Taco Comfort Solutions FuelMizer SR501-OR-4 Manual de usuario

Instruction Sheet

FuelMizer®SR501-OR-4 Switching Relay with Outdoor Reset

A Taco Family Company

102-431

SUPERSEDES: March 1, 2013 EFFECTIVE: December 20, 2013

Plant ID# 9300-2871

MULTI-ZONE INSTALLATION WITH ZONE CONTROL

AND WITH INDIRECT DHW

ONE ZONE

SWITCHING RELAY

WITH OUTDOOR RESET

SR 501OR-4

LED

INDICATORS

POWER

TSTAT

DHW

OVERRIDE

BOILER

RELAY

INPUT

120 VAC

ZONE 1

120 VAC

AMP

BOILER TSTAT

WCR

DHW

OUTDOOR

SENSOR

SUPPLY

SENSOR

DESIGN OUTDOOR

TEMPERATURE

FOR 180°F SUPPLY

TEMPERATURE

OFF

-30

-20

-10 10

SW1

OFF

SYSTEM

CIRCULATOR

(OPTIONAL)

POWER

INPUT

(120 VAC)

BOILER

CONTROL

OUTDOOR

SENSOR

BOILER

SUPPLY

SENSOR

POT1

1234

ZONE 1

1234

ZONE 2

1234

ZONE 3

EXISTING

ZONE VALVE CONTROL

POWER IN

24 VAC

N/O

COM

N/C

PUMP END

SWITCH

FUSE

5 AMP

ZONE 3 PUMP

END SWITCH

THERMOSTATS

(24VAC)

TSTAT 1 VALVE 1

T STAT 2 VALVE 2

T STAT 3 VALVE 3

POWER

LED

INDICATORS

ZONE 1 ZONE 2 ZONE 3

ISOLATED

XX RW RW RW

END SWITCH THERMOSTATS PRIORITY

24 VAC ZONE VALVES PRIORITY

ZONE 3

PRIORITY

OFF

CCC

2 WIRE ZONE VALVE

(NO END SWITCH)

MUST USE JUMPER TACO 3 WIRE

ZONE VALVE

JUMPER

3 & 4

TACO 3 WIRE

ZONE VALVE

DHW

AQUASTAT

CONTROL STRATEGY:

Outdoor Reset:

In order to properly control a hot water heating system, the heat sup-

plied to the building must equal the heat lost by the building.

• The heat supplied to a building is proportional to the temperature of

the supply water and the surface area of the heating element. A

small surface area such as baseboard radiators requires a higher

water temperature than a larger surface area such as radiant floors.

• The heat lost from a building is dependent on the outdoor tem-

perature, as well as other factors. As the outdoor temperature

drops, the building heat loss increases.

Reset Ratio:

Operation of a hot water heating system can generally be improved by

modulating the supply water temperature as the outdoor temperature

changes. Using this approach, the heat lost from the building is

matched by the heat input to the building. The SR501-OR boiler reset

control utilizes a reset ratio to set the relationship between outdoor tem-

perature and supply water temperature. The reset ratio determines the

amount the supply water temperature is raised for every 1° drop in out-

door air temperature, and it is determined from the starting point and

the system design conditions. In order for the control to automatically

determine the reset ratio, outdoor design conditions must be estab-

lished. This is usually the typical coldest outdoor temperature or it can

be set by using AS ARE standards for Design Outdoor Temperature

for specific geographic locations.

APPLICATION:

The SR501-OR is a microprocessor-based control designed to regulate

the supply water temperature of a single boiler, based on the outdoor

temperature. The SR501-OR is a boiler reset control and switching relay

in one unit. The SR501-OR is ideal for retrofit application, but may also

be used in new installations as well.

The SR501-OR includes functions such as automatic reset ratio calcu-

lation, warm weather shut down (WWSD), minimum boiler temperature

setting, and boiler differential setting. The control also has boiler sensor

and outdoor sensor error checking.

40 30 20 10

-10

-20

-30

-20

130

110

150

170

180

190

210

90 80 70 60 50 40 30 20 10 0 -10

OUTDOOR TEMPERATURE (°F)

BOILER SUPPLY TEMPERATURE vs. OUTDOOR TEMPERATURE (°F)

FOR OUTDOOR DESIGN TEMPERATURES

BOILER SUPPLY TEMPERATURE (°F)

For information on Taco’s

Switching Relays (SR)

including catalog sheet,

instruction sheets, Visio sten-

cils and our highly praised

Zone Controls Wiring Guide,

scan the QR code above or

go to our website:

http://www.TacoComfort.com.

ONE ZONE INSTALLATION W/O INDIRECT DHW

ONE ZONE

SWITCHING RELAY

WITH OUTDOOR RESET

SR 501OR-4

LED

INDICATORS

POWER

TSTAT

DHW

OVERRIDE

BOILER

RELAY

INPUT

120 VAC

ZONE 1

120 VAC

AMP

BOILER TSTAT

WCR

DHW

OUTDOOR

SENSOR

SUPPLY

SENSOR

DESIGN OUTDOOR

TEMPERATURE

FOR 180°F SUPPLY

TEMPERATURE

OFF

-30

-20

-10 10

SW1

OFF

SYSTEM

CIRCULATOR

(OPTIONAL)

POWER

INPUT

(120 VAC)

24 VAC

THERMOSTAT

BOILER

CONTROL

OUTDOOR

SENSOR

BOILER

SUPPLY

SENSOR

POT1

See NOTE

NOTE: Resistor

(1KΩ, 1⁄2W)

may be needed

between Wand C

terminals.

Boiler Operation:

The supply water temperature from a boiler can be controlled by

cycling the boiler on and off. Modulation of the boiler’s operating tem-

perature in hot water heating systems not only provides more comfort

but also offers significant energy savings. The cooler the boiler runs,

the more efficient it is due to less heat losses up the flue and reduced

boiler jacket losses.

Differential:

An on / off boiler must be operated with a differential in order to pre-

vent short cycling. When the supply water temperature drops below

the bottom rail of the differential, the boiler is turned on. The boiler is

then kept on until the supply water temperature rises above the top

rail of the differential. If the differential is too wide, there can be large

supply water temperature swings; however, if the differential is too

narrow, the boiler short cycles and operates inefficiently. This control

can be set for two different boiler differentials, 10°F (6°C) or 20°F

(12°C). This setting will help to achieve an appropriate balance

between temperature swings and boiler efficiency.

Minimum Boiler Supply:

Most boilers require a minimum supply water temperature in order to

prevent corrosion from flue gas condensation. The control should

therefore only modulate the boiler supply water temperature down to

the boiler manufacturer’s minimum recommended operating temper-

ature. Some boilers are designed to condense and should be operat-

ed at low water temperatures as much as possible for maximum effi-

ciency.

SUPPLY WATER TEMPERATURE

TIME

Differential = 10°F (5°C

)

165

°F(74°C)

155°F (68°C)

160°F (71°C)

BOILER ON BOILER ON

BOILER OFF BOILER OFF

OUTDOOR AIR TEMPERATURE

(10)

(-1)

(-12)

-10

(-23)

(21)

(32)

WWSD

TEMPERATURE

°F(

°C)

SUPPLY WATER TEMPERATURE

110 (43)

70 (21)

90 (32)

210 (99)

170 (77)

150 (65)

130 (54)

190 (88)

RESET

RATIO

BOILER

MINIMUM

SEQUENCE OF OPERATION:

Powering Up the Control:

After the SR501-OR is powered up, the green power LED light will be on.

Heating Demand:

The SR501-OR receives a heating demand from thermostat or zone

control end switch closure on the R and W thermostat terminals. The

thermostat red LED light will also be turned on. The control can be

setup for boiler temperature reset or ON – OFF boiler operation.

Reset Demand:

When the SR501-OR receives a heating demand the controls enable

the boiler based on the reset curve. The Boiler Relay red LED light

will be turned on when the boiler relay is energized.

DHW Demand:

When the SR501-OR receives a D W demand the controls enable

the boiler and ignore the boiler reset curve. The D W Override red

LED light will also be turned on.

Warm Weather Shut Down (WWSD):

When the outdoor temperature rises above 70°F (21°C), the control

turns off the boiler and blinks the Thermostat LED light. This function

only applies for space heating and does not affect D W operation.

Boiler Operation:

When the SR501-OR has a reset demand, the system supply water

temperature is controlled by turning the boiler on and off. The control

calculates the target supply water temperature based on the outdoor

temperature, and the settings that were entered. The boiler operates

around a differential that is manually set by dip switch number 2. The

control includes a minimum on and off time for the boiler, in order to

minimize short cycling.

Maximum Boiler Supply:

The SR501-OR does not allow the boiler target temperature to

exceed the boiler design temperature setting plus 10°F (6°C) up to a

maximum of 225°F (107°C).

Minimum Boiler Supply:

The SR501-OR has a 140°F minimum boiler setting which is used in

order to prevent corrosion from flue gas condensation. During mild

outdoor conditions, the boiler cycles around the minimum boiler set-

ting. This programmed function can be set to the OFF setting for con-

densing and electric boilers.

INSTALLATION:

Step One:

Check the contents of this package. If any of the contents listed are

missing or damaged, please contact your sales representative for

assistance. The SR501-OR includes:

SR501-OR Boiler Reset Control and Switching Relay Combination

One Outdoor Sensor

One Strap on Sensor

Instruction Sheet

Replacement sensors are available from Taco, Inc.:

Strap on Sensor – 9300-2044RP

Outdoor Sensor – 9300-2052RP

Note: Carefully read the details of the Sequence of Operation section

in this brochure to ensure that you have chosen the proper control for

your application.

Step Two:

Installing the Control:

The enclosure is to be mounted flush onto a wall or any ridge surface.

• The mounting holes in the enclosure accept #6 screws.

• Line voltage to enter from bottom of control and low voltage to

enter from top of control.

Installing the Outdoor Sensor:

Note: The temperature sensor (thermistor) is built into the enclosure.

• Use one round or pan head screw to attach the base of the sen-

sor to the wall.

• The sensor is wall mounted and the wiring enters through the

bottom of the enclosure. The hole for the cable entry must face

downward in order to prevent water from entering and filling the

enclosure.

CAUTION: Improper installation and operation of this control

could result in damage to the equipment and possibly even

personal injury. It is your responsibility to ensure that this con-

trol is safely installed according to all applicable codes and

standards. This electronic control is not intended for use as a

primary limit control. Other controls that are intended and cer-

tified as safety limits must be part of the control circuit.

• The sensor should be mounted on a wall which best represents

the heat load on the building (i.e. a northern wall for most build-

ings and a southern facing wall for buildings with large south fac-

ing glass areas). The sensor should not be installed near heat

sources such as ventilation or window openings.

• The sensor should be installed at an elevation above the ground

that will prevent accidental damage or tampering.

• Install the Outdoor Sensor and run the wiring back to the control

mounting location.

Installing the Boiler Sensor:

Note: This sensor is designed to mount on a pipe or in a temperature

immersion well.

• The sensor can be strapped directly to the pipe using the cable

tie provided. Insulation should be placed around the sensor to

reduce the effect of air currents on the sensor measurement.

• The Boiler Sensor should be placed downstream of a pump or

after an elbow or similar fitting. This is especially important if

large diameter pipes are used because the thermal stratification

within the pipe can result in erroneous sensor readings. Proper

sensor location requires that the fluid is thoroughly mixed within

the pipe before it reaches the sensor.

Step Three:

Wiring to the Zone Control:

Line Voltage Connections –

Connect 120VAC incoming line voltage; ot to the terminal and

Neutral to the N terminal.

Connect 120VAC circulator; OT lead of circulator to Zone ter-

minal and Neutral lead of circulator to Zone N terminal.

Low Voltage Connections –

Connect thermostat or zone control end switch to the R and W

thermostat terminals.

Connect the D W aquastat to the R and W D W override terminals

(optional).

Connect boiler’s T and T terminal to the X and X boiler end switch

terminals.

Wiring the Sensors:

Do not apply power to these terminals as this will damage the

control.

Outdoor Sensor

Connect the two wires from the Outdoor Sensor to the Outdoor

Sensor terminals. The Outdoor Sensor measures the outdoor air

temperature.

Boiler Sensor

Connect the two wires from the Boiler Sensor to the Supply

Sensor terminals and insulate. The Boiler Sensor measures the

supply water temperature going from the boiler to the system.

SETTINGS:

Before adjusting the settings, read through the sequence of operation

to ensure that you understand how the control operates. The following

page describes how to program these settings into the control once it

has been powered up.

Step Four:

Outdoor Design Temperature:

The Outdoor Design setting is the outdoor tem-

perature used in the heat loss calculation. It is

set to the typical coldest outdoor temperature.

Using a small screwdriver adjust the reset ratio

knob to appropriate Outdoor Design

Temperature. When set to OFF, the boiler tem-

perature will not be reset and boiler will fire to

high limit when there is a call for heat.

Boiler Minimum Supply Temperature (Dip Switch #1):

Most boilers require a minimum operating temperature to prevent cor-

rosion from flue gas condensation. The minimum boiler dip switch

should be set to ON (140°F) supply water temperature so boiler can

operate without causing the boiler flue gases to condense. Consult

the boiler manufacturer for recommended minimum boiler supply

temperatures. The dip switch can also be set to OFF (70°F) when

condensation is not a concern.

Differential (Dip Switch #2):

The differential adjustment sets how far the actual boiler supply water

temperature may deviate from the desired temperature before the boil-

er is turned on or off. This is a function of the water content of the boiler

and the flow rate through the system pump relative to the heat output

of the boiler. The differential can be set by dip switch #2, set to OFF for

10°F (6°C) or set to ON for 20°F (12°C).

Pump Operation (Dip Switch #3):

The pump operation is controlled by dip switch #3. When the dip

switch is set to ON, the pump output will energize when thermostat or

D W calls for heat. When set to OFF, the pump will only come on

when the thermostat calls for heat not the D W.

Warm Weather Shut Down:

When the outdoor temperature rises above 70°F (21°C), the control

turns off the boiler and blinks the Thermostat LED light. This function

only applies for space heating and does not affect D W operation.

TROUBLESHOOTING:

Step Five:

As in any troubleshooting procedure, it is important to isolate a prob-

lem as much as possible before proceeding. The blinking error LED

light greatly simplifies troubleshooting of the SR501-OR. If you sus-

pect a wiring fault, return to step three and carefully check all external

wiring and wiring connections.

Sensor Errors:

• If an outdoor sensor fault occurs, the SR501-OR will assume a

fixed outdoor temperature of 32°F (0°C) and will target the

appropriate supply water temperature. The Boiler light will blink

twice every 5 seconds to indicate the outdoor sensor error.

• If a boiler sensor fault occurs, the SR501-OR turns the boiler off

and the Boiler light will blink once every 5 seconds to indicate the

boiler supply sensor error.

Adjustment of Settings:

• If the outdoor temperature is cold and the rooms are cold,

increase the Outdoor Design setting by 5°F (3°C) per day.

• If the boiler is cycling too often, increase the Differential setting.

Testing the Sensors:

A good quality test meter capable of measuring up to 5,000 kΩ(1 k =

1000 Ω) is required to measure the sensor resistance. In addition to

this, the actual temperature must be measured with either a good

quality digital thermometer, or, if a thermometer is not available, a sec-

Ω

Do not apply voltage to a sensor at any time

as damage to the sensor may result.

Note: When the outdoor temperature rises above 70°F (21°C), the

control turns off the boiler and blinks the Thermostat LED light.

DHW will still operate.

OFF

-30

-20

-10

Taco, Inc. will repair or replace without charge

(at the company’s option) any product or part

which is proven defective under normal use with-

in three (3) years from the date of start-up or

three (3) years and six (6) months from date of

shipment (whichever occurs first).

In order to obtain service under this warranty, it

is the responsibility of the purchaser to promptly

notify the local Taco stocking distributor or Taco

in writing and promptly deliver the subject prod-

uct or part, delivery prepaid, to the stocking dis-

tributor. For assistance on warranty returns, the

purchaser may either contact the local Taco

stocking distributor or Taco. If the subject prod-

uct or part contains no defect as covered in this

warranty, the purchaser will be billed for parts

and labor charges in effect at time of factory

examination and repair.

Any Taco product or part not installed or operat-

ed in conformity with Taco instructions or which

has been subject to misuse, misapplication, the

addition of petroleum-based fluids or certain

chemical additives to the systems, or other

abuse, will not be covered by this warranty.

If in doubt as to whether a particular substance

is suitable for use with a Taco product or part, or

for any application restrictions, consult the

applicable Taco instruction sheets or contact

Taco at [401-942-8000].

Taco reserves the right to provide replacement

products and parts which are substantially simi-

lar in design and functionally equivalent to the

defective product or part. Taco reserves the right

to make changes in details of design, construc-

tion, or arrangement of materials of its products

without notification.

TACO OFFERS T IS WARRANTY IN LIEU OF

ALL OT ER EXPRESS WARRANTIES. ANY

WARRANTY IMPLIED BY LAW INCLUDING

WARRANTIES OF MERC ANTABILITY OR

FITNESS IS IN EFFECT ONLY FOR T E

DURATION OF T E EXPRESS WARRANTY

SET FORT IN T E FIRST PARAGRAP

ABOVE.

T E ABOVE WARRANTIES ARE IN LIEU OF

ALL OT ER WARRANTIES, EXPRESS OR

STATUTORY, OR ANY OT ER WARRANTY

OBLIGATION ON T E PART OF TACO.

TACO WILL NOT BE LIABLE FOR ANY SPE-

CIAL, INCIDENTAL, INDIRECT OR CONSE-

QUENTIAL DAMAGES RESULTING FROM

T E USE OF ITS PRODUCTS OR ANY INCI-

DENTAL COSTS OF REMOVING OR REPLAC-

ING DEFECTIVE PRODUCTS.

This warranty gives the purchaser specific rights,

and the purchaser may have other rights which

vary from state to state. Some states do not

allow limitations on how long an implied warranty

lasts or on the exclusion of incidental or conse-

quential damages, so these limitations or exclu-

sions may not apply to you.

LIMITED WARRANTY STATEMENT

ond sensor can be placed alongside the one to be tested and the read-

ings compared. First measure the temperature using the thermometer

and then measure the resistance of the sensor at the control. The wires

from the sensor must not be connected to the control while the test is

performed. Using the chart below, estimate the temperature measured

by the sensor. The sensor and thermometer readings should be close.

If the test meter reads a very high resistance, there may be a broken

wire, a poor wiring connection or a defective sensor. If the resistance is

very low, the wiring may be shorted, there may be moisture in the sen-

sor or the sensor may be defective. To test for a defective sensor, mea-

sure the resistance directly at the sensor location.

The installer must ensure that this control and its wiring are isolated

and/or shielded from strong sources of electromagnetic noise. This

device complies with part 15 of the FCC Rules. Operation is subject to

the following two conditions: (1) This device may not cause harmful inter-

ference, and (2) this device must accept any interference received, includ-

ing interference that may cause undesired operation.

TECHNICAL DATA:

SR501-OR Boiler Reset Control Relay:

Control: Microprocessor PI control. This is not a

safety (limit) control.

Enclosure: TYPE 1

Dimensions: 41⁄4" W x 51⁄4" x 23⁄4" D

Approvals: UL listed for US and Canada, Temperature

Indicating and Regulating Equipment.

Power Supply: 120/60/1 VAC, 12 amps maximum

Relays: Boiler Relay 1 amp @ 24 VAC

Circulator Relay 1⁄3P (6 FLA, 36

LRA)

Thermostat: 24 VAC Class 2 Output

Sensors: NTC thermistor, 10 kΩ@ 77°F

(25°C ±0.2°C) ß=3892

Outdoor Design Temp.: -30°F to 40°F (-35°C to 5°C)

Boiler Minimum: 70°F or 140°F (21°C or 60°C)

Differential: 10°F or 20°F (6°C or 12°C)

WWSD: 70°F (21°C), blinks TSTAT light when

>70°F

WARNING: Wiring connections must be made in accordance with all applicable electrical codes. Use copper wire only. 120 VAC wiring must have a min-

imum temperature rating of 75°C. Failure to follow this instruction can result in personal injury or death and/or property damage. 12-18 gauge wire rec-

ommended for 120 VAC connections, 14-22 gauge wire for thermostat connections, and 14-22 gauge wire for 24 VAC source connections.

TEMPERATURE RESISTANCE

°F °C Ω

-30 -34 234,196

-20 -29 165,180

-10 -23 118,018

0 -18 85,362

10 -12 62,465

20 -7 46,218

TEMPERATURE RESISTANCE

°F °C Ω

30 -1 34,558

40 4 26,099

50 10 19,900

60 16 15,311

70 21 11,883

80 27 9,299

TEMPERATURE RESISTANCE

°F °C Ω

90 32 7,334

100 38 5,828

110 43 4,665

120 49 3,760

130 54 3,050

140 60 2,490

TEMPERATURE RESISTANCE

°F °C Ω

150 66 2,045

160 71 1,689

170 77 1,403

180 82 1,172

190 88 983

200 93 829

Optional power stealing thermostat resistor part number: SRTR-001RP

(Value: 1000 Ohms, 1/2 watt or higher)

Replacement Switching Relay fuses part number: SR6A-001RP

(Manufacture: Littlefuse, Part Number: 229006)

A Taco Family Company

2016

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