Thermo Technologies USDT 3002 Manual de instrucciones

USDT 3002

Thanks for buying.

Read this manual carefully to get the best perfomance from this unit.

USDT 3002

Unit Mounting

Power Connections

Operation

Troubleshooting

manual

USDT 3002

| 2

Contents

Safety Regulations ...............................................................2

Technical data and unit capacity ........................................3

1. Installation .............................................................4

1.1 Mounting .................................................................................. 4

1.2 Electrical wiring ...................................................................... 4

1.2.1 Standard solar system ........................................................... 5

1.2.2 Solar system with 2nd relay. ................................................ 5

2. Operation and function ........................................6

2.1 Adjustment buttons .............................................................. 6

2.2 System monitoring display ................................................... 6

2.2.1 Channel indication ................................................................. 6

2.2.2 Tool bar .................................................................................... 6

2.2.3 System screen ......................................................................... 7

2.3 Blinking codes ......................................................................... 7

2.3.1 System-Screen Blinking codes ............................................. 7

2.3.2 LED Blinking codes ................................................................ 7

3. Activating the Operating System ........................8

4. Control parameter and indication channels ......8

4.1 Channel overview .................................................................. 8

4.1.1-6 Indication channels ................................................................ 9

4.1.7-18 Adjustment channels ...........................................................10

5. Tips for fault localization ................................... 13

5.1 Miscellaneous ........................................................................14

6. Accessory ............................................................ 16

Reprinting / copying

This manual including all parts is copyrighted. Any

use outside of the copyright requires the approval of

Thermo Technologies. This especially applies for copies,

translations, micro ﬁlms and electronic storage media.

Editor: Thermo Technologies

Important notice:

Accuracy of all texts and drawings in this manual are to

the best of Thermo Technologies knowledge and consent.

The information and illustrations contained in this manual

should act only as a reference point and in no way replace

the user‘s own calculations and plans.

No liability is assumed for incorrect, incomplete or false

information and the resulting damages.

Errors and technical changes excepted.

Safety regulations:

Please read the following information carefully before

installing and operating the controller. This will avoid damage

to the solar system by incorrect installation. Mounting should

be adapted to the characteristics of the building and conform

to all state and federal regulations.

CU 72060171 01

UL 60730-1A:2002

CSA E60730.1:2002

USDT 3002

3 |





• System status diagnostics

• Symbolic display of all para-

meters

• Up to 4 temperature sensors

Pt1000

• Manual override of pump for

system testing

• Two Relay Outputs

• Adjustable factory settings of

Delta T

• Flow meter capability

• Simple 3-Button operation

• Emergency collector shut-off

temperature

• Solar operating hours counter

• Energy collection measure-

ments

Package includes:

1 x USDT 3002

1 x accessory bag

1 x spare fuse T4A

2 x screws and dowels

4 x strain relief and screws

Additionally enclosed in the full kit:

1 x sensor FKP6

2 x sensor FRP6

Unit Externals

Housing:

plastic, PC-ABS and PMMA

Protection type: IP 20 / DIN 40050

Environmental temp.: 0 ... 104 °F

Size: 172 x 110 x 46 mm

Mounting: wall mounting, mounting

into patch-panels is possible

Power supply:

115 V~

Total power supply:

2 x 1 A

Mode of operation:

Typ 1.b

Breaking capacity per relay:

electromechanical relay:

2 x 1 A

At the factory, USDT 3002 is set

to control a standard solar water

heating system with an auxiliary relay

to divert surplus heat. The auxiliary

relay can be used to maintain the

tank temperature, protect the system

from overheating or provide another

heat source to heat the storage tank.

The controller has inputs for four

PT1000-sensors.

The fourth sensor may be used as

for an additional temperature reading

or for a ﬂow meter. A 3-key-panel

below a large LCD serves as the

user interface. Simple icons give

information about the function and

operational mode of the controller

and the system performance.

USDT 3002

| 4

display

pushbutton

can fuse 4A

cable conduits with strain

relief

cover

1.1 Mounting

The unit must only be located internally. It is not suited

for installation in hazardous locations and should not be

sited near an electromagnetic ﬁeld. The controller must

be positioned 1/8" from walls, LS-switches or fuses. Please

pay attention to a separate laying of the cable lines and

installation of AC power supply.

1. Unscrew the cross-recessed screw of the cover and

remove it from the housing.

2. Mark the upper fastening point on the wall and premount

the enclosed dowel and screw.

3. Hang up the housing at the upper fastening point and mark

the lower fastening point on the underground (hole pitch

5"5 mm), afterwards put the lower dowel.

4. Fasten the housing at the underground.

1. Installation Warning!

Switch-off power supply before

opening the housing.

1.2 Electrical wiring The power supply to the controller must be via an external

power supply switch (last step of installation!) and the line

voltage must be 115 Volt (50...60 Hz). Flexible lines are to

be ﬁxed at the housing by enclosed strain relief supports

and screws.

The controller is equipped with 2 relays for connection

to system counterparts e.g. pumps, valves etc. can be con-

nected:

• Relay 1

18 = conductor R1

17 = neutral conductor N

13 = ground clamp

• Relay 2

16 = conductor R2

15 = neutral conductor N

14 = ground clamp

The temperature sensors (S1 up to S4) will be connected

to the following terminals independently of the polarity:

1 / 2 = Sensor 1 (e.g. Sensor collector 1)

3 / 4 = Sensor 2 (e.g. Sensor tank 1)

5 / 6 = Sensor 3 (e.g. Sensor TSPO)

7 / 8 = Sensor 4 (e.g. Sensor TRL)

The power supply terminals are:

19 = neutral conductor N

20 = conductor L

12 = ground clamp

hanging

ﬁxation

Electrostatic discharge can damage electronic

components

Dangerous voltage on contact

1 2

S1 S2 S3

3456

Temp. Sensor

Pt1000

LNR1NR2N

201918171615

7 8 141312

2 (1) A 115

(1) A 115 V~

T4A

115 V~

net clamps

fuse

consumer clamps

Sensor clamps earthing clamps

USDT 3002

5 |

S4 / TRF

1.2.1 Allocation of terminals for system 1 Standard solar system with 1 tank, 1 pump and 3 sensors.

The sensor S4 / TRF can optionally be used for a ﬂow meter

or 4th temperature sensor

Arr 1

R1 S3

S4 / TRF

Solars system with 1 tank, 3 sensors and 2nd relay (R2).

The sensor S4 / TRF can optionally be used fas a ﬂow meter

or a 4th temperature sensor.

Arr 2

1.2.2 Allocation of terminals for system 2 (Arr 2)

Symbol Speciﬁcation

S1 collector sensor

S2 tank sensor below

S3 tank sensor at the top

S4 / TRF optional sensor for ﬂow

- meter/additional tempe-

rature input

R1 solar pump

R2 pump for heat exchange

Symbol Speciﬁcation

S1 Collector sensor

S2 Tank sensor below

S3 Tank sensor at the top

(optionally)

S4 / TRF 4th s ensor for or ﬂow

meter (optionally)

R1 Solar pump

USDT 3002

| 6

backwards forward

SET

(selection / adjustment mode)

The system monitoring display consists of 3 blocks: indica-

tion of the channel, tool bar and system screen (active

system scheme).

The indication channel consists of two lines. The upper

line is an alphanumeric 16-segment indication. This displays

the channel names / menu items. In the lower 7-segment

indication, the channel values and the adjustment parameter

are indicated.

Temperatures and temperature differences are indicated

in or .

2.2.1 Channel indication

only channel indication

2.2.2 Tool bar

The additional symbols of the tool bar indicate the current

system status.

only tool bar

2. Operation

2.1 Pushbuttons for adjustment

The controller is operated by the 3 buttons below the

display. The forward-key (1) is used for scrolling forward

through the indication menu or to increase the adjustment

values. The backwards-key (2) is accordingly used for the

reverse function.

Select a channel channel using the forward/back keys (1

and 2). Brieﬂy press the center key, so that „SEt“ ﬂashes

Adjust the value using the foward/back keys

then brieﬂy press the center key, so that „SEt“

permanently appearsThe adjusted value is now saved.

Additional channels (i.e. manual operation of pump,

activation of 2nd relay, cooling etc.) become available by

holding down the forward key (1) for two seconds

2.2 System monitoring display





Complete Monitoring-Display

Symbol standard ﬂashing

relay 1 active

relay 2 active

maximum tank temperature

active / maximum tank

temperature exceeded

collector cooling function or

reccoling function active

antifreeze- function activated collector minimum limitation

or antifreeze function active

collector security shutdown or

tank securtiy shutdown active

+ sensor defect

+ manual operation active

an adjustment channel is

changed SET-mode

USDT 3002

7 |

The system screen (active system scheme) displays the full

system operation. It consists of several system component

symbols, which are - depending on the current status of the

system - either ﬂashing, permanently displayed or hidden.

Sensor

Collector 1

Pumps

Additional symbol for

operation of the burner

Tank

Tank heat exchanger Tank 2 or or 2nd relay option

(with additional symbol)

Sensor tank top

Collectors

with collector sensor

Pump

3-way-valves

The ﬂow direction or the current bre-

aking capacity are always shown.

Heating circuit

Tank 1 and 2

with heat exchanger

After-heating

with burner symbol

Temperature sensor

2.2.3 System screen

only system screen

Constantly green: System functioning correctly

Red/green blinking: blinking initialisation phase of manual

operation

Red blinking: sensor defect

2.3 Blinking codes

2.3.2 LED blinking codes

2.3.1 System screen blinking codes

• Pumps blink during starting phase

• Sensors blink if the respective sensor-indication channel

is selected.

• Sensors blink rapidly in case of sensor defect.

• Burner symbol blinks if 2nd relay is activated

USDT 3002

| 8

3. Activating the Operating System

User has the option of a one or two relay system

backwards forward

SET

(Selection / Adjustment mode)

Operation cont-

rol lamp

Arr 1 Arr 2

1. AC power supply must be activated. The controller passes

an initialisation phase in which the operating control lamp

ﬂashes red and green. At this point the controller is in au-

tomatic operation with factory settings.

Arr 1. Controller is ready for operation o the user may

activate the 2nd relay:

2. - Arr 2: Extended Solar System (with second relay)

-locate Arr by holding down forward key for 2 seconds

-press center key to begin set

-increase to Arr 2 using forward key

-press center key to save adjustment

Now the controller is ready for operation.

4. Controller parameter and indication channels

4.1 Channel-overview

Legend:

Corresponding channel is available.

Corresponding channel is available if the appropriate option

is activated.



Corresponding channel is only available if the option heat

quantity measurement is activated (OWMZ).

MEDT

The channel antifreeze content (MED%) is only shown if a

medium other than water or Tyfocor LS / G-LS (MEDT

0 or 3) is used. The adjustment is only appropriate when

using other types of antifreeze.



Corresponding channel is only available if the option heat

quantity measurement is deactivated (OWMZ).

Please note:

S3 and S4 are only indicated if sensors are connected.

channel Arr speciﬁcation page

1 2*

COL x x Temperature collector 1 9

TST x Temperature tank 1 9

TSTL x Temperature tank 1 below 9

TSTU x Temperature tank 1 above 9

S3 x Temperature sensor 3 9

TRF   Temperature return sensor 9

S4   Temperature sensor 4 9

h P1 x Operating hours relay 1 9

h P2 x Operating hours relay 2 9

kWh   Heat quantity kWh 10

MWh   Heat quantity MWh 10

Arr 1-2 System 8

DT O x x Switch-on temperature difference 10

DT F x x Switch-off temperature difference 10

S MX x x Maximum temperature tank 1 10

EM x x emergency temperature collector 1 10

channel Arr speciﬁcation page

1 2*

OCX x x Option collector cooling collector 1 11

CMX x* x* Maximum temperature collector 1 11

OCN x x Option minimum limitation collector1 11

CMN x* x* Minimun temperature collector 1 11

OCF x x Option antifreeze collector 1 11

CFR x* x* Antifreeze temperature collector 1 11

OREC x x Option reccoling 11

O TC x x Option tube collector 12

AH O x Switch-on temp. for thermostat 1 12

AH F x Switch-off temp. for thermostat 1 12

OHQM x x Option WMZ 12

FMAX   Maximum ﬂow 12

MEDT   Antifreeze type 10

MED% MEDT MEDT Antifreeze content 10

HND1 x x Manual operation relay 1 12

HND2 x x Manual operation relay 2 12

LANG x x Language 12

UNIT x x Change over °FAH / °CEL 12

PROG XX.XX Program number

VERS X.XX Version number

USDT 3002

9 |

4.1.1 Indication of collector temperatures

4.1.2 Indication of tank temperatures

4.1.3 Indication of sensor 3 and sensor 4

4.1.4 Indication of other temperatures

4.1.5 Operating hours counter

Displays the current collector temperature.

• COL : collector temperature (1-collector-system)

COL:

Collector temperature

display range: -40 ... +482 °F

Displays the current tank temperature.

• TST : tank temperature (1 relay)

• TSTL/U: tank temperature (2 relays)

TST:

Tank temperatures

Display range: -40 ... +482 °F

Displays the current temperature of the corresponding

additional sensor (without control function).

• S3 : temperature sensor 3

• S4 : temperature sensor 4

Note:

S3 and S4 are only indicated if the temperature sensors

are connected (shown).

S3, S4:

Sensor temperatures

Display range: -40 ... +482 °F

Displays the current temperature of the connected sensor.

TRF:

other measured

temperatures

Display range: -40 ... +482 °F

h P1, h P2:

Operating hours counter

Display channel

The operating hours counter adds up the solar operating

hours of the respective relay (h P). Completed hours are

shown on the display and may be reset back to 0. Select the

operating hours channel (h P). The center button for approx.

2 seconds in order to get back into the RESET-mode of the

counter. The display-symbol is ﬂashing and the operating

hours will be set to 0. Press the center button again to save

the adjustment.

In order to ﬁnish the RESET-procedure, the button must

be pressed in order to conﬁrm.

In order to interrupt the RESET-procedure, no button

should be pressed for about 5 seconds. The controller re-

turns automatically into the indicaton mode.

4.1.6 Measuring Collected Energy

OHQM:Energy Collection

Measuring

Adjustment range: OFF ... ON

Factory setting: OFF

The unit may be used in conjunction with a ﬂow meter for

energy collection calculations. This option is activated in the

channel OHQM.

The parameters of the ﬂowmeter (l/min) must be adjusted

in the channel FMAX. Antifreeze type and concentration

of the heat transfer medium are indicated on the channels

MEDT and MED%.

FMAX:

Volume ﬂow in l/min

Adjustment range 0 ... 20

in steps of 0,1

Factory setting 6,0

USDT 3002

| 10

4.1.7 ∆ Delta T Adjustment

Type of antifreeze:

0 : water

1 : propylene glycol

2 : ethylene glycol

3 : Tyfocor® LS / G-LS

kWh/MWh: Collected

Energy in kWh / MWh

Display channel

MEDT: Type of antifreeze

Adjustment range 0 ... 3

Factory setting 1

MED%: Concentration of

antifreeze in (Vol-) %

MED% is blinded out by

MEDT 0 and 3.

Adjustment range 20 ... 70

Factory setting 45

The transportation of collected energy is measured by the

volume ﬂow (S1) and the return ﬂow (S4). These references

are displayed in both kWh and MWh in their respective

channels. The sum of all channels = total heat output.

As soon as one of the display channels of the collected

energy is selected, the symbol is permanently shown

on the display. The center button (SET) must be pressed for

approx. 2 seconds in order return to RESET-mode of the

counter. The display-symbol is ﬂashing and the energy

value will be set to 0.

Pressing the center button again saves the adjustmentIf

adjustments are not made within 5 seconds the RESET pro-

cedure is interrupted. The controller returns automatically

into indication mode.

Please note: Switch-on temperature difference DO must

be at least 2 °Ra higher than the switch-off temperature-

difference DF.

DT O:

Switch-on temperature

Adjustment range

2,0 ... 40,0 °Ra

Factory setting 12.0

DT F:

Switch-off temperature diff.

Adjustment range

1,0 ... 38 °Ra

Factory setting 8.0 °Ra

Primarily the controller works in the same way as a standard

differential controller. If the switch-on difference (DT O)

is reached, the pump is activated. If the adjusted switch-off

temperature is underrun (DT F), the controller switches-

off.

4.1.8 Maximum tank temperature

If the adjusted maximum temperature is exceeded, a

further loading of the tank is stopped so that damage

through overheating can be avoided. If the maximum tank

temperature is exceeded, on the display is shown and .

Please note: The controller is equipped with a security-

switch-off of the tank, which avoids a further loading of the

tank if 203 °F are reached at the tank.

S MX:

Maximum tank temp.

Adjustment range

40 ... 205 °F

Factory setting 140 °F

4.1.9 Emergency Shutdown of Collector

Collector emergency shutdown

If the adjusted collector limit temperature (EM) is exceeded,

the solar pump (R1/R2) is deactivated in order to avoid a

damaging overheating of the solar components (collector

emergency shutdown). The limit temperature is set to

285 °F but may be changed within the adjustment range of

230 ... 400 °F. This is displayed as (ﬂashing).

EM:

Limit collector temperature

Adjustment range

230 ... 400 °F,

Factory setting 285 °F

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