HEATING CIRCUIT CONTROLLER

WITH SOLID FUEL BOILER

OPERATION MANUAL V0.15 (10.12.2013 from program v0.15)

The controller controls the central heating installation with a boiler featuring an automated fuel feeder. The PID algorithm applied enables operation with automatic boiler work modulation – the required amount of heat is generated, and therefore the combustion process is uniform (there are no rapid changes of temperature in the combustion chamber or the stack), more effective and guarantees a longer service life of the heating installation. The controller controls the work of the fan, the HUW (Hot Utility Water) loading pump and two circuits CH1 (Central Heating) and CH2 equipped with mixing valves and room thermostats, as well as the work of the circulation pump.

1. Basic parameters of the controller Power supply 230V/50Hz Power consumption without load 10W Maximum connection power 1400W Working conditions 5÷50 oC, moisture 10÷80%, no condensation Feeder control output 300W/230VAC Fan control output 250W/230VAC smooth rotation regulation Pump control output 150W/230VAC Biomass combustion heater control output 450W/230VAC Fuse 6.3A/250V Boiler temperature sensors NTC 2.2k Accuracy of temperature measurement 2 oC with 0.1 oC resolution

2. General information

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The controller is a modular device. It consists of an “RT16” OPERATION PANEL mounted on the boiler and an “RT161” ACTUATOR MODULE mounted on a DIN rail under the boiler casing or in the control cabinet. The measurement signals from the sensors and the supply of the actuating devices are connected to the actuator module. The operation panel is connected with the actuator module by means of a standard RJ45 1:1 UTP5 computer cable.

Fig. 1. The actuator module connection

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INPUTS: Tzew - External temp. sensor Tcwu - Hot utility water tank temp. sensor Tkcz - Boiler supply temp. sensor Tkcp - Boiler return temp. sensor Tpod - Feeder temp. sensor TZ - Fuel tank cover closure sensor (opened on opening the cover) Tco1 - Central heating temp. sensor (behind the mixing valve no. 1) Tco2 - Central heating temp. sensor (behind the mixing valve no. 2) Tkom - Control by means of another heating circuit (e.g. fireplace) TP1 - CH1 circuit room thermostat TP2 - CH2 circuit room thermostat Tspal - Exhaust temp. sensor RS485 - Connector to other actuator modules (option) RJ45 - Connector to the RT16 operation panel OUTPUTS: M2 - Drive of mixing valve no. 2 (a terminal marked “-“ means closing the valve), max. 150W M1 - Drive of mixing valve no. 1 (a terminal marked “-“ means closing the valve), max. 150W G - Biomass combustion heater, max. 450W P.CR - CR (circulation) pump, max. 150W P.CO2 - CH2 pump, max. 150W P.CWU - HUW pump, max. 150W P.CO1 - CH1 pump, max. 150W STB - Safety thermostat W - Fan, max. 250W PD - Feeder drive, max. 300W SERVICE: LED service lamp signals the module working: - orange flash – waiting for the start of the controller - green flash – correct work - rapid red flash – no connection with the operation panel, disconnection of outputs. A maintenance switch is used for the connection of subsequent actuator modules. It should be set according to the figure, i.e. both “ON” positions

! The work of the boiler requires the connection of Tkcz (boiler supply temp.), Tpod (feeder temp.), TZ (fuel tank cover closure) sensors

! The presence of other sensors activates additional functions of the controller: Tcwu - controls HUW tank loading by means of P.CWU (HUW) pump Tco1 - the connection of this sensor indicates that the CH installation has an M1 electrically controlled mixing valve installed. The sensor controls the M1 valve opening level so as to achieve the fixed temperature of the CH1 circuit Tkcp - connected with the M1 four-way valve, the sensor activates the function of the boiler protection from too low temperature of water returning from the installation (protection from accelerated corrosion) Tco2 - the connection of this sensor indicates that an M2 electrically controlled mixing valve is mounted in the CH installation. The sensor controls the valve 2 opening level so as to achieve the fixed temperature of the CH2 circuit Tkom - control from another source of heat (e.g. fireplace) turns off the CH1 pump and closes the M1 mixing valve TP1 - room thermostat limits heating in the CH1 circuit when the temp. exceeds the value determined in the in the thermostat TP2 - room thermostat limits heating in the CH2 circuit when the temp. exceeds the value determined in the thermostat Tzew - external temp. sensor enables the connection of the weather compensation of the CH1 and CH2 circuits Tspal - exhaust temp. sensor is required for the automatic biomass combustion

! CH pump work: P.CO1 (without M1 mixer) – the pump is turned on after the boiler min. temp. is exceeded (the boiler protection from corrosion). In case the TP1 room thermostat is activated, the pump works cyclically to limit the heat supplied to the circuit. The P.CO1 (CH1) is activated in emergency after the boiler max. temp. is exceeded. P.CO1 (M1 mixer installed) – the pump works continuously, and it may be turned off in emergency after the circuit max. temp. is exceeded. P.CO1 is activated in emergency after the boiler max. temp. is exceeded. P.CO2 - The installation of an M2 mixing valve in the heating system triggers the creation of another CH2 which consists of: an M2 valve, a P.CO2 pump, a Tco2 sensor and, possibly, a TP2 room thermostat and a Tzew

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(external temp.) sensor. The P.CO2 pump works continuously and may be turned off in emergency after the circuit max. temp. is exceeded.

! Configuration of CH1 and CH2 heating circuits: Heating circuits may work in the following systems: SERIAL – there is a CH1 circuit (radiator-related) at the boiler output which in turn is connected with the CH2 (floor-related) circuit. In such a configuration, the CH2 (floor-related) circuit work is not modified by such functions, as priority HUW loading, boiler return protection, etc. PARALLEL – two radiator circuits CH1 and CH2 with independent settings (e.g. two houses heated from one boiler room) are located at the boiler output. In such a configuration the work of both circuits is modified by such functions, as priority HUW loading, boiler return protection, etc. The factory settings (SERIAL circuits) may be modified in OPCJE SERWISOWE (service options).

! P.CR hot utility water circulation pump work: The pump is working when “WŁ (ON)” was set in MENU “15 Pompa Cyrkulacyjna (Circulation pump)”, and the current time is consistent with one of the five time zones. Time may be set every 15 min. within 0:00 a.m./11:45 p.m. (0:00 a.m. is displayed as --:--, which means the zone disconnection).

3. The controller operation The moment the boiler is on, the operation panel is on as well, with its elements controlling the controller’s work (Fig. 1). The status of the device is displayed on the graphic display (1). The screens displayed inform about the work of the devices, temperature of the sensors, they enable the change of the parameters, etc.

(1) Display (2) return key (3) value increase or menu up key (4) confirmation key (5) value decrease or menu down key (6) information key (7) Controller status lamp: WORK (green) FAILURE (red) STANDBY TIME (orange) (8) USB external memory connection (USB flash drive) protected with a cover

Fig. 1 View of the operation panel

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3.1 Start-up screen

The moment the power supply is connected, a start-up screen is displayed, which means the controller waiting for service actions (e.g. software update). The stars displayed indicate the time elapsed until the start.

If key is pressed within this time period, a piece of information about the versions of the software installed is screened:

3.2 Home screen The home screen presents the most important information about the boiler work. It reports emergency situations and enables the activation of menu functions in order to change the settings.

Box: (1) Indication of EXTERNAL temp. sensor (2) Indication of HUW temp. sensor (3) Indication of CH1 temp. sensor (4) Indicator of momentary power of the boiler (5) Indication of work in PID, PIDS or MANUAL COMBUSTION mode (with the feeder off) (6) Current temp. measured at the output of the boiler (7) Message box (8) Additional indications

! Note: in the absence of a sensor “--” is displaye

(81) Biomass combustion heater on (82) Turning off the CO by another source (e.g. fireplace) (83) Active TP2 room thermostat (84) Active TP1 room thermostat (85) Boiler contamination (high exhaust temp.) (86) Work in LATO (SUMMER) mode (HUW only) or “rainy umbrella”, i.e. JESIEŃ (AUTUMN) (CH2 circuit disconnected) (87) The controller activated another return temperature protection raising the temp. of the boiler (88) Biomass combustion cycle on

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At the home screen level the keys perform the following functions: entry into the controller MENU (see item 3.2.1) performing the combustion function (see item 3.2.1.1) switch to the information screen (see item 3.3)

3.2.1 MENU layout We select items from the menu by means of and keys. Pressing key means the entry into a selected item, and pressing key - the escape from a selected item.

01 Heating temperature 1 The fixed temp. for the main CH1 heating circuit

02 Heating temperature 2 The fixed temp. for the CH2 heating circuit. Function inactive without an actuator on the M2 mixing valve.

03 DHW temperature Max. temp. of loading the HUW tank.

04 Operation mode Enables the switch into manual combustion (feeder function disconnected) if an additional furnace is used.

05 Feeder break The time between subsequent cycles of feeding fuel to the boiler in the course of automated work.

06 Fan capacity The fan power adjusted respectively to the fuel, boiler, and the chimney draught

05 PID – capacity Sets the boiler power at the min. (30% loading)/average (50% loading)/max. (100% loading)

! Note: an option available at PID control on 06 PID - parameters

Correction (expressed in %) of air and fuel settings with regard to the default values.

! Note: an option available with the PID control on 07 Feeder – stand-by

The time, after which the controller disconnects the feeder and the fan to prevent the boiler extinguishing. 08 Boiler model/fuel type

The selection of the type of fuel used (pea coal or biomass), as well as the type of the boiler. During a boiler selection “Klimosz INNE” (Klimosz OTHERS), set the time of feeding the fuel, however, other boilers have this parameter preset.

! Note: when PID control is on, the list of available boilers is limited to the power of 45kW. 09 Burner ignition

Manual control of the feeder and the fan in the process of heating up the boiler. Select a desired option pressing and :

STOP FEEDER FAN FEEDER+ FAN PRELIMINARY START-UP– enables blocking the boiler return temp. protection for 0.5 h or 3 h (facilitates the start-up of the installation after a prolonged break) Heating up the fuel by means of key finishes the heat-up phase and the combustion continues according to the automated work settings.

10 HEATING (SUMMER/WINTER) Selection of the mode of cooperation with the HUW tank: SUMMER only HUW preparation AUTUMN the CH2 circuit off WINTER all circuits active WINTER+PRIORYTET CWU priority of loading HUW over CH circuits WINTER+HUW TIME PRIORITY priority of loading HUW over the CH circuits. A priority limited in time, in accordance with “CWU priorytet-czas” (HUW priority-time) service parameter

11 Equithermal curve 1 Setting the heating curve and the room temp. to set the H1 circuit supply temp. (see item 5).

12 Equithermal curve 2 Setting the heating curve and the room temp. to set the CH2 circuit supply temp (see item 5).

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13 Thermostat 1 temp. decrease

CH1 temperature reduction after the connection of the TP1 room thermostat 14 Thermostat 2 temp. decrease

CH2 temperature reduction after the connection of the TP2 room thermostat 15 Circulation pump

The hot utility water circulation pump on/off. Setting up to five time zones where the pump works (default settings are 6:00-8:00 a.m. and 3:00-10:00 p.m.).

16 OTHER settings 01 Sounds and alerts

The sound of keys and the alert signal on/off. 02 Clock

Setting the current date and hour. 03 Screen backlight

Setting the screen backlight degree during the inactive status of the controller. 17 Service settings

These are additional settings specifying the work of the controller. This function requires providing a password.

! THE SERVICE OPTIONS ADJUST THE CONTROLLER TO THE PROPERTIES OF THE BOILER AND THE HEATING INSTALLATION. THEIR CHANGE REQUIRES THE CONSENT OF THE MANUFACTURER OF THE BOILER OR THE INSTALLER. ANY UNREASONABLE CHANGES MAY LEAD TO UNSTABLE AND INEFFECTIVE WORK OF THE SYSTEM.

01 Minimal boiler temperature

Limits the minimum value of the boiler fixed temp. If the temp. drops, the CH1 pump is off (variant without the mixing valve) or the mixing valve is closed.

02 Maximal boiler temperature Limits the maximum boiler temp.

03 Critical boiler temperature The maximum temperature (P02) exceeded at the output of the boiler by critical value (P03) triggers alert action aiming at fast cooling of the boiler. CH1 and HUW pumps are turned on, the mixing valve is being opened, and the feeder and the fan are on.

04 Boiler protection temperature M1 mixing valve is closed below this value of the boiler return temperature, protecting the boiler from accelerated corrosion. To be active this function requires a controlled M1 valve and “Tkcp” return temperature sensor.

05 Feeder temperature Sets a permanent fuel level in the retort.

06 Fan – ignition mode Sets the airflow force in the course of heating up the boiler.

07 Feeder ALARM temperature Exceeding the feeder temp. activates alert fuel pushing in order to prevent the heat withdrawal.

08 Heating pump operation Sets the working and break time of the CH1 pump in a configuration without the M1 mixing valve, with the TP1 room thermostat active (in order to limit heat supply to the heating circuit).

09 BOILER hysteresis The temperature hysteresis of the boiler switching into the maintenance mode.

10 DHW hysteresis The temperature hysteresis of the HUW tank loading.

11 DHW priority – time Turns off the HUW priority unless the HUW heat up occurs at a fixed time.

12 DHW added boiler temperature Raises the boiler temp. in case the priority HUW heat up is necessary.

13 No fuel alarm on/off Turns off the function of fuel shortage detection (on the basis of analysis of the temp. at the boiler output).

14 No fuel detection time The time of fuel shortage detection before reporting the fuel shortage error.

15 Flue gas temperature Exhaust temperature whose exceeding triggers the necessity of cleaning the boiler. The boiler power will be reduced in PIDS mode.

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16 PID on/off The PID or PIDS function activation (PID with the exhaust temp. limited).

17 Added boiler temperature Increasing the boiler temp. in the course of work in a heating installation with a mixing valve).

18 Heating circ. CH1 CH2 Configures the heating circuits as serial (dependent) heating circuits or parallel (independent) heating circuits

19 Zone thermostats Configures the number and type of room thermostats (see item 4)

20 MAIN mixing valve M1 Configures the M1 mixing valve work):

01 Operating mode (on/off) 02 Opening time 03 Min circuit temp. 04 Max. circuit temp. 05 Response time correction

21 3-way mixing valve M2 Configures the M2 mixing valve work):

01 Operating mode (on/off) 02 Opening time 03 Min. circuit temp. 04 Max. circuit temp. 05 Response time correction

22 Biomass ignition Configures the biomass combustion process

01 Starting automatic heating up 02 Initial fill 03 Feeder operation time 04 Feeder break time 05 Initial fill 06 Heater operation time 07 Heat up turn off temperature 08 Fire detection delay time

18 Controller test The test may check all inputs and force RT161 actuator module output. � key serves to switch reading screen inputs. � In the case of TP1 and TP2 room thermostats, “++” means a function activation and “—” inactivity

(depending on the thermostat type configuration). � In the case of TKOM input (control from another source of heat), “++” means a function activation and “—”

– inactivity. � In the case of TZ input (cover locking sensor), ”—” means the right status, i.e. the cover closed (TZ is

closed), and “!!” means TZ activation or opening. � In the case of STB input, “—”means the right status, i.e. the STB is closed, and “!!” means the activation of

STB or the opening. � key serves to switch the output screen. Pressing and keys you can select subsequent outputs, only

one being on at a time – the one currently illuminated. � Press key to escape the test and return to automatic work.

19 Factory settings

The function confirmation leads to a query about the language version and then the deletion of the settings and return to the default values.

3.3 Emergencies Any emergency situation causes stopping the boiler operation. It is indicated by flashing the red indication lamp on the operation panel, a sound signal (if acoustic alert is on) and an appropriate inscription in the message box of the home screen. Press key to obtain detailed information on the reason for the emergency. The alert deletion and return to normal work (if the reason for the alert no longer applies) takes place on pressing key again. The following conditions are indicated:

� Damaged RT161 actuator module (no communication with the module). � Improper version of RT161 actuator module software.

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� Improper version of USB operation panel software. � Damaged boiler temperature sensor. � Open fuel tank cover. � Damaged feeder temperature sensor. � The boiler temp. exceeded the critical value. � Failure to combust biomass. � Additional STB thermal security activated. � Fuel or flame shortage, or low calorific value of fuel. � Exceeded feeder temp. Alert fuel pressing out. � Risk of freezing. The boiler or feeder temp. is below zero.

3.4 Information screens The status of basic controller circuits may be checked when the home screen is displayed on the operation panel. Press

to display other information screens: Screen 1

On the right of the screen the numeric values present: 1. Indication of SUPPLY boiler temp. sensor 2. Indication of RETURN boiler temp. sensor 3. Indication of CH1 temp. sensor 4. Indication of FEEDER temp. sensor 5. Indication of EXHAUST temp. sensor 6. Indication of EXTERNAL temp. sensor 7. (The boiler icon) FIXED temperature of the BOILER, i.e. the one calculated by the controller

! Note: in the absence of a sensor, “--.-“ is displayed

! Note: if the initial start-up is set (temporary blocking the return security), the indication of the RETURN boiler 2 temp. is displayed interchangeably with the time left until the end of the start-up.

Box: (1) presents the CH1 pump operation (when it works, the icon flashes) (2) the FIXED BOILER temperature, e.g. the temperature calculated by the controller (3) presents the main CH1 mixing valve operation (upward pointing arrow - opening, downward pointing arrow - closing) (4) presents the fan operation (when it works, the icon flashes) (5) presents the feeder operation (when it works, the icon flashes)

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Screen 2:

On the right of the screen the numeric values present: 1. Indication of SUPPLY boiler temp. sensor 2. Indication of RETURN boiler temp. sensor 3. Indication of CH1 temp. sensor 4. Indication of HUW temp. sensor 5. Indication of CH2 temp. sensor 6. - 7. -

! Note: in the absence of a sensor, “--.-“ is displayed

Box: (1) presents the HUW pump operation (when it works, the icon flashes) (2) presents the CR circulation pump operation (when it works, the icon flashes) (3) presents the CH1 pump operation (when it works, the icon flashes) (4) presents the operation of the mixing valve 3-way CH2 circuit (upward pointing arrow - opening, downward pointing arrow - closing) (5) presents the CH2 pump operation (when it works, the icon flashes) (6) presents the main mixing valve operation (upward pointing arrow - opening, downward pointing arrow - closing) Screen 3:

Versions of the main controller module (MA) software, USB communication module (UA) and actuator module (1A). Press key again or key any time to return to the main screen.

3.5 The controller software update

! A function designed for the service and trained users. Any improper update of the software may block the controller. The controller features a connection “flash drive”-like USB external memory and the software modification (update) function. Its use requires the following steps: 1. Preparing a typical USB memory designed for work with PCs, compatible with WINDOWS system (with a system of FAT16 or FAT32 files). 2. Upload the “RT16_0” subfolder received from the service along with three sets with “x” extension and names beginning with letters “U” (USB communication software), “M” (the main controller program) and “A” (actuator module software) to the main file of the USB memory. 3. With the controller/boiler supply off, connect the USB memory to the connection on the operation panel (Fig. 1 item 8).

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4. Turn on the controller supply. The following screen should appear on the operation panel:

5. The lack of such a screen or “OK.” indication in box (1) means no USB memory recognition. In such a case repeat actions 3. and 4. Unless it works, try using another USB memory. 6. Using key select shaded box (6), (3) or (4), namely: � Box (6) – switching files by means of keys and (the default file “RT16_0” may be changed into “RT16_1” … “RT16_9” if proper sets are saved there) � Box (3) - start of the update process on pressing key � Box (4) – discontinuation of the update process and starting the controller � Time for decision making is limited, which is reminded by box (2). On the meter exhaustion the update process is discontinued and the controller started 7. At first the initiated update covers the operation panel. The USB communication software – box (8) as well as the main program – box (7) change. A revolving indicator and then the end of the operation status are displayed. � E-DIR no file with data � E-FILE no set with data � E-CONF data not compliant with the hardware version � Exx “xx” internal error of the programming process � OK programming completed correctly 8. The correct update of the operation panel should last 1…2 min. and finish with the display of two statuses “OK.” in box 7) and 8). 9. After a while the controller activates the newly uploaded main program and, as compatible with it, starts updating the software of the actuator module. The following screen appears:

10. The actuator module update starts. A revolving indicator, and, finally, the operation status is displayed in box (2) � E-DIR no file with data � E-FILE no set with data � E-CONF data not compliant with the hardware version

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� Exx “xx” internal error of the programming process � OK programming completed correctly 11. The correct update of the actuator module should last 2…3 min. and finish with screening the “OK.” status. 12. The completion of the update process is indicated by box (1) flashing, which reminds to disconnect the USB memory. It will be followed by activating a new USB communication program and the actuator module. The controller will be reset featuring the new software.

! During the reset process the controller checks the software integrity. Any incompliance of the software version is indicated as a configuration error.

4. Room thermostat The controller is equipped with outputs which enable the connection of a room thermostat (TP) of any type, equipped with a potential-free contact output. The TP1 concerns the main heating circuit. If the M2 mixing valve is available, the other heating circuit may be equipped with its own TP2 thermostat or be controlled by TP1 thermostat (then parameter “RT 1 assignment” must be properly set in SERVICE OPTIONS “Room thermostats”. The controller works normally until the temp. measured by the thermostat is lower than the one set. When the temp. exceeds the fixed temp., which is indicated with an icon on the main screen, the controller modifies its work: the fixed temperature of the heating circuit lowers by a value provided in parameter “thermostat X reduction”, and the CH pump works cyclically unless the circuit is equipped with a mixing valve.

If the thermostat is equipped with terminals which close when the temp. in the room is higher than the fixed one, parameter “Thermostat terminal type” must be set in SERVICE OPTIONS “Room thermostats” as COM+NC . In the case of closed terminals COM+NO must be set.

! The thermostat must be located in a control room with no thermostat radiator valves. It must be positioned at the height of c.a. 1.5 m over the ground, far from windows or heaters.

5. Weather compensation (weather control) The controller may automatically determine the fixed temperature of the heating circuit on the basis of the measurement of the external temp. of the programmed heating curve. The slope (number) of the heating curve characterises the thermal properties of the building:

Heating Building No. of the heating curve

Insulated 1..2 Floor Not

insulated 3..4

Insulated 3..4 medium insulated

5..7 Radiator

Insulated 7..13

If the heating curve is selected well, the internal temperature should remain constant, regardless of the external temperature. If the internal temp. drops with the drop of the external temp., a greater no. of the curve must be selected. However, if it rises, the no. of the curve must be lower.

The required room temp. is determined by the “Tpok” curve parameter. It moves the curve up or down to provide the proper thermal comfort. The controller provides a function of independent selection of weather compensation for the CH1 and CH2 circuit. The selection of the curve no. 0 means turning on the weather compensation– then we set up the fixed temperature directly by means of parameter PO1 “Heating temperature 1” (respectively P02 parameter in the case of CO2).

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Parameter P11 “Weather characteristics 1” enables setting the heating curve for CH1 (respectively P12 for CH2). Press key to select the highlighted box: (1) room temperature (2) no. of the curve. The fixed temp. values selected by the controller will be automatically indicated on chart (3). Press key to enter a new setting.

! The external temp. sensor must be installed on a wall of the building not exposed to the sun, at half height, 2 m or higher above the ground, far from windows or ventilation openings.

6. PID and PIDS mode The PID algorithm applied enables work with automatic boiler power modulation – appropriate amount of heat is generated, and therefore the combustion process is uniform. The PID algorithm in the extended form of PIDS additionally reduces the boiler power in case of exceeding the MAX exhaust temp. Such additional power reduction is indicated in the Home Screen with flashing icon “PIDS” (see item 3.2. box no. 5).