Bosch Worcester TDS 10 User manual

INSTALLATION,

USER INSTRUCTIONS &

CUSTOMER CARE GUIDE

6 7 2 0 6 1 1 6 7 5 - 0 0 . 1 R

TDS 10

SOLAR SYSTEM CONTROLLER

FOR WORCESTER SOLAR HEATING SYSTEMS

TDS 10 - Umschlag 25.04.2005 9:56 Uhr Seite 1

Contents

6 720 612 217 (05.03)

Contents

1 Product details 4

1.1 Intended use 4

1.2 Standard package 4

1.3 Technical data 4

1.4 Description of function 5

1.5 Key to illustrations in

Appendix 6

1.6 Unvented DHW

Cylinders 6

2 Regulations 7

3 Installation 7

3.1 Installing the controller 7

3.2 Installing the

temperature sensors 8

3.3 Electrical connections 8

4 Commissioning 9

5Operation 10

5.1 General information 10

5.2 Controls 10

5.3 Settings 11

5.3.1 Storage tank

temperature limit 11

5.3.2 Manual mode 11

5.3.3 Viewing temperature

readings 11

5.3.4 Power failure 11

6 Maintenance 11

7 Troubleshooting 12

7.1 Faults indicated on the

display 12

7.2 Faults not indicated

on the display 14

Appendix 20

Safety precautions

6 720 612 217 (05.03)

Safety precautions

BTo ensure the equipment functions

properly, always follow the instruc-

tions in this manual.

BThis accessory may only be fitted by

an approved installer and must not

be commissioned until the solar

heating system has been installed

and filled.

BAlways install and commission

equipment in accordance with the

relevant instructions.

Usage

BThis accessory should only be used

in conjunction with a solar heating

system. Electrical connections must

be made according to the wiring dia-

gram.

Electrical equipment

BBefore installing this accessory:

Disconnect the power supply

(230 V AC).

BDo not install this accessory in damp

areas.

Explosive and easily combustible

materials

BDo not use or store easily combusti-

ble materials, liquids or gases near

to this accessory.

Symbols

Signal words indicate the seriousness

of the hazard in terms of the conse-

quences of not following the safety

instructions.

•Caution indicates that minor dam-

age to property could result.

•Warning indicates that minor per-

sonal injury or serious damage to

property could result.

•Danger indicates that serious per-

sonal injury could result. In particu-

larly serious cases, lives could be at

risk.

Notes contain important information in

cases where there is no risk of per-

sonal injury or damage to property.

Safety instruc-

tions in this docu-

ment are identified

by a warning-trian-

gle symbol and are

printed on a grey

background.

Notes are identified

by the symbol shown

on the left. They are

bordered by horizontal

lines above and below

the text.

Product details

6 720 612 217 (05.03)

1Productdetails

The TDS 10 is a controller for use with

thermal solar heating systems that use

heat from the sun to heat a hot water

tank or intermediate heat store.

1.1 Intended use

This accessory may only be used in the

types of system specified above.

Any other type of use is beyond the

purpose for which this device is

intended. The manufacturer will not be

liable for any loss or damage resulting

from such use.

1.2 Standard package

• Solar system controller TDS 10.

• 2 PTC-type temperature sensors:

– Solar-panel temperature

sensor.

– Storage tank temperature

sensor for lower tank zone.

1.3 Technical data

Temperature sensor readings

(PTC)

Device dimensions

(LxWxH) 136x133x37 mm

Weight 250 g

Power supply 230 V (±15%)

50 Hz

Power consumption ≤1 W

Temperature-sensor

inputs 2 x PTC

Output for solar

heating system

pump

230 V AC

max. 800 W

Permissible ambient

temp.

0...+45 °C

Internal fuse 4 A MT, 250 V

Ingress Protection

rating

IP 20/

DIN 40050

Temperature sensor:

Sensor

Lead (silicon)

Range

PTC, Ø6 mm

1.5 m

up to 180 °C

Table 1

°C 0 1020304050

Ω1000 1039 1078 1117 1155 1194

°C 60 70 80 90 100 110

Ω1232 1271 1309 1347 1385 1423

°C 120 130 140 150 160 170

Ω1461 1498 1536 1573 1611 1648

Table 2

Product details

6 720 612 217 (05.03)

1.4 Description of function

For a simplified diagram of the system,

refer to Figure 2 on page 16.

Temperature differential regulator

The temperature differential regulator

controls the operation of the solar heat-

ing system pump.

• The solar heating system pump is

switched on when the difference

between the solar panel tempera-

ture and the storage tank temper-

ature exceeds the ON threshold

8 K (°C).

The display shows the sun symbol

and the symbol moves (Fig. 3).

• The solar heating system pump is

switched off when the difference

between the solar panel tempera-

ture and the storage tank temper-

ature falls below the OFF

threshold of 4 K.

The sun symbol disappears from the

display and the symbol stops

moving (Fig. 3).

ON threshold for solar heating sys-

tem pump:

- ≥temperature difference of 8 K

OFF threshold for solar heating sys-

tem pump:

- ≤temperature difference of 4 K.

Storage tank temperature limiter

The storage tank temperature limiter

prevents the domestic hot water

becoming too hot:

Normal setting = 60°C.

Function:

• The solar heating system pump is

switched off if the storage tank tem-

perature sensor reading exceeds

the set temperature. The symbol

stops moving and max flashes

(Fig. 4, page 16).

• The solar heating system pump is

switched on again as soon as the

storage tank temperature drops

below the set temperature limit by

4 K. The symbol moves and max

disappears from the display (Fig. 4,

page 16).

Warning: Risk of

scalding from storage

tank temperatures

over 60 °C!

BFit a thermostatic mix-

er to the hot water

draw off pipe and set

to 60 °C max.

Product details

6 720 612 217 (05.03)

Solar panel high-temperature cut-

out (fixed setting)

• Above a temperature of 130 °C at

the solar panel temperature sensor

the solar heating system pump

switches off.

The display shows the hot panel/

evaporation symbol and the sym-

bol stops moving (Fig. 5, page 16).

• The solar heating system pump

does not switch on again until the

solar panel temperature has

dropped below 127 °C and the stor-

age tank temperature sensor

calls for heat.

• At temperatures above 140 °C the

convector fluid evaporates in the

solar panel.

Indication of excessive tempera-

ture difference (fixed setting)

• If the temperature difference -

is greater than 80 K, this can be a

sign that there is air in the system or

that the solar heating system pump

is defective.

Display error message: SYS.

1.5 Key to illustrations in

Appendix

Key to Figures 1 to 10 on pages 16

to 18:

Solar heating system pump

Solar panel temperature sensor

(PTC)

Storage tank temperature

sensor (PTC)

No function

1Top fixing hole

2Bottom fixing holes

230 V AC Power supply connection

3Spare fuse, 4 A MT, 250 V

4Fuse 4 A MT, 250 V

5Cable exits to rear

6Cable exits to underneath

7Inner programmer cover

(protects electronics)

SMode selector switch

Si Fuse, 4 A MT, 250 V

TDS 10 Solar heating system

programmer

1.6 Unvented DHW Cylinders

When connecting the Greenskie's

Solar Heating System to an un-vented

hot water storage cylinder, it is recom-

mended that the electrical supply to

the solar control system is taken via the

thermal cut-out device on the cylinder.

Regulations

6 720 612 217 (05.03)

2 Regulations

This accessory conforms to the rele-

vant EN regulations.

The following regulations and require-

ments must be observed:

• Requirements and regulations of the

relevant local electricity supplier

• Trade and fire safety requirements

and regulations.

The installation of the Worcester Solar

System and controller must be carried

out in accordance with the relevant

requirements for safety, current

IEE wiring regulations, local building

regulations, building standards (Scot-

land) (Consolidation) regulations,

health and safety document No 635

(Electricity at Work Regulations 1989),

BS 5918: Latest version.

3Installation

3.1 Installing the controller

When installing the controller, refer to

Figs. 6 and 7 on page 17.

BSelect a suitable installation site.

BRemove the top part of the controller

cover.

BDrill the top fixing hole.

BInsert screw into hole.

BLocate top fixing hole in controller

backplate over screw.

BMark position of bottom fixing holes.

BRemove controller again.

BDrill bottom fixing holes.

BRelocate programmer over top

screw.

BInsert screws in bottom holes and fix

programmer in position.

BRefit top part of programmer.

Danger: risk of elec-

tric shock!

BBefore installing this

accessory:

Disconnect the pow-

er supply (230 V AC).

The controller can be fit-

ted directly onto cable

trunking.

Installation

6 720 612 217 (05.03)

3.2 Installing the tempera-

ture sensors

To install immersion sensors and

BInsert temperature sensor in the

pocket on the solar panel flow side

and screw in place. The sensor and

lead must be inserted to a depth of

170 mm into the panel and screwed

in tightly.

BInsert temperature sensor in the

lower pocket on the hot water stor-

age tank and fix in place.

3.3 Electrical connections

For details of electrical connections,

refer to Figs. 8 to 10 on page 18.

BSensor leads can be up to 100 m

long. 1.5 m is supplied.

BWiring run lengths and cross-sec-

tional areas for low-voltage wiring:

BFor the 230 V power supply use

general duty, 300-500 V PVC

coated, 0.75 mm2electrical cable.

BRoute all low-voltage leads sepa-

rately from 230 V or 400 V cables in

order to avoid inductive interference

(minimum separation 100 mm).

BIf there is a likelihood of external

inductive interference, e.g. from

high-power cables, tram power

lines, electricity substations, radio

and television equipment, amateur

radio transmitters, microwaves or

the like, shielded low-voltage leads

should be used.

BTo ensure the programmer complies

with the IP 20 Ingress Protection rat-

ing:

– Only break open as many cable

exits as absolutely necessary.

– Only make the holes just big

enough for the cables used.

– Cable exits to underneath:

Cut a slot on each side with a suit-

able tool and break off from the

programmer casing (Fig. 8)

Use only genuine PTC-

type temperature sen-

sors (see Section 1.3).

Danger: risk of elec-

tric shock!

BBefore making any

electrical connec-

tions, disconnect the

power supply (230 V

AC) to the heating

system.

Length up to 50 m 0.75 mm2

Length up to 100 m 1.5 mm2

Table 3

Commissioning

6 720 612 217 (05.03)

Cable exits to rear:

Break open with a suitable tool

through the programmer casing

backplate (Fig. 6).

Cable exit to underneath:

BSecure cable with cable grip.

Cable exit to rear:

BProvide means of securing cable

outside programmer casing.

BUse a screwdriver to lock the snap-

fit terminals (Fig. 9).

BMake all electrical connections (see

Fig. 10).

4 Commissioning

BSwitch on power supply.

BSet mode selector switch Sto auto-

matic mode.

AUT briefly appears on the display

and the controller is set to automatic

mode.

On fine wire leads:

BUse cable-end

sleeves.

Maximum lead cross-sec-

tion 2.5 mm2 for each

snap-fit terminal.

The sensors and

have to be connected be-

fore the TDS 10 will func-

tion.

Check that the solar

heating system has

been filled and vented

according to the in-

structions for the solar

panel and the solar

pump station.

Operation

6 720 612 217 (05.03)

5Operation

5.1 General information

The TDS 10 basic settings are

already pre-programmed to suit the

most common applications.

5.2 Controls

For overview of controls, see Fig. 1 on

page 16.

Information to be given

to the user by the in-

staller:

BExplain to the user

how to operate the

controller.

BGive the user all the

documents supplied

with the controller.

Control

Description

Display

Factory

setting

Sset to

automatic

mode AUT

E.g. 48 °C

moves / stops

Display backlight-

ing yellow

S set to

manual

mode, solar

heating

pump ON

ON flashes

moves

Display backlight-

ing red

S set to

manual

mode, solar

heating

pump OFF

OFF flashes

stops

Display backlight-

ing red

Changes display to next setting or

increases figure

Press and hold: switches to maxi-

mum storage tank temperature

setting

Press and release: saves settings

and switches to automatic mode

Changes display to previous set-

ting or reduces figure

Table 4

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