ZilanSolar SR981S User manual

SR981S/SR982S operation manual of solar pump station
Page 0 of 85
Operation manual
SR981S/SR982S
Solar Pump Station
Please read this manual carefully before using!

SR981S/SR982S operation manual of solar pump station
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Contents
1. Safety information................................................................................................... 5
1.1 Important information............................................................................................ 5
1.2 About this manual................................................................................................. 5
1.3 Liability waiver...................................................................................................... 5
1.4 Description of symbols.......................................................................................... 5
2. Overview of solar station......................................................................................... 6
3. Mounting the solar station....................................................................................... 8
4. Attention Items for solar station installation ............................................................. 9
5. Connection terminal of built-in controller................................................................10
5.1 Open the connection terminal box .......................................................................10
5.2 Terminal connection.............................................................................................12
6. Operation manual of built-in controller ...................................................................13
6.1 Operation button..................................................................................................13
6.2 Signal description................................................................................................14
6.3 Set up clock/week................................................................................................15
6.4 Manu structure ....................................................................................................16
6.5 Menu description .................................................................................................17
6.6 System overview .................................................................................................19
6.7 System description ..............................................................................................20
System 1: Standard system - 1 tank ..........................................................................20
System 2: 1 tank + 1 solid fuel boiler .........................................................................21
System 3: 1 tank + T-valve to heat tank in layer.........................................................22
System 4: 2 tanks controlled by pump logic...............................................................23
System 5: 2 tanks controlled by thermal enegy transfer logic.....................................24
System 6: 2 tanks controlled by T-valve logic.............................................................25
System 7: East/West collector array + 1 tank controlled by pump logic ......................26
System 8: East/West collector array + 1 tank controlled by T-Valve logic ...................27
System 9: East/West collector array + 2 tanks controlled by T-Valve logic..................28
System 10: 1 tank + T-valve controlled by return heating ...........................................29
System 11: East/west collector array +1 tank + T-valve controlled by return heating ..30

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System 12: Standard solar system with heat exchanger ............................................31
System 13: 2 tanks controlled by T-valve logic + T-valve for return heating................32
System 14: 2 tanks controlled by pump logic + T-valve for return heating ..................33
System 15: 2 tanks controlled by T-valve logic + heat transfer between 2 tanks.........34
6.8 East/west collector array with double pumps station..........................................36
7. Functions operation and parameters setup (user grade)........................................37
7.1 THET Timing heating...........................................................................................37
7.2 CIRC DHW circuilation function activated /deactivated ........................................41
7.3 tCYC Tempeature or time setting for DHW pump in three time sections...............41
8. Functions operation and parameter setup (engineer grade)...................................44
8.1 Access main menu ..............................................................................................44
8.2 Access submenu .................................................................................................45
8.3 DT Temperature difference for solar circuit pump.................................................45
8.4 TEMP Temperature main menu ...........................................................................46
8.4.1 EMOF Maximum switch-off temperature of collector (for collector emergency
close function)...........................................................................................................47
8.4.2 CMX Maximum limited temperature of collector (collector cooling function).......48
8.4.3 CMN Low temperature protection of collector ...................................................49
8.4.4 CFR frost protection temperature of collector....................................................50
8.4.5 REC Recooling temperature of tank..................................................................51
8.4.6 SMX1 Maximum temperature of tank 1.............................................................51
8.4.7 SMX2 Maximum temperature of tank 1.............................................................52
8.4.8 MAX1 Maximum switch-off temperature for heat transfer between tank and heat
return.........................................................................................................................52
8.4.9 MIN1 Minmium switch-on temperature for heat transfer between tank and heat
return.........................................................................................................................53
8.4.10 MAX2 Maximum switch-off temperature for heat transfer between heat
exchanger and tank...................................................................................................53
8.4.11 MIN2 Minmium switch-on temperature for heat transfer between heat
exchanger and tank...................................................................................................54
8.4.12 C＿F Switch between Celsius and Fahrenheit ................................................54
8.5 FUN Auxiliary functions........................................................................................55

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8.5.1 DVWGAnti legionnaires' function .....................................................................56
8.5.2 SFB Switch-on/off of the solid fuel boiler...........................................................57
8.5.2.1 SFON Minimum switch-on temperature of tank..............................................58
8.5.2.2 SFOF Maximum switch-off temperature of tank..............................................58
8.5.2.3 MAX3 Maximum switch-off temperature of solid fuel boiler.............................58
8.5.2.4 MIN3 Minimum switch-on temperature of solid fuel boiler...............................58
8.5.3 PUMP1 P1 pump operation mode selection......................................................59
8.5.3.1 nMIN Pump1 speed adjustment (RPM)..........................................................59
8.5.3.2 DTS Standard temperature difference of pump 1 (for pump 1 speed adjustment)
..................................................................................................................................60
8.5.3.3 RIS Gain for circulation pump 1 (for pump1 speed adjusting).........................61
8.5.4 PUMP2 P2 pump operation mode selection......................................................61
8.5.4.1 n2MN Pump 2 speed adjustment (RPM)........................................................62
8.5.4.2 DT2S Standard temperature difference of pump 2 (for pump 2 speed
adjustment ) ..............................................................................................................63
8.5.4.3 RIS2 Gain for circulation pump 2 (for pump 2 speed adjustment)...................63
8.5.10 OHQM Thermal energy measuring .................................................................63
8.5.9 FTYPE Flow meter type selection.....................................................................64
8.5.9. FTYP2 Flow meter type selection ....................................................................65
8.5.10.1 FMAX Flow rate...........................................................................................65
8.5.10.2 MEDT Type of heat transfer liquid................................................................66
8.5.10.3 MED% Concentration of heat transfer liquid.................................................66
8.5.11 PRIO Tank priority...........................................................................................66
8.5.11.1 tRUN Intermission heating run-on time.........................................................67
8.5.11.2 tSTP Intermission heating run-off time..........................................................68
8.5.12 INTV pump Intermission function....................................................................69
8.5.12.1 IRUN Pump interval run-on time ..................................................................69
8.5.12.2 ISTP Pump interval run-off time...................................................................70
8.5.13 COOLTank cooling function............................................................................70
8.5.14AHO Automatical thermostat function..............................................................71
8.5.15 BYPR Bypass function (high temperature)......................................................72
8.6 HND Manual control ............................................................................................73

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8.7 PASS Password set.............................................................................................75
8.8 REST Recovery to factory set..............................................................................76
8.9 “ON/OFF” Controller switch on/off button.............................................................76
8.10 Holiday function.................................................................................................76
8.11 Manual heating ..................................................................................................77
8.12 Temperature checking function ..........................................................................78
9. Protection function.................................................................................................78
9.1 Memory protection...............................................................................................78
9.2 Screen protection ................................................................................................78
9.3 Pump P1/P2 dry running protection .....................................................................78
10. Trouble shooting..................................................................................................79
10.1 Trouble protection..............................................................................................79
10.2 Trouble checking ...............................................................................................79
11. Quality Guarantee................................................................................................81
12. Product specification............................................................................................82
13. Package list.........................................................................................................82
14. Device matched to this pump station ...................................................................83

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1. Safety information
1.1 Important information
We have carefully checked the text and pictures of this manual and provided the best of
our knowledge and ideas, however inevitable errors maybe exist. Please note that we
cannot guarantee that this manual is given in the integrity of image and text, they are just
some examples, and they apply only to our own system. Incorrect, incomplete and
erroneous information and the resulting damage we do not take responsibility. Please
understanding!
1.2 About this manual
This manual describes the installation, functions and operation of a solar station, which
integrates a solar controller. When installing the remaining components e.g. the solar
collectors and the storage unit, please be sure to observe the appropriate installation
instructions provided by each manufacturer. Installation, electrical connection,
commissioning and maintenance of the device may only be performed by trained
professional personnel. The professional personnel must be familiar with this manual and
follow the instructions contained herein.
1.3 Liability waiver
The manufacturer can’t monitor the compliance with these instructions or the
circumstances and methods used for installation, operation, utilization and maintenance of
this pump station. Improper installation can cause damages to material and person. This is
the reason why we do not take over responsibility and liability for losses, damages or cost
that might arise due to improper installation, operation or wrong utilization and
maintenance or that occur in some connection with the aforementioned. Moreover we do
not take over liability for patent infringements or infringements –occurring in connection
with the use of this pump station on the third parties rights. The manufacturer preserves
the right to put changes to product, technical date or installation and operation instructions
without prior notice. As soon as it becomes evident that safe operation is no longer
possible (e.g. visible damage). Please immediate take the device out of operation. Note:
ensure that the device can’t be accidentally placed into operation.
1.4 Description of symbols
Safety indication: Safety instructions in the text are marked with a warning
triangle. They indicate measures which can lead to injury of person or safety risks.

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Operation steps: small triangle “►”is used to indicate operation step.
Notes: Contains important information about operation or functions.
2. Overview of solar station
SR981S Single Line Pump Station
SR982P Double Pumps Station
2.2
2.13
2.1
2.3
2.4
2.6
2.7
2.8
2.12
2.9
2.10
2.11
2.16
2.18
2.17
2.5
2.14
2.15
2.12
5
SR982S Double Lines Pump Station

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2.1
Collector flow pipe connections, male thread G1/2( to collector)
2.2
Sensor on the tank output pipe, NTC10K, B=3950
2.3
Safety valve, release pressure 6 bar
2.4
Pressure gauge, measuring range: 0~10bar system pressure
2.5
Expansion connection, male thread G1/2
2.6
Filling valve connection, male thread G1/2
2.7
One –way stop valve
2.8
Circulation pump ( for solar liquid)
2.9
Draining valve connection, male thread G1/2
2.10
Electrical flow meter
2.11
Connection terminal box of built-in controller
2.12
Tank output pipe connection ( from tank), male thread G1/2
2.13
Tank input pipe connection(to tank), male thread G1/2 (not on SR981S single pipe
pump station)
2.14
Manual and automatic combined air separator (not on SR981S single pipe pump
station)
2.15
Sensor on the collector return pipe ( high temperature) NTC10K, B=3950 (not on
SR981S single pipe pump station)
2.16
Collector return pipe connection, male thread G1/2 ( from collector) (not on SR981S
single pipe pump station)
2.17
Front cover of pump station
2.18
Display and control panel of built-in controller
2.19 Specification of pump station
Components
Parameters
Remark
Size of pump station
Height (not include the pipe connection)
420mm
Width (not include the pipe connection)
280mm
Thickness (not include the pipe connection)
155mm
Safety components
Pressure of safety valve
6bar
Display range of pressure gauge
0～10bar
Connection of expansion vessel
G1/2,male thread
Maximum permission pressure
10 bar
Maximum permission temperature
115oC
Pump parameter
Pump type
Wilo RS15/6
Grundfos 15-65
Maximum flow rate
2.5(t/h)
2.5(t/h)
Maximum water head
5.5m
5.5m

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Maximum operation pressure
10bar
10bar
Suitable liquid temperature range
-10～110oC
-10～110oC
Stop units
Ball valve size
G1/2
One –way stop valve
Withstand pressure
0～16bar
Maximum permission temperature
-20～110oC
Flow meter
Measuring range
0.1～20L/min
Manual/automatic air separator
Not on SR981S
Filling/draining connection unit
Connection size
G1/2
Insulation
Insulation material
EPS
Built-in solar controller
see controller manual part
Sensor on collector return pipe
NTC10K, B=3950
Not on SR981S
Sensor on collector flow pipe
NTC10K, B=3950
3. Mounting the solar station
►Drill the upper fixing hole
►Fasten the screw, hang the station(Picture1)
►Mark the bottom fixing hole(Picture2)
►Drill the bottom hole
►Fasten the bottom screw
Picture1 Picture2

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4. Attention Items for solar station installation
Note: In order to avoid jam the digital flow meter and in result to displays no flow on solar
station, the filter must be installed on the return and flow pipeline of solar station.
All devices connected to the controller must conform to the technical specifications of
the controller, assembly, installation and maintenance work may only be performed by
properly qualified and authorized personnel with a generally recognized qualification.
The solar station must be installed indoors, prior to installation, remove sealing caps
from solar station.
According to the manual of expansion vessel to install and adjust it, the pipeline for
connecting pump station and expansion vessel should be not insulated.
Safety valve: Risk of scalding from hot steam with discharge from the safety valve due
to heating and excess pressure in the hydraulic pipes. Using a copper pipe to drain the
discharged liquid from the safety valve to the barrel and disposed it in an eco-friendly
Filter

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way, according to valid technical regulations and local codes, do not allow solar fluid to
leak into the environment.
Be careful of scald from hot fluid. Maximum temperature of collectors during filling/leak
check or installation/maintenance should be below 70oC, allow collectors to cool down
if necessary.
Please ensure hydraulic connections are pressure-tight, connections pipe should be
insulated, and unused connections must be sealed tightly with a suitable end plug.
Air-separator: if the system is pressure-tight ( no leakage), connect the power supply
to the solar controller, using the manual mode of controller to circuit system for 15
minutes, then switch-off power supply, solar fluid is heated gradually, air dissolved in
fluid is released out, through air –separator to release air. If necessary, repeats this
process until no more air is vented out. If the system pressure drops due to over air
release, then it is necessary to refilling fluid to the required pressure.
After filling the system, please check safety valve according to its manual.
All safety regulations for working on the power supply are valid, All installation and
maintenance work should be performed when power is switched-off.
5. Connection terminal of built-in controller
5.1 Open the connection terminal box
►Loosen the 4 fixing screws (picture A) which are on the back of connection box.
Note: 2 screws inside circle are for fixing the box, not need to loosen it.
A

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B
C
►Parallel pull out the connection box downwards parallel.
►Loosen the protection screw (picture B), open the cover of terminal upwards
►Using proper tools (like knife) to take out the plastic (picture C) piece, wires can
penetrate connection terminal through pre-prepared holes.
Note: Please use delivered clamps to fix wires correctly. (Picture D)
D

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5.2 Terminal connection
Terminal ports layout
Power connection
Input: for power connection, L is for live wire, N is for neutral line.
is for connection with ground.
Input ports
Input T0 ~ T1: PT1000 temperature sensor, for measuring the collector temperature
Input T2～T6: NTC10K，B=3950 temperature sensor, for measuring tank and pipeline
temperature
Note: T7、T8 pipeline temperature sensors have been wired on built controller,so no
position on the input ports(SR981S NO T8).
Advice regarding the installation of temperature sensors:
①Only original factory equipped Pt1000 temperature sensors are approved for using
with the collector, it is equipped with 1.5meters silicon cable and suitable for all
weather conditions, the cable is temperature resistant up to 280oC, not necessary to
distinguish the positive and negative polarity of the sensor connection.
②Only original factory equipped NTC10K,B=3950 temperature sensors are approved for
using with tank and pipe, it is equipped with 1.5mr PVC cable, and the cable is
temperature resistant up to 105oC, not necessary to distinguish the positive and
negative polarity of the sensor connection.
③All sensor cables carry low voltage, and to avoid inductive effects, must not be laid
close to 230 volt or 400 volt cables (minimum separation of 100mm).
④If external inductive effects are existed, e.g. from heavy current cables, overhead train
cables, transformer substations, radio and television devices, amateur radio stations,
microwave devices etc, then the cables to the sensors must be adequately shielded.

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⑤Sensor cables may be extended to a maximum length of ca. 100 meters, when
cable’s length is up to 50m, and then 0.75mm2cable should be used. When cable’s
length is up to 100m, and then 1.5mm2cables should be used.
Output ports
Output R1: electromagnetic relay, max. switching current 3.5A
Output R2: electromagnetic relay, max. switching current 3.5A
Output R3: electromagnetic relay, max. switching current 3.5A
Output H1:electromagnetic relay, max. switching current 3.5A, (for back-up heat
source)
Note: P1、P2 solar pumps have been wired on built controller,so no position on the
output ports.
6. Operation manual of built-in controller
6.1 Operation button
Set button Exit/confirm upwards downwards
ON/OFF button manual heating Holiday button
Note:
Connect the sensors, pumps or switching valves to the controller before you connect
the power.
After power is switched on, you can set time, password, select system and relevant
parameters.

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6.2 Signal description
Signal on the display screen shows the current status. Its meaning is explained in following
table.
Signal status
Display
Flashing display
Back-up electrical heater is in
active
Collector safety temperature
function is in active
Tank urgent stop function is in
active
Collector low temperature
protection function is in active
Collector frost protection function is
in active
Tank re-cooling function is in active
Collector cooling function is in
active
Tank high temperature
protection function is in active
Tank thermostat function is
triggered
Tank thermostat function is in active
Manual function is in active
Holiday function is in active

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6.3 Set up clock/week
►Press “SET” button, “TIME” displays on the screen.
►Press” SET” button, hour area “00” blinks on the screen.
►Press“ ” button to adjust hour.
►Repress “SET” button, minute area “00” blinks.
►Press“ ” button to adjust minute.
►Repress “SET” button to adjust week, week area “MO”
blinks.
►Press“ ” button, to adjust week.
►Press “ESC” to exit setup menu, or wait for 20 seconds to exit, set parameters are saved
automatically.
Code
Weekday
MO
Monday
TU
Tuesday
WE
Wednesday
TH
Thursday
FR
Friday
SA
Saturday
SU
Sunday

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6.4 Manu structure
Note: according to the different of system, menu structure of the system may be different.
Submenu: Through submenu you can setup more detailed, please make sure to
understand the content in submenu.

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6.5 Menu description
Code
Main
menu
Code
Submenu
Code
Submenu
Description
SCH
System
DT
Temperature difference
TEMP
Temperature ( for setup relevant temperature
parameters)
EMOF
The maximum switch-off temperature of collector
EMON
The maximum switch-on temperature of collector
CMX
The maximum temperature of collector
(Collector cooling function)
CMN
Low temperature protection of collector
CFR
Frost protection temperature of collector
REC
Cooling temperature of Tank
SMX1
Maximum temperature of tank 1
SMX2
Maximum temperature of tank 2
MAX1
Maximum switch-off temperature ( for heat transfer
between tank and heating circuit )
MIN1
Minimum switch-on temperature ( for heat transfer
between tank and heating circuit )
MAX2
Maximum switch-off temperature ( for heat transfer
between heat exchanger and tank)
MIN2
Minimum switch-on temperature ( for heat transfer
between heat exchanger and tank)
C_F
Switch between Celsius and Fahrenheit
FUN
Auxiliary functions
DVWG
Anti legionnaires’ bacteria function
SFB
Solid fuel boiler function
SFON
Minimum switch-on temperature of tank
SFOF
Maximum switch-off temperature of tank
MAX3
Maximum switch-off temperature of solid fuel

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boiler
MIN3
Minimum switch-on temperature of solid fuel boiler
PUMP1
Running mode of circulation pump
1( ONOF,PLUS,HEA)
nMIN
Speed adjustment of pump 1 ( RPM control
function)
DTS
Standard temperature difference of pump 1
(for speed adjustment )
RIS
Gain for circulation pump 1 (for speed
adjustment)
PUMP2
Running mode of circulation pump
2( ONOF,PLUS,HEA)
n2MN
Speed adjustment of pump 2 ( RPM control
function)
DT2S
Standard temperature difference of pump 2
(for speed adjustment )
RIS2
Gain for circulation pump 2 (for speed
adjustment)
OHQM
Thermal energy measuring
FTYPE1
Flow meter type 1 selection
FTYPE2
Flow meter type 2 selection
FMAX
Flow rate
MEDT
Heat transfer liquid type
MED%
Concentration of heat transfer liquid
PRIO
Priority of tank
tRUN
Interval heating run-on time
tSTP
Interval heating run-off time
INTV
Intermission function
IRUN
Pump intermission run-on time
ISTP
Pump intermission run-off time
COOL
Tank re-cooling function
AHO
Switch-on temperature of thermostat function

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AHF
Switch-off temperature of thermostat function
BYPR
Bypass ( high temperature)
HDN
Manual controlling
REST
Recovery to factory set
PASS
Password setup
6.6 System overview