Prozeda BDC 102 User manual

BDC 102
Microprocessor-controlled control unit for solar thermal systems
IMPORTANT
Before installing and using this device, you must read through the
instructions carefully.
Failure to observe the instructions and safety information contained in
these installation and operating instructions will void the guarantee for
the device described/installed.
STORE THESE INSTRUCTIONS IN A SAFE PLACE.
31.01.2007
1328BED001-10B-E
Installation and Operating Instructions

Installation and Operating Instructions
BDC 102 1328BED001-10B-E Status 01/07
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Table of contents
1SAFETY INSTRUCTIONS 3
2SYMBOLS AND ABBREVIATIONS 5
3DEVICE DESCRIPTION 6
3.1 Usage 6
3.2 Device features 6
3.3 Layout diagram 6
4OVERVIEW OF DEVICE COMPONENTS 7
5DEVICE INSTALLATION 7
6ELECTRICAL CONNECTION 8
6.1 230V connection 8
6.2 Connection of temperature sensor 8
6.3 Replacing the fuse 8
7COMMISSIONING 9
8OPERATION / INDICATORS 10
8.1 Adjustment of control values 10
8.2 Indicators 10
9REGULATOR FUNCTIONS 11
10 RECTIFICATION OF FAULTS 11
10.1 Indicated faults (display): 11
10.2 Faults that are not indicated 12
11 TECHNICAL DATA 13
12 RESISTANCE TABLE PT1000 SENSOR 13
iSubject to change without notice

Installation and Operating Instructions
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1 SAFETY INSTRUCTIONS
This control unit must be disconnected from the mains before any installation
and wiring work is carried out.
This device may only be opened, connected and commissioned by trained
personnel. In so doing, the
relevant safety regulations, especially VDE 0100
must be adhered to.
•Prior to any installation or wiring
work on the electric motors, always
fully disconnect the device from the
operating voltage and ensure that the
mains supply cannot be reactivated.
Never mix up the connections for the
protective safety low voltage area
(sensor, flow meter) with the 230 V
connections. This could result in
damage and hazardous voltages to the
device itself and to the attached sensors
and devices.
•Solar thermal systems can become very
hot. There is a risk of being burnt. Take
care when installing the temperature
sensor.
•Install the BDC 102 in such a way that
no excessive operating temperatures
(>50°C) result, e.g. as a result of heat
sources.
•BDC 102 is not protected against
splashing and dripping. You should
therefore install it in a dry location.
•If there are signs of damage to the
control unit, cables or attached pumps
and valves, the systems must not be
operated.
•Check whether the materials used for
the piping, thermal insulation, pumps
and valves are suitable for the
temperatures that will occur in the
system.
If you have any questions concerning your solar thermal system or your control unit, please
contact your installer or supplier for advice.

Installation and Operating Instructions
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2 SYMBOLS AND AB BREVIATIONS
Warning!
This symbol indicates potential dangers
Warning: 230 Volts
This symbol indicates risk to life through high voltages.
•List
iInformation on operation/special features
Instructions/procedure
?Test/check

Installation and Operating Instructions
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3 DEVICE DESCRIPTIO N
3.1 Usage
BDC 102 is a microprocessor-controlled,
temperature difference regulator for
controlling the functions of solar thermal
systems with one storage cylinder and one
collector.
The control unit is for use in dry rooms,
indoors and in private homes, business and
commercial premises.
The control unit may be used only as a
solar control unit. If used in other scenarios,
the installer must check whether the
standards and safety regulations stipulated
for the area of use are met.
Use of the device in ways other than that
intended by the manufacturer requires the
approval of the manufacturer, failing which
the guarantee shall not apply.
3.2 Device features
BDC 102 is characterised by the following features:
•Compact design
•Minimal installation work
•2 LED “power-on” indicators
•Monitoring of operation
•Adjustable temperature regulator
value
•Pump block protection
•Installation protection
3.3 Layout diagram
The layout diagram for the BDC 102 control
unit is shown below. This control can be
used in similar systems that function in the
same way. This diagram is not a complete,
hydraulic circuit diagram.
Picture 1
storage
cylinder
collector array

Installation and Operating Instructions
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4 OV E R V I E W O F DE V I C E C O M PO N ENTS
No.: Function
1 Connection to supply voltage
2 Connection to solar circuit pump (A1)
3 Connection to collector sensor (T1)
4 Connection to storage cylinder
sensor (T2)
5 Adjustment of maximum storage
cylinder temperature TSPmax
6 Green light for “Mains”:
device is connected to power supply
Green light for “Pump”:
7 Red light for “Fault”
8 Fuse
5 DEV I C E INS T AL L AT I O N
The BDC 102 may be installed only in dry rooms where there is no risk of
explosion. Installation on a flammable base is not permitted.
The casing of the BDC 102 is designed for surface mounting.
Picture 2
1 5
6
7
8
2 3 4

Installation and Operating Instructions
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6 ELEC T R I C AL C O N NECTI ON
You must observe the safety instructions in chapter 1
Do not carry out wiring work when the device is connected to
the electricity supply!
6.1 230V connection
The control unit is supplied with electricity as soon as it is connected to the mains supply. The
pump is connected using a terminal screw on the control unit.
The device must be opened in order for it to be wired up.
6.2 Connection of temperature sensor
The BDC 102 operates with accurate platinum temperature sensors of type PT1000.
The terminal screws for the temperature sensors allow simple attachment.
Installation/wiring of temperature sensor:
Install the sensors at the requisite places
on the collector (T1) and the storage
cylinder (T2). In so doing, ensure good
temperature transmission and, if
necessary, use a thermally conductive
paste.
Attach the cable to the control unit. The
cables of the temperature sensors can
be extended. For lengths up to 15 m, a
cross-section of 2 x 0.5 mm² is required;
for lengths up to 50 m, a cross-section of
2 x 0.75 mm² is necessary. For lengths
exceeding 10 meters, a shielded cable is
recommended. Sensor cables must not
be laid parallel to 230 Volt power cables
as these can cause faults.
To protect the collector sensor within the
control unit, the use of a lightning
protection device (accessories) is
recommended.
Connect the collector sensor to the
terminals labelled T1. There is no need
to observe a particular polarity (see page
6, figure 2).
Connect the storage cylinder sensor to
the terminals labelled T2. There is no
need to observe a particular polarity (see
page 6, figure 2).
6.3 Replacing the fuse
The device is protected against overload
and short circuit by means of a switching
output with a fine-wire fuse. The fuse is
located in the top left part of the casing in
the green mount.
If the fuse is defective, e.g. if none of the
lights glow when the control unit is
connected - you can replace the fuse with
an identical one.
Only prescribed fuse types may be used:
fine-wire fuse 5 mm x 20 mm 2A/T (2A current, surge-proof version)

Installation and Operating Instructions
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7 COM M I S S I O N I NG
Commission your control unit in the following sequence:
?Are the collector and storage cylinder sensors
correctly mounted
?Has the correct sensor type been selected
(PT1000)?
Yes No  Select and install the correct sensor

?Is the power cable for the pump connected
correctly to the pump and the control unit?
Yes No  Connect the cables correctly

If the pump is powered directly via a mains
cable: does the pump work?
Yes
Unplug the mains cable
No
Unplug the mains plug

Test the pump cable,
test the pump

Reconnect the pump to the control unit
?Are the sensor cables for the collector and
storage cylinder sensors correctly connected to
the relevant control unit terminals?
Yes No  Connect sensors correctly

With the mains supply switched off, connect the
control unit and then switch on the mains supply
(e.g. via a safety fuse):
?Does the green “Mains” light lights up
Yes No  Test the fuse on the device
Check the fuse protection on the
mains

?Does the “Fault” light flash
No Yes  Rectify fault as described in section 9

If the “Pump” light lights up, check whether the
pump is working.
Yes No  Rectify fault as described in section 9

Control unit is ready for use. If necessary:
carry out settings for TSPmax*
Write down your settings:
Date TSPmax
°C
°C
* TSPmax: maximum
temperature storage cylinder
* TSPmax:

Installation and Operating Instructions
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8 OP E R AT I O N /IN D I C AT O R S
8.1 Adjustment of control values
Adjustment of maximum storage cylinder temperature TSPmax
This setting determines the maximum temperature that the storage cylinder may reach. This
value is set using the TSPmax adjustment knob such that the arrow points to the required
temperature. Values between 20°C and 95°C are possible.
The low values are intended primarily for operation of swimming pool heating systems.
For hot water storage cylinders, values of between 60°C and 90°C are usual.
A temperature of 80°C is preset at the factory.
8.2 Indicators
The operating status and potential faults are indicated by two lights. For easier identification, a
pump symbol is shown next to the green LED and a warning symbol next to the red
LED.
LED Display colour Meaning
Green LED
“Mains” Continuous green
light Control unit is switched on
Green LED
“Pump” Flashing green
light Pump is switched on
Red LED “Fault” Continuous red
light
No circulation, although pump is switched
on, or system protection
Red LED “Fault” Red flashing light Error on collector or storage cylinder
sensor
Please observe the specifications laid down by the manufacturer of the storage
cylinder

Installation and Operating Instructions
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9 REG UL ATO R F U N CTI O N S
Temperature difference control
The BDC 102 regulates the difference in
temperature between the collector and the
storage cylinder:
If the collector temperature is more than 7K
higher than that of the storage cylinder, the
pump is switched on.
If the collector temperature falls below the
value: storage cylinder + 3K, the pump is
switched off.
The pump is always switched off if the
storage cylinder temperature is higher than
the value set for TSPmax.
Sensor monitoring
The two temperature sensors and their
connecting cables are monitored for
interruption and short circuit. A defective
sensor is indicated by a flashing “Fault”
light. An incorrect sensor type is generally
also indicated as a “short circuit” or
“interruption”.
Monitoring of circulation
Whilst the system is operating, the control
unit checks (pump = “on”), whether, with the
pump switched on, the difference in
temperature between the collector and the
storage cylinder exceeds the amount of
60°C+7K for 30 minutes. If this occurs, a
fault – continuous red light – is displayed.
Pump block protection
If the solar thermal system is not in use due
for example, to continuous bad weather, the
solar circuit pump can “seize”. To prevent
this from happening, the control unit
switches the pump on for 30 seconds at 10-
day intervals.
Installation protection
If the collector temperature exceeds 120°C,
the control unit switches off the solar circuit
pump. The pump is switched on again at
105°C, equivalent to a hysteresis of 15K.
10 RECT I FI C AT I O N OF F AULTS
There are basically two kinds of system
fault:
•Faults that are recognised by the control
unit and which it can therefore indicate
•Faults that cannot be indicated by the
control unit
10.1 Indicated faults (display):
These faults are indicated by means of the red “Fault” LED. The frequency with which a light
flashes within a space of a few seconds indicates a specific error number. The possible
corresponding error sources are listed in the following table:

Installation and Operating Instructions
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Fault indication Possible causes Action
Flashes once •Interruption in the
cable to the collector
sensor
•Sensor defective
Check cables
Check sensor resistance value,
replace sensor if necessary
Flashes twice •Short circuit in the
cable to the collector
sensor
•Sensor defective
Check cables
Check sensor resistance value,
replace if necessary
Flashes three times •Interruption to the
cable to the storage
cylinder sensor
•Sensor defective
Check cables
Check sensor resistance value,
replace sensor if necessary
Flashes four times •Short circuit in the
cable to the storage
cylinder sensor
•Sensor defective
Check cables
Check sensor resistance value,
replace if necessary
Light permanently on No circulation:
•Air in the system
•Error in pump
connection
•Pump defective
•Pump has seized
Installation protection
De-aerate the system
Check the pump connection
Replace the pump
Ensure the pump is running
Collector temperature >= 120°C, wait
until the temperature has fallen below
105°C
10.2 Faults that are not indicated
Faults and errors that are not displayed can
be tested using the following table and
possible causes and sources of error
identified. If, based on the description, fault
rectification is not possible, please contact
the supplier or installer of the system.
Error Possible causes Action
No display function •No 230V power supply
Switch on or connect the control unit
Check domestic fuse box for
connection
•Fuse within device is
defective
Test fuse, replace with new, type
2A/F fuse if necessary.
Test 230V components for short
circuit
•Device defective Contact the supplier
Green LED “pump” light
blinks, but pump does not
work
•Connection to pump
interrupted.
•Pump has seized.
•No power supply to
switching output.
Test cable to pump
Ensure the pump is running
Control unit defective. Contact
supplier.

Installation and Operating Instructions
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11 TECHN I C AL D AT A
Housing
Material 100% recyclable ABS casing for surface-mounte
d
installation
Dimensions(H x W x D) in mm, weight 80 x 80 x 52; approx. 180 g
Protection class IP65 in accordance with VDE 0470
Electrical values
Operating voltage AC 230 Volt, 50 Hz, -10...+15%
Internal device fuse Micro-fuse 5 x 20mm 2A/surge-proof
Radio interference level N in accordance with VDE 0875
Terminals for sensors Cross-section max. 0.75 mm² fine-strand/single-strand
Temperature sensor / temperature
range
PTF6 - 25°C - 200°C
PT1000, 1000 kΩat 0°C
Testing voltage 4 kV 1 min in accordance with VDE 0631
Switching output 230 V∼/ 2 A / approx. 230 VA for cos ϕ= 0.7 – 1.0
Operating temperature 0 ... + 50°C
Storage temperature -10 ... + 65°C
Regulator functions Temperature difference regulator
Maximum storage cylinder temperature Adjustable from approx. 20°C to 95°C
Temperature difference Temp. difference at which pump switches on 7K
Temp. difference at which pump switches off 3K
Pump block protection function Every 10 days
Sensor monitoring Interruption and short circuit
System monitoring Circulation, system protection
12 RESI ST ANCE TAB L E PT1000 S E NSO R
The correct function of the temperature sensor can be checked against the following
temperature resistance table, using a resistance measurement device:
Temperature in °C Resistance (Ohms) Temperature in °C Resistance (Ohms)
-30 882 60 1232
-20 921 70 1271
-10 960 80 1309
0 1000 90 1347
10 1039 100 1385
20 1077 120 1461
30 1116 140 1535
40 1155 200 1758
50 1194
Manufacturer of BDC 102 control unit devices: PROZEDA GmbH.