INSTRUCTIONS. For model u1.xx, Rev. 1, 2-Jun-14 MULTI-FUNCTION CONTROLLER FOR PELLET BOILERS WITH AUTOMATIC BOILER OUTPUT CONTROL FOR OPERATING:

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1 BIOMAX 741G INSTALLATION AND OPERATING INSTRUCTIONS For model u1.xx, Rev. 1, 2-Jun-14 MULTI-FUNCTION CONTROLLER FOR PELLET BOILERS WITH AUTOMATIC BOILER OUTPUT CONTROL FOR OPERATING: DIRECT CIRCULATION PUMP DHW LOADING PUMP DHW CIRCULATION PUMP 2 MIXING CIRCUITS Pb COMPIT, ul.wielkoborska 77a, Częstochowa, tel./fax (34)

2 Table of Contents 1 CONTROLLER OVERVIEW Functions BIOMAX 741G Controller Operation Diagram Controller Operation and Handling Control panel Key description Initial pellet feeding Ignition Setting the set boiler temperature SUMMER/WINTER mode Setting the temperature values for mixers 1 and Setting the set DHW temperature MENU BOILER SETTINGS MIXERS 1 AND 2 SETTINGS DHW SETTINGS TIME CLOCK SETTINGS SERVICE TEST Mulfunctions Warnings Installation Technical data Operating conditions Operating unit installation Control panel operating unit Electrical supply and 230V mains Grounding Sensor installation Sensor characteristics Connecting the room thermostat Connecting the STB safety temperature limiter Service information Detailed description of controller operation modes Pump activation temperature CH pump operation DHW tank loading DHW tank disinfection Weather-compensated mixer operation Mixer operation Season-end rundown Digital NANO operating unit DECLARATION OF CONFORMITY CONTROLLER OVERVIEW BIOMAX 741G is a multi-function controller for controlling boiler rooms with pelletfired boilers. It is a modular unit comprising a control panel and an operating unit interconnected with a flat multi-wire cable. The operating unit has connections for all the sensors, thermostats and other controlled devices. The new communication protocol C14 ensures communication with 3 NANO room units and the operation of 2 mixing circuits via R803BB unit.

3 1.1 Functions Algorithm of the AUTOMATIC SELECTION OF BOILER POWER automatically selects one of the four operational modes of the boiler in order to adjust boiler operation to the actual load. Combustion process control the controller's algorithm enables a fully automatic operation of the boiler. It controls the process of ignition, fuel burning, and it starts the shuts-down process when there is no current heat demand. Weather function it increases the comfort of operating the controller by automatic adjustment of the heating system to the external temperature. Boiler protection from operating at too low temperature the pumps are not switched on until the boiler reaches the required temperature. Two mixing circuits control controlling the secondary heating cycle by using R803BB unit. DHW storage tank control hot water tank temperature is measured continuously and, when necessary, the controller activates DHW loading. This feature has been designed to maintain the tank temperature at an appropriate level. Operation with room thermostat this function ensures maintaining the requested temperature in the rooms being heated. Operation with NANO digital readout units NANO readout unit offers integrated thermostat-timer operation and enables selection of the set boiler temperature, and offers external temperature, boiler and DHW tank temperature readout and alarm signal display. Automatic recovery after a power cut after a power cut the controller checks the boiler and either starts the operation or the shut-down process. Boiler overheat protection when maximum temperature is exceeded or in the case of a sensor failure, the burning process is interrupted and the CH and DHW pumps are switched on. Bivalent heat source control it requires an extension unit. DHW circulation control it requires an extension unit. Anti-freeze function boiler pump is activated when the temperature drops below 6 C

4 1.2 BIOMAX 741G Controller Operation Diagram digital interface Fig. 1: BIOMAX 741G operation diagram Legend: T1 weather sensor T2 boiler temperature sensor T3 flue gas temperature sensor T4 feeder temperature sensor T5 DHW tank temperature sensor TM mixer temperature sensor Foto photosensor TN1 NANO 1 room thermostat TN2 NANO 2 room thermostat TP room thermostat PCO CH direct circulation pump PM mixer pump PC circulation pump PCWU DHW loading pump PM mixer circulation pump Pod1 main feeder Pod2 secondary feeder Wen fan Z igniter R803BB mixer control unit

5 2 Controller Operation and Handling 2.1 Control panel Graphic illuminated LCD screen Keypad 2.2 Key description - It starts and stops the boiler operation. Cancels alarm. When pressed shortly it goes back to the main display window. To stop boiler operation (combustion), you need to press it down for 3 seconds. The controller will activate BURNING-OFF the remaining fuel and will switch to the STOP mode. - press this button to go from parameter value setting to parameter viewing mode or go from a submenu to the menu, or go from the menu to the main display window. - press it to switch between viewing parameters and setting the value of a chosen parameter. - it is used to move along the parameter list or decrease parameter value - it is used to move along the parameter list, or increase parameter value 2.3 Initial pellet feeding When in the STOP mode, press and hold down for 10 seconds button. This activates the main feeder, which can be stopped by pressing button or button. However, the feeder will not work longer than the factory setting in parameter F69. MAXIMUM FEEDING TIME 2.4 Ignition When the power supply is on, the controller starts operating in the same the mode as before the power cut. It can remain in the STOP mode or automatically resume its operation if it was operational before switching off the power. If the controller is in the STOP mode, then pressing button changes the mode to IGNITION. After ignition the boiler the controller starts automatic operation with the boiler output adjusted as needed. If three successive attempts to ignite the boiler fail, then ALARM 2 FUEL IGNITION FAILURE is signalled.

6 2.5 Setting the set boiler temperature You can set the set boiler temperature when the boiler is not in the weather operating mode (parameter A.10 BOILER OPERATION WEATHER MODE = NO). You can set the set boiler temperature on the main display window. boiler pump season-end pump off off signal time clock operating mode /alarm code feeder heating zone circulation operating mode fan boiler temperature summer/winter maintained boiler temperature set boiler temperature Press and the set temperature of the boiler will illuminate, which means that by using or button you can change the set temperature. After you have selected the required value, press again. Now SUMMER or WINTER is illuminated. If you press once again, then you will leave the editing mode in this window. 2.6 SUMMER/WINTER mode The SUMMER mode is a special mode in which heating cycles are off and the boiler only operates to heat the DHW tank. You can change the mode by illuminating SUMMER or WINTER in the window presented in the Fig. above. Button switches on the WINTER mode and button switches on the SUMMER mode.

7 2.7 Setting the temperature values for mixers 1 and 2 You can set mixer 1 temperature value when the controller shows that mixer 1 function is switched on (parameter F.01 IS MIXER 1 CIRCUIT AVAILABLE shows YES) and the mixer is not in the weather mode (parameter B.04 MIXER OPERATION WEATHER MODE = NO) Display the mixer window presented below. Temperature measured in in the mixer circuit Time clock Set mixer temperature Maintained temperature Selected operating mode Pump operation signal Press button and the mixer set temperature will illuminate, which means that by using buttons or you can change the set temperature. After you have selected the required value, press button again. Set mixer 2 temperature is entered in a similar way to mixer 1 temperature. 2.8 Setting the set DHW temperature You can set the DHW temperature value when the DHW circuit is on (parameter F.03 IS DHW CIRCUIT AVAILABLE shows YES). Go to the DHW display window shown below. DHW circulation pump DHW loading pump Heating zone signal Selected operating mode Temperatura zmierzona CWU Time clock Set DHW temperature Maintained temperature

8 Press button, which will illuminate the set temperature of the floor. This means that using buttons or you can change the set temperature. After you have set the required temperature, press button again. 2.9 MENU In the controller s MENU the following parameter groups are available: Information displayed Description A.BOILER SETTINGS B.MIXER 1 SETTINGS C.MIXER 2 SETTINGS D.DHW SETTINGS E.CLOCK SETTINGS G.LANGUAGE H.TEST Boiler and direct CH settings Mixer circuit settings Floor circuit settings DHW and DHW circulation settings Setting day of the week and time. Service settings Selecting the language Output test BOILER SETTINGS A.BOILER SETTINGS 01.MEASUR DISPLAY FEEDER TEMP -5 C FL-GAS TEMP 10 C PHOTOSENSOR 840 A.BOILER SETTINGS 02.FEEDER OPER TIME MAX OUTPUT 15s MIN 5 MAX 999 A.BOILER SETTINGS 03.FEEDER BREAK TIME MAX OUTPUT 40s MIN 10 MAX 999 A.BOILER SETTINGS 04.FAN SPEED MAX OUTPUT 30% Measurements display This screen shows the measured feeder and flue gas temperatures and the photosensor input value. The photosensor input value decreases with the light intensity. Feeder operating time at the maximum boiler output. Default setting: 15 s Break time between feeds at the maximum boiler output. Default setting: 40 s Fan speed for the maximum boiler output. Default setting: 30 % MIN 10 MAX 100

9 A.BOILER SETTINGS 05.BOILER DYNAMICS 7 MIN 1 MAX 10 A.BOILER SETTINGS 06.PERIODIC CLEANING func disabled! MIN 0 MAX 24 A.BOILER SETTINGS 07.CH OPERATION CLOCK MODE A.BOILER SETTINGS 08.CH REDUCTION 5 C MIN 0 MAX 40 A.BOILER SETTINGS 09.CH PUMP MODE CONT PUMP OPER The higher the value, the quicker the controller reacts to boiler temperature changes. Periodic cleaning of the burner. The controller shuts down the burner at the elapse of the time period set in this parameter. CH OPERATION: NANO 3 OPERATING MODE NANO 2 OPERATING MODE NANO 1 OPERATING MODE WITH THERMOSTAT CLOCK MODE WITHOUT THERMOSTAT CIRCUIT DISABLED Default setting CLOCK MODE CH reduction. The value by which the clock or thermostat will reduce the set boiler temperature. Default setting: 5ºC CH pump operating mode CONTINUOUS PUMP OPERATION THERMOSTAT PUMP OFF Default setting: CONTINUOUS PUMP OPERATION A.BOILER SETTINGS 10. TIME FOR BIVAL SOURCE func disabled! MIN 0 MAX 120 A.BOILER SETTINIGS 11.BOILER OPERATION WEATHER MODE NO Time left to the moment when the controller will activate an additional heat source if the set temperature is not reached. Bivalent source control requires an extension unit. Default setting: function disabled! Weather mode of the boiler operation NO the set temperature is entered manually YES the set temperature is calculated on the basis of external temperature and entered on the heating curve displayed subsequently. Default setting: NO

10 A.BOILER SETTINGS EKO Heating curve setting. The curve is drawn on the right of the display. EKO end of heating season temperature when the temperature outside is +10 then the set temperature of the heating cycle is 30 C, etc. A.BOILER SETTINGS 13.BOILER OPERATION MONDAY/FRIDAY Boiler operation on week days (from Monday to Friday) from 06:00 to 08:00 from 15:00 to 22:00 A.BOILER SETTINGS 14.BOILER OPERATION SATURDAY Boiler operation on Saturday from 06:00 to 22:00 from 24:00 to 24:00 A.BOILER SETTINGS 15.BOILER OPERATION SUNDAY Boiler operation on Sunday from 06:00 to 22:00 from 24:00 to 24:00

11 2.9.2 MIXERS 1 AND 2 SETTINGS Mixer 1 settings are not available if the service parameter F.01 IS MIXER 1 CIRCUIT AVAILABLE is set to: NO. Mixer 2 settings are not available if the service parameter F.02 IS MIXER 2 CIRCUIT AVAILABLE is set to: NO. Both mixer circuits have the same parameters. B.MIXER 1 SETTINGS 01.MIXER OPERATION WITHOUT THERMOSTAT MIXER OPERATION: NANO MODE WITH THERMOSTAT CLOCK MODE WITHOUT THERMOSTAT CIRCUIT DISABLED Default setting WITHOUT THERMOSTAT B. MIXER 1 SETTINGS 02.MIXER TEMP REDUCTION 5 C MIN 0 MAX 40 B. MIXER 1 SETTINGS 03.MIXER PUMP MODE CONTINUOUS PUMP OPERATION Mixer temperature reduction. The value by which the time clock or the thermostat will reduce the set mixer temperature. Default setting: 5 ºC Mixer pump operating mode CONTINUOUS PUMP OPERATION THERMOSTAT PUMP OFF Default setting: CONTINUOUS PUMP OPERATION B. MIXER 1 SETTINGS 04. MIXER OPERATION WEATHER MODE NO B. MIXER 1 SETTINGS EKO Mixer operation in the weather mode: NO the set temperature is entered manually YES the set temperature is calculated on the basis of the external temperature and the set heating curve. Default setting: NO Heating curve setting. The curve is drawn on the right of the display. EKO end of heating season temperature when the temperature outside is +10 then the temperature of the heating cycle is 30 C, etc.

12 B. MIXER 1 SETTINGS 06.MIXER OPERATION MONDAY/FRIDAY Mixer operation on week days (from Monday to Friday) from 06:00 to 08:00 from 15:00 to 22:00 B. MIXER 1 SETTINGS 07. MIXER OPERATION SATURDAY Mixer operation on Saturday from 06:00 to 22:00 from 24:00 to 24:00 B. MIXER 1 SETTINGS 08. MIXER OPERATION SUNDAY Mixer operation on Sunday from 06:00 to 22:00 from 24:00 to 24:00

13 2.9.3 DHW SETTINGS DHW settings are not available if the service parameter F.03 IS DHW CIRCUIT AVAILABLE is set to: NO. D.DHW SETTINGS 01.DHW OPERATION COMFORT MODE DHW operation: CLOCK MODE COMFORT MODE CIRCUIT DISABLED Default setting: COMFORT MODE D. DHW SETTINGS 02.DHW REDUCTION 5 C MIN 0 MAX 40 D. DHW SETTINGS 03.DHW PRIORITY NO D. DHW SETTINGS 04.DHW STOP HOLIDAY MODE YES D. DHW SETTINGS 05.DHW CIRCULATION OPERATION CIRCUIT DISABLED D. DHW SETTINGS 06.DHW CIRCULAT PUMP OPER TIME DHW temperature reduction. The value by which the clock or the thermostat will reduce the set DHW temperature. Default setting: 0 C DHW priority NO parallel DHW operation with other circuits YES other circuits are off while the tank is being loaded Default setting: NO DHW is switched off in the holiday mode. This parameter is used with the NANO unit, which makes it possible to select the HOLIDAY mode. YES DHW is switched off when in the holiday mode NO DHW operates as usual when in the holiday mode Operation of DHW circulation CIRCUIT DISABLED COMFORT MODE CLOCK MODE Default setting: CIRCUIT DISABLED Attention: the function controlling the DHW circulation requires an extension unit Operation time of the DHW circulation pump Default setting: 10 min 10min MIN 0 MAX 200

14 D. DHW SETTINGS 07.DHW CIRCULATION BREAK TIME DHW circulation break time Default setting: 20 min. 20min MIN 0 MAX 200 D. DHW SETTINGS 08.DHW OPERATION MONDAY/FRIDAY DHW operation on week days (from Monday to Friday) from 06:00 to 08:00 from 15:00 to 22:00 D. DHW SETTINGS 09.DHW OPERATION SATURDAY DHW operation on Saturday from 06:00 to 22:00 from 24:00 to 24:00 D. DHW SETTINGS 10.DHW OPERATION SUNDAY DHW operation on Sunday from 06:00 to 22:00 from 24:00 to 24: TIME CLOCK SETTINGS E.CLOCK SETTINGS 01.TIME THURSDAY 10:12.30 Subsequent pressing of button switches between setting day of the week, hour and minute. You can leave the clock menu by pressing button or.

15 2.9.5 SERVICE Parameters accessible with the service code. Setting the appropriate code allows for editing the other SET SERVICE CODE service parameters IS MIXER 1 CIRCUIT AVAILABLE NO 02. IS MIXER 2 CIRCUIT AVAILABLE NO 03.IS DHW CIRCUIT AVAILABLE NO The controller operates mixer 1 by using the extension R803BB unit. When such unit is connected, BIOMAX 741G needs to be informed about it by setting this parameter to YES. Default setting: NO. The controller operates mixer 2 by using the extension R803BB unit. When such unit is connected, BIOMAX 741G needs to be informed about it by setting this parameter to YES. Default setting: NO. If the user intends to use the DHW circuit, he needs to inform the controller about it by setting this parameter to YES. Default setting: NO. 04 PUMP OPERATION STOP MODE YES Pump operation in the STOP mode. Selecting YES enables the controller to operate the pumps when the boiler is in the STOP mode. Default setting: YES 05.DHW LOADING HYSTERESIS DHW tank loading hysteresis Default setting: 3 C 3 MIN 0 MAX 10

16 06.CH EXCESS FOR DHW LOADING 5 MIN 0 MAX DHW PUMP RUNDOWN TIME Boiler temperature excess for loading the DHW tank Default setting: 5 C DHW pump rundown time. Default setting: 3 min 3min MIN 0 MAX PERIODIC CH PUMP ACTIVATION BREAK 0min MIN 0 MAX MIXER 1 DYNAMICS 5 MIN 0 MAX MIXER 2 DYNAMICS 5 MIN 0 MAX BOILER EXCESS FOR MIXERS 5 MIN 0 MAX 15 Periodic CH pump activation break. If in parameter A.09 CH PUMP MODE the option THERMOST PUMP OFF is selected, then this parameter determines the operation of the CH pump. If the parameter value is set to 0, then when the room thermostat is on the pump will be switched off for good. If the set value is other than 0, then after the room thermostat is on, the controller will stop the pump. However after the elapse of the set time the CH pump will be activated for 130s. Default setting: 0 min Mixer 1 dynamics determines how quickly temperature is adjusted. Increasing the value speeds up the adjustment, but then oscillations might occur. Default setting: 5. Mixer 2 dynamics determines how quickly temperature is adjusted. Increasing the value speeds up the adjustment, but then oscillations might occur. Default setting: 5. Boiler excess for mixers. Boiler temperature is automatically increased to the highest set temperature of the system mixer plus the excess set in this parameter. It is supposed to make up for temperature drops in the system caused by e.g. heat exchangers. Default setting: 5 C

17 12.FAILURE SOUND SIGNAL TAK Failure sound signal Default setting: YES 13.NETWORK ADDRESS RS485 1 MIN 0 MAX NETWORK OPER MODE RS485 MASTER 15.CASCADE OPER MODE NO 16.SEASON-END RUNDOWN YES Network address RS485. Default setting: 1 Network operation mode. MASTER initiates communication SECONDARY does not initiate communication. Default setting: MASTER Cascade operation mode. When selecting YES you should select SECONDARY in parameter F.14 NETWORK OPERATION MODE RS485 and connect the cascade master controller through the RS485 interface. When cascade operation mode is selected, then the controller does not control the mixers or the DHW circuit. Default setting: NO. Pump and mixer season-end rundown. Default setting: YES. 17.FEEDER OPER TIME IGNITION MODE 45s MIN 1 MAX BOILER TEMP RISE FOR STANDBY MODE 5 C MIN 0 MAX 30 Fuel feeding time before starting the igniter in the IGNITION mode. Default setting: 45 s. If the boiler temperature rises over the value set in this parameter, then the controller will shut down the boiler and will go to the STANDBY mode. Tip: do not set less than 5 C. Default setting: 5 C

18 19.FAN SPEED BURN-OFF MODE 25% MIN 1 MAX SHUT-DOWN TIME 240s MIN 1 MAX FAN SPEED SHUT-DOWN MODE 25% MIN 1 MAX SHUT-DOWN TIME 240s Fan speed in the BURN-OFF mode. Default setting: 25%. Time taken by the SHUT-DOWN mode Default setting: 240s. Fan speed in the SHUT-DOWN mode. Default setting: 25%. Time taken by the SHUT-DOWN time. Default setting: 240s. MIN 1 MAX IGNITION SENSOR DETECTION LEVEL 800 MIN 1 MAX FAN SPEED MIN IGNITION 13% The level of the photosensor illumination below which the controller assumes there is flame in the combustion chamber. When set to 0, flame detection by a photosensor is switched off. In such case a flue gas temperature sensor should be connected. Default setting: 800. Minimum speed of the fan during the ignition Default setting: 23%. MIN 1 MAX FAN SPEED MAX IGNITION 30% Maximum speed of the fan during the ignition Default setting: 25%. MIN 1 MAX 100

19 26.IGNITION TIME MIN SPEED 20s MIN 1 MAX IGNITION SPEED BOOST TIME 25s MIN 1 MAX SUMMER DHW MODE SIMPLIFIED NO MIN 0 MAX 1 29.DHW OVERHEAT func disabled! Time of maintaining minimum fan speed counted from the moment of switching on the igniter. Default setting: 20s. Time of increasing the fan speed by 1 % during the ignition. Default setting: 25s. DHW pump operation mode in the SUMMER mode YES the controller does not switch off the pump when the set tank temperature has been reached NO the controller will switch off the pump when the DHW temperature has been reached Default setting: NO. DHW overheat is done on a weekly basis for the purpose of the tank sterilization. Default setting: function DISABLED! 30.MIXER 1 MAX TEMP 65 C MIN 0 MAX MIXER 1 MIN TEMP 25 C MIN 0 MAX MIXER 2 MAX TEMP 65 C Mixer 1 maximum temperature. Default setting: 65 C Mixer 1 minimum temperature. Default setting: 25 C Mixer 2 maximum temperature. Default setting: 65 C MIN 0 MAX 95

20 33.MIXER 2 MIN TEMP 25 C MIN 0 MAX CH PUMP RUNDOWN TIME Mixer 2 minimum temperature. Default setting: 25 C CH pump rundown time. Default setting: 3 min 3min MIN 0 MAX 60 Factory settings 35.MAX SET BOILER TEMP 85 C MIN 0 MAX MIN SET BOILER TEMP 50 C MIN 0 MAX EMERGENCY PUMP ACTIVATION TEMP 90 C MIN 0 MAX MAX SET DHW TEMP 65 C The maximum set temperature of the boiler. Default setting: 85 C The minimum set temperature of the boiler. Default setting: 50 C Emergency pump activation temperature. Default setting: 90 C Maximum set temperature of DHW. Default setting: 65 C MIN 0 MAX 95

21 39.BOILER EMERGENCY TEMP 95 C MIN 0 MAX HW PUMP EMERGENCY ACTIVATION BLOCKED YES Boiler emergency temperature. Default setting: 95 C Blocked emergency activation of HW pump after boiler overheat. Default setting: YES. 41.PUMP ACTIVATION TEMP 42 c MIN 32 MAX FEEDER MAX TEMP 90 C Pump activation temperature. Default setting: 42 C Feeder maximum temperature. Default setting: 90 C 43.MAX HEATING COIL OPER TIME 360s MIN 1 MAX HEATING COIL BREAK TIME 20s MIN 0 MAX COMPLETE IGNITION FLUE GAS TEMP 90 C Operating time of the igniter s heating coil during ignition. Default setting: 360s Time between subsequent ignition attempts. Default setting: 20s If the flue gas temperature exceeds this value, the controller switches from the IGNITION to the OPERATION mode. Default setting: 90 C MIN 0 MAX 350

22 46.COMPLETE IGNITION FLUE GAS TEMP RISE 10 C MIN 0 MAX AMPLITUDE H1 IGNITION 2 C MIN 1 MAX AMPLITUDE H2 BIVAL. 2 C MIN 1 MAX FLUE GAS TEMP SHUT-DOWN 90 C MIN 0 MAX SHUT-DOWN CRITER TIME 30min MIN 1 MAX BOILER VENTILATION TIME 20s MIN 1 MAX FEEDER OPER TIME OUTPUT 50% 70% If the flue gas temperature rises by this value during ignition, the controller goes to the OPERATION mode. Default setting: 10 C Amplitude h1 Ignition. This parameter determines by what value the temperature must fall below the set temperature for the controller to start the IGNITION process. Default setting: 2 C Amplitude h2 BIVAL. This parameter determines by how many degrees the boiler temperature must be lower than the set temperature for the boiler to start counting down the time to the activation of a bivalent source. Default setting: 2 C End of shut-down flue gas temperature. If the measured temperature falls below the value set in this parameter, then the controller, after the lapse of time set in parameter F.50.SHUT-DOWN CRITERIUM TIME, will switch off the boiler and display ALARM 6 informing on the boiler shut-down. Default setting: 90 C Time counted down from the moment when flue as temperature falls below the value set in parameter F.49.FLUE GAS TEMP SHUT-DOWN Default setting: 30min Boiler ventilation time. Duration time of the CLEANING mode and the second stage of ignition, when the fan works at full speed to ventilate the boiler. Default setting: 20s Feeder operating time at 50% output defined as the percentage of feeder operating time at maximum output. Default setting: 70% MIN 10 MAX 100

23 53.FEEDER BREAK TIME OUTPUT 50% 100% MIN 10 MAX FAN SPEED OUTPUT 50% 70% MIN 10 MAX FEEDER OPER TIME OUTPUT 25% 55% MIN 10 MAX FEEDER BREAK TIME OUTPUT 25% 100% MIN 10 MAX FAN SPEED OUTPUT 25% 55% MIN 10 MAX FEEDER OPER TIME OUTPUT 12% 40% MIN 10 MAX FEEDER BREAK TIME OUTPUT 12% 100% Feeder break time at 50% output defined as the percentage of feeder break time at maximum output. Default setting: 100% Fan speed at 50% output defined as the percentage of fan speed at maximum output. Default setting: 70% Feeder operating time at 25% output defined as the percentage of feeder operating time at maximum output. Default setting: 55% Feeder break time at 25% output defined as the percentage of feeder break time at maximum output. Default setting: 100% Fan speed at 25% output defined as the percentage of fan speed at maximum output. Default setting: 55% Feeder operating time at 12% output defined as the percentage of feeder operating time at maximum output. Default setting: 40% Feeder break time at 12% output defined as the percentage of feeder break time at maximum output. Default setting: 100% MIN 10 MAX 100

24 60.FAN SPEED OUTPUT 12% 45% MIN 10 MAX FEEDER OPER TIME MAX OUTPUT 999s MIN 10 MAX FEEDER BREAK TIME MAX OUTPUT 999s MIN 10 MAX FAN SPEED MAX OUTPUT 100% MIN 10 MAX Kp COEFFICIENT 8 MIN 3 MAX FEEDER 2 ADVANCE TIME 5s MIN 0 MAX FEEDER 2 DELAY TIME 5s Fan speed at 12% output defined as the percentage of fan speed at maximum output. Default setting: 45% Upper time limit for feeder operation at maximum output. Default setting: 999s Upper time limit for feeder break at maximum output. Default setting: 999s Upper limit of fan speed at maximum output. Default setting: 100% Controller gain coefficient. Default setting: 8 The time of advanced activation of feeder 2 before the main feeder. Default setting: 5s The time of delayed switch-off of feeder 2 after the main feeder. Default setting: 5s MIN 0 MAX 200

25 67.GRATE OPERATION TIME 10s MIN 0 MAX GRATE BREAK TIME 60s MIN 0 MAX MAX CHARGE TIME 120s Grate operating time. Default setting: 10s Break time in the grate operation. Default setting: 60s Maximum charging time following manual feeder activation in the STOP mode. Default setting: 120s MIN 0 MAX TEST The MANUAL MODE is on when the controller is in the STOP mode and the test code = If the boiler temperature exceeds the maximum value then CH and DHW pump outputs are on for safety reasons. When o is displayed, it means the output is off, while means it is on. H.TEST SET TEST CODE Setting the test code G.TEST CH PUMP DHW PUMP CIRCULATION PUMP MIXER 1 MIXER 2 IGNITER o o o o o o To enable a selected output highlight the right caption and press. In the case of mixer, sequential activation of the pump, valve opening and valve closing relays takes place Mulfunctions The controller displays information on failures that prevent normal operation of the boiler.

26 ALARM 1 BOILER OVERHEAT! ALARM 1 boiler temperature has exceeded the value set in parameter Boiler emergency temp (default setting 95 C) ALARM 2 NO FUEL ALARM 2 three successive attempts to ignite the boiler failed. IGNITION LARM 3 FEEDER IGNITION! ALARM 3 feeder temperature exceeded or feeder sensor failure. ALARM 6 BOILER ALARM 6 boiler shut-down. The reason could be no fuel. SHUT-DOWN! ALARM 7 FLUE GAS SENSOR FAILURE ALARM 8 BOILER ALARM 7 flue gas sensor failure. If the controller is to operate without a flue gas sensor, then the value in parameter F.23.IGNITION SENSOR DETECTION LEVEL should be set higher than 0 ALARM 8 boiler temperature sensor failure. SENSOR FAILURE To cancel an alarm, press Warnings TEMPERATURE SENSOR FAILURE NO CONNECTION! This warning is displayed in the selected circuit window, when the circuit is on but the right sensor is not connected or the sensor doesn t work This warning is displayed in mixer 1 or mixer 2 window if the mixer unit is not connected through RS485 interface or it is disabled.

27 TEMPERATURE SENSOR FAILURE NANO 1 NO COMMUNICATION This warning is displayed in the selected circuit window, when the circuit is on but the right sensor is not connected or the sensor doesn t work This warning is displayed in the window of the circuit configured to operate with the NANO 1 unit if the NANO 1 is not connected through RS485 interface or is disabled. Similar warnings can be displayed for NANO 2 and NANO 3. 3 Installation This controller must be enclosed. It may not be used as a stand-alone device. Any installation work may only be carried out by duly authorized and qualified persons in accordance with the currently established standards. Installation can only be carried out after power supply has been disconnected. Make sure that the circuit is not supplied with voltage. Electronic disconnection of the connected devices has been used in the controller (2Y according to PN-EN ), which does not ensure safe disconnection. 3.1 Technical data Power supply: 230V, 50Hz Power consumption: I = 0.03A Max. rated current: Protection class: Ambient temperature: Storage temperature: Relative humidity: Photosensor type: Measuring range: Pk1 CH pump (6)... 4(2)A Pk2 DHW pump (8)... 4(2)A Pk3 feeder 2 (10)... 4(2)A Pk4 grate (11)...4(2)A Pk5 igniter (12)... 4(2)A Pk6 mixer (13)... 1(0,6)A Pk7 mixer + (14)... 1(0,6)A Pk8 mixer pump... 1(0,6)A Tk1 feeder 1 (19)... 2A Tk2 fan (21)... 2A IP C C 5 80% no vapour condensation A T external (26) C T mixer (28) C T flue gas (29) C T DHW (34) C T boiler (35) C T feeder (36) C

28 Measurement accuracy: T ext (26)... 1 C T mixer (28)... 1 C T flue gas (29)... 1 C T DHW (34)... 1 C T boiler (35)... 1 C T feeder (36)... 1 C Terminals: Display: Control panel size: Operating unit size: Weight of the set: Screw terminals 1x1.5mm² graphic LCD display 128x98x35mm 142x115x65mm 0.9 kg 3.2 Operating conditions The controller has been designed for use in environments with dry conducting pollutants or non-conducting pollutants that turn conducting as a result of anticipated condensation (3 rd pollution level according to PN-EN ). However, due to the risk of coal dust ignition the controller operating unit should be placed in a dust-proof housing, or when placed in a non dust-proof housing, it should be used in environments where no combustible dust is present or where it is systematically removed. The ambient temperature should be within the range of 0-55 C. 3.3 Operating unit installation The protection class for the operating unit is IP20, so it must be used with an additional housing. It has been designed to be fitted on a DIN TS35 mounting rail, it can be enclosed in a standard electrical cabinet (nine times the unit width) or another housing which ensures adequate protection from the environmental conditions and prevents access to dangerous voltage points. 53mm 30mm 105mm 9mm 20mm 45mm 65mm 30mm 142mm 20mm Rysunek Fig. 3: Minimum 2: Minimalne size of wymiary housing obudowy for E BIOMAX na moduł 741G wykonawczy operating unit E BIOMAX 741G

29 Ambient temperature of the operating unit may not exceed the range of 0-55 C. The space required for the operating unit is presented in Fig. 2. In order to install the unit on the rail, you need to: 1. Pull back the lower catches, 2. Place the unit on the upper notches, 3. Press the lower catches until they click on the rail, 4. Make sure the unit is secure and cannot be removed without using a suitable tool. 3.4 Control panel operating unit BIOMAX 200 control panel is designed to be plate-mounted; it can be fitted on boiler casing. Apply suitable thermal insulation between hot surfaces of the boiler, the panel and the connection cable. Minimum space required by the control panel is shown in Fig. 3. Ambient temperature of the panel should not exceed 55 C. In order to install the panel: 1. Cut a mounting hole in the casing as shown in Fig Pull the cover and plug the ribbon cable making sure it is properly placed in the socket. Place the cover back to protect the connection. 3. Place the panel in the mounting hole and fix it with metal screws max. 3 mm in diameter. 110mm 88mm 136mm Fig. 4: Drilling holes in the BIOMAX 741G installation panel. 3.5 Electrical supply and 230V mains The controller should be supplied from 230V/50Hz mains. The wiring system requires a three conductor cable and should be equipped with a residual-current switch and overcurrent safety device suitable for the load and cable cross-section. The connection cables should not touch surfaces with temperatures exceeding cable standard operating temperature rating. Cable wire end should be secured with clamping collet. Controller screw terminals allow for connecting cables of maximum cross-section of 1.5mm².

30 Electrical connections are shown in Fig PCO PCW Zapalarka Pompa miesz. Podajnik 1 Dmuchawa Pk1 Pk2 Pk3 Pk4 Pk5 Pk6 Pk7 Pk8 Tk1 Tk2 Termostat T2001 T2001 T2001 Fotokomórka T1401 T1006 T1002 RS 485 A RS 485 B BIOMAX 741G 740 E9 termostat T podajnika T kotła T CWU Podajnik 2 Ruszt Fotokomórka Mieszacz - Mieszacz + T spalin T mieszacza T zewnętrzna Złącze do podłączenia panelu sterującego Zasilanie 230V/50Hz N L Bezp. F 4A Bezpiecznik Max 6,3A 250V C 1 STB L L L Podajnik 2 L Ruszt L Zapalarka N Podajnik 1 N Dmuchawa N N N N N L L Pompa Pompa CO CW Rysunek Fig 6: SBIOMAX 5: Schemat 741G podłączenia E9 operating urządzeń unit connections do modułu wykonawczego BIOMAX 741G E9 Terminals 1-25 are meant for connecting 230V/50Hz circuits. Terminals placed opposite, numbered and the connection for multi-wire ribbon cable are powered with voltage not exceeding 12V. Connecting 230V~ circuits to terminals will damage the controller and create the risk of an electric shock. 3.6 Grounding Protective conductors of the power supply cord and of the connection cables should be connected together to the grounding connection and to the boiler casing. BIOMAX 741G controller does not have a grounding connection.

31 3.7 Sensor installation Measured temperature Terminal Sensor type Outdoor temperature 26,27 T1002 Mixer temperature 28,27 T1006 / T1001 Flue-gas temperature 29,30 T1401 DHW temperature 34,32 T2001 Boiler temperature 35,32 T2001 Feeder temperature 36, 37 T2001 Table 1: Sensors. T2001 and T1001 sensors include a measuring probe placed in a stainless steel sleeve of 6 mm in diameter and a 2 m long temperature resistant cable (up to 100ºC). The sensor cable may be extended up to 30 m with a cable cross-section of min. 0.5 mm². The sensors are not watertight and may not be immersed in any type of liquid. T2001 sensors cannot be replaced with other types of sensors e.g. T1001, T1002, T1401! Make sure there is a good thermal contact between the sensor and the surface measured. If necessary, use thermal grease. A minimum spacing of 30 cm between the sensor cables and parallel live network cables is required. Smaller spacing may result in unstable temperature readings. Sensors' location is shown in Fig. 1 System diagram. 3.8 Sensor characteristics Temperature Resistance Temperature Resistance [ C] [Ω] [ C] [Ω] Table 2: T2001 sensor resistance values for selected temperatures. Temperature Resistance Temperature Resistance [ C] [Ω] [ C] [Ω] , , , , , , , , , , Table 3: T1001, T1002, T1006, 1401 sensor resistance values for selected temperatures.

32 3.9 Connecting the room thermostat When the room thermostat is connected, boiler temperature can be reduced by the set value or the pumps can be stopped. This offers economical room temperature control in spring and autumn periods, reduced costs and added comfort. A bimetallic or an electronic thermostat may be used, which after exceeding the set temperature opens its contacts. It should be connected to controller terminals 38 and 37. The thermostat must not supply any voltage to the controller! The room thermostat should be installed in a place representative of the whole building away from heat sources, windows and doors, about m above the floor level Connecting the STB safety temperature limiter The STB safety device stops the feeder and the fan if boiler temperature is too high. This can happen due to a boiler failure or faulty settings. The STB safety device should be connected to terminals 16 and 17. If the system is to operate without the STB limiter, terminals 16 and 17 should be connected with a jumper.

33 4 Service information 4.1 Detailed description of controller operation modes STOP The fan and feeder are switched off. The controller is not maintaining the boiler temperature. If the parameter F.01 PUMP OPERATION STOP MODE is set to YES, then the circuits which are switched on operate as usual. If season-end rundown functions are activated, then every Tuesday at 12:00 the controller activates the pumps and performs the cycle of opening and closing the mixer. The boiler can be switched on by pressing button. IGNITION if the controller is in STANDBY mode (boiler not working) and the conditions for starting the boiler are met (boiler temperature is lower than the set value and the room thermostat input is closed) the boiler is started. The following operations are carried out: Checking if the boiler furnace is fired up. If flue gas temperature is high enough or the photosensor detects flame in the furnace, the ignition is not started. The contoller dir ectly enters OPERATION mode. Cleaning the boiler furnace by blowing it through at full fan speed for the time set in F.51 BOILER VENTILATION TIME. Feeding the fuel for the time set in F.17.FEEDER OPER TIME in the IGNITION mode. Starting the fan. Starting the ignition rod for the time set in F.43.MAX HEATING COIL OPER TIME - at this time the controller verifies if the ignition has been successful. In case of failure, another attempt is made after time lapse set in F.44.HEATING COIL BREAK TIME. If the third attempt fails and the boiler is not started, the controller enters the alarm mode and the boiler is stopped. You can exit the alarm mode by pressing button. Boiler ignition can be detected with either the flue-gas temperature sensor or the photosensor depending on the settings. Photosensor detection: if the value measured by the photosensor is lower than the one set in Photosensor illumination the controller assumes there is fire in the boiler furnace. Flue gas temperature detection: It operates when the parameter value in Photosensor illumination is set to 0. For the ignition to be successful, the temperature must reach the value set in Tflue complete ignition or increase at least by dtflue complete ignition. When starting the boiler manually, remove unburnt fuel from the furnace. OPERATION the controller controls boiler operation to maintain the set temperature. Temperature control according to the algorithm of AUTOMATIC BOILER OUTPUT CONTROL involves changing the amount of the air and fuel supplied depending on the boiler load. Operation mode parameters are set for the maximum boiler output power. Lower values are calculated on the basis of coefficients specified by the manufacturer. SHUT-DOWN the fan is started to operate for the time set in F.22.CZAS SHUT- DOWN TIME at the speed set in F.21.FAN SPEED SHUT-DOWN MODE, and then it performs the CLEANING and enters the STANDBY mode.

34 STANDBY the boiler is off, the fan and the feeder are not working. If boiler temperature drops below the set value by the value in F.47.AMPLITUDE H1 IGNITION, the controller enters the IGNITION and then OPERATION mode. BURN-OFF the fan is switched on to operate for the time set in F.20.BURN-OFF TIME at the speed set in F.19.FAN SPEED BURN-OFF MODE. VENTILATION the fan is started at full speed to operate for the time set in parameter F.51.BOILER VENTILATION TIME. The STOP mode can be entered manually by pressing button for 3 s. If the boiler is switched off manually, the controller enters the BURN-OFF mode (the fuel remaining in the boiler is burnt off), then the CLEANING is performed and finally the controller enters the STOP mode. 4.2 Pump activation temperature Parameter F.41 PUMP ACTIVATION TEMPERATURE specifies the temperature which the boiler must reach in order to activate the pumps. Heat output from the boiler is not possible below the set value. 4.3 CH pump operation In parameter A.09 CH PUMP MODE you can select whether the thermostat will switch off the pump. If you wish so,, select THERMOSTAT PUMP OFF, setting PUMP CONTINUOUS OPERATION will not allow the thermostat to switch off the pump. CH pump will be switched off during the DHW tank loading if the DHW priority is switched on. If the boiler temperature has risen 20ºC above the value set in parameter F.35 MAXIMUM SET BOILER TEMPERATURE or has exceeded the value of parameter F.37 EMERGENCY PUMP ACTIVATION TEMPERATURE, then the CH pump is activated to reduce the boiler temperature. 4.4 DHW tank loading DHW tank loading is switched on in parameter D.01 DHW OPERATION If DHW operation is set in the clock mode, then the controller maintains the set DHW tank temperature in the selected zones while outside those zones the temperature is reduced by the value set in parameter D.02 DHW REDUCTION. The tank is loaded if its temperature drops below the set value by the value specified in parameter F.05 DHW LOADING HYSTERESIS. The controller increases the boiler temperature to the value allowing for the tank loading. If the boiler temperature is higher than the tank temperature as wee as the value given in F.41 PUMP ACTIVATION TEMPERATURE, then the tank loading pump is activated. Loading is finished when the tank temperature reaches the set temperature. The DHW pump rundown makes it possible to gradually reduce boiler output after finishing the loading of the DHW tank. This enables the controller to adjust boiler temperature better. After the tank has been loaded, the DHW pump might continue to work for the time set in parameter F.07 DHW PUMP RUNDOWN TIME 4.5 DHW tank disinfection DHW tank overheat is activated in parameter F.29 DHW OVERHEAT. DHW storage tank disinfection takes place every Monday between 1:00 a.m. and 2:00 a.m. Tank loading ends after reaching the temperature of 72 C or if the set tank temperature is not reached by 2:00 a.m.

35 4.6 Weather-compensated mixer operation Weather-compensated mixer operation is activated in parameter B.04 MIXER OPERATION WEATHER MODE. The set mixer temperature is determined on the basis of outdoor temperature readout and the programmed heat curve. The heat curve is shaped by entering set mixer temperatures for 4 outdoor temperature values. Parameter Outdoor temp. CH off makes it possible to specify the outdoor temperature at which the controller will switch off the heating. The controller calculates the set mixer temperature on the basis of the two closest points of the heat curve. For instance, for the outdoor temperature of -5 C and the programmed values of the curve where Tzew 0 = 28 C and Tzew -10 = 34 C, the calculated temperature is 31 C. The set mixer temperature can be reduced by the thermostat and the time-controlled heating program. However, it cannot be any lower than the value specified in F.31 MIXER 1 MIN TEMP e.g. 25 C or exceed the value set in parameter F.30 MIXER 1 MAX TEMP e.g. 40 C. Mixer 2 has a separate set of identical parameters. T max T mixer T mieszacza T min T outdoor T zewnętrzna Fig. 7: Shaping and calculating the heat curve 4.7 Mixer operation The set temperature of the mixer circuit can be determined by the weather algorithm or entered manually by the user. The controller with a three-point output maintains the set temperature in the mixer circuit. It is done by gradual closing and opening of the valve. The bigger the difference between the measured temperature and the set temperature, the more often and in bigger steps the controller opens and closes the valve. If the measured temperature equals the set one, then the controller does not move the actuator. The controller works with actuators for three-point control equipped with limit switches. The actuator makes a stroke only when there is a signal to open or to close. After the signal fadeout it cannot change its position. This system cannot operate with thermal actuators or actuators with analog input or with a return spring for continuous operation. 4.8 Season-end rundown Season-end rundown function protects the pumps and mixer from getting blocked as a result of buildup and dirt. Pumps are activated every Tuesday at 12:00 for 30 seconds.

36 The mixer is opened for 90 seconds and then is closed for 120 seconds. After they have been activated, the season-end rundown functions operate independently of the controller s other functions. 4.9 Digital NANO operating unit BIOMAX 741G controller is designed to work with the NANO room thermostat using C14 protocol. You can set a weekly and a daily heating schedule on the thermostat. Additionally, the NANO unit provides readout of the outdoor temperature as well as the boiler and DHW tank temperatures, and it also signals an emergency detected in BIOMAX 741G. The thermostat operating modes are easy to change, thus allowing the user to quickly adjust circuit operation to the user s on-going needs (clock mode, reduction, no reduction, holiday mode). NANO should be connected with a four-wire cable whose wires have the cross-section of minimum 0.5 mm 2 as shown in the diagram. If you want a given heating circuit to communicate with the NANO unit, you need to configure it. Termostat pokojowy NANO A B G U NC NC Pk Pk For instance, in the case of direct CH circuit you need to enter parameter A.07 CH OPERATION and select NANO 1 OPER MODE. NANO thermostat is activated in the same way for the mixer and floor circuits. After the NANO thermostat has been connected, you can no longer edit the time or day of the week on BIOMAX 741G controller as the clock settings are moved to the NANO unit. When NANO is communicating with the BIOMAX 741G, the symbol status line. A B G U Moduł wykonawczy R540 E9 BIOMAX 740G E9 shows in the

37 5 DECLARATION OF CONFORMITY COMPIT Piotr Roszak ul. Wielkoborska Częstochowa hereby declares that the product Microprocessor Contoller model: BIOMAX 741G with BIOMAX 741G E9 operating unit meets the following requirements when applied in conformity with its intended use and according to the Manufacturer s Installation and Operating Instructions: 1. Directive 2006/95/EC (LVD) of the European Parliament and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits (Ordinance of the Minister of Economy of 21 August 2007 on basic requirements for electrical equipment and transposing Directive 2006/95/EC) 2. Directive 2004/108/EC (EMC) of the European Parliament and of the Council of 15 December 2004 on the approximation of laws of Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC (OJ UE L 390 of , p. 24) (Act of 13 April 2007 on electromagnetic compatibility implementing Directive 2004/108/EC) List of harmonized standards concerning the fundamental requirements of the abovementioned directives: PN-EN :2006, EN : A1: A11: A12: A2:2005, w połączeniu z PN-EN : A12: A13: A14:2006, EN : A11: A12: A13: A1: A14:2005 Identifying mark of the year in which the CE marking was affixed: 14 Częstochowa, Piotr Roszak, Owner

38 SERVICE CODES NOTE: Service code = 199 Test code = 5511 Service codes should not be made available to the user. This sheet is intended for the service use only and should be cut off.

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