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Sorel TDC4 Installation And Operating Instructions Manual

Temperature difference controller
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Temperature Difference Controller TDC4
Installation and operating instructions
TDC 4
Temperatur-Differenz-Controller
Read carefully before installation, commissioning and operation

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Summary of Contents for Sorel TDC4

  • Page 1 Temperature Difference Controller TDC4 Installation and operating instructions TDC 4 Temperatur-Differenz-Controller Read carefully before installation, commissioning and operation...
  • Page 2 Index EC declaration of conformity 5.14 Thermostat periods General instructions 5.15 „Party Function“ Explanation of symbols 5.16 Energy saving mode EC declaration of conformity 5.18 TecoS3 Warranty and liability Protective functions Specifi cations Seizing protection About the controller Frost protection Scope of supply System protection Disposal and pollutants...

  • Page 3: Safety Instructions

    Safety instructions A.1. - EC declaration of conformity By affi xing the CE mark to the unit the manufacturer declares that the Temperature- Difference-Controller 4, hereinafter refererred to as TDC 4 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...
  • Page 4 Safety instructions A.4. - EC declaration of conformity Changes to the unit can compromise the safety and function of the unit or the entire system. Danger Changes, additions to or conversion of the unit are not permitted without the writ- ten permission from the manufacturer It is likewise forbidden to install additional components that have not been tested together with the unit...

  • Page 5: Description Of Controller

    Description of controller B.1. - Specifi cations Electrical specifi cations: Mains voltage 230VAC +/- 10% Mains frequency 50...60Hz Power consumption Switched power Electronic relay R1 min.20W...max.120W for AC3 Mechanical relay R2 460VA for AC1 / 185W for AC3 Mechanical relay R3 460VA for AC1 / 185W for AC3 0..10V Output for 10 k Ω...
  • Page 6 Description of controller B.3. - About the controller The Temperature Difference Controller TDC 4 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.
  • Page 7 Description of controller B.6. - Hydraulic variants The following illustrations should be viewed only as schematic dia- grams showing the respective hydraulic systems, and do not claim to be complete. The controller does not replace safety devices under any circumstances. Depending on the specifi c application, additional system Caution components and safety components may be mandatory, such as check valves, non-return valves, safety temperature limiters, scalding protec-...

  • Page 8: Installation

    Installation C.1. - Wall installation Install the controller only in dry areas and under the ambient conditions de- scribed under „B.1. - Specifi cations“ on page 5. Carry out the following Caution steps 1-8. 1. Unscrew cover screw completely C.1.1. 2.
  • Page 9 Installation C.2. - Electrical connection 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 compli- Danger ance with the applicable regulations.
  • Page 10 Installation 1.Select necessary program/hydraulics C.2.1. (Fig. B5 resp. D.1 - D.16) 2.Open controller as described under C.1. 3.Strip cables by 55mmmax., insert, fi t the strain relief devices, strip the last 8-9mm of the wires (Fig. C.2.1) 4.Open the terminals using a suitable screwdriver (Fig.

  • Page 11: Installing The Temperature Sensors

    Installation C.3. - Installing the temperature sensors The controller operates with Pt1000 temperature sensors which are accurate to the degree, thus ensuring optimal control of system functions. If desired the sensor cables can be extended to a maximum of 30m using a ca- ble with a cross-section of at least 0.75mm².

  • Page 12: Terminal Connection Diagrams

    Installation D. - Terminal connection diagrams D.1. - Solar with storage tank Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank Sensor 3 (optional) Sensor 4 Flow (optional) not used...
  • Page 13 Installation D.3. - Solar with bypass Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank Sensor 3 forward fl ow Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 14 Installation D.5. - Solar with 2 zone storage tanks Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank low Sensor 3 storage tank top Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 15 Installation D.7. - Solar 2 coll. (east/west) Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector 1 Sensor 2 storage tank Sensor 3 collector 2 Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 16 Installation D.9. - Solar 2 Storage tank/valve Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank 1 Sensor 3 storage tank 2 Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 17 Installation D.11. - Solar with follow-on storage tank/Solar & transfer“ Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank 1 Sensor 3 storage tank 2 Sensor 4 Flow (optional) not used...
  • Page 18 Installation D.13. - Solar storage tank/pool Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank Sensor 3 swimming pool Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 19 Installation D.15. - Solar + cooling 2 Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank Sensor 3 optional Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 20 Installation D.17. - Solar + solid fuel boiler Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage tank Sensor 3 solid fuel boiler Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 21 Installation D.19. - Universal ΔT controller Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 (control) Sensor 2 (reference) Sensor 3 (thermostat) Sensor 4 Flow (optional) not used 0..10V / PWM (s.
  • Page 22 Installation D.21. - Solar with heat exchanger, valve and 2 zone storage Sensor side Low voltage max. 12VAC/DC connection in the left-hand Mains side max. 12V terminal compartment! 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage low Sensor 3 storage top Sensor 4 fl...
  • Page 23 Installation D.22. - Solar with heat exchanger, valve and 2 storages Low voltage max. 12VAC/DC connection in the left-hand Sensor side Mains side terminal compartment! max. 12V 230VAC Terminal: Connection for: Danger Caution Sensor 1 collector Sensor 2 storage 1 Sensor 3 storage 2 Sensor 4 fl...

  • Page 24: Operation

    Operation E.1. - Display and input The display (1), with its extensive text and graphics mode, is almost self-explanatory, allowing easy operation of the controller. The LED (2) lights up green when a relay is switched on. The LED (2) lights up red when operating mode “Off”...
  • Page 25 Parametrisation E.2. - Commissioning help The fi rst time the controller is turned on and after the language and time are set, a query appears as to whether you want to parametrise the controller using the commissioning help or not. The commis- sioning help can also be terminated or called up again at any time in the special functions menu.
  • Page 26 Operation E.4. - Menu sequence and menu structure The graphics or overview mode appears when no key has been press for 2 min- utes, or when the main menu is exited by pressing “esc“. Pressing a key in graphics or overview mode takes you directly to the main menu.

  • Page 27: Measurement Values

    Measurement values 1. - Measurement values The menu “1. Measurement values” serves to display the currently measured temperatures. The menu is closed by pressing “esc” or selecting “Exit measurement values”. Selecting “Info” leads to a brief help text explaining the measurement values. Selecting “Overview”...
  • Page 28 Statistics 2. - Statistics The menu “2. Statistics” is used for func- tion control and long-term monitoring of the system. The menu is closed by pressing “esc” or selecting “Exit statistics”. For analysis of the system data it is essential for the time to be set ac- curately on the controller.

  • Page 29: Display Mode

    Display mode 3. - Display mode Menu “3. Display mode” is used to defi ne the controller’s display for normal opera- tion. This display appears whenever two min- utes go by without any key being pressed. The main menu appears again when a key is pressed.

  • Page 30: Operating Modes

    Operating modes 4. - Operating modes In menu “4. Operating modes” the con- troller can either be placed in automatic mode, switched off, or placed in a manual operating mode. The menu is closed by pressing “esc” or selecting “Exit operating modes”. 4.1.
  • Page 31 Settings 5. - Settings The necessary basic settings required for the control function are made in menu “5. Settings”. This does not under any circumstances replace the safety facilities to be provided by the customer! Caution The menu is closed by pressing “esc” or select- ing “Exit settings”.
  • Page 32 Settings 5.4. - Tmax S2 Switch-off temperature at sensor 2 If this value is exceeded at sensor 2 and the other conditions are also met, then the controller switches the associated pump and/or valve off. If sensor 2 falls below this value again and the other conditions are also met, then the controller switches the pump and/or valve on again.
  • Page 33 Settings 5.7. - ∆T R2 Switch-on/Switch-off temperature difference for relay R2 If this temperature difference between the reference sensors is exceeded and the other conditions are also met, then the controller switches the pump and/or the valve When the temperature drops to ΔT Off, then R1 is switched off. Settings range: ΔT from 4°C to 20°C / ΔTOff from 2°C to 19°C Settings range: ΔT 10°C / ΔT off 3°C.
  • Page 34 Settings 5.10. - Priority sensor Charging priority in systems with two storage tanks A setting must be made as to which storage tank (storage tank sensor) has priority for charging. Charging of the lower-priority storage tank is interrupted at regular intervals to check whether the temperature increase at the collector can enable charging of the higher-priority storage tank.
  • Page 35 Settings 5.15. - „Party Function“ With the party function the storage temperature is heated up once to the reference temperature (TrefS3, respectively TminS3 in energy saving mode). The party mode is enabled by pressing the „esc“-key for 3 seconds in the main menu. While this mode is active, the system heats up to the reference value + hysteresis, unattached to preset thermostat times.
  • Page 36 Settings...

  • Page 37: Protective Functions

    Protective functions 6. - Protective functions Menu „6. - Protective functions“ can be used to activate and set various protective functions. This does not under any circumstances replace the safety facilities to be provided by the customer! Caution The menu is closed by pressing “esc” or select- ing “Exit settings”.

  • Page 38: Collector Protection

    Protective functions Protective functions 6.4. - System protection priority protection System protection prevents overheating of system components by automatic shutdown of the solar pump. If “SProt Ton” is exceeded at the collector, the pump is switched off. The pump is activated again when the temperature drops below “SProt TOff”. Automatic shutdown - settings range: On / Off / Default: on SProt Ton - settings range: 60 °C to 150 °C / Default: 120 °C SProt Toff - settings range: 50 °C to Ton minus 5 °C / Default: 115 °C...
  • Page 39 Protective functions 6.4.1. - Cooling functions The hydraulic variants are set in menu „7.1 Program selection“ Hydraulic Variant D.14 Solar + cooling 1: If „CProt Ton“ is exceeded at S1, the cooler at R2 is switched on till the temperature drops to „CProt Toff“.

  • Page 40: Anti-Legionella

    Protective functions 6.7. - Anti-Legionella With the “AL function” activated the TDC 4 makes it possible to heat the storage tank up once at certain intervals (the “AL frequency”) to a higher temperature (“AL Tsetpoint S2”), assuming that the energy source allows this. AL function setting range: On or Off/default setting: Off AL Tsetpoint S2 setting range: from 60°C to 99°C/default setting: 70°C AL frequency setting range: from 1 to 28 days/default setting: 7 days...

  • Page 41: Special Functions

    Special functions 7. - Special functions Menu “7. Special functions” is used to set basic items and expanded functions. Other than the time all settings may only be made by a specialist. Caution The menu is closed by pressing “esc” or select- ing “Exit special functions”.
  • Page 42 Special functions 7.4. - Commissioning Starting the commissioning help guides you in the correct order through the basic set- tings necessary for commissioning, and provides brief descriptions of each parameter in the display. Pressing the “esc” key takes you back to the previous value so you can look at the se- lected setting again or adjust it if desired.
  • Page 43 Special functions 7.7. - Heat meter One of the available heat meter modes can be selected here (Off, calculated heat quantity by preset fi xed fl ow rate or more precise heat metering via VFS sensor). Ad- ditional parameters like the type of glycol, and VFS type and position can be made. The setting „VFS position“...
  • Page 44 Special functions 7.8. - Start aid function 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 inac- curately 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...
  • Page 45 Special functions 7.9. - Speed control If the speed control is activated, the TDC 4 makes it possible to vary the speed of standard pumps at relay R1 by means of special internal electronics. This function should only be activated by a specialist. Depending on the pump and pump stage used, the minimum speed should not be set too low, because otherwise the pump or the system may be damaged.
  • Page 46 Special functions 7.9.2. - Type of pump This menu is used to set the type of speed controlled pump that is connected. Settings range: Standard, PWM, 0-10V / Default: Standard The TDC 4 is capable of using speed control on standard pumps via phase control or the control of e.g.

  • Page 47: Purging Time

    Special functions Technical data 0-10V: 0-10V: 2V bis 10V (20% bis 100%) for 10 k Ω working resistance 10V = 100% speed 5V = 50% speed 2V = 20% speed 0V = Off Relay 1 is running simultanously with the PWM/0-10V signal with the same speed (phase control), so a standard pump can be used together with the PWM/0-10V pump.
  • Page 48 Special functions 7.9.5. - Max. speed The maximum speed of the pump at relay R1 is specifi ed here. During the setting the pump runs at the specifi ed speed and the fl ow rate can be determined. Setting range: from 70 to 100%/default setting: 100% The indicated percentages are guide values that may vary to a greater or lesser extent depending on the system, pump and pump stage.
  • Page 49 Special functions 7.10. - Relay 3 functions This menu is used to assign specifi c functions to relay 3. On default, R3 is switched off. Protective functions R3 is switched on when a protective function is activated., In menus 7.10.2 - 7.10.7 the protective function that trigger the activation of R3 can be selected.
  • Page 50 Menu lock 8. - Menu lock Menu “8. Menu lock” can be used to secure the controller against unintentional changing of the set values. The menu is closed by pressing “esc” or select- ing “Exit menu lock”. The menus listed below remain completely accessible despite the menu lock being activated, and can be used to make adjustments if necessary: Measurement values Analysis...

  • Page 51: Service Values

    Service values 9. - Service values The menu “9. Service values” can be used for remote diagnosis by a specialist or the manu- facturer in the event of an error, etc. Enter the values at the time when the error occurs e.g. in the table. Caution The menu can be closed at any time by press- ing “esc”.
  • Page 52 Language 10. - Language Menu “10. Language” can be used to se- lect the language for the menu guidance. This is queried automatically during initial commissioning. The choice of languages may differ, however, depending on the device design. Language selection is not available in every device design!

  • Page 53: Malfunctions With Error Messages

    Malfunctions Z.1. Malfunctions with error messages If the controller detects a malfunction, the red light fl ashes and the warning symbol also appears in the display. If the error (LED fl ashes + is no longer present, the warning symbol warning symbol) changes to an info symbol and the red light no longer fl...

  • Page 54: Replacing The Fuse

    Malfunctions Replacing the fuse Repairs and maintenance may only be performed by a specialist. Before working on the unit, switch off the power supply and secure it against Danger being switched on again! Check for the absence of power! Only use the supplied spare fuse or a fuse of the same design with the following specifi...
  • Page 55 Useful notes/tips and tricks Instead of setting the fl ow rate for the system using a fl ow rate limiter, it is better to adjust the fl ow rate using the switch on the pump and by means of the “max. speed” setting on the controller (see 7.9.4). This saves electricity! The service values (see 9.) include not only current measurement val- ues and operating states, but also all of the settings for the controller.
  • Page 56 Subject as a basic principle to errors and technical changes. Manufacturer: Your specialist dealer: SOREL GmbH Mikroelektronik Jahnstr. 36 D - 45549 Sprockhövel Tel. +49 (0)2339 6024 Fax +49 (0)2339 6025...

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