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

2
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

3
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.
i
Notes are identified
by the symbol shown
on the left. They are
bordered by horizontal
lines above and below
the text.

4
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

5
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
of
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.

6
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.

7
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).
i
The controller can be fit-
ted directly onto cable
trunking.

8
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)
or
i
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

9
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.
i
On fine wire leads:
BUse cable-end
sleeves.
i
Maximum lead cross-sec-
tion 2.5 mm2 for each
snap-fit terminal.
i
The sensors and
have to be connected be-
fore the TDS 10 will func-
tion.
i
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.

10
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.
i
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

11
Maintenance
6 720 612 217 (05.03)
5.3 Settings
5.3.1 Storage tank temperature
limit
BPress and hold the button for
approx. 2 seconds until the flashing
symbol max appears on the dis-
play (Fig. 11).
BSet the maximum storage tank tem-
perature using the / but-
tons.
BSave setting by pressing the
button.
5.3.2 Manual mode
Switching on the solar heating system
pump, e.g. for commissioning or servic-
ing:
BSet the mode selector switch Sto
solar heating pump ON.
– The solar heating system pump
will run continuously.
– The display backlighting is red,
ON flashes and the symbol
moves (Fig. 12).
5.3.3 Viewing temperature read-
ings
BPressing the / button
allows you to view the following
readings:
– Solar panel temperature
– Storage tank lower-zone tempera-
ture .
5.3.4 Power failure
• None of the settings are lost if there
is a power failure.
• When the power is restored, the
TDS 10 automatically starts working
again according to the set pro-
gramme.
6 Maintenance
When carrying out maintenance work
on the system:
BSet the mode selector switch S to
solar heating pump OFF.
– The solar heating pump will stop.
– The display backlighting is red,
OFF flashes and the symbol
stops moving (Fig. 13).
BSwitch off the power supply.
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.

12
Troubleshooting
6 720 612 217 (05.03)
7 Troubleshooting
7.1 Faults indicated on the display
Display shows
(flashing red/yellow) Cause Remedy
Short circuit on sensor lead to
solar panel temperature sen-
sor
Check sensor lead .
Short circuit on sensor lead to
solar panel temperature sen-
sor
Check sensor lead .
Break in sensor lead to solar
panel temperature sensor
Check sensor lead .
Break in sensor lead to solar
panel temperature sensor
Check sensor lead .
Table 5
6 720 611 675-11.1J
6 720 611 675-19.1J
6 720 611 675-12.1J
6 720 611 675-20.1J

13
Troubleshooting
6 720 612 217 (05.03)
Deleting displayed faults
BTo delete a displayed fault, press
any button.
Indication of a fault in the sys-
tem, e.g. shut-off valves
closed, air in the system or
defective solar heating system
pump.
Check that the shut-off
valves are open.
Check the system.
If necessary have the sys-
tem bled.
Check whether the solar
heating system pump is
working (see
Section 5.3.2).
Display shows
(flashing red/yellow) Cause Remedy
Table 5
6 720 611 675-13.1J

14
Troubleshooting
6 720 612 217 (05.03)
7.2 Faults not indicated on the display
Problem Cause Remedy
Display blank, solar heating
system pump not running even
though storage tank tempera-
ture is below solar panel tem-
perature.
No power supply, fuse blown
or power lead defective.
Have electrical system
checked by qualified
electrician.
Solar heating system pump
not running even though stor-
age tank temperature is below
solar panel temperature.
Solar heating system pump
switched off by mode selector
switch S.
Set mode selector switch
S to automatic mode.
Storage tank temperature
is close to or above the set
maximum storage tank temper-
ature, storage tank tempera-
ture limiter has switched off
solar heating system pump.
As soon as the storage
tank has cooled down or
sufficient water is drawn
off, the solar heating sys-
tem pump will switch on
again.
Solar panel temperature is
above 130°C, solar panel tem-
perature cut-out has switched
off solar heating system pump.
Solar heating system
pump is not switched on
again until solar panel
temperature has dropped
below 127 °C .
Table 6

15
Troubleshooting
6 720 612 217 (05.03)
Solar heating system pump
not running even though
symbol on the display is mov-
ing.
Break in connecting lead to
solar heating system pump or
lead not connected.
Check lead.
Fuse (SI, Fig. 10) has blown. Check fuse and replace if
necessary.
Solar heating system pump
defective.
Check solar heating sys-
tem pump and replace if
necessary.
symbol on display is mov-
ing, solar heating system
pump is “humming”.
Pump is jammed. Unscrew slotted-head
bolt from pump cover and
free pump shaft with a
screwdriver. Do not strike
the pump shaft!
Temperature sensor shows
incorrect reading.
Temperature sensor not fully
inserted in pocket or excessive
temperature loss at point of
measurement.
Push temperature sensor
all the way into pocket
and fix in position.
Provide insulation if nec-
essary.
Domestic hot water too hot Storage tank temperature limit
set too high.
Set lower storage tank
temperature limit.
Domestic hot water not hot
enough (or not enough
domestic hot water).
Hot water temperature control
on boiler or heating program-
mer is set too low.
Set temperature accord-
ing to the relevant operat-
ing instructions
(recommended max.
60 °C).
Problem Cause Remedy
Table 6

16
Troubleshooting
6 720 612 217 (05.03)
Appendix
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
S
6 720 611 675-06.1J
TDS 10
6 720 611 675-18.1J
6 720 611 675-14.1J
6 720 611 675-15.1J
6 720 611 675-16.1J

17
Troubleshooting
6 720 612 217 (05.03)
Fig. 6
Fig. 7
6 720 611 675-01.1J
1
2
3
5
6
2
4
7
6 mm
3,5 mm
6 mm
1.
2.
3.
1.1
6 720 611 675-05.1J

18
Troubleshooting
6 720 612 217 (05.03)
Fig. 8 Fig. 9
Fig. 10
6 720 611 675-02.1J
6720611675-03.1O
LR1 N E1 E2 E3
230V AC
6 720 611 675-04.1O
Si
N

19
Troubleshooting
6 720 612 217 (05.03)
Fig. 11
Fig. 12
Fig. 13
6 720 611 675-17.1J
6 720 611 675-08.1J
6 720 611 675-09.1J

INSTALLATION,
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. [phone] Fax. [phone]
www.worcester-bosch.co.uk
Worcester Bosch Group is a trading name of
BBT Thermotechnology UK Ltd.
6 720 612 217 (05/03) OSW
TDS 10 - Umschlag 25.04.2005 9:56 Uhr Seite 2