Danfoss 102 Assembly Instructions

102
Installation & User Instructions
including Factory Replacement Units (FRU)
electro-mechanical mini-
programmer for controlling
hot water and heating

2
INDEX
Index
Installation
Product specification 3
Installation 4-5
Wiring 6
User
Your programmer 7
Setting the time of day 8
Setting the programme 8-9
Selecting operating mode 10
Temporary overrides 11
Contact details 12

3
Please Note:
This product should only be installed by a qualified
electrician or competent heating installer, and
should be in accordance with the current edition of
the IEEE wiring regulations.
Specification
Power supply 230Vac ± 15%, 50 Hz
Switching action 1 x SPST, Type 1B
Max. Switch rating 264Vac, 50/60Hz, 6(2)A
Timing Accuracy ±1 min./month
Enclosure Rating IP20
Max. Ambient Temperature 55°C
Dimensions, mm (W, H, D) 112 x 135 x 69
Design standard EN 60730-2-7
Control Pollution Situation Degree 2
Rated Impulse Voltage 2.5kV
Ball Pressure Test 75°C
Product specification
Installation & Specification
Installation Instructions

4
Installation
1. Loosen the fixing screw in
the base of the unit to release
the grey plastic Wiring Cover.
Ensure the protective tape
over the thumbwheel remains
in place.
2. Holding the unit clockface
downwards, press firmly in
the centre of the wallplate
and slide it from the module
as shown.
Installation
Pre-Selector wheel
Selector switch
Plug-in replacement
module
Wallplate/Terminal
block (not with FRU
units)
wallplate/
terminal
block
plug-in
module
NB. For FRU units - go straight to to point 4 on page 5

5
3. Fix the Wallplate/Terminal Block to the wall with
countersunk No.8 woodscrews or to a steel box to BS
4662. 1970 or a surface mounting steel or moulded
box having centres of 23/8” (60.3mm).
4. Referring to the Wiring Diagrams on page 6, connect
the unit as shown. Ensure that terminals 3 and 6 are
linked where required (Mains Voltage applications) with
insulated cable capable of carrying full load current.
5. Ensure all dust and debris has been cleared away
from the area, then plug the module firmly into the
wallplate ensuring that the hook at the top of the
wallplate engages with the slot at the back of the body.
Press the module down until it locates solidly.
6. Cut a cable aperture in the Wiring Cover if necessary;
replace the Wiring Cover, and tighten the fixing screw.
7. Switch on Mains & test for correct operation as follows:
i) Remove protective tape from pre-selector wheel.
ii) Remove dial cover & rotate the clock dial two
complete revolutions to clear the mechanism.
ii) Check that all positions of the Selector Switch
and Tappets operate correctly. (See instructions
in User Booklet.)
8. Replace the dial cover. Finally leave this booklet,
containing the USER instructions with the Householder.
9. If the unit is to be left turned off and is in a dusty
atmosphere, protect the pre-selector wheel by re-
affixing the protective tape.
IMPORTANT: Remove tape prior to putting unit into service.
Installation

6
Wiring
102, 102E5, 102E7
Wiring
LN
LNLN
LN
Motor
Brown
Call
Grey
Blue
HP2 spring return
zone valve
Cylinder Stat
L641A
Orange
To Boiler & Pump
Room
Stat
Com
N
Room
Stat
Com
Call
Boiler
Pump
Mains
Supply
Mains
Supply
Link Link L
L
NN
1235612356
N
12
102 Terminals
102 Terminals
C
1) Typical domestic gas or oil fired system
with gravity hot water and pumped heating
(if a room stat is not required, wire pump L
directly to terminal 2 on the 102).
2) Fully pumped system with cylinder stat in
HW circiut and room stat and 2 port spring
return zone valve in heating circuit.

7
User Instructions
Your programmer
Your 102 mini-programmer allows you to switch your
heating and hot water on and off at times that suit you.
Normally the 102 provides 2 ON periods and 2 OFF
periods each day. However 1 ON and 1 OFF period can be
obtained by using the Pre-Selector Wheel (see page 11).
You can choose whether the 102 controls your hot water &
heating together, just the hot water or neither system (OFF)
using the manual rocker switch.
Overview
Preselector wheel
Dial cover
Wiring cover
Rocker
switch to
manually
select
programme
operation

8
Setting the time of day
The dial on the front of the 102 displays the hours of the
day using the 24hour clock.
 Remove dial cover (turn
slightly to the left and
pull off)
 Turn the dial clockwise
until the correct time is
aligned to the TIME
mark (as shown).
IMPORTANT: turn the dial clockwise only
Remember you will have to re-set the time after
a power-cut, and also when the clocks change
in Spring and Autumn.
Setting the programme (Tappets A, B, C, D)
1. If not already done so, remove the dial cover (turn
slightly to the left & pull off)
2. Decide when you want your hot water and heating
to come on and go off. While gripping the dial knob
slide the RED tappets to the required ON times and
the BLUE tappets to the required OFF times (the
tappets may be quite stiff to move)
Note: Tappets can be moved around the dial in a clockwise
or anti-clockwise direction, as convenient.
TIME mark
Setting the time & the programme
!

9
Example:
If you want your system ON between 8am and 10am
and again between 4pm and 11pm, set the tappets as
shown. (A to 8, B to 10, C to 16, D to 23).
Remember:
Red tappets (A and C) switch ON
Blue tappets (B and D) switch OFF
3. Ensure that the installer has removed the protective
tape covering the pre-selector wheel.
4. Using the dial knob, rotate the dial completely at least
twice, clockwise only, to clear the mechanism.
Setting the programme
A = 1st ON
B = 1st OFF
C = 2nd ON
D = 2nd OFF

10
Selecting operating mode
Selecting operating mode
The Rocker Switch on the side of the unit is used to select
how your 102 controls your hot water & heating system.
You can manually select either:

hot water only
 hot water & heating together
 neither (system OFF)
Switch positions
The 102 unit is now set,
and the current status of
the mini-programmer can
be seen on the wheel at the
top righthand corner of the
unit, (e.g. “OFF UNTIL C”).
Hot water only
System OFF
Heating & Hot Water together

11
Overriding the programe using the
Pre-Selector wheel
The pre-selector wheel can be used
to override the set programme on
occasions when you need to change
from your normal heating routine.
By turning the wheel anti-clockwise
you can turn the unit ON when it is
OFF and vice versa.
Example:
 Your programme is set so that your heating comes on
at 4pm but you arrive home earlier than usual, at 2pm
and need the heating ON immediately.
 Turn the wheel anti-clockwise until it displays ON
UNTIL `D’ as shown.
 Thus the system is turned ON manually at 2pm but will
revert to the set programme at the next operation (i.e.
OFF at 11pm)
Some other useful pre-selections are:
ALL DAY ON (1 ON/1 OFF)
Turn the Wheel to display “ON UNTIL D”.
ALL DAY OFF
Turn the Wheel to display “OFF UNTIL A”.
Note: Do not operate the pre-selector whilst a tappet
is close to the TIME mark. This may cause the time
of day setting of the clock to be altered, and the time
would then need to be reset as shown on page 8.
!
Temporary overrides

Danfoss Randall Ltd
Ampthill Road
Bedford
MK42 9ER
Tel: [phone]
Fax: [phone]
Still having problems?
Call your local heating engineer:
Name:
Tel:
Visit our website:
www.danfoss-randall.co.uk
Email our technical department:
[email protected]
Call our technical department
0845 121 7505
(8.45-5.15 Mon-Thurs, 8.45-4.45 Fri)
For a large print version of these
instructions please contact the Marketing
Services Department on 0845 121 7400.
Part No 7478 Issue 2 05/05