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  5. Assembly And Service Manual

Plum ecomaxx 800 R2 Assembly And Service Manual

Manual is about: for solid fuel boilers

Summary of ecomaxx 800 R2

  • Page 1

    Boiler regulator ecoma x x 800, model r2 for solid fuel boilers a, b, c – functions chich are available in module, respectively: a, b, c * room panel ecoster200 (module b, c and ecoster200 are not part of standard equipment) service and assembly manual issue: 1.3 softwaree: module panel v.01.Xx.Xx v...

  • Page 3

    Principles for usage of individual fuzzy logic controlled boiler: the regulator must be programmed individually for the given type of boiler and fuel, p. 21.1! It is inadmissible to change the type of gear-motor, fan, and to make other changes in the boiler fittings which can influence the burning p...

  • Page 4

    Table of contents 1 recommendations regarding safety............... 5 2 general information .......................................... 6 3 information about documentation ............... 6 4 storage of documentation ............................... 6 5 applied symbols ...................................

  • Page 5

    5 1 recommendations regarding safety requirements concerning safety are described in detail in individual chapters of this manual. Apart from them, the following requirements should in particular be observed. Before starting assembly, repairs or maintenance, as well as during any connection works, p...

  • Page 6

    6 2 general information boiler regulator ecomax 800 model p1, version l, is a modern electronic device intended to control pellet boiler operation. The regulator is a multipurpose device: it automatically maintains a preset boiler temperature by controlling the fuel combustion process, it controls t...

  • Page 7: Ecomaxx 800R2

    Regulator instruction manual ecomaxx 800r2.

  • Page 8

    8 7 operating the regulator 7.1 buttons description fig. 1 view of control panel. Legend: 1. Menu button 2. ,,touch and play” knob 3. Exit button turning the “touch and play" knob increases or decreased the edited parameter. This is an element of quick operation of the regulator. Pushing this knob a...

  • Page 9

    9 details can be found in section 7.21. Note: the fuel level can be viewed also on room panel ecoster200. Fig. 4 auxiliary window with fuel level indication 7.3 regulator start-up press the knob to start-up the regulator. 7.4 setting the preset boiler temperature set the preset boiler temperature in...

  • Page 10

    10 if the user does not switch-over the regulator to operation mode, the regulator will heat-up the boiler to preset temperature + 10 c, and will automatically enter operation mode, and subsequently supervision because the preset boiler temperature has been reached. In case actual boiler temperature...

  • Page 11

    11 7.8 operation–fuzzy logic mode upon change of boiler regulation mode from standard to fuzzy logic, regulator works in operation mode and modulates the boiler output to achieve constant preset boiler temperature. Fuzzy logic regulation mode may be set in: menu boiler settings burner settings regul...

  • Page 12

    12 in supervision mode, the regulator supervises that the fire in the furnace has not damped. For this purpose, the fan and the feeder work intermittently and operate for a certain time, less frequently than in operation mode. This does not cause any further temperature increase. The fan does not wo...

  • Page 13

    13 7.14 disinfection of huw container the regulator has a function of automatic, periodic heating of huw container to 70 °c to eliminate bacterial flora from the huw container. Keep the tenants informed of activating disinfection function as there is a risk of being burnt with hot utility water. 7.1...

  • Page 14

    14 example. Preset temperature in heating room (set in ecoster200) = 22 degrees c. Measured temperature in room (using ecoster200) = 20 degrees c. Room temperature factor = 15 preset mixer temperature will be increased by (22 degrees c – 20 degrees c) x 15/10 = 3 degrees c. Correct value of paramete...

  • Page 15

    15 this feature enables automatic reduction of preset temperature, which improves heat comfort and reduces fuel consumption. It is indicated with a sign . Select temperature reduction and beginning and end of respective time interval. Fig. 11 time intervals 7.18 control of huw circulating pump setti...

  • Page 16

    16 fuel level indicator service each time when fuel silo is filled to required level it is necessary to press and keep the knob in main window. Following info will appear: fig. 13 operation of fuel level indicator once yes has been selected and confirmed, fuel level is set at 100%. Fuel may be reple...

  • Page 17: Ecomaxx 800, Model R2

    User manual of controller installation and service settings ecomaxx 800, model r2.

  • Page 18

    18 8 hydraulic diagrams 8.1 diagram 1 fig. 14 diagram with 4-way control valve for central heating circuit 3 , where: 1 – boiler, 2 – ecomaxx regulator – module a, 3 – ecomaxx regulator – control panel, 4 – fan, 5 – feeder temperature sensor, 6 - gear-motor, 7 – boiler temperature sensor, 8 – huw te...

  • Page 19

    19 output h circulating pump menu service settings circulation support on m enu pump service settings 8.2 diagram 2 fig. 15 diagram with 3-way thermostatic valve to secure return water temperature 5 , where : 1 – boiler, 2 – ecomaxx regulator – module a, 3 – ecomaxx regulator – control panel, 4 – fa...

  • Page 20

    20 8.3 diagram 3 fig. 16 diagram with two additional mixer circuits upon connection of additional module b 7 , where :1 – boiler, 2 – ecomaxx regulator – module a, 3 – ecomaxx regulator – control panel, 4 – fan, 5 – feeder temperature sensor, 6 - gear-motor, 7 – boiler temperature sensor, 8 – huw te...

  • Page 21

    21 circulation support on pump service settings serwisowe operation mode: return protection off service settings boiler settings return protection 4d 8.4 schemat 4 fig. 17 diagram with heat buffer and additional module b 9 , where:1 – boiler, 2 – ecomaxx regulator – module a, 3 – ecomaxx regulator –...

  • Page 22

    22 once the heat buffer (36) has been loaded, the regulator stops the pump (6) and enters supervision mode. The pump (6) starts in-spite of loaded buffer (36) once the boiler temperature has exceeded the preset value by 10 c. Pumps (12) and (13) are stopped, and servo (14) is closed once the buffer ...

  • Page 23

    23 step 2 remove the lid (5), plug the cable (6) and put the lid (5) back on, securing it with screws (4). The cable should be lead out through the round groove in the enclosure. Fig. 19connecting lead to the panel, where: 4- b3x6 screw for thermoplastic materials, 5 – lid, 6 – lead connecting the c...

  • Page 24

    24 fig. 22 space requirements for operating unit mounting fig. 23 methods of operating unit installation: a – in modular housing with access to front surface, b – in the cover without access to front surface. 11.5 ip protection rate enclosure of the regulator’s executive module provides various ip p...

  • Page 25

    25 the protective conductor of the feeder cable should be connected to a neutral strip contacted with the metal casing of the regulator. The fitting should be connected to the regulator terminal marked with symbol and with grounding terminals of the devices connected to the regulator. (fig. 25). Fig...

  • Page 26

    26 condition of pm pump operation is the setting: service settings mixer 1 settings mixer support = pump only (in case mixer sensor t4 is not installed, this option is not available) condition of pc pump operation is the setting: service settings mixer 1 settings mixer support =pump only or = off (i...

  • Page 27

    27 fig. 26 wiring diagram - modules b and c: t1 – mixer 2 or 4 temperature sensor ct4, t2 – mixer 3 or 5 temperature sensor ct4, t3 – upper temperature sensor of the buffer, t4 – lower temperature sensor of the buffer ct4, t5 – reserve, re – relay (5÷6v, max 80ma) to connect reserve boiler r, alarm ...

  • Page 28

    28 good thermo contact should be maintained between sensors and measured surface. To this purpose thermoleading paste should be used. It is not acceptable to lubricate sensors with water or oil. Wires of sensors should be separated from network electrical wires. In such a case wrong readings of temp...

  • Page 29

    29 set-up the operation of room thermostat in: menu → boiler settings → room thermostat → thermostat selection → universal once the preset room temperature has been reached, thermostat opens its contacts and the display shows: once the temperature in the room, in which the room thermostat is install...

  • Page 30

    30 set the temperatures of reserve boiler switch on/off: menu service settings boiler settings reserve boiler reserve boiler deactivation temperature . Control of reserve boiler is off upon setting this parameter at ,,0”. Now, set-up output h on reserve boiler: menu service settings output h = reser...

  • Page 31

    31 limit switches), note: contacts 22, 21, 24 must have galvanic separation from contacts 12,11,14. 11.13 connection of alarm signalling the regulator may announce alarm condition by activating external device (e.G. Bell or gsm device to send sms). Alarm signalling and reserve boiler control use the...

  • Page 32

    32 - determine direction of servo closing/ opening. For this purpose, set the selector located on the housing of electric servo at manual control and find the positions of the valve in which the temperature in mixer circuit is maximum and minimum (it corresponds to the setting of the regulator of "1...

  • Page 33

    33 11.17 connection of temperature limiter to avoid boiler overheating in case of regulator failure, provide stb or other appropriate safety temperature limiter. Connect stb limiter to terminals 1-2 shown in fig. 25 . Once the limiter has tripped, fan and fuel feeder motor are off. Safety temperatur...

  • Page 34

    34 2-wire connection: for two-wire connection, power supply of 5v dc and rated current of min. 200ma is required. Disconnect gnd and +5v wires from the module (2) and re-connect them to external power supply unit arranged near ecoster200 (1). Ps unit is not included in the regulator supply. Max. Len...

  • Page 35

    35 12 boiler service settings burner settings → blow in output superv. Power of the fan in supervision mode - too high value may cause boiler overheating or flash back to the feeder; too low value - may result in fuel pouring. → feeding time supervision time of fuel feeding in supervision mode; too ...

  • Page 36

    36 → operation mode this parameter switches on and off the boiler return protection function performed using mixing valve with electric servo. Note: do not switch on this function if the valve is not provided with electric servo! → min. Return temp boiler return temperature below the value at which ...

  • Page 37

    37 max. Huw temperature this parameter is available upon connection of huw sensor. It defines max. Temperature to which huw container will be heated-up during discharge of excess heat from the boiler in emergency conditions. This parameter is important, because setting of too high value may cause th...

  • Page 38

    38 14 service settings of mixer mixer support → off mixer servo and mixer pump are off → ch on it is used when the mixer circuit supplies ch radiator system. Max. Temperature of mixer circuit is not limited, mixer is fully opened during alarms e.G. Boiler overheating. Note: do not activate this opti...

  • Page 39

    39 emergency valve opening it is a % valve opening during active boiler overheating alarm. This parameter is used for cast-iron boilers, and is available in some regulators only. Proportional range this parameter influences the range of mixer servo motion. Increase of its value causes actual mixer t...

  • Page 40

    40 17 alarm description 17.1 no fuel in case the boiler temperature dropped in operation mode by the value of delt lack of fuel below the boiler preset temperature, the regulator starts counting no fuel detection time. Menu service settings boiler settings no fuel detection time if, upon elapsing th...

  • Page 41

    41 17.4 feeder temp. Sensor damaged this alarm occurs in case of boiler temperature sensor damage and excess of its measurement range. Upon occurrence of this alarm, boiler, huw and mixer pumps start to possibly cool down the boiler. To reset the alarm - switch off and on the regulator. Check the se...

  • Page 42

    42 in order to remove the fuse, push in its socket with a flat screwdriver and turn it counter clockwise. 19.2 control panel replacement in case of replacement of control panel only - make sure the software used in new panel is compatible with the software of operating unit. Compatibility is guarant...

  • Page 43

    20 troubleshooting faults hints 1. The display is blank despite connection to power supply. Check:  if the main fuse is burnt-out, replace if so,  if the lead connecting the panel with the module is properly plugged in, and if it’s not damaged. 2. Preset ch temperature on the display is different ...

  • Page 44

    7. When the individual fuzzy logic mode is on, the fuel burns out too intensively.Paliwa  reduce fuel feeding rate by lower setting of the parameter fuel correction in fuzzy logic mode. See sec. 7.8,  check whether incompletely burnt fuel comes from operation in supervision mode. If yes- adjust th...

  • Page 45

    13. In hydraulic system with mixing valve and servo - mixer is closed  the reason may be response of return protection function - see sec.35. If the return protection function is active, i.E. Return protection 4d = on - check whether the sensor of water return to the boiler is thermally isolated fr...

  • Page 46

    22 change record v1.1 – change of fig. 33 and fig. 34.V1.2 – change of fig. 16 diagram with two additional mixer circuits upon connection of additional module b, where :1 – boiler, 2 – ecomaxx regulator – module a, 3 – ecomaxx regulator – control panel, 4 – fan, 5 – feeder temperature sensor, 6 - ge...

  • Page 48

    Ignatki 27a, 16-001 kleosin poland tel. +48 85 749-70-00 fax +48 85 749-70-14 plum@plum.Pl www.Plum.Pl www.Plumelectronics.Eu.