Operating instructions THETA control unit for heating contractors. ROTEX control unit: - THETA 23R - THETA RS - THETA HEM1

Transcription

1 Operating instructions THETA control unit for heating contractors. ROTEX control unit: - THETA 23R - THETA RS - THETA HEM1

2 Introduction Introduction The ROTEX THETA control unit is a simple to operate digital control system, which can undertake all control tasks required for ROTEX heating systems. The central control units THETA 23R are integrated into all new ROTEX series A1 oil fired condensing boilers (A1), GasSolarUnit/ GasCompactUnit (GSU/GCU) and E-SolarUnit (ESU). In addition, they are installed as heating circuit extension modules into wall mounting bases (HEM1). Apart from the weather-compensated control of the heat source, each additional device offers the opportunity to regulate one direct and one mixed heating circuit as well as a cylinder primary system (DHW circuit). The integral digital time switch offers, for each heating circuit, three individually adjustable single and 7-day programs, which are preset in the form of standard time programs for the most common applications. For the individual heating circuits, separate heating curves and set temperatures can be programmed. The set DHW cylinder temperature can also be timer controlled. Special programs for holidays, party, extraordinary DHW demand, short term economy control and screed drying are also available. To protect pumps and mixing valves against seizing up due to opened, if the system is shut down, such devices are started daily for approx. 20 seconds or shut down the mixers are opened,if the system is shutdown longer than 24 hours, during the summer shutdown or frost protected standby operation. Every heat source also offers the option of connecting a DHW circulation pump (with timer program), the remote changeover of the operating mode via an external modem and a zero-volt burner blocking contact, if an additional heat source (e.g. wood burning boiler or solar heating system) is linked to the heating as a heating system. As heating circuit extension or to create a cascade of heat sources, up to five additional devices can be linked together. Every heating circuit can be extended with an optional room controller, which facilitates the remote control of the heating system from the installation room or the hook-up of a room temperature-dependent controller. For this, the room station THETA RS (part no ) offers convenient operating options; this device too offers a large, background-lit plain text display, just like the central control unit. The room controller set THETA RFF (part no ) represents an affordable solution, with which simple changes to the operating mode and the set room temperature can be achieved. The following describes all activities and controls required for the operation and individual adjustment. The installation, connection and commissioning of the heat source must be carried out by an authorised contractor. Afterwards, the system should be handed over by the installer to the user. For this, the user must be instructed in the operation and control of the heating equipment. The handover should be recorded by jointly completing and signing the installation and training form supplied with the boiler. The symbol and further warning symbols highlight safety information. The symbol identifies text passages that are particularly important to achieve an optimum utilisation (adjustments, monitoring, etc). Although the same controller is used in all devices, some equipment settings and operating paths are different for the various heat sources. The following symbols identify sections in these instructions that only apply to certain pieces of equipment. only for the A1 not for the A1 only for the GSU/GCU not for the GSU/GCU only for the ESU not for the ESU only for the HEM1 not for the HEM1 The equipment is VDE tested and certified. All equipment meets the requirements of the following EU Directives: 89/336/EEC - Electro-magnetic compatibility (EMC) and 73/23/EEC - Low Voltage Directive 0366 [ 2 ]

3 Contents Safety 4 General warranty terms 4 Chapter 1: Description of the controls Controls of the THETA control unit 5 Operation and symbols - General functions 5 Display areas 6 Standard display 6 Special displays 6 Function of control keys/buttons 6 Day room temperature 6 Functions and adjustment options at the user interface - summary 7 Setback room temperature 8 DHW temperature 8 Extraordinary DHW demand 8 Selecting the operating mode 8 Selecting a time switch program 9 Scanning system information 10 Chapter 2: Commissioning Automatic setting function 11 Manual setting function 11 Standard THETA level structure 11 Access to the operating levels 11 Entering the access code 13 Chapter 3: Programming switching times Timer program level 14 Matching switching times programs to user lifestyle 14 Block programming 15 Copying complete 7-day time programs 16 Reloading standard programs 17 Timer program level parameters 18 Chapter 4: Time and date 19 Time-date level parameters 20 Chapter 5: Adjusting system parameters Heating curves 21 Language 22 Automatic summer shutdown 22 Resetting system parameters to their factory settings 23 DHW economy temperature 23 Pasteurisation 23 Operating mode 23 Screed function 23 Hydraulic level parameters 25 System level parameters 26 DHW level parameters 27 Unmixed heating circuit level parameters 28 Mixer circuit level parameters 29 Heat source level parameters 30 Information parameters for the burner control unit level 31 Burner control unit level parameters 32 Cascade level parameters 33 BUS level parameters 34 Sensor matching level parameters 35 Chapter 6: System extension with room controllers and several central control units BUS system 36 Control functions via the BUS 36 Cascading of heat sources in the BUS link 37 Chapter 7: Accessories and installation information Information regarding an EMC-compliant installation 38 Recommended cable cross-sections and maximum permissible cable lengths 40 Installation information for central control units 40 Terminal allocation - boiler control panel 41 Installation information for heating circuit extension module HEM1 with wall mounting enclosure 42 Terminal allocation HEM1 43 Installation information room station THETA RS 45 Chapter 8: Specification General specification 46 Sensor parameters 47 Chapter 9: Commissioning information, maintenance and troubleshooting Limiter test 48 Relay test level 48 Fault message level 48 Test options at the relay level 49 Fault codes 50 Fault memory with the last five fault messages 51 Troubleshooting 52 Global controller reset 52 Setting tables 52 Form: Individual settings of the time switch program 53 Form: Individual parameter adjustments 54 Chapter 10: Emissions testing and emergency mode Emissions testing (by the flue gas inspector) 56 Manual mode (emergency mode) 56 [ 3 ]

4 Safety instructions and warranty Safety Before any work on the heating system, switch OFF the mains electrical isolator and protect against unauthorised reconnection. Any work on the heating system must only be carried out by authorised and trained personnel (heating contractor). The electrical installation must only be carried out by an authorised electrician, who must observe all local and national regulations. In addition, observe the requirements specified by the relevant electricity supply company. Before connecting the equipment to the power supply, compare the rated voltage stated on the type plate (230 V/50 Hz) with the supply voltage. An incorrect installation can be dangerous and will void our warranty. Closely observe all safety requirements and warnings in the operating instructions (control unit, boiler). Any physical modification of the equipment may have safety implications and must therefore be avoided. General warranty terms Within the warranty period, ROTEX will repair the equipment free of charge through an authorised contractor. ROTEX reserves the right to supply replacement equipment. The warranty only applies if the equipment has verifiable been correctly installed by a qualified contractor. As verification, we strongly recommend that the installation and instruction form supplied with the heat source is completed and returned to ROTEX. Warranty periods The warranty period commences with the date of installation (invoice date of the installing contractor), but no later than six months after the date of manufacture (invoice date). The warranty period will not be extended by the return of the equipment for repair or replacement. Warranty period: 2 years [ 4 ]

5 Chapter 1: Description of the controls Controls of the THETA control unit 1 Rotary selector for selection and adjustment 2 Plain text display 3 Day key - set day room temperature 4 Night key - selected setback room temperature 5 DHW key - set DHW cylinder temperature 6 OM key - operating mode selector 7 Time program key - for the setting of the automatic time program 8 Info key - for system information 9 Manual key - for emissions testing and manual mode (only central control unit) 10 Compartment for the abridged operating instructions (only central control unit) Fig. 1.1: Central control unit ROTEX THETA 23R Operation and symbols - General functions The rotary selector (1) enables control settings to be selected and set values to be changed; changes are saved by lightly pressing the selector afterwards. Turning clockwise (+): increasing adjustment Turning anti-clockwise ( ): decreasing adjustment Light push: Accepting the selected value, saving Long push: Accessing the programming level (level selection) General: The rotary selector is designed as the central navigation element. Prolonged pressing of the rotary selector accesses the program selection level, from which menus further down the tree can be controlled (e.g. programming switching times). Within the menu level, a brief activation of the Info key (7) always returns the next higher level. Pressing the operating mode selector lightly returns the standard display. Fig. 1.2: Room station ROTEX THETA RS The display illumination automatically switches off when the controller has not been activated for a few minutes. Every key activation turns the illumination on again. [ 5 ]

6 Display array (Fig. 1.3) A Display area 1 B Display area 2 C Display area 3 D Special symbols E Time bar display Plain text (alphanumerical) is displayed in the areas A to C. The symbols in area D identify certain operating modes and special operational situations. Day time programs are graphically displayed in area E. Standard display Fig. 1.3: Display area allocation Special displays Function of control keys/buttons Fig. 1.4a: Standard display at the central control unit The following are displayed: day, date, time and heat source temperature. The marking bar at the lower edge identifies the active operating mode (example: AUTO- MATIC time program P2). Fig. 1.5: Display when system frost protection has been enabled Snowflake: System frost protection enabled Tab. 1.1 summarises the functions and setting options that are accessible immediately from the user interface. After that, the functions and their meaning are briefly explained. In the following diagrams, the key operation starts from the standard display; it may be necessary to first press the OM key (6): Day key (3): Select the required day room temperature Temperature Fig. 1.4b: Standard display at the room controller In addition to the standard display on the central control unit in automatic mode, the bar display at the upper edge shows the active time switch program and the operating phase: Day mode Setback mode Fig. 1.6: Display when summer shutdown has been enabled Parasol: Summer shutdown enabled (heating switched OFF, DHW according to time program P1) change Setting range: 5 to 30 C Accept the change Fig. 1.8: Set room temperature for heating mode Note: This setting is the base value for the individually adjustable temperature defaults for the day room temperature when programming the switching times. Temperature adjustments made in the time switch programs are modified by the same amount as any alteration of this setting. Fig. 1.7: Example of a fault message display Fault message (e.g. DHW: cylinder sensor faulty) alternates with the standard display - request a service [ 6 ]

7 [ 7 ] Tab.1.1: Functions and adjustment options at the user interface

8 Night key (4): Select the required setback room temperature Temperature change Accept the change Fig. 1.9: Room temperature in setback mode Note: For the operating mode for separate heating circuits (see system level, section operating mode), initially select the associated heating circuit an confirm the selection by lightly pressing the rotary selector prior to selecting the day or setback room temperature or selecting a time program. DHW key (5): Select the required DHW temperature Set temperature change Setting range: 5 to 30 C Setting range: 10 C to DHW max. temp. Accept the change Fig. 1.10: Set DHW temperature in day mode Note: This setting is the base value for the individually adjustable temperature defaults for the DHW temperature when programming the switching times. Temperature adjustments made in the time switch programs are modified by the same amount as any alteration of this setting. Extraordinary DHW demand Set temperature change Outside the DHW standby times, DHW can be heated manually to the set day temperature. OM key (6): Select the operating mode The following operating modes can be selected: 1. Temporary operating modes: HOLIDAY ABSENT PARTY 2. Automatic mode: Frost-protected shutdown of DHW and central heating during holidays Short interruption of the heating operation during an absence Extended heating operation beyond the regular heating period; DHW in accordance with the day mode setting AUTOMATIC Automatic heating and setback mode in accordance with a time switch program SUMMER press for approx. 5 seconds Setting range: 0 to 240 minutes Setting 0: singe reheating Alt. setting: time-limited reheating Accept the change Fig. 1.11: Enable extraordinary cylinder heating Only DHW operation in accordance with a time switch program, heating shutdown with frost protection 3. Constant operating modes: HEATING REDUCED STANDBY Constant heating mode without time limit; DHW constantly in accordance with the day mode setting Constantly reduced heating mode without time limit; DHW constantly in accordance with the night mode setting (see DHW level) Frost-protected shutdown of DHW and central heating. The DHW cylinder is reheated to 8 C if the DHW temperature falls below 5 C. Note: In the setback phases of the automatic program and the operating modes Absent and Reduced, the control unit operates in accordance with the operating mode ECO (Standard) or ABS defined at the heating circuit level. DHW is heated constantly in accordance with the night temperature selected at the DHW level. In ECO mode, the pumps are shut down (with frost protection) and the mixers are closed. Below the frost protection temperature, the heating circuit temperatures are automatically regulated in accordance with the ABS operating mode (poss. cycling see system level, par.19). The connected room station only operates the pumps as long as the set room temperature is being maintained. In setback mode (ABS setting), the heating circuits are operated according to the setback heating curves. [ 8 ]

9 Selecting the operating mode: The currently enabled operating mode flashes after lightly pressing the OM key. All other operating modes can be selected and activated with the rotary selector; for this the marker bar at the lower edge of the display indicates the associated symbol. Note: For the operating mode for separate heating circuits (see system level, section operating mode), initially and confirm select the associated heating circuit and confirm the selection by lightly pressing the rotary selector. Example: Selecting and enabling the automatic mode Automatic adjust the currently enabled operating mode flashes enable Fig. 1.12: Selecting the automatic operating mode For the temporary operating modes, the associated times, such as the return date (HOLIDAY), return time (ABSENT) or extended heating mode (PARTY) can be entered. Example: Selecting and enabling the holiday program Holiday select Return adjust the currently enabled operating mode flashes accept enable Fig. 1.13: Selecting the holiday operating mode The control unit reverts to automatic mode after the defined temporary time has expired. For the holiday program, a period of up to 250 days after the current date can be selected. The return occurs when the day changes to the selected return date. The duration of the short-term programs Party and Absent is factory-set to three hours from activation. The previously selected duration will be defaulted upon renewed call-up. To terminate a temporary operating mode prematurely, simply select the required operating mode. Time program key (7): Selecting a time switch program Three individually adjustable automatic heating programs are available and preset, i.e. for: Working occupants: Program P1 Heating circuit Day Heating operation from/until Boiler circuit Mo Fr 05:00 08:00 h, 16:00 22:00 h Sa & Su 07:00 23:00 h DHW circuit Mo Fr 04:30 08:00 h, 15:30 22:00 h Sa & Su 06:30 23:00 h Mo Su 00:00 06:00 h, 22:00 24:00 h Mixer circuit Mo Fr 04:00 08:00 h, 15:00 22:00 h Sa & Su 07:00 23:00 h Family: Program P2 Heating circuit Day Heating operation from/until Boiler circuit Mo Fr 05:00 22:00 h Sa & Su 07:00 23:00 h DHW circuit Mo Fr 04:30 22:00 h Sa & Su 06:30 23:00 h Mo Su 00:00 06:00 h, 22:00 24:00 h Mixer circuit Mo Fr 04:00 22:00 h Sa & Su 06:00 23:00 h Solar: Program P3 Heating circuit Day Heating operation from/until Boiler circuit Mo Fr 05:00 22:00 h Sa & Su 07:00 23:00 h DHW circuit Mo Su 04:30 07:30 h, 16:00 22:00 h Mo Su 06:00 23:00 h Mixer Tab. circuit 1.2: Weekend Mo switching Fr 04:00 times 22:00 h (factory settings) Sa & Su 06:00 23:00 h Time program select Setting range: I, II or III Accept the change Fig. 1.14: Adjusting a time switch program [ 9 ]

10 Info key (8): Scanning system information Turning the rotary selector anti-clockwise: Information can be scanned, starting with operating conditions Turning the rotary selector clockwise: Information can be scanned, starting with system temperatures Info parameters select OUTSIDE (average value) Current temperature Outside temperature After lightly pressing the information key, all system parameters and operating conditions of all system components can be scanned in order by means of the rotary selector: System temperatures (outside, heat source, return, flue gas, DHW etc.) Function and values of variable inputs Meter and consumption details Heating circuit information, such as Type of program (holiday, absent, party, automatic, summer etc.) Current time switch program Operating mode (day, setback, ECO) Heating circuit (HC, MC, DHW subject to system version) Status of the respective heating circuit pump (OFF-ON) Status of the mixer servomotor (OPEN-STOP-CLOSE) Status of the heat source (OFF-ON) the sun symbol will be displayed when a flame is recognised Status and function of the variable outputs Note: The system information will only be displayed if the respective components are connected. Manual key (9): Emissions test, manual mode See chapter 10 Return to the standard display Fig. 1.15: Scanning information AUTO-P2 HC AUTO-P2 MC ECO ON/OFF RED ON/OFF ACTUATOR MC OPEN/STOP/CLOSE AUTO-P2 DHW HEAT GENR -/DHW OUTPUT VO-1 SMA OUTPUT VO-2 CIR. DAY ON/OFF ON/OFF ON/OFF ON/OFF HOURS RUN (STARTS) Actual value Operating mode Unmixed circuit/pump status Operating mode Mixer circuit/pump status Actuator Mixer circuit/status Operating mode DHW circuit/pump status Heat source Sun symbol indicates Flame burns Circuit 1) /Status 1) a flashing display indicates a pump run-on Central fault message Fig. 1.16: Scanning system details (values in brackets are only displayed after the rotary selector has been pressed) Note: Automatic return time The display will return from any level to the standard control unit display, if no key is pressed for approx. 2 minutes. After pressing the Info key, the return to the standard display will occur after approx. 1.5 minutes. AT Min. value HEAT GENR (set value) DHW (set value) RETURN Blocking BR FLUE GAS (limit) MIN/MAX Max. value Actual value Actual value Actual value ON/OFF Actual value DHW circulation pump ROOM TEMP HC (set value) Actual value Hours run ROOM TEMP MC (set value) Actual value MODEM Active operating mode Outside temperature (00:00 24:00 h) Boiler temperature DHW cylinder temperature Return temperature Burner blocking contact Blocking contact/status Flue gas temperature Room temperature of the unmixed circuit room sensor Room temperature of the mixer circuit room sensor However, this return time (INFO TIME) is adjustable after holding down the Info key for some time. [ 10 ]

11 Chapter 2: Commissioning Automatic setting function After initially switching ON the power supply, the THETA central control unit checks which sensors are connected. The display shows AUTO-SET. The Auto-Set function recognises which heating circuits are to be controlled. Heating circuits that are not required are automatically signed off. Fault messages regarding sensors (short circuit, lead break) are suppressed during this time. This function will only continue during any system start, until the commissioning date has been saved. The commissioning date will be saved with the first date change on the day the controller is switched ON. Afterwards, a change in the sensor configuration will only be possible via the manual setting function. Manual setting function The Auto-Set function can be called up at any time. The call-up is initiated by pressing the rotary selector during the version display after switching the equipment ON, until AUTO-SET is displayed. The standard display will be activated after the function has been executed. Please note: No automatic Set function is carried out for the Elektro-SolarUnit ESU and the heating circuit extension module HEM1. Manual set functions must also not be implemented, otherwise fault messages or nonsensical info parameters will be displayed (flue gas temperature, even though no flue gas sensor is connected). For these devices, the sensors must be manually logged in at the respective heating circuit level by your heating contractor. General THETA level structure The control concept of the THETA control unit is structured so that the most frequently required setting options as described in chapter 1 are quickly and directly accessible. To keep the controllability clear and simple, less frequently required setting options are arranged at lower control levels. After entering the level selection, various parameters, information and test menus become accessible. Subject to access rights and programming unit, a different number of levels and parameters becomes accessible. Operating level Standard display Access to the level selection press for approx. 3 seconds Level selection TIME-DATE Date and time selections TIMER PROGRAMS Settings of the time switch programs SYSTEM General system settings DHW Settings for the DHW circuit UNMIXED CIRC Settings for the unmixed heating circuit MIXER Settings for the mixer circuit Most adjustments can also be made from the room stations THETA RS. Special heat source adjustments and those appertaining to the heating system configuration are only accessible from the central control unit THETA 23R. Access to the operating levels For access, press the rotary selector for approx. three seconds. The level selection always starts with the timer program level; all other levels available for selection are selected with the rotary selector. Lightly pressing the rotary selector provides entry to the selected level. Access to the level accept Parameter selection Example: System level LANGUAGE SELECTION Selection of the plain text language SUMMER Settings for the summer shutdown RESET All parameters to their factory settings Fig. 2.1: Level structure with general access rights from the central control unit Example of the access to the general system settings [ 11 ]

12 Substantially more levels and parameters become accessible with the contractor s access rights. Operating level Access to the level selection Level selection Access to the level Parameter selection TIME-DATE Date and time selections Standard display press for approx. 3 seconds TIMER PROGRAMS Settings of the time switch programs HYDRAULIC Settings of the heating system configuration Example: System level SYSTEM General system settings accept LANGUAGE SELECTION Selection of the plain text language DHW Settings for the DHW circuit OPERATING MODE Parameter for the heating circuit selection mode UNMIXED CIRC Settings for the unmixed heating circuit SUMMER Settings for the summer shutdown MIXER Settings for the mixer circuit HEAT GENR Settings for the heat source BOILER CONTROL Settings for the modulating gas fired boiler CASCADE Settings for several heat sources BUS Communication settings Heating contractor parameters PARAMETER 05 Parameter for the system frost protection PARAMETER 09 Parameter for the climate zone PARAMETER 10 Parameter for the building type etc. PARAMETER 23 Parameter for child proofing RELAY TEST Service test functions PARAMETER 24 Parameter for the climate zone ALARM Service information RESET All parameters to their factory settings Fig. 2.2: Level structure with contractor access rights from the central control unit Example of the access to the system settings SENSOR ADJ Service function for sensor fine adjustment [ 12 ]

13 Entering the access code Without the special access rights, the available settings are limited to the parameters normally required by the system user. If required by the system user, the heating contractor can enter an individual code (system level, parameter 23), which completely bars any unauthorised access to the control unit operation (child lock). Operation can then only take place after entering the access code. As standard, the child lock is disabled it will be automatically enabled, if a value other than 0000 is assigned to that parameter. Entering the contractor code enables additional adjustment options at the different parameter levels. Entering the code: Calling up the code entry through simultaneous activation of the day and the DHW key for approx. 5 seconds. Adjust the flashing position in line with the code using the rotary selector and save by lightly pressing the selector. Process further items in the same way. If a faulty figure has been entered, holding down the rotary selector longer will jump back one position. The controller confirms the correct entry of the code. The end-user code is: Resetting the code: The code entry will be automatically reset if, after entering the code, no further activation of the controller follows within the next 10 minutes. Switching the equipment OFF/ON also resets the access code. Important: The contractor code will be notified in a separate letter delivered with the equipment documentation. The contractor code is: [ 13 ]

14 Chapter 3: Programming switching times Timer program level At this level, you can create individual time switch programs for central heating and DHW operation. As part of this process, the factory-set standard programs P1, P2 and P3 (see Tab. 1.2) of the respective heating circuit or DHW circuit will be overwritten with individual switching times and temperature defaults. This is particularly advantageous, if specific heating programs need to be created for periodically recurring occupation patterns with various occupation times (e.g. shift work and similar). A maximum of three heating cycles with one ON and one OFF time each are available to program the switching times for every day of the week. In addition, each heating cycle can be combined with one freely selectable temperature default. Note: Standard programs are not lost by overwriting with individual programs you have created. However, reloading standard programs will wipe individual programs, which will then have to be re-established. For that reason, enter the individual ON and OFF times and the temperature defaults into the tables provided for this purpose (Tab. 9.5). Matching switching times programs to user lifestyle Generally, when entering the level selection the time switch programming will appear first. Every setting value flashing on the display can be corrected with the rotary selector and be accepted by lightly pressing the selector. Pressing the Info key returns you to the previous step, pressing the OM key or inactivity for approx. 2 minutes returns the standard display Entry into level selection: Press the rotary selector for approx. 3 seconds Call up the timer program level Entry into the timer program level Select the heating or DHW circuit Setting range: Unmixed heating circuit (HC), mixer heating circuit (MC)*, DHW circuit (DHW)* * if installed accept Select the switching times program Setting range: P1, P2, P3 accept Select the day and heating cycle Setting sequence: Mo cycle 1 - Mo cycle 2, Tu cycle 1 - Tu cycle 2... Su cycle 2, Note: A third cycle will become available when the second cycle is allocated. accept Heating start (= Start time 1) select Setting range: 00:00 to 23:50 h Note: The start time is also displayed in the upper time bar by means of a flashing segment. save Heating end (= Stop time 1) select Setting range: 00:10 to 24:00 h Note: The stop time is also displayed in the upper time bar by means of a flashing segment. save Cycle temperature (= set room temperature sensor during heating mode) select, setting range for heating circuits (HC, MC): 5 to 30 C, DHW circuit (DHW): 10 C to max. DHW temperature limit Important: When adjusting the required day room temperature or DHW temperature via the key, all associated cycle temperatures will also be adjusted by the amount of the adjustment. save Select the next day or the next heating cycle select as described under point 4 and program correspondingly. Exit from programming the switching times. Return to the standard display [ 14 ] Fig. 3.1: Programming switching times

15 Standard display press for approx. 3 seconds Level SELECTION Block programming The copy function enables a source day to be copied to any target days or to all weekdays (7-day programming). All source day cycles will then be copied over. Individual heating cycles cannot be copied. TIME-DATE TIMER PROGRAMS SYSTEM DHW etc. accept Heating circuit Example: DHW circuit select TIMER PROGR. HC Unmixed heating circuit TIMER PROGR. MC Mixer circuit TIMER PROGR. DHW DHW circuit STANDARD COPY HEATING CIRCUITS accept Program Example: Program 1 select TIMER PROGR. DHW P1 Time program P1 TIMER PROGR. DHW P2 Time program P2 TIMER PROGR. DHW P3 Time program P3 accept Copying function Example: Monday cycle to Tuesday and Wednesday select MONDAY Heating cycle 1 MONDAY Heating cycle 2 MONDAY Heating cycle 3 TUESDAY Heating cycle 1 We - Th - Fr - Sa SUNDAY Heating cycle 3 COPY Day/Week COPY FUNC- TION Day/Week accept Source day Example: Monday select COPY FROM MO MO...SU Target day 1 Example: Tuesday Source day copy to target day 1 select accept COPY MO TO TU Target day 1 or 1-7 (Mo...Su) or 1-5 (Mo...Fr) or 6-7 (Sa...Su) accept Source day Acknowledgement COPY Tuesday like Monday 2 s Target day 2 Example: Wednesday Source day copy to target day 2 select COPY MO TO WE accept Source day Target day 2 Acknowledgement COPY Wednesday like Monday If required, select and copy additional target days. Cancel Back STANDARD DISPLAY Fig. 3.2: Example of the day program copy function [ 15 ]

16 TIME-DATE Standard display press for approx. 3 seconds TIMER PRO- GRAMS SYSTEM Level SELECTION DHW etc. Copying complete 7-day time programs Heating circuit programs cannot be copied to DHW circuits, as these have different cycle temperatures. A DHW circuit cannot be selected anymore as target circuit, if a heating circuit has been selected as source circuit. The DHW circuit as source circuit is also the target circuit. In that case, only DHW circuit programs are copied amongst themselves. accept Copying function select TIMER PROGR. HC Unmixed heating circuit TIMER PROGR. MC Mixer circuit TIMER PROGR. DHW DHW circuit STANDARD COPY HEATING CIR- CUITS accept Source circuit Example: Unmixed heating circuit select SOURCE HC SOURCE MC SOURCE DHW accept Time program Source circuit Example: Time program P1 select SOURCE HC P1 SOURCE HC P2 SOURCE HC P3 accept Target circuit Example: Mixer circuit select TARGET HC TARGET MC accept Time program Target circuit Example: Program P2 select TARGET MC P1 TARGET MC P2 TARGET MC P3 Copy accept Acknowledgement COPY OK Program P1 (unmixed heating circuit) = program P2 (mixer circuit) If required, copy additional heating circuits Cancel Back STANDARD DISPLAY Fig. 3.3: Example of the heating circuit program copy function [ 16 ]

17 Reloading standard programs By reloading standard programs, the switching times of individual or all time switch programs can be reset to their factory settings. The individual setting values will then be lost and may possibly need to be reprogrammed in accordance with Fig Standard display press for approx. 3 seconds Level SELECTION TIME-DATE TIMER PRO- GRAMS SYSTEM DHW etc. accept Standard select TIMER PROGR. HC Unmixed heating circuit TIMER PROGR. MC Mixer circuit TIMER PROGR. DHW DHW circuit STANDARD COPY HEATING CIR- CUITS accept Heating circuit Example: Mixer heating circuit select DIR. HEAT.CIRC. HC P1 MIXER MC P1 DHW DHW P1 ALL accept Target program Example: Program P3 select RESET MC accept P1 RESET MC P2 RESET MC press for approx. 5 seconds, until acknowledgement -OK- is displayed P3 Reset RESET MC OK Cancel Back STANDARD DISPLAY Fig. 3.4: Example of a reset of a heating circuit program to its factory settings Tab. 3.1 summarises the parameters and access rights of the time switch level. [ 17 ]

18 [ 18 ] Tab. 3.1: Timer program level parameters

19 Chapter 4: Setting the date and time Date and time are factory-set and require no updating in the control unit. Should these details not match the details of the installation location, the current time and date can be adjusted manually at the Time-date level (Fig. 4.1). An internally preset calendar ensures the automatic time changeover at the annual summer/winter time changeover dates. Your heating contractor can switch the automatic time change OFF, if required. The current day (Mo to Su) will be automatically determined from the calendar dates and requires no adjustment. Generally, when entering the level selection, the time switch level will appear first. Turning the rotary selector one position anti-clockwise leads to the Time-Date level. Every setting value flashing on the display can be corrected with the rotary selector and be accepted by lightly pressing the selector. Pressing the Info key returns you to the previous step, pressing the OM key or inactivity for approx. 2 minutes returns the standard display. Tab. 4.1 summarises the parameters and access rights of the TIME-DATE level. select select TIME - DATE TIME YEAR accept accept accept 18: DAY-MONTH FR Time adjust Standard display press for approx. 3 seconds TIMER PROGRAMS Set the year Set the date (day) SYSTEM etc. select accept DAY-MONTH FR Set the date (month) select accept select CHANGEOVER SU-WI AUTO Automatic time changeover (contractors only) Automatic: last Sunday in October and in March Manual: no changeover - winter time Fig. 4.1: Plan for setting the time and date [ 19 ]

20 [ 20 ] Tab. 4.1: Time-date level parameters

21 Chapter 5: Adjusting system parameters This chapter provides an overview of all available system parameters and setting options. Tables 5.1 to 5.11 contain all parameters, sorted according to level (see chapt. 2), their access rights, setting options and their explanations. Parameters that are accessible without special access rights are carefully explained. In addition, settings that are important for the ROTEX heating system are detailed separately. Boiler flow temperature ( C) Please note: Generally speaking, the THETA control system offers even more setting options, the access to which is blocked at the factory to provide a simpler operation and greater clarity. Check with your local ROTEX expert, if your specific application conditions cannot be adequately covered by the setting options described in this manual. Heating curves The heating curves match the heating output to the building conditions, subject to the relevant outside temperature. Generally, the heating curve describes the relationship between any flow temperature change and changes in the the outside temperature. For large area heating surfaces, for example underfloor heating systems, the heating curve is less steep than with smaller heating surfaces (e.g. radiators). The heating curves apply within the limits for minimum and maximum temperature that have been selected for the respective heating circuit (Unmixed heating circuit level, mixer circuit level). Outside these limits, the flow temperature is regulated exclusively according to the selected limits in each case. With 50 % switching differential. Deviations may occur between the actual room temperature in the living area and the selected set room temperature, which may be compensated with the installation of a room controller (THETA RS or THETA RFF - see chapt. 6) Fig. 5.1: Heating curves Important: At the factory, the control unit is set up so that the heating curve will be adjusted automatically when room controllers are used. It is therefore very important that room controllers are installed in a suitable reference room and to ensure that it is not subject to the direct influence of external heat sources (direct solar or lamp radiation, draught from tilted windows, etc.). Should the automatic heating curve adaptation not be required, it can be disabled at the relevant heating circuit level subject to contractor access rights. Information regarding the adjustment phase: Use the most commonly occupied room relative to the associated heating circuit to monitor the room temperature. Only make corrections in small steps after one to two days. Subject to radiators being correctly sized, thermostatic radiator valves are Outside temperature only designed to compensate for the effects of external heat and should therefore always be fully opened. Never use additional external heat sources, such as open fireplaces, stoves etc., during the adjustment phase. Also prevent excessive airing/ventilation during the observation period to prevent external cold air from disturbing the adjustment process. Generally, the observation period covers the heating mode phases. Subject to the heating curve being correctly adjusted, the room temperature will be maintained at an almost constant level corresponding to the selected day room temperature, independent of fluctuations in the outside temperature. Guidelines for the adjustment: Underfloor heating: Radiators, system 70: [ 21 ]

22 Adjusting the heating curve Level select Heating circuit select Heating curve change Entry into level selection: Press the rotary selector for approx. 3 seconds Setting range: switching times, system, DHW*, unmixed circuit, mixer*, timedatedc = unmixed heating circuit MC= mixer circuit * if installed Accept the heating circuit Set the output value or, if the room temperature is too high: reduce the value Room temperature too cold: increase the value Accept the setting Note: Only make corrections in small steps after one to two days. Fully open any thermostatic radiator valves. Cancel (return to the standard display) Fig. 5.2: Adjusting the heating curves As with Fig. 5.2, at the system level, under a) LANGUAGE SELECTION a language may be selected (setting options D, GB, F, I) b) SUMMER the outside temperature, at which the control unit automatically changes over to summer mode, can be defined c) RESET all parameters can be returned to their factory settings. At the DHW level under a) NIGHT, the DHW temperature for the setback period can be selected (setting range: 10 C DHW day) b) LEGION.PROT the day, when the DHW is heated to a high temperature to provide protection against legionnaires bacteria (setting range: Off, Mo Su, every day). Language Generally, four languages are stored for the plain text display, namely German, English, French and Italian. The setting of the interface language is made at the system level with parameter LANGUAGE SELECTION (see Fig. 5.2 in the heating curve section). Automatic summer shutdown This function is only effective in the automatic mode. This cancels and restarts the heating operation subject to outside temperature (pumps OFF, mixer closed). The setting of the shutdown outside temperature is made at the system level with parameter SUMMER (see Fig. 5.2 in the heating curve section). The parasol in the standard display indicates an active summer shutdown. A shutdown will be initiated when the average outside temperature exceeds the selected value. A shutdown will be cancelled when the average outside temperature drops 1K below the selected value (Fig. 5.3). In addition, the respective heating circuit will be shutdown, when the calculated set flow temperature enters the range of the current set room temperature. The heating circuit will be shutdown when the calculated set flow temperature is less than 2 K higher than the current set room temperature. It is started again when the calculated set flow temperature is more than 4 K higher than the current set room temperature. Note: The heating curves are the only parameters in the heating circuit level without particular access rights in other words, they are immediately accessible after entering the parameter level. When entering the system with contractor access rights, the heating curve parameters are respectively found at the end of the menu. Quick access is achieved by turning the rotary selector one position anti-clockwise after entering the heating circuit level. Current outside temperature Summer shutdown Selected value Adjusted outside temperature Fig. 5.3: Effect of the summer shutdown [ 22 ]

23 Resetting system parameters to their factory settings The RESET parameter at the system level offers the opportunity of returning any incorrect adjustment at the parameter levels to their factory settings. Important: Only carry out a reset of all individually entered values if these should be replaced by the factory settings. All parameters (except the time switch programs) which can be accessed and modified with the currently valid access rights will be returned to their factory settings. When the reset display (RESET) flashes, the flashing reset standby (SET) will be indicated after lightly pressing the rotary selector. The reset will be implemented when the rotary selector is held down for approx. 5 seconds. The control unit will implement a restart (as if the system was switched on) after the parameters have been reset. DHW economy temperature A DHW cylinder temperature can be defaulted, which will be maintained during the setback operating phases, in order to reduce standby losses from the DHW cylinder to a minimum and to maintain a minimum DHW convenience. The setting of the DHW economy temperature is made at the DHW level with parameter NIGHT (see Fig. 5.2 in the heating curve section). Protection against legionnaire s bacteria The cylinder can be pasteurised every day or every week to prevent bacterial growth inside the cylinder. For this, the cylinder is heated daily or on the selected day to the pasteurisation temperature. The setting of the pasteurisation day is made at the DHW level with parameter LEGION.PROT (see Fig. 5.2 in the heating curve section). The factory settings provide for the DHW cylinder to be heated at 02:00 h, if the DHW temperature at that time is below 65 C. The heating time and pasteurisation temperature can be modified with the contractor access rights. Operating mode To ensure as easy an operation as possible for the majority of applications, a common operation for all heating systems is provided as standard. The currently active time switch program is depicted in automatic mode in the standard display by a clock symbol and the Roman numeral for the currently selected program. For the rather rare case where each heating circuit must be operated separately (for example in case of a separate setting for a tenant and the home owners), this operating mode must be enabled by the heating contractor via parameter 03 at the system level. This would, for example, allow the mixer circuit to be operated with the time switch program P3, whilst the DHW circuit operates in accordance with the time switch program P1. In the operating mode for a separate heating circuit selection, the clock symbol is hidden in the display of the central control unit. You can scan the currently active time switch program with the Info key. Screed function The screed function is designed exclusively for the specified drying of newly laid screeds for underfloor heating systems. This program is based on the recommendation of the Federal Association of area heating engineers [Germany] for heating in readiness for the application of floor coverings [heating according to specific temperature profiles). It is a special function, and will not be interrupted by any other operating mode (not even manual mode or emissions test). The screed function can be enabled by the heating contractor for mixer circuits and, under certain conditions, also for unmixed heating circuits (see comments in Tab. 5.4). The screed function is enabled at the respective heating circuit level with parameter 16 (see Fig. 5.2 in the heating curve section). After the screed function has been enabled, all weather-compensated control functions of that heating circuit will be switched OFF. The respective heating circuit operates independently of the operating mode (switching times) with a constant temperature. A started screed function can be disabled at any time (parameter setting screed function = OFF). After the screed function has terminated, the heating circuit will operate again in accordance with the selected operating mode. The screed function comprises of two steps, which can be enabled individually or in sequence: [ 23 ]

24 Step 1: Function heating acc. to DIN EN 1264 part 4 (set value: 1 for standard underfloor heating systems, 4 for ROTEX System 70) Selected maximum temperature 40 C - At the starting day and the following three days, constantly at 25 C (38 C for System 70). - Then for a further four days with the selected maximum flow temperature, however limited to 55 C (70 C for System 70). Step 2: Heating ready for covering (set value: 2 for standard underfloor heating systems, 5 for ROTEX System 70) The heating ready for covering follows a set temperature profile. Starting with 25 C (38 C for System 70) on the first day, the demand value rises by 5 K for each following day, until the maximum temperature for that heating circuit has been reached. That temperature will then be held for a further 11 days. The set value will then be reduced in steps of the same magnitude, until the low-end point of 25 C (38 C for System 70) has been reached again. Example: Selected heating circuit maximum temperature = 40 C Day 1: constant heating with 25 C Day 2: constant heating with 30 C Day 3: constant heating with 35 C Day 4: constant heating with 40 C Day 5-15:constant heating with the maximum flow temperature Day 16: reduced heating with 35 C Day 17: reduced heating with 30 C Day 18: reduced heating with 25 C On the starting day, the system heats at 25 C until midnight (38 C for System 70). From 00:00 h of the following day, day 1 begins the heating ready for covering. Prior to enabling the screed function ensure that the respective screed has been dried long enough: Cement screed: 21 days Calcium sulphate (anhydride) screed: 7 days Fig. 5.4: Time sequence of the screed function during function heating Step 1+2: Function heating with subsequent heating ready for covering (set value: 3 for standard underfloor heating systems, 6 for ROTEX System 70) Both steps are processed in sequence: Note: The maximum profile temperature is determined by the respective maximum flow temperature. Selected maximum temperature 40 C Fig. 5.5: Time sequence of the screed function during heating ready for covering Selected maximum temperature 40 C Fig. 5.6: Time sequence of the screed function during function heating and heating ready for covering In case of a short power failure or a new start, any previously active screed function will continue from the point of interruption. After the screed function has been completed, the parameter will be automatically set to OFF. If required, a screed function can be enabled again. When a screed function is active, after pressing the Info key, the status display for the respective heating circuit will show SCREED instead of the current operating mode. [ 24 ]

25 Hydraulic level Tab. 5.1: Hydraulic level parameters [ 25 ]

26 System level [ 26 ] Tab. 5.2: System level parameters

27 DHW [ 27 ] Tab. 5.3: DHW level parameters

28 Unmixed heating circuit level [ 28 ] Tab. 5.4: Unmixed heating circuit level parameters

29 Mixer circuit level Tab. 5.5: Mixer circuit level parameters [ 29 ]

30 Heat source level [ 30 ] Tab. 5.6: Heat source level parameters

31 Burner control unit level Tab. 5.7: Information parameters for the burner control unit level [ 31 ]

32 Burner control unit level [ 32 ] Tab. 5.8: Burner control unit level parameters

33 Cascade level [ 33 ] Tab. 5.9: Parameters of the cascade level (only accessible if several heat sources are joined and linked via a BUS cable)

34 BUS system [ 34 ] Tab. 5.10: BUS level parameters (see chapt. 6)

35 Sensor adjustment level [ 35 ] Tab. 5.11: Sensor adjustment level parameters (see chapt. 9)

36 Chapter 6: System extension with room controllers and several central control units BUS system The THETA control units can be linked up via a BUS (Fig. 6.1). This enables the control of additional heating or DHW circuits by adding up to four central control units (heating circuit extension modules HEM1), the connection of THETA RS and THETA RFF room stations to the central control units and to allocate heating circuits, the utilisation of variable inputs and outputs for additional tasks, up to five heat sources each with an integral central control unit to be cascaded. A unique address must be allocated to each individual equipment in the THETA BUS system. This address is selected through the BUS ADDRESS parameter at the BUS level. The allocation is made in accordance with Tab Important: One controller with the BUS address 10 must be the management controller in the BUS array. Ensure that each BUS address is only allocated once. Addresses that occur more than once lead to a faulty BUS operation. Connect all equipment in parallel via the BUS connections BUS A and BUS B. Interchanging the connections will lead to faults. Use only screened cable as BUS. For the recommended implementation, see chapter 8. Control functions via the BUS DHW mode (cylinder priority operation) Every central control unit can manage the cylinder primary function. During cylinder heating in priority mode, all other heating circuits and DHW primary functions in the BUS system will be blocked. If the cylinder is heated in parallel mode, all heating circuits in the system can remain enabled and further DHW primary functions can be enabled with the selected parallel operation (DHW level, Par. 07). Fig. 6.1: Maximum possible extension of the BUS system Heating circuit demand Every heating circuit demand within the BUS system is processed by the managing controller (address 10). This accepts the highest demand and transfers that to the heat source as set value. A manual mode selection with manual temperature default will also be interpreted as a demand. Time synchronisation The time is distributed by the managing controller (address 10) to the entire system. This time becomes the system time, to which all time switch programs relate. Room temperature transfer The room stations and room temperature sensors regularly transfer their current room temperature to their allocated heating circuits. Fault messages / operating displays Fault messages and operating displays are transferred by each central control unit to the allocated room stations, where they are displayed. Operation of room stations THETA RS A room station THETA RS can be connected to every heating circuit (unmixed heating circuit, mixer circuit) of a central control unit. This enables not only the capturing of the room temperature, but also the remote control (e.g. from the living room) of the central control unit or all central control units linked in a BUS system. Adjustments can be made for all existing heating circuits, as long as the room station is allocated at the BUS level as caretaker. Only the allocated heating circuit can be influenced, if user rights tenant have been allocated to a room station. The BUS address of the room controller determines which heating circuit the room temperature sensor (room influence) should affect. When a THETA-RS is first connected to the BUS system, the selection of the address of the heating system which is to be allocated to the room station is expected. The display shows BUS ADDRESS. This is selected with the rotary selector in accordance with Tab After the entry has been made, the following response will be given: BUS, the allocated heating circuit (HC, MC) and the central control unit (CC) to which the room controller has been allocated will be displayed. [ 36 ]

37 Please note: The same BUS address may not be allocated more than once and would inevitably lead to errors in the data transmission and subsequently to faulty control patters in your heating system. Changing BUS addresses If a BUS address is to be modified later, proceed as follows: 1 Disconnect the remote control station from the BUS cable (unplug at the lower end from the plug-in connector). 2 Plug the remote control station back in, whilst holding the rotary selector down, until the address setting appears. 3 Select and confirm the new BUS address. Operation of room controller set RFF A room controller set THETA RFF can be connected to every heating circuit (unmixed heating circuit, mixer circuit) of a central control unit. With this, the room temperature can be captured, the set room temperature matched and the operating mode for one heating circuit can be modified by remote control. These settings only apply to the allocated heating circuit. The BUS address of the room controller determines, which heating circuit the room temperature sensor and the operating mode change should affect. For more detailed information, see the separate instructions supplied with the room controller set. Cascading boilers in the BUS link The control system can link and cascade several boilers in a single heating system. For a cascade it is irrelevant, what kind of heat source is used. For example, a ROTEX A1 oil fired condensing boiler can be combined with an ESU. In addition, heating circuit extension modules can be added, subject to not more than five central control units being combined in a single control system. Cascades are automatically recognised. For a cascade operation, an additional cascade level for controlling the associated parameters is shown in the display of the central control unit with the BUS address 10. Tab. 5.9 describes the available parameters and setting ranges, as well as their operation. Control characteristics The heat source added last controls the defaulted set value. All other heat sources operate with the defaulted maximum temperature (base load). One boiler stage will be switched OFF when the controlling stage has removed the demand from the heat source, and the boiler water temperature rises in excess of a defaulted set value, plus the selected switching differential. Each heat source will indicate the current demand value to be achieved as set value. Any heat source that is not available in the system (fault, external blocking or outside temperature block) will be skipped within the stage control, and the next available heat source will be activated. Operation with burner control units The switching sequence of the condensing boilers connected to the central control unit will always correspond to the selected address of the heat source BUS interface (RS485 interface), and cannot be modified by altering parameters. The management for regulating the burner control unit only transfers the number of the stages to be started to the cascade management. Consequently, the boiler water temperature of the control unit with the lowest address in the system will be determined and called upon to be achieved. The capturing of the burner runtime only affects the burner control unit with the lowest address. Characteristics with special functions Manual mode: The heating circuits of the corresponding controller, where manual mode has been enabled, function in MANUAL mode. The selected demand value will be transferred to the energy management of the cascade controller and achieved via the available boiler stages. Emissions test: This function acts as described under Emissions test (chapt. 10) with the following extension: The effect on the heating circuit will be extended to every heating circuit in the system. The heat sources (burners) will only be enabled on those boilers, where emissions testing has been activated. LIMITER: This function acts as described under Limiter test (chapt. 9) with the following extension: All heating circuits will be blocked as soon as a LIMITER TEST function has been recognised within the BUS link. Emergency mode: The cascade control takes place in the central control unit with the BUS address 10. If this controller drops out through a fault, the remaining stages will operate in emergency mode. For this, all heat sources will operate with the same set boiler value (parallel operation). The cascade control will be automatically activated when the cascade manager restarts. [ 37 ]

38 Chapter 7: Accessories and installation information The ROTEX heat sources are delivered fully wired. The flow and return temperature sensors, the DHW cylinder temperature sensor and, for oil fired and gas fired condensing boilers, the flue gas sensor are part of the standard delivery; all are fitted to the boiler control panel and are terminated with PCB plugs. The outside temperature sensor is supplied in the accessories pack. Fit this at a height representing approx. one third of the building height (minimum distance from the ground: 2 m) on the coldest side of the building (north or north-eastern side). Never mount the sensor near external heat sources, otherwise the temperature it captures could be substantially falsified (chimneys, hot air from air ducts, direct sunlight etc.). The cable outlet must always point downwards to prevent the ingress of moisture. For the electrical installation, a 2-core cable with a minimum cross-section of 1 mm 2 is recommended. Connect the lead to both screw terminals inside the sensor enclosure; the cores are not pole-sensitive. Connect the on-site sensor lead via a distribution box to the outside sensor cable pre-assembled in the boiler control panel. Where a mixer circuit is to be connected, the mixer circuit contact sensor TMKF (part no ) is required as an accessory. This can be simply terminated at the plug provided in the boiler control panel - see the heat source installation instructions. For remote control and room influence hook-up of a heating circuit, the room station THETA RS (part no ) or a room controller set THETA RFF (part no ) can be connected (see chap. 6). Connect room controllers with correct pole orientation to the BUS A and BUS B terminals of the corresponding plug in the heat source control panel. If more than one mixer circuit or an additional cylinder primary circuit (e.g. for swimming pool heating) should be connected to a heat source, or if an additional control function is to be achieved, they cannot be achieved directly using the central control unit (e.g. demand contact for a fan heater bank), the heating circuit extension module THETA HEM1 (part no ) represents a suitable accessory. The HEM1 is supplied in a suitable wall mounting enclosure. It is also connected to the central control unit of the heat source via the 2-wire BUS. Up to four HEM1 can be connected to a single heat source. Subject to the control task to be implemented, order the necessary mixer contact sensor TMKF and cylinder temperature sensor TSF (part no ) separately. Warning: Electric shocks can cause severe burns and life-threatening injuries. Incorrect attempts to plug in live equipment can lead to the destruction of the controller and to dangerous electrical shocks. Isolate the heating system from the power supply prior to carrying out any installation and maintenance work on the THETA control system. Information regarding the EMCcompliant installation Generally route power cables and sensor or BUS cables/leads separately. Maintain a minimum clearance between such leads/cables of 2 cm. Cables/leads may be crossed over. For control units with their own mains power supply ensure, that power cables and sensor or BUS cables/leads are routed separately. When using cable ducts provide these with separating webs. When installing control or remote control units, maintain a minimum distance of 40 cm towards other electrical equipment that emit electro-magnetic interference, such as contactors, motors, transformers, dimmer switches, microwave ovens, TV sets, loudspeaker boxes, computers, wireless telephones etc. BUS cable Fig. 7.1: Maintaining minimum distances between data and power lines [ 38 ]

39 MCB 16 A Boiler room main isolator Connect the boiler room lights and power sockets only to a separate power circuit Screen 2-core BUS cable Distribution terminal Junction box Room equipment Fig. 7.4: Earthing for star-shaped BUS networks Heat source Fig. 7.2: Separation of the heating system power supply from that of other electrical consumers In circumstances where interference is likely to occur (close proximity to radio masts, powerful electric motors and similar), we recommend the use of screened cables. For the recommended implementation, see chapter 8. Specification Earth the cable screen on one end only, e.g. at the heat source earth terminal. Multiple earthing of a screened cable is not permissible (leakage pickup). Never provide a duplex earth for star-shaped BUS networks. Provide the earth connection on one end in the star point. Never install the outside temperature sensor near transmission or receiving equipment (on garage walls near the receiver of garage door openers, amateur radio aerials, alarm transmitter systems or in the immediate vicinity of major transmitter systems etc.). Never earth at this point! Boiler user interface, central equipment Fig. 7.3: Earthing for screened cables only on one side [ 39 ]

40 Fig. 7.5: Installing/removing the THETA 23R central control unit Recommended cable cross-sections and maximum permissible cable lengths All mains power lines (power supply, burner, pumps, servomotors): 1.5 mm 2. Maximum permissible length: No limitation within the range of the domestic installation. All cables/leads conducting a low voltage (sensors, internal switches for burner blocking contact, modem cables, analog signal lines etc.): 0.5 mm 2. Maximum permissible length: 100 m (twin cable). Avoid longer cables to prevent the irradiation of interference. BUS cables: 0.6 mm Recommended implementation: J-Y(St)Y 2 x 0.6 Maximum permissible length: 50 m (twin cable). Avoid longer cables to prevent the irradiation of interference. Installation information for central control units The central control units THETA 23R are designed for integration. They are mounted from the front into the cut-out of the respective control panel or the wall mounting enclosure. Route the electrical connections via the PCB to the intended plugin sockets in the control panel or the terminal boxes of the wall mounting enclosure. The central control units are secured inside the enclosures with both lateral quick-acting clamps (1). When replacing the equipment, release the screws by turning them anticlockwise (Fig. 7.5). This enables the controller to be easily removed from the enclosure it may be necessary to lever the THETA carefully out with a flat ended screwdriver to release it from the plug-in sockets. Install in reverse order. Please note: Generally speaking, terminals in the red areas operate with mains power. Any terminals outside this area operate with low voltage and must never come into contact with the mains power. Nonobservation will inevitably lead to the destruction of the equipment and will void the warranty. [ 40 ]

41 Terminal allocation Plug Pin Allocation Power supply Mains 1 Earth conductor (equipment earth) 2 Earth conductor 3 N - mains 230 V~ (neutral) 4 L - mains 230 V~ (phase) Pump P K 1 Earth conductor 2 N - neutral 3 L - phase DHW circulation pump P Z 1 Earth conductor 2 N - neutral 3 L - phase Three-way diverter valve (3W-UV) or cylinder primary pump P 1) L 1 Earth conductor 2 Neutral 3 L switched phase 4 L constant phase (3W-UV) Burner 1 Earth conductor Earth conductor N/A 2 N - neutral N - neutral N/A 3 L1 switched phase L constant phase N/A (burner ON) (power supply for the burner control unit) 4 Burner fault indicator N/A N/A 5 BZ1 burner start counter N/A N/A 6 Burner reset N/A N/A Mixer 1 Pump earth 2 N - pump neutral 3 L - pump phase 4 Mixer earth 5 N - mixer neutral 6 L1 mixer close 7 L2 mixer open Terminals with low voltage Communication with the burner control unit COM 1 N/A Earth N/A 2 N/A Internal BUS B N/A 3 N/A Internal BUS A N/A 12-PIN sensor plug 1 System BUS A 2 System BUS B 3, 4 Burner blocking contact 5, 6 Modem switched input resistor (see Tab par. 9) 7, 8 Mixer circuit flow sensor 9, 10 Outside temperature sensor 11, 12 DHW (cylinder) temperature sensor Sensor plug (internal) 1 Provided for the PWM signal (earth) 2 Provided for the PWM signal (+) 3, 4 Flue gas temperature sensor 5, 6 Return temperature sensor 7, 8 Flow temperature sensor Tab. 7.1: Connection plug allocation for the boiler control panel 1) A separate connecting cable is required for the cylinder primary pump, which is available as accessory part no. E Fig. 7.5: Terminal allocation in the boiler control panel [ 41 ]

42 Installation information for heating circuit extension module HEM1 with wall mounting enclosure Fig. 7.7: HEM1 with open terminal boxes Fig. 7.6: Heating circuit extension module HEM1 1. Central control unit THETA 23R 2. L.h. terminal box (LV terminal strips X5 and X6) 3. R.h. terminal box (power terminals terminal strips X7 to X10) 4. Locking screws for the terminal box cover 5. Mains electrical isolator In the following steps, the HEM1 will be fitted and connected: a) Remove the central control unit THETA 23R in accordance with the Installation information for the central control unit b) Break out the cable entries subject to number and size in line with the position of the cable duct at the knock-outs provided at the top or bottom. Please note: If no cable duct is used, apply an on-site strain relief to the cable. c) Position the locking screws (4) horizontally, and pull the terminal box cover off to the side. d) Fit the wall mounting enclosure securely with the screws and rawl plugs provided on a level surface. e) Implement the electrical wiring in accordance with the system version and terminal allocation diagram (see Fig. 7.8 and 7.9). Please note: The terminals in the terminal strips X5 and X6 in the l.h. terminal box carry LV power and must never come into contact with mains power. Non-observation will inevitably lead to the destruction of the equipment and will void the warranty. The terminals of the terminal strips X7 to X10 in the r.h. terminal box carry mains power, subject to equipment version and operating state. When making connections, push the clamping lever of the screwless terminals down before feeding the conductor into the terminal. f) Push the lateral terminal box covers down and lock them into place. g) Re-insert the THETA 23R central control unit and tighten the quick-acting clamps (Fig. 7.5). h) The equipment can be switched ON at the main ON/OFF switch after all other components of the THETA controller system have been correctly installed and connected. [ 42 ]

43 Terminal strip Terminal THETA plug-in Allocation base terminal X 7 1 X3/2 T1 - Control connection (output) 2 - L - Mains 230 V~ (phase) 3 - bridged with terminal 2 4 X3/6, X4/12, X2/2 L1 bridged with terminal 5 5 X3/6, X4/12, X2/2 L1 - Mains 230 V~ (phase, switched via the mains electrical isolator) 6 - L - Mains 230 V~ (phase to the mains electrical isolator) 7 X2/20 B4 - Hours run counter 8 X2/19 not available 9 X4/18 not available 10 X4/17 not available 11 X4/16 not available X 8 1 X3/1 T2 - Control connection (input) 2 X3/3 DKP - Unmixed heating circuit pump 3 X3/5 SLP - Cylinder primary pump 4 X3/7 Mixer servomotor (OPEN) 5 X3/8 Mixer servomotor (CLOSE) 6 X3/9 MKP - Mixer heating circuit pump 7 X4/10 LVA1 - Variable output 1 (phase) 8 X4/11 LVA2 - Variable output 2 (phase) 9 X4/13 not available 10 X4/14 not available 11 X4/15 not available X 9 all X2/21 N - Mains 230 V~ (neutral) X 10 all Earth conductor - Tab. 7.2: Terminal allocations for the r.h. terminal box power supply Terminal allocation Connection allocation Fig. 7.8: R.h. terminal box power supply [ 43 ]

44 Terminal strip Terminal THETA plug-in Allocation base terminal X 5 1 X1/25 System BUS B 2 X1/23 GND (THETA common earth contact) 3 X1/23 GND (THETA common earth contact) 4 X1/23 GND (THETA common earth contact) 5 X1/23 GND (THETA common earth contact) 6 X1/23 GND (THETA common earth contact) 7 X1/23 GND (THETA common earth contact) 8 X1/23 GND (THETA common earth contact) 9 X1/23 GND (THETA common earth contact) 10 X1/23 GND (THETA common earth contact) 11 X1/23 GND (THETA common earth contact) 12 X1/23 GND (THETA common earth contact) X 6 1 X1/24 System BUS A 2 X1/26 Outside temperature sensor 3 X1/27 Unmixed circuit flow temperature sensor 4 X1/28 DHW (cylinder) temperature sensor 5 X1/29 Mixer circuit flow sensor 6 X1/30 Variable input 1 - not enabled 7 X1/31 Variable input 2 - modem 8 X1/32 Variable input 3 - burner blocking contact 9 X1/33 Not available 10 X1/34 Not available 11 X1/35 Unmixed circuit return temperature sensor 12 X1/36 Not available 2-pole terminal A X1/37 COM A internal BUS - not available B X1/38 COM B internal BUS - not available Tab. 7.3: Terminal allocations for the terminal strip inside the l.h. terminal box - sensor and BUS connections Fig. 7.9: L.h. terminal box - sensor and BUS connections Please note: The data connection to other standard THETA devices or room controllers must be connected at the terminal strips X5 and X6. The separate screw terminal (2-pole) is provided for internal communication and is not used for ROTEX system applications. [ 44 ]

45 Room station installation information THETA RS Place of installation: Install the equipment at a height of approx to 1.50 m in a neutral location, i.e. a position which is representative for all rooms. An internal wall of the coolest room occupied during the day would be appropriate for this purpose. Fit the remote control station on its own on a wall to ensure adequate air circulation. Note: The following are unsuitable locations: - places with direct solar irradiation (consider the position of the sun in winter). - Close to equipment which generates heat, i.e. TV sets, refrigerators, wall lamps, radiators etc. - On walls behind which heating pipes, hot water pipes or live chimneys are located - Uninsulated external walls - In corners or wall recesses, shelves or behind curtains (insufficient air circulation) - Near doors to unheated rooms (external cold influence) Disable any room controller in the installation room to prevent any mutual influence between the controllers. Also, fully open all thermostatic radiator valves or underfloor heating system valves. Note: Provide a plaster box to ensure the correct cable entry. Seal the cable inlets within the plaster box to prevent any influence of cold through a chimney effect in the installation pipes. Ensure the BUS cable is connected with the correct pole orientation. Electrical connection Connect the 2-core BUS cable to terminals A and B of the 2-pole terminal strip on the mounting plate. The connections are not interchangeable, and must therefore be installed in accordance with the markings A/B in the plinth. Interchanging these cores leads to a loss of display. After the electrical connection has been correctly made, the room station is hooked at a right angle into the base and pivoted down in accordance with Fig. 7.11, until it audibly clicks into place. Fig. 7.10: Lift the programming unit from the wall base; for this, press down the locking tabs Installation: After releasing the top (Fig. 7.10), the wall mounting base can be removed and can be fitted at the place of installation with the rawl plugs and screws supplied. Insert the BUS cable through the lower knockout. Fig. 7.11: Insert the programming unit into the wall base [ 45 ]

46 Chapter 8: Specification Power supply voltage: 230V +6%/ -10% Rated frequency: Hz Power consumption: max. 5.8 VA Mains fuse: max. 6.3 A (slow) Output relay contact rating: max. 2 (2) A BUS interface: T2B for the connection of external equipment (additional central control units, room station, modem or gateway) Power supply via the T2B BUS: 12V/ 150 ma Ambient temperature: C Storage temperature: C Protection level: IP 30 Safety class to EN 60730: II Safety class to EN 60529: III Software class A Interference protection: EN (1993) Resistance to jamming: EN (1995) EC conformity: 89/336/EEC Electro-magnetic Compatibility 73/23/EEC EC Low Voltage Directive VDE symbol approval: Tab. 8.1: General specification Tab. 8.2: Recommended installation lines Certificate no file reference /A403J6 Enclosure dimensions central control unit: 144 x 96 x 75 mm (W x H x D) Enclosure dimensions room station: 90 x 138 x 35 mm (W x H x D) Enclosure dimensions heating circuit extension module: 282 x 96 x 90 mm (W x H x D) Enclosure material: Connection technology: ABS with antistatic agent Plug-in screw terminals Mains power cables (power supply, burner, pumps, servomotors): Cross-section: 1.5 mm 2 Maximum permissible length: No limitation within the range of the domestic installation. Low voltage cables/leads (sensors, external switches for burner blocking contact, modem cables, analog signal lines etc.) Cross-section: 0.5 mm 2 Maximum permissible length: BUS cables Cross-section: 0.6 mm 2 Maximum permissible length: Recommended implementation: J-Y(St)Y 2 x m (twin cable); avoid longer connecting cables to prevent the risk of interference. 50 m (twin cable; longest run between a central control unit and equipment to be supplied); avoid longer connecting cables to prevent the risk of interference. [ 46 ]

47 Sensor type Sensor temperature in C Sensor resistance in Ohm PTC (KTY) Outside temp All water temp. Pt-1000 Flue gas temp Tab. 8.3: Resistance values for temperature sensors Sensor resistance in Ω PTC sensor (outside temp. and water temp.) PT 1000 sensor (flue gas sensor) Fig. 8.1: Resistance curves of the THETA temperature sensors Temperature in C [ 47 ]