 3
A.3. - Explanation of symbols 3
A.4. - Changes to the unit 3
A.5. - Warranty and liability 4
A.6. - About the controller 4
A.7. - Scope of supply 4
A.8. - Disposal and pollutants 4
B. - Description of controller 5
B.1. - Specifi cations 5
B.2. - Temperature resistance table
for Pt1000 sensors 5
C. - Installation 6
C.1. - Wall installation 6
C.2. - Electrical connection 7
C.3. - Installing the temperature sensors 8
C.4. - RC 21 Remote adjuster with thermostat 9
D. - Terminal connection 10
D.1. - Terminal connection 10
D.2. - Terminal connection diagram 10
D.3. - Hydraulic variants / Schemes / Systems 11
E. - Operation 19
E.1. - Display and input 19
E.2 Commissioning help 19
E.3 Free commissioning 20
E.4 Menu sequence and menu structure 20
1. - Measurement values 21
2. - Statistics 21
2.1. - Operating hours 21
2.2. - Heat output 21
2.3. - Graphic overview 21
2.4. - Message log 21
2.5. - Reset/clear 21
3. - Operating modes 22
3.1. - Automatic 22
3.2. - Manual 22
3.3. - Off 22
3.4. - Fill system 22
4. - Settings 23
4.1. - Tmin S (X) 23
4.2. - Tmax S (X) 23
4.3. - Tmax SB 23
4.4. - T Solar S (X) 23
4.5. - Priority S(X) 24
4.6. - T-priority 24
4.7. - Loading time 24
4.8. - Increase 24
5. - Protections / Protective functions 25
5.1. - System protection 25
5.2. - Collector protection 25
5.3. - Recooling 25
5.4. - Frostschutz 26
5.5. - Seizing protection 26
5.6. - Collector alarm 26
6. - Special functions 27
6.1. - Program selection 27
6.2. - Speed control 27
6.2.1. - Variant 27
6.2.2. - Type of pump 27
6.2.3. - Pump menu 28
6.2.3.1. - Pump 28
6.2.3.2. - Output Signal 28
6.2.3.3. - PWM off 28
6.2.3.4. - PWM on 28
6.2.3.5. - PWM Max 28
6.2.3.6. - 0-10V off 28
6.2.3.7. - 0-10V on 28
6.2.3.8. - 0-10V Max 28
6.2.3.9. - Speed when „On“ 28
6.2.3.10. - Show signal 28
6.2.4. - Purging time 29
6.2.5. - Sweep time 29
6.2.6. - max. speed 30
6.2.7. - min. speed 30
6.2.8. - Setpoint 30
6.3. - Solar bypass 30
6.3.1. - Variant 30
6.3.2. - Bypass (sensor) 30
6.4. - Thermostat 31
6.4.1. - TH Set 31
6.4.2. - TH hysteresis 31
6.4.3. - Thermostat sensor 1 31
6.4.4. - Thermostat sensor 2 31
6.4.5. - T eco 31
6.4.6. - Storage 31
6.4.7. - Energy saving mode 31
6.4.8. - Periods 31
6.5. - Cooling 32
6.5.1. - Co T set 32
6.5.2. - Co hysteresis 32
6.5.3. - Cooling (sensor) 32
6.5.4. - Periods 32
6.6. - Return fl ow increase 32
6.6.1. - RF Tmax 32
6.6.2. - T return fl ow 32
6.6.3. - Return fl ow (sensor) 32
6.6.4. - Storage (sensor) 32
6.7. - Collector fi eld cooling 33
6.7.1. - Tmax fi eld 33
6.7.2. - Hys min 33
6.7.3. - Hys max 33
6.7.4. - Field cooling sensor 33
6.8. - Anti Legionella 34
6.8.1. - AL T set 34
6.8.2. - AL residence time 34
6.8.3. - Last AL heat 34
6.8.4. - AL sensor 1 34
6.8.5. - AL Sensor 2 34
6.8.6. - AL-times 34
6.9. - Heat transfer 35
6.9.1. - T Heat transfer 35
6.9.2. - Setpoint 35
6.9.3. - HT Tmin 35
6.9.4. - HT Source (sensor) 35
6.9.5. - HT Drain (Target sensor) 35
6.10. - Difference 36
6.10.1. - T difference 36
6.10.2. - DF source (sensor) 36
6.10.3. - Diff Tmin 36
6.10.4. - DF Drain (sensor) 36
6.10.5. - DF Tmax 36
6.11. - Solid fuel boiler 37
6.11.1. - SF Tmax 37
6.11.2. - SF Tmin 37
6.11.3. - T SF 37
6.11.4. - Boiler sensor 37
6.11.5. - Storage sensor 37
6.12. - Error message 37
6.13. - Pressure monitor 38
6.13.1. - Pressure monitor 38
6.13.1.1. - RPS1 / RPS2 38
6.13.1.2. - Pmin 38
6.13.1.3. - Pmax 38
6.14. - Booster pump 38
6.14.1. - Filling time 38
6.15. - Parallel operation R (X) 38
6.15.1. - Delay 38
6.15.2. - Followup time 38
6.16. - Always on 39
6.17. - Heating circuit 39
6.17.1. - Room set day 39
6.17.2. - Room set night 39
6.17.3. - Room sensor 39
6.17.4. - Periods 39
6.18. - Heat quantity 40
6.18.1. - Flow sensor (X) 40
6.18.2. - Return sensor 40
6.18.3. - Anti freeze type 40
6.18.4. - Glycole percentage 40
6.18.5. - Flow rate (X) 40
6.18.6. - Offset T 40
6.18.7. - VFS (X) 40
6.18.8. - VFS - Position 40
6.18.9. - Reference sensor 40
6.18.10. - Pressure monitor 41
6.18.11. - Pressure monitor 41
6.18.11.1. - RPS1 / RPS2 41
6.18.11.2. - Pmin 41
6.18.11.3. - Pmax 41
6.19. - Sensor calibration 41
6.20. - Commissioning 41
6.21. - Factory settings 41
6.22. - SD-Card 42
6.22.1. - Logging 42
6.22.2. - Free storage 42
6.22.3. - Load confi guration 42
6.22.4. - Save confi guration 42
6.22.5. - Firmware update 42
6.22.6. - Unmount 42
6.23. - Start aid function 42
6.24. - Time and date 42
6.25. - Daylight saving time 42
6.26. - Sleep mode 43
6.27. - Ethernet 43
6.27.1. - Ethernet 43
6.27.2. - MAC Adress 43
6.27.3. - TCP/IP Adress 43
6.27.4. - Network Mask 43
6.27.5. - Gateway 43
6.27.6. - Login 43
6.28. - Temperature unit 43
7. - Menu lock 44
8. - Service values 44
9. - Languages 44
Z.1. Malfunctions with error messages 45
Z.2 Replacing the fuse 46
Z.3 Maintenance 46
Table of content
3
Safety instructions
By affi xing the CE mark to the unit the manufacturer declares that the XTDC conforms to the following relevant safety regulations:
- EC low voltage directive 2006/95/EC
- EC electromagnetic compatibility directive 2004/108/EC
Conformity has been verifi ed and the corresponding documentation and the EC declaration of conformity are kept on fi le by the manuf-
acturer.
A.1. - EC declaration of conformity
These installation and operating instructions contain basic instructions and important information regarding safety, installa-
tion, commissioning, maintenance and the optimal use of the unit. Therefore these instructions must be read completely and
understood by the installation technician/specialist and by the system user before installation, commissioning and operation of
the unit.
The valid accident prevention regulations, VDE regulations, the regulations of the local power utility, the applicable DIN-EN
standards and the installation and operating instruction of the additional system components must also be observed. The con-
troller does not under any circumstances replace any safety devices to be provided by the customer!
Installation, electrical connection, commissioning and maintenance of the unit may only be carried out by specialists who pos-
sess the appropriate training.
For the user: Make sure that the specialist gives you detailed information on the function and operation of the controller. Always
keep these instructions in the vicinity of the controller.
A.2. - General instructions
Danger
Caution
A.3. - Explanation of symbols
Failure to observe these instructions can result in danger to life from electric voltage.
Danger
Failure to observe these instructions can result in serious damage to health such as scalding, or even
life-threatening injuries.
Caution
Failure to observe these instructions can result in destruction of the unit or the system, or damage to the
environment.
Information which is especially important for the function and optimal use of the unit and the system.
A.4. - Changes to the unit
• Changes, additions to or conversion of the unit are not permitted without the written permission from the manufacturer
• It is likewise forbidden to install additional components that have not been tested together with the unit
• If it becomes clear that safe operation of the unit is no longer possible, for example because of damage to the housing,
then turn the controller off immediately
• Any parts of the unit or accessories that are not in perfect condition must be exchanged immediately
• Use only original spare parts and accessories from the manufacturer.
• Markings made on the unit at the factory must not be altered, removed or made illegible
• Only the settings actually described in these instructions may be made on the controller
Changes to the unit can compromise the safety and function of the unit or the entire system.
Danger
4
Safety instructions
The controller has been manufactured and tested with regard to high quality and safety requirements. The unit is subject to the
statutory guarantee period of two years from the date of sale.
The warranty and liability shall not include, however, any injury to persons or material damage that is attributable to one or
more of the following causes:
- Failure to observe these installation and operating instructions
- Improper installation, commissioning, maintenance and operation
- Improperly executed repairs
- Unauthorised structural changes to the unit
- Installation of additional components that have not been tested together with the unit
- Any damage resulting from continued use of the unit despite an obvious defect
- Failure to use original spare parts and accessories
- Use of the device for other than its intended purpose
- Operation above or below the limit values listed in the specifi cations
- Force majeure
A.5. - Warranty and liability
The Temperature Difference Controller XTDC facilitates effi cient use and function control of your solar or heating system. The
device is impressive most of all for its functionality and simple, almost self-explanatory operation. For each step in the input
process the individual entry keys are assigned to appropriate functions and explained. The controller menu contains head-
words for the measured values and settings, as well as help texts or clearly-structured graphics.
The XTDC can be used as a solar controller for the various system variants illustrated and explained under „D.3. - Hydraulic
variants / Schemes / Systems“ on page 11.
Important characteristics of the XTDC:
- Depiction of graphics and texts in a lighted display
- Simple viewing of the current measurement values
- Analysis and monitoring of the system by means of statistical graphics,etc.
- Individual confi guration of special functions
- Extensive setting menus with explanations
- Menu block can be activated to prevent unintentional setting changes
- Resetting to previously selected values or factory settings
- A wide range of additional functions are available.
A.6. - About the controller
- Solar controller XTDC
- 3 screws 3,5x35mm and 3 plugs 6mm for wall installation
- 12 strain relief clips with 24 screws, replacement fuse 1x T2A / 250V
- Installation and instructions manual XTDC
Optionally contained depending on design/order:
- 2-8 PT1000 temperature sensors and immersion sleeves
- Ethernet
Additionally available:
- Pt1000 temperature sensor, immersion sleeves, overvoltage protection,
- CAN Bus Data Logger
A.7. - Scope of supply
A.8. - Disposal and pollutants
The unit conforms to the European RoHS directive 2002/95/EC for the restriction of the use of certain hazardous substances
in electrical and electronic equipment.
Caution
The unit must not under any circumstances be disposed of with ordinary household refuse. Dispose of the unit only
at appropriate collection points or ship it back to the seller or manufacturer.
5
Description of controller
Electrical specifi cations:
Mains voltage 100 - 240VAC
Mains frequency 50 - 60Hz
Power consumption 0,5 - 3 W
Switched power
Entire switched power for electronic relays R1 - R2: 460VA for AC1 / 240W for AC3
Electronic relay R1 min.5W...max.120W for AC3
Electronic relay R2 min.5W...max.120W for AC3
Entire switched power for mechanical relays R3 - R6: 460VA for AC1 / 460W for AC3
Mechanical relay R3 460VA for AC1 / 460W for AC3
Mechanical relay R4 460VA for AC1 / 460W for AC3
Mechanical relay R5 460VA for AC1 / 460W for AC3
Mechanical relay R6 460VA for AC1 / 460W for AC3
potentialfree relay R7 460VA for AC1 / 460W for AC3
0..10V Output for 10 k working resistance
PWM Output Freq. 1 kHz, level 10 V
Internal fuse 3x T2A / 250V slow blow
Protection category IP40
Protection class II
Overvoltage Category II
Degree of Pollution Category II
Sensor inputs 8 x Pt1000 temperature sensors
2x Grundfos Direct Sensors
1x RC21
Measuring range
PT1000 -40°C to 300°C
Grundfos Direct Sensor: 0°C-100°C (-25°C /120°C short term)
1 l/min - 12 l/min (VFS1-12)
2 l/min - 40 l/min (VFS2-40)
5 l/min - 100 l/min (VFS5-100)
10 l/min - 200 l/min (VFS10-200)
Permissible cable length of sensors and appliances:
Collector and outdoor sensor <30m
other PT1000 sensors <10m
VFS/RPS Sensoren <3m
CAN <3m
PWM / 0...10V <3m
electronic relay <3m
mechanichal relay <10m
Network connections
Ethernet (optional)
CAN Bus
Real Time Clock RTC with 24 hour power reserve
Permissible ambient conditions:
Ambient temperature
for controller operation 0°C...40°C
for transport/storage 0°C...60°C
Air humidity
for controller operation max. 85% rel. humidity at 25°C
for transport/storage no moisture condensation permitted
Other specifi cations and dimensions
Housing design 3-part, ABS plastic
Installation methods Wall installation, optionally panel installation
Overall dimensions 228 x 180 x 53 mm
Display Fully graphical display, 128 x 128 dots
Light diode 2: 1x red, 1x green
Operation 4 entry keys
B.1. - Specifi cations
B.2. - Temperature resistance table for Pt1000 sensors
°C 0 102030405060708090100
1000 1039 1077 1116 1155 1194 1232 1270 1308 1347 1385
6
Install the controller only
in dry areas and under
the ambient conditions
described under B.1
“Specifi cations”.
Controller must be inac-
cessible from the rear.
Installation
Caution
Caution
C.1. - Wall installation
1. Unscrew cover screw completely.
2. Remove Terminal connection cover. Unscrew the 2 small screws left and right and
remove the upper part of the controller by lifting it out of the socket.
3. Mark the 3 mounting holes on the wall (see „C.1.1. Socket“). Make sure that the wall
surface is even so that the housing does not become distorted when it is screwed
on.
4. Using a drill and size 6 bit, drill 3 holes at the points marked on the wall and push
in the plugs.
5. Hang the controller on the upper screw.
6. Align the housing and tighten the lower screws.
C.1.1. Socket
161
11,8 195,4
9
R4.5
4.4
3333
139,3
n
3.5
169.3
7
Installation
Terminal connection
cover
Cover screw
Controller and VFS sensor have to have the same ground potential. The VFS sensor has a functional earth con-
nector (PELV). The PE-connector of the controller has to be connected to the pipe system near the sensor.
Caution
C.2. - Electrical connection
Danger
Before working on the unit, switch off the power supply and secure it against being switched on again! Check
for the absence of power!
Electrical connections may only be made by a specialist and in compliance with the applicable regulations.
Do not use the controller if the housing shows visible damage.
Caution
Low-voltage cables such as temperature sensor cables must be routed separately from mains voltage cables.
Feed temperature sensor cables only into the left-hand side of the unit, and mains voltage cables only into the
right-hand side.
Caution
The customer must provide an all-pole disconnecting device, e.g. a heating emergency switch.
Caution
The cables being connected to the unit must not be stripped by more than 55mm, and the cable jacket must
reach into the housing just to the other side of the strain relief.
8
1. Select necessary program/hydraulics (s. „D.3. - Hydraulic
variants / Schemes / Systems“ on page 11)
2. Remove terminal connection cover (s. „D.2. - Terminal
connection diagram“ on page 10)
3. Strip cables by 55mmmax., insert, fi t the strain relief de-
vices, strip the last 8-9mm of the wires (Fig. „C.2.1.“)
4. Open the terminals using a suitable screwdriver (Fig.
„C.2.2.“) and make electrical connections on the controller
5. Refi t terminal connection cover and fasten screw.
6. Switch on mains voltage and place controller in operation.
C.2.1.
C.2.2.
Installation
The temperature sensor cables must be routed separately from mains voltage cables, and must not, for
example, be routed in the same cable duct!
Caution
Caution
The controller operates with Pt1000 temperature sensors which are accurate to the degree, thus ensuring optimal control of
system functions.
Caution
If desired the sensor cables can be extended to a maximum of 30m using a cable with a cross-section of
at least 0.75mm². Make sure that there is no contact resistance!
Position the sensor precisely in the area to be measured!
Only use immersion, pipe-mounted or fl at-mounted sensor suitable for the specifi c area of application
with the appropriate permissible temperature range.
Connect the VFS sensors with the matching jacks.
To prevent damage to the Direct Sensors it is highly recommended to install them in to the return.
When installing the Vortex Flow Sensors (VFS), observe the correct fl ow direction!
Instructions for clamps:
1. Insert screw driver into the upper hole. Push the lock
clamp inside down.
Keep the screw driver in this position.
2. Insert cable into the lower opening.
3. Remove screw driver. The clamp will lock the cable.
C.3. - Installing the temperature sensors
9
Installation
The remote adjuster with integrated thermostat RC21 provides you with easy to use temperature controlled adjustment of
heating from within your living space.
Settings
The dial is used to parallel translate the heating curve. The fl ow temperature (still regarding the outdoor temperature) is raised
or lowered respectively by your adjustement by max. 5°.
Sensor
The RC21 contains a temperature sensor which is used by the controller.
If the settings in the controller allow it, the sensor is used to alter the fl ow temperature.
The switch changes the operation mode of the controller.
In Timer mode the temperature is controlled according to the set thermostat periods.
In Continous day mode the set periods are ignored and the temperature is controlled according to the Day time settings.
In Continous night mode the temperature is usually set to lowest. This setting is best suited for periods of long absence
like e.g. holidays.
Installation
Carefully remove the dial from the casing with a screwdriver.
Loosen the screw beneath. Remove the bright part of the casing from the black socket.
The RC21 is connected via terminal block to the controller.
Clamp connections:
1: Remote adjuster
2: Sensor
3: Sensor earth
Connection for remote adjuster (grey)
Connection for sensor (green)
Connection for sensor earth (white)
Connect only low voltages!
C.4. - RC 21 Remote adjuster with thermostat
The RC21 is an optional accessory and is not supplied by default.
The XTDC is fully functional without RC21
Danger
Caution
10
Installation
Caution
Low voltage max. 12VAC/DC
Terminal: Connection for:
S1 Sensor 1
S2 Sensor 2
S3 Sensor 3
S4 Sensor 4
S5 Sensor 5
S6 Sensor 6
S7 Sensor 7
S8 Sensor 8
V1 0-10V / PWM
V2 0-10V / PWM
VFS1 Grundfos Direct Sensor
VFS2 Grundfos Direct Sensor
RC Room Controller
Mains voltage 230VAC 50-60Hz
Terminal: Connection for:
R1 Relay 1
R2 Relay 2
R3 Relay 3
R4 Relay 4
R5 Relay 5
R6 Relay 6
N Mains neutral conductor N
L Mains phase conductor L
The PE protective conductor must be
connected to the PE metal terminal
block!
Potential free
Relay
NO
Normally open
C
Common
NC
Normally closed
SD Card Slot
for Data logging
and fi rmware up-
dates
Make sure that the
SD card‘s orienta-
tion is correct!
Card must be
inserted without
pressure. False
insertion can dam-
age the card slot!
Ethernet
for LAN network
operations
max. 12V
Caution
mains side
230VAC
Danger
D.1. - Terminal connection
The mains part of the terminal connection room is covered by a plastic sheet. Make sure that the controller is without voltage before
removing it.
V2 V1 S8 S7
VFS2RC VFS1
SD Card
MainsRelaisPF-RelaisKleinspannungen
Ethernet
S6 S5 S4 S3 S2 S1 GND R6NC C NO R5R4R3R2R1 N L
D.2. - Terminal connection diagram
VFS1VFS2
bridge
bridge
low voltage PF relay relays mains
42
Special functions
Under no circumstances switch off the controller during update, this can lead to irrevocable damages.
Settings may be changed by an update. Reset the controller to factory settings after reset and commence the
commissioning process.
Current settings are over written.
Caution
Caution
6.22. - SD-Card
Settings for the data logging and fi rmware update function with SD card.
6.22.1. - Logging
Activate the logging function and set the fi le format used.
Settings range: CSV, TSV, JSON, Off / Default setting: Off
6.22.2. - Free storage
Displays the available space on the SD card.
6.22.3. - Load confi guration
This is used to load settings from the SD card.
6.22.4. - Save confi guration
All settings can be stored on the SD card.
6.22.5. - Firmware update
This is used to update the controllers fi rmware with one saved on the SD card.
6.22.6. - Unmount
To prevent damage to the SD card or loss of data, please unmount the card before removing it from the controller.
With some solar systems, especially with vacuum tube collectors, it may occur that the measurement value acquisition at the
collector sensor occurs too slowly or too inaccurately because the sensor is often not at the hottest location. When the start
help is activated the following sequence is carried out:
If the temperature at the collector sensor increases by the value specifi ed under “Increase” within one minute, then the solar
pump is switched on for the set “Purging time” so that the medium to be measured can be moved to the collector sensor. If this
still does not result in a normal switch-on condition, then the start help function is subject to a 5-minute lockout time.
Start help setting range: on, off/default setting: off
Purging time setting range: 2 ... 30 sec./default setting: 5 sec.
Increase setting range: 1°C....10°C/default setting: 3°C/min.
6.23. - Start aid function
Caution
This function should only be activated by a specialist if problems arise with acquisition of measurement values.
In particular follow the instructions from the collector manufacturer.
Caution
This menu is used to set the current time and date.
When this function is active, the controller’s clock changes automatically to and from DST (DST, Daylight Savings Time).
6.24. - Time and date
6.25. - Daylight saving time
For analysis of the system data it is essential for the time to be set accurately on the controller. Please note
that the clock does not continue to run if the mains voltage is interrupted, and must therefore be reset.
… 42 …


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