Technical Information Ti.b. Rematic 2945 C3K Control
User Manual: Rematic 2945 C3K - Control Technical Information
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rematic® 2945 C3 K Technical information rematic® 2945 C3 K • rematic® 2945 C3 K 1 rematic® 2945 C3 K TABLE OF CONTENT Preface 6 1 Safety notice 1.1 Intended use 1.2 Safety 1.3 Danger 7 7 7 7 2 General information 2.1 Installation notes and preparing for operation 8 8 3 Controls and displays 9 4 Specialist adjustments 4.1 Documenting the adjustments 4.2 General procedures 4.2.1 Performing 3rd -level adjustments 4.2.2 Performing 4th, 5th and 6th -level adjustments 10 10 10 10 11 5 Level 3 adjustments 5.1 Heating curve (adjustments 3-0 and 3-2) 5.1.1 Adjusting the heating curve slope and base point 5.1.2 Fine-adjusting the heating curve 5.1.3 Compensating differences between set and current room temperature 5.2 Maximum common flow / boiler flow temperature (adjustment 3-1) 5.3 Summertime limits 5.3.1 Summertime limit in heating mode (adjustment 3-3) 5.3.2 Summertime limit in night setback mode (adjustment 3-4) 5.3.3 Frost protection 5.4 Optimised start - pre-heat time (adjustment 3-5) 5.4.1 Calculation formula for pre-heat time based on outside temperature 5.4.2 Calculation formula for pre-heat time with room temperature correction 5.4.3 Correcting the basic value 5.5 Room temperature compensation (adjustment 3-6) 5.5.1 Calculation formula for room temperature compensation 5.6 Number of slaves and their addressing (adjustment 3-7) NOT AVAILABLE IN UK 13 13 13 15 2 15 15 16 16 16 16 16 17 17 17 18 19 19 5.7 5.8 6 7 8 Nature of the controller (adjustment 3-8) 5.7.1 Procedure for performing adjustment 3-8: Minimum modulation percentage (output) (adjustment 3-9) 5.8.1 Procedure for performing adjustment 3-9: 19 20 20 21 Level 4 adjustments 6.1 Domestic hot water operation modes 6.1.1 Simultaneous or priority D.H.W. heating (adjustment 4-0) 6.1.2 D.H.W. heating using a pump or a diverter valve (adjustment 4-1) 6.2 Flow water temperature for D.H.W. heating (adjustment 4-2) 6.3 Run-on time of domestic hot water pump (adjustment 4-3) 6.4 Legionnaires’ disease protection temperature (adjustment 4-4) 6.5 Legionnaires’ disease protection mode (adjustment 4-5) 6.6 Adaptive heating curve (adjustment 4-6) 6.7 Minimum boiler temperature (adjustment 4-7) 6.8 Flow temperature excess in °C in relation to the heating curve(s) (adjustment 4-8) 6.9 Adapting to the heating circuit (adjustment 4-9) 21 21 21 22 22 22 22 22 23 23 Level 5 adjustments 7.1 Boiler output at full load (adjustment 5-0) 7.2 Grouping boilers (adjustment 5-1) 7.3 Cut-in output of the follow-up boiler (adjustment 5-2) 7.4 Minimum boiler return temperature TBR MIN (adjustment 5-3) 7.5 Minimum fan speed with boiler switched off (adjustment 5-4) 7.6 Return temperature control selection (adjustment 5-5) (NOT USED IN THE UK) 7.7 Allocation of boiler relay outputs for on/off or high/low boilers (adjustment 5-6) (NOT USED IN THE UK) 7.8 Sequence changeover of boilers in groups 1 and 3 (adjustment 5-7) 7.9 P-band (proportional band) (adjustment 5-8) 7.10 I-band (integral proportion) (adjustment 5-9) 24 24 24 25 25 25 Level 6 adjustments 8.1 Maximum common flow temperature (adjustment 6-0) 8.2 Run-on time of the D.H.W. pump dependent on time or temperature (adjustment 6-1) 8.3 Boiler safety modes (adjustment 6-2) 8.4 Delayed cut-in of boiler stages 8.4.1 Delayed cut-in of 1st boiler (adjustment 6-3) 8.4.2 Delayed cut-in of subsequent boilers (adjustment 6-4) 27 27 3 23 23 25 26 26 26 27 27 27 28 28 29 rematic® 2945 C3 K 8.5 8.6 8.7 9 Blocking of boiler groups dependent on outside temperature 8.5.1 Blocking of boiler groups 3 and 4 dependent on outside temperature (adjustment 6-5) 8.5.2 Blocking of boiler groups 1 and 2 dependent on outside temperature (adjustment 6-6) Neutral zone for the internal Pl-behaviour of the controller (adjustment 6-7) Ramp mode to limit the speed of changes in output Pump functions 29 29 29 29 29 30 10 Remote control operation 10.1 Remote control FS 3611 10.1.1 Connecting the FS 3611 remote control (RED CIRCUIT NOT USED IN THE UK) 10.1.2 Operation with the FS 3611 remote control 10.2 Remote control FB 5240 (NOT USED IN THE UK) 10.2.1 Connecting the FB 5240 remote control 10.2.2 Operation with the FB 5240 remote control 31 31 11 Connector pinouts 11.1 Boiler control interface (in the UK the interface is supplied with the relevant controls package kit) 11.2 Connector layout (rear of controller) 11.3 Connector terminal pinouts 11.3.1 Live connections (230 Vac) 33 12 Functional tests and checks 12.1 Service program 12.1.1 Starting the service program 12.1.2 Terminating the service program 12.2 Test mode for controller output signals 12.2.1 Operation 12.2.2 Display 12.2.3 Closing the test mode 12.2.4 Meaning of keys and allocation to modes 12.3 Checking the temperature sensors 12.4 Checking temperature settings 12.4.1 Displayed symbols and their meanings 12.5 Temperature sensor resistance values 37 37 37 37 37 37 38 38 38 39 39 40 41 4 31 31 32 32 32 33 34 34 34 13 Control of modulating boilers 42 14 Error messages 43 15 Explanation of terms 44 16 Technical data 45 17 Dimensions and fitting instructions 17.1 Dimensions 17.2 Panel cut-out 17.3 Fitting instructions (For UK see seperate fitting instructions) 45 45 46 46 18 Adjustment keys, boiler data and system data 18.1 level 3 controls 18.2 level 4 controls 18.3 level 5 controls 18.4 level 6 controls 18.5 Data for Remeha modulating boilers in a single-boiler installation 18.6 Data for Remeha modulating boilers in a multiple boiler installation 18.7 Installations with slave controllers rematic 2940 C3 S and/or 2945 C3 S 47 47 49 51 52 54 54 55 5 rematic® 2945 C3 K PREFACE This rematic® controller is a modern electronic device with numerous functions for operating a heating system at maximum efficiency. Most adjustments and set points are performed just once by the installation specialists. These technical instructions contain useful and important information for the correct operation and commissioning of the rematic® optimising / weather compensator - rematic® 2945 C3K-m. This controller is capable of controlling from 1- 8 boilers using direct modulation or 1 boiler on high/low control, with independant time and temperature control over domestic hot water production - rematic® 2945 C3-s This rematic® weather compensator is available as an optional extra for the Remeha Quinta 45/65 and Gas 210 ECO series of boilers only. The 2945 Slave can control 2 mixing circuits a calorifyer and 1 high/low boiler. - rematic® 2940 C3-s: the 2940 C3 Slave can control 1 mixing circuit and a calorifyer. With the maximum lay-out of one Master and 4 Slaves, 5 high/low boilers can be controlled (leaving space for 3 modulating boilers to be controlled additionally) and up to 10 independent heating circuits. These rematic® weather compensators are prepared for the modulating control of the Remeha Quinta 45/65 and Gas 210 ECO boilers. Read these instructions carefully before putting the controller into operation, familiarise yourself with it’s control functions and operation, strictly observing the instructions given. Instructions in the text that are marked by a warning symbol must be observed under all circumstances. Failure to do so may unnecessarily raise energy consumption, invalidate warranty or prevent the installation from operating properly. For User Guidelines see the separate booklet with details on the programming of the time clock and use of the 1st & 2nd level controls. The installation and commissioning of the controller must be carried out by a competent Engineer, with the relevant product training and general certification i.e.: CORGI, ACOPS, IEE regs. etc. If you have any questions, or if you need more information about specific subjects relating to this controller, or it’s installation please do not hesitate to contact us. The data published in these technical instructions is based on the latest information (at date of publication) and may be subject to revisions. We reserve the right to continuous development in both design and manufacture, therefore any changes to the technology employed may not be retrospective nor may we be obliged to adjust earlier supplies accordingly. Please read the Safety Notice in section 1 before commencing the work. 6 1 SAFETY NOTICE 1.1 Intended use The controller is an electronic device for use in conjunction with a hydraulic circuit in accordance with the manufacturer’s specifications. The device is not to be used for any other purpose. The controller complies with the following EU guidelines: - 72/23/EWG “Low Voltage Guidelines” - 89/336/EWG “EMC Guidelines”, including amendment guideline 92/31/EWG 1.2 Safety Power supply to the boiler must be isolated before carrying out any modifications to the wiring of the controller. This device uses the latest technology and complies with applicable safety regulations. 1.3 Danger The controller and associated connection panel has a 230V power supply taken from the boiler. Unauthorised repairs or installation by unqualified persons may result in a life-threatening electric shock hazard. Installation and commissioning must be performed by adequately qualified specialist personnel. This unit is factory sealed and unauthorised access and repairs will invalidate any warranty therefore any repairs to the unit must be carried out by manufacturer. Instructions in the text that are marked by a warning symbol must be observed under all circumstances. 7 rematic® 2945 C3 K 2 GENERAL INFORMATION 2.1 Installation notes and preparing for operation The installation and commissioning of the controller must be carried out by a competent Engineer, with the relevant product training and general certification i.e.: CORGI, ACOPS, IEE regs. etc. It is strongly recommended to leave the controller under power, even during the summer season. (For further installation details, see section 11 onwards and the separate fitting instructions.) Warning: Power supply to the boiler must be isolated before carrying out any modifications to the wiring of the controller. Once the controller is completely installed and ready for operation re-establish the power supply. The normal display (unlit) should appear on the control. If the normal display fails to appear , press the reset button using a fine pointed object (recessed to the right of the 2nd-level controls), set the time and day of week, if necessary. This operation will start the controller, without affecting existing settings or the clock programme. If the normal display does not appear please check the following: - Are all the required cables and connectors plugged together? - Are the electrical fuses in order? - Is the power supply on? Note 1: The controller should reset itself automatically when power supply is established, exchanging data with the boiler control(s). The display may show the DHW sensor temperature as 99 °C until this process is completed. Note 2: All references to the red zone and mixing valve zones are not applicable in UK. Only one heating and one DHW timed zone is supported in UK 8 3 CONTROLS AND DISPLAYS Heating circuit toggle key (dual circuit controller only) 1st -level controls 2nd -level controls Reset button (recessed) P 3rd till 6th -level controls (specialist levels) Fig. 01 The 1st and 2nd -level controls are explained in chapter “2.3 User controls and display” of the User Guidelines. The specialist-level controls have multiple functions, i.e. the same key may have different functions at the 3rd, 4th, 5th and 6th levels. The key selects between the 3rd till 6th specialist levels; the procedure is described under chapter “3 Specialists adjustments”. The 5th and 6th specialist levels are protected by a code. Adjustments are numbered using the operating level (3, 4, 5 or 6), plus the number to the right or left of the key. Dual circuit controllers (not applicable to the UK) include certain adjustments that apply to specific heating circuits (identified by the display background colour). The desired circuit must be set using the toggle key (see Fig. 01). 9 rematic® 2945 C3 K Fig. 02 From level 3 onwards, the manufacturer, or system installers acting on manufacturer’s instructions, may restrict access to individual adjustments or entire operating levels. The symbol “\” appears in the display, together with the set value, when ever a protected key is pressed. 4 SPECIALIST ADJUSTMENTS 4.1 Documenting the adjustments Record all initial settings and subsequent adjustments in the tables contained in the section “18 Adjustment keys, boiler data and system data”. These tables provide a full overview of 3rd till 6th level adjustment options. Note: Some adjustments (ie heating slope and parallel shift) do not show an immediate response. Therefore it is unwise to make more than one adjustment at a time – waiting to see the reaction before making another. 4.2 General procedures The basic procedure for performing a specialist adjustment is always the same. The example below demonstrates the principle. 4.2.1 Performing 3rd -level adjustments P t Fig. 03 10 - Remove the cover (press down on the arrow marks on the bottom edge in the centre), and press once on the key corresponding to the desired adjustment, for example the key . The present setting appears in the display. - Adjust by pressing the “–” or “+” side of the key. Changes take effect immediately. The display returns to normal after 1 minute, or you can press the key to restore the normal display. You can make further 3rd -level adjustments without returning to the normal display. Simply press another 3rd-level key and perform the adjustment. To proceed to the 4th, 5th or 6th level, press the move to the next level) key one or more times (each action 4.2.2 Performing 4th, 5th and 6th -level adjustments P t Fig. 04 - Remove the cover (press down on the arrow marks on the bottom edge in the centre), and press key to access the specialist levels. The first time you press this key, “3 - -” shows in the display. You can now perform 3rd -level adjustments (see the previous section). Press the key again and “4 - -” appears in the display meaning that you are now at the 4th operating level. The next time you press the key, the word “out” is displayed. This is the test level, where outputs may be switched on and off for testing purposes (see section “12.2 Test mode for controller output signals”). The next time you press the key, the word “codE” is displayed. The 5th operating level is protected by a code, which means that in order to be able to perform adjustments in this level you must enter the correct code (see section “18.3 level 5 11 rematic® 2945 C3 K controls”) and press key again. If you press the key without entering the code, the word “not” is displayed, pressing the key again returns you back to the 3rd operating level, and so on. P t Fig. 05 - Press once on the key corresponding to the desired adjustment, for example in level 4 on key The present setting appears in the display. - Adjust by pressing the “–” or “+” side of the key (ON/OFF toggle in this example). Changes take effect immediately. The display will return to normal after 1 minute of inactivity, or you can press the key to restore the normal display right away. You can make further adjustments in the present level without returning to the normal display. To do so, press another key in the current operating level and perform your adjustments. To switch to the 4th, 5th or 6th operating levels before returning to the normal display, press the key the required number of times. Press the key repeatedly to cycle through the various operating levels. 12 5 LEVEL 3 ADJUSTMENTS °C Slope Base point flow temperature (TF) Slope 5.1 Heating curve (adjustments 3-0 and 3-2) The heating curve indicates the relationship between the flow water and the outside temperature, ∆TF/∆TO. 90 80 Set point maximum flow / boiler 70 60 50 40 25 °C Set point room temperature 30 15 °C 20 10 -20 -15 -10 Outside temperature -5 TO °C 5 0 10 15 20 °C Fig. 06 NOTE: Because of the building’s thermal inertia, it is recommended to perform no more than one adjustment step per day. Remember to record each change and reaction to the change. 5.1.1 Adjusting the heating curve slope and base point The heating curve is governed by the following adjustments: 13 rematic® 2945 C3 K Adjuster button Function Basic setting performed by: Slope Specialists Flow temperature base point Specialists Desired heating temperature User Desired night setback temperature User Table 01 The table below will assist in determining the heating curve appropriate to a given heating system. You will need to know the type of heating system, and the climatic zone in which it will operate. High-temperature 90/70 Radiator heating Standard-temperature 81/70 Radiator heating Low-temperature 70/50 Radiator heating Ultra-low temperature 50/35 Underfloor heating Climatic zone where the building is located: - 10°C = A - 8°C = B - 6°C = C - 4°C = D - 2°C = E base Heat curve rate rise = ∆TF/∆TO point TF at TO = + 15°C 50/35 20°C 25°C 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 Heating system A B C A B C D D E 70/50 30°C 35°C E A B A B C D C D 81/70 30°C 35°C A 90/70 39°C Table 02 14 E E A B C D B C D E A B C D E E Example: Heating system class = 81/70 Base point at TO 15°C = 35°C Climatic zone - 2°C = E Resulting slope = 2.7 5.1.2 Fine-adjusting the heating curve At day time outside temp. between +5°C and +15°C -20°C and +5°C room temperature too cold too warm set 0,2 lower and set 0,2 higher and set 5ºC higher set 5ºC lower set 0,2 higher set 0,2 lower Table 03 5.1.3 Compensating differences between set and current room temperature The end user programs temperature set points in terms of a room temperature (oC) with buttons and . Even if the heating curve slope is correctly adjusted, depending on the heating system there may still be a difference between the room temperature measured by a thermometer (actual temperature) and the temperature defined in the controller (set temperature). This may be adjusted by moving the base point with button . Room temperature Key too low Increase by pressing [ + ] too high Decrease by pressing [ - ] ) Table 04 Increasing or decreasing the set point influences the room temperature. A 5°C change in flow temperature set point alters the calculated room temperature as follows: - Underfloor heating: approx. 2°C - Radiator heating: approx. 1°C 5.2 Maximum common flow / boiler flow temperature (adjustment 3-1) The flow water temperature is limited to the pre-set value (Note: this cannot override the boilers flow temp set point). This limiting value applies to the selected heating circuit or to the cascade temperature, depending on usage. 15 rematic® 2945 C3 K This adjustment is not intended as a safety device! Underfloor heating may require an additional control to prevent overheating. 5.3 Summertime limits This set point read with the outside sensor will, if exceeded, hold the heating in the off position 5.3.1 Summertime limit in heating mode (adjustment 3-3) Heating ceases once the average outside temperature exceeds the set temperature. Domestic hot water keeps on operating. Heating resumes once the average outside temperature drops more than 2°C below the set temperature. 5.3.2 Summertime limit in night setback mode (adjustment 3-4) This adjustment defines the maximum outside temperature in order for the flow temperature to be controlled according to the night setback heating curve. Heating ceases at outside temperatures above the set temperature. Once the outside temperature drops more than 2°C below the set temperature, the flow water temperature is controlled according to the night setback heating curve. Setting a value below 2°C activates frost protection at outside temperatures between 2°C and the set temperature, see section “5.3.3 Frost protection”. 5.3.3 Frost protection The circulation pump is switched on cyclically below an outside temperature of 2°C (frost protection limit). In each cycle it runs for 6 minutes, then switches off for 54 minutes. If the adjustment 3-4 is set above 2°C, the “frost protection mode” is overruled by the “summertime limit in night setback mode” as described under section “5.3.2 Summertime limit in night setback mode (adjustment 3-4)”. 5.4 Optimised start - pre-heat time (adjustment 3-5) Pre-heat time gives the heating system a “warm up time” in order to attain operating temperature at set occupancy time. A basic value for the pre-heat time, based on the type of heating system, has to be programmed so that the controller is able to calculate the actual start time to achieve room temperature set point at set occupancy time. The controller takes the following factors into account: - measured outside temperature - measured room temperature, assuming that a room sensor or remote control is fitted. Recommended basic value: - Underfloor heating: 210 (minutes) - Radiator heating 150 (minutes) 16 The basic value is the pre-heat time, valid for an outside temperature of -10°C (= the so called standard climatic zone). The higher the outside temperature, the shorter the pre-heat time, which decreases to 0 minutes at 20°C. 5.4.1 Calculation formula for pre-heat time based on outside temperature: The controller calculates according the following formula: PHTCAL= 20-TOMES x basic value 20-climate point PHT CAL = calculated pre-heat time prior to occupancy time TO MES = measured outside temperature Example: PHTCAL= basic value Outside temperature = 150 minutes = 5°C 20 - 5 x 150 = 75 minutes 20 - - 10 5.4.2 Calculation formula for pre-heat time with room temperature correction If a room sensor or remote control is connected, the measured ambient room temperature is included in the pre-heat time calculation. The pre-heat time calculated earlier is shortened by a factor that is calculated as follows: PHTCOR = TRSET - TRMES 5 PHT COR PHT CAL TR SET TR MES = = = = Example: TR SET = 20°C TR MES = 18°C PHTCOR = x PHTCAL corrected pre-heat time calculated pre-heat time prior to occupancy time set room temperature measured room temperature 20 - 18 5 x 75 = 30 minutes 5.4.3 Correcting the basic value Should the design temperature be reached before or after occupancy time, correct the basic value as follows: TR SET is reached: Button too early reduce basic value (press [ - ] side) too late increase basic value (press [ + ] side) Table 05 17 rematic® 2945 C3 K It is recommended that modifications of the basic value be no shorter than the following: - Underfloor heating 30 minutes - Radiator heating 20 minutes If the heating system start-up does not need to be optimised in this way, set the basic value to 0. The heating system then commences operation at the programmed time. 5.5 Room temperature compensation (adjustment 3-6) This adjustment is relevant only if a room sensor or remote control is connected. If the temperature measured by a room sensor or remote control deviates from the set point (e.g. as a result of external heating such as solar gain), the controller corrects the water flow temperature according to the compensation value. This specifies the increase or decrease in water flow temperature (in °C) per °C room temperature deviation. - Room over-temperature = reduced flow temperature - Room under-temperature = increased flow temperature The effect of the setting is shown in Fig. 07. Recommended settings: No room compensation Underfloor heating Radiator heating • Mild compensation • Medium compensation • Strong compensation 0 1-4 1-3 4-6 7–9 0 3 6 9 -4 -3 -2 -1 +1 ∆TF = Change in flow water temperature ∆TR = Change in room temperature Fig. 07 18 +2 +3 +4 Einstellwert Setpoint 3-6 ∆TF (°C) ∆TR (°C) 5.5.1 Calculation formula for room temperature compensation Deviation of the room temperature from the set point causes a change in the flow water temperature. The resulting flow water temperature set point is calculated as follows: TF CAL “NEW” TF CAL TR SET TR MES K = TF = = = = CAL + ((TR SET – TR ) x K) MES calculated flow temperature set room temperature measured room temperature compensation factor (adjustment 3-6) Example: Desired room temperature (TR set) 20°C Current room temperature (TR MES)(elevation due to e.g. incoming sunshine) Room temperature compensation K (adjustment 3-6) 4 °C/°C Flow water temperature setting (TF CAL)(according to heating curve) 45°C TF CAL “NEW” 22°C = 45 + ((20 - 22) x 4) = 37°C 5.6 Number of slaves and their addressing (adjustment 3-7) NOT AVAILABLE IN UK This adjustment determines whether the controller at hand is used as a master or as a slave controller and simultaneously the number and sequence of the slaves are indicated. - Master controller: By entering one of the codes 0, 1, 2, 3 or 4, the number of connected slaves is programmed. With only one controller in the installation, adjustment 3-7 should be set at 0. - Slave controller: The slave controller is assigned an address by entering one of the codes F1, F2, F3 or F4.(F= follower controller). When adjustment 3-7 is incorrectly programmed, the master controller can communicate neither with the slave controllers, nor with the boiler(s). 5.7 Nature of the controller (adjustment 3-8) This sets the controller to the number of boilers and method of control (Modulation or High / Low) One master controller can operate up to 8 modulating boilers. With one master - and 4 slave controllers 5 on/off or high low boilers can be handled. As long as the total number of boilers does not exceed 8 and the number of on/off - or high/low boilers does not exceed 5, any combination of modulating -, on/off - or high/low boilers can be controlled.(NOT AVAILABLE IN THE UK) 19 rematic® 2945 C3 K The settings which may be chosen are as follows: Master controller: (adjustment 3-7 is set to 0, 1, 2, 3, or 4) Adjustment 3-8 must be set for each boiler in the installation. b1 = setting for an on/off boiler b2 = setting for a high/low boiler FA. = setting for communication with a modulating boiler control -= setting for those boiler positions (of 8) which are not in use Slave controller: (adjustment 3-7 is set to F1, F2, F3, or F4) NOT AVAILABLE IN THE UK -= setting for the slave that only controls supplementary mixing circuits b1 = setting for the slave that controls a supplementary on/off boiler b2 = setting for the slave that controls a supplementary high low boiler If the controller has been programmed with the FA.- - setting, it detects whether the sensors are connected at the controller or at the boiler control and the controller itself supplements the FA. setting with a number as follows (If an error occurs it might help to program the correct FA setting directly by hand): Adjustment 3-8 D.H.W. sensor at: Flow sensor at: FA1 Compensator Compensator FA2 Boiler control Compensator FA3 Compensator Boiler control FA4 Boiler control Boiler control Table 06 The outside sensor packed in the rematic® kit must be connected to the controller adapter plate. (See also the relevant fitting and wiring diagrams) 5.7.1 Procedure for performing adjustment 3-8: - Select adjustment 3-8 by pushing key one time. - If boilers are connected, use the P key to invoke the boiler for which the adjustments are to apply. Instead of the time bar, the points in the display indicate how many boilers are programmed. The point of the invoked boiler flashes. You can now perform the required adjustment or ad more boilers. 5.8 Minimum modulation percentage (output) (adjustment 3-9) The minimum output of the boiler may be entered as a percentage of the nominal output of the boiler. The minimum modulation percentage must be set for each boiler. 20 5.8.1 Procedure for performing adjustment 3-9: - Select adjustment 3-9 by pushing key one time. - If multiple boilers are connected, use the P key to invoke the boiler for which the adjustments are to apply. Instead of the time bar, the points in the display indicate how many boilers are programmed. The point of the invoked boiler flashes. You can now perform the required adjustment. 6 LEVEL 4 ADJUSTMENTS 6.1 Domestic hot water operation modes NOTE: In a cascade installation if the DHW is controlled by the rematic® controller all boilers connected to the control will be made available to satisfy the demand. Domestic hot water heating is activated when the DHW time channel is in the on position and the connected DHW sensor shows that the water temperature in the calorifier is 5 °C below the set point. When the D.H.W. set point is reached the demand is deactivated. 6.1.1 Simultaneous or priority D.H.W. heating (adjustment 4-0) The domestic hot water may be heated simultaneously with the heating circuits, or be given priority. Setting adjustment 4-0 to “OFF”: D.H.W. heating has priority over the heating circuits The heating circuits are switched off while the domestic hot water is heated. (i.e. system pumps “OFF) The heating circuits are enabled once the domestic hot water has reached the set temperature. The D.H.W. pump continues to operate for a period set by adjustment 4-3. If a heating circuit demands a higher flow temperature, the controller immediately shuts off the domestic hot water pump. A diverting valve can be used In place of a D.H.W. primary pump (see section 6.1.2). Setting adjustment 4-0 to”ON”: Simultaneous operation of D.H.W. heating (Requires the use of a D.H.W. primary pump and is not possible with a diverting valve). The controller will boost the flow temperature from the compensated level to the DHW flow temp set point which will mean that the heating flow temperature may also be elevated 21 rematic® 2945 C3 K 6.1.2 D.H.W. heating using a pump or a diverter valve (adjustment 4-1) Depending on the heating system, it is possible to select a pump or a diverter valve for D.H.W. heating. Setting of adjustment 4-1 to “OFF” : Domestic hot water heating using a pump See section 6.1.1 for explanation Setting of adjustment 4-1 to “ON” : Domestic hot water heating using a diverting valve Together with the diverting valve, the system pump feeds flow water to the calorifyer heat exchanger. The pump therefore continues to run during D.H.W. heating. Simultaneous D.H.W. and heating is not possible with this setting. (see also section “6.1.1 Simultaneous or priority D.H.W. heating (adjustment 4-0)”). 6.2 Flow water temperature for D.H.W. heating (adjustment 4-2) The D.H.W. temperature set point, increased by the value set here, gives the set flow temperature of the boiler(s) for D.H.W. heating. 6.3 Run-on time of domestic hot water pump (adjustment 4-3) The value set here determines how long, after attaining the set D.H.W. temperature, the domestic hot water pump continues to run and the diverting valve is in the DHW mode. 6.4 Legionnaires’ disease protection temperature (adjustment 4-4) The domestic hot water temperature programmed here (minimum setting is 60 °C) is initiated on the day set in adjustment 3-4 (see section “6.5 Legionnaires’ disease protection mode (adjustment 4-5)”). Adjustment 4-4 is set higher than the normal domestic hot water temperature, set with button and is used to protect against Legionnaires’ disease. 6.5 Legionnaires’ disease protection mode (adjustment 4-5) In accordance with the code set here, the Legionnaires’ disease protection temperature, set with adjustment 4-4 (see section 6.4 “Legionnaires’ disease protection temperature (adjustment 4-4)” is enabled for two hours during the first D.H.W. heating on each day in question. The set codes are as follows: 1 = Mondays 6 = Saturdays 2 = Tuesdays 7 = Sundays 3 = Wednesdays 8 = daily 4 = Thursdays 9 = continuously at the temperature set with adjustment 4-4 5 = Fridays 0 = no Legionnaires’ disease protection mode 22 6.6 Adaptive heating curve (adjustment 4-6) If a remote control or room sensor (supplied as standard in the UK) is connected to the controller, it can automatically correct the heating curve to suit the buildings properties. Adjustment 4-6 can be set for each heating circuit separately. Adaptive heating curve “inactive” (“OFF” setting) The operator-defined heating curve is not automatically modified (useful if there is another heat source such as an open fireplace). Adaptive heating curve “active” (“ON” setting) The controller automatically determines the optimal heating curve. It might take more than a week before the optimal curve is reached. 6.7 Minimum boiler temperature (adjustment 4-7) The controller maintains a minimum flow temperature for the boiler(s) in heating and night set back mode. This adjustment is used to prevent the compensator lowering the flow temp below the min required for heat emitters used in the system (ie fan convectors may have a min flow requirement of 55 oC). Note : This set point should not be set below to the boiler manufacturer’s specifications. 6.8 Flow temperature excess in °C in relation to the heating curve(s) (adjustment 4-8) During the heating season, the set flow temperature for the boiler(s) is higher, by the value set here, than the highest flow temperature, requested by one of the heating circuits. This adjustment must be set for each heating circuit. Recommended settings: 0 = for direct heating circuits 5 = for mixed heating circuits 6.9 Adapting to the heating circuit (adjustment 4-9) Before performing this adjustment, the required heating circuit must be selected! (Only setting 2 for UK) Setting 0 = 3-point output for mixer drives with 230 V motor with 2 directions of rotation The direction of rotation of the mixer is controlled by energising the “ON” or the “OFF” relay in the controller. Setting 1 = 2-point output for mixer drives with automatic return, e.g. 230 V thermal mixer drives The mixer drive opens the valve on energising the “ON” relay in the controller. It closes automatically if the controller de-energises the “ON” relay. The controller maintains a certain valve position by intermittently energising the “ON” relay. Setting 2 = setting for a direct heating circuit with no output for a mixer drive The system pump for this circuit runs continuously during the heating season. (The mixer symbol is not displayed.) 23 rematic® 2945 C3 K 7 LEVEL 5 ADJUSTMENTS The adjustments in the 5th operating level make it possible to adapt the controller adjustments to the features and allocation of each boiler in a multiple boiler installation. Access to this operating level is coded. Improper changes in this operating level may impair the functioning of the boiler(s). The adjustments 5-0 to 5-6 described below must be individually adjusted for each boiler. The number of boilers has been programmed with adjustment 3-8. Select the adjustment, e.g. 5-3, then use the P key to select the relevant boiler. The display shows a row of points instead of the time bar. The flashing point indicates which boiler has been selected. You can now adjust the value of the selected boiler. 7.1 Boiler output at full load (adjustment 5-0) The full load output of the selected boiler must be entered in the controller in kW. This setting is essential for modulating boilers. The nominal output specification on the data badge of the boiler is definitive. It is not compulsory to enter this value for connected on/off or high/low boilers (controlled by relay contacts in the controller). 7.2 Grouping boilers (adjustment 5-1) Each boiler in a multiple boiler installation is assigned to a group. There are 4 groups to be selected. The following group features should be noted when assigning boilers: - Groups 1 and 3 have automatic sequence changeover (see section “7.8 Sequence changeover of boilers in groups 1 and 3 (adjustment 5-7)”). - Groups 3 and 4 are switched off when the outside temperature rises above the set heating limit value (see section “8.5.1 Blocking of boiler groups 3 and 4 dependent on outside temperature (adjustment 6-5)”). - Groups 1 and 2 are switched off when the outside temperature drops below the set heating limit value (see section “8.5.2 Blocking of boiler groups 1 and 2 dependent on outside temperature (adjustment 6-6)”). Normally all modulating condensing boilers are programmed in group 1. The sequence of the groups is as follows: With increasing heat demand, the boilers in group 2 will not be started before all boilers in group 1 are in service at full load. The same principle applies for groups 3 and 4. The allocation of boilers to groups allows the energy saving operation of installations with condensing boilers and standard boilers. It also allows the bivalent operation of installations with heating boilers and heat pumps. It permits automatic output limitation as a function of outside temperature. Automatic sequence changeover allows you to programme a load compensation for the boilers. 24 7.3 Cut-in output of the follow-up boiler (adjustment 5-2) This set value determines the percentage output of the selected boiler with which the following boiler is to be switched on. The first boiler is switched on immediately after the time, set with adjustment 6-3, is elapsed. 7.4 Minimum boiler return temperature TBR MIN (adjustment 5-3) The boiler return control is active for the selected boiler if the set value of TBR MIN is greater than 0. Heating circuits are enabled when the return temperature of the boiler rises above the set point. This adjuster is not active for stages programmed with FA. 7.5 Minimum fan speed with boiler switched off (adjustment 5-4) The minimum speed of the boiler fan is adjustable for modulating burners as a percentage of the maximum fan speed. 0 = OFF, which means the fan is not required with burner switched off. This adjustment might be of use when ventilation problems occur. 7.6 Return temperature control selection (adjustment 5-5) (NOT USED IN THE UK) The return temperature of the boiler(s) can be controlled in several ways, which can be separately set for each boiler. The settings have the following meaning: 0 = U0...U5 corresponding to the boiler safety modes.(see section “8.3 Boiler safety modes (adjustment 6-2)”) 1 = Return temperature control by the heating circuit mixer(s). The boiler circuit pump Uw operates continuously during the heating season. 2 = Return temperature control by the heating circuit mixer(s) without boiler circuit pump Uw. The controller calculates a variable minimum boiler flow temperature based on the set value for the minimum boiler return temperature (adjustment 5-3). The lower the measured return temperature, the higher the required minimum boiler flow temperature TF MIN. 3 = The “green” heating circuit mixer is used as return temperature control. The mixer Mr itself, as well as the boiler circuit pump Uw are mounted in the return pipework of the boiler. Operation and display for the green circuit are blocked, with the exception of the temperature display. 25 rematic® 2945 C3 K 4 = The “green” heating circuit mixer is used as return temperature control without the assistance of a boiler circuit pump. The mixer Mr itself is mounted in the flow pipework of the boiler. Operation and display for the green circuit are blocked, with the exception of the temperature display. The controller calculates a variable minimum boiler flow temperature based on the set value for the minimum boiler return temperature (adjustment 5-3). The lower the measured return temperature, the higher the required minimum boiler flow temperature TF MIN. 5 = Return temperature control only with boiler circuit pump Uw. The pump Uw switches off on reaching the minimum return temperature TBR MIN. No mixer Mr is used. No heating circuit mixer is influenced by the set min. boiler return temperature TBR MIN. 6 = The “green” heating circuit mixer is used as return temperature control for all boilers in a multiple boiler installation. The mixer Mr itself is mounted in the common return pipework of the boilers. Each boiler has its own boiler circuit pump Uw. Operation and display for the green circuit are blocked, with the exception of the temperature display. The sequence changeover (adjustment 5-7) does not influence this mode. 7.7 Allocation of boiler relay outputs for on/off or high/low boilers (adjustment 5-6) (NOT USED IN THE UK) If relay contacts are used to control on/off and/or high/low boiler(s), they must be allocated to a controller. The settings are as follows: --- = no boiler relay function (there is no on/off or high/low boiler in the installation) M = boiler relay function at the master (the 1rst boiler is an on/off or high/ low boiler) F1 = boiler relay function at slave 1(the 2nd boiler is an on/off or high/ low boiler) F2 = relay function at slave 2 (the 3rd boiler is an on/off or high/ low boiler) F3 = relay function at slave 3 (the 4th boiler is an on/off or high/ low boiler) F4 = relay function at slave 4 (the 5th boiler is an on/off or high/ low boiler) 7.8 Sequence changeover of boilers in groups 1 and 3 (adjustment 5-7) OFF = continuous forward operation ON = continuous backward operation 10 ... 999 = sequence changeover after the set number of running hours of the first boiler. 7.9 P-band (proportional band) (adjustment 5-8) The P-band indicates the deviation between the actual flow temperature and flow temperature set point at which 100% boiler output (for all boilers) is required (setting band 0 to 30 °C). With increasing deviation, a low set value produces a large change in output. The heat production reacts quickly on changes in heat demand. With 26 increasing deviation, a high set value produces a small change in output. The heat production reacts slowly on changes in heat demand. The factory setting rarely needs modification. 7.10 I-band (integral proportion) (adjustment 5-9) The I-proportion indicates, at a constant deviation between the actual flow temperature and flow temperature set point, how long (minutes) the controller takes to double the output needed according to the P-band. A low set value produces a rapid change in output where there is a deviation. The heat production reacts quickly, even where there is only a short term temperature deviation. A high set value produces a slowly increasing change in output where there is a deviation. The heat production reacts slowly on an existing temperature deviation. The factory settings rarely needs modification. 8 LEVEL 6 ADJUSTMENTS 8.1 Maximum common flow temperature (adjustment 6-0) To prevent the common flow temperature exceeding the setpoint, the controller will throttle the output of the boiler(s) or switch them off. This adjustment has priority over all other requirements. 8.2 Run-on time of the D.H.W. pump dependent on time or temperature (adjustment 6-1) With adjustment 6-1 the run-on time of the D.H.W. pump can be programmed dependent on time or dependent on temperature. Setting “off”: time-dependent run-on time After domestic hot water heating is completed, the D.H.W. pump continues to operate for the period set with adjustment 4-3 (see section “6.3 Run-on time of domestic hot water pump (adjustment 4-3)”). Setting “on”: temperature-dependent run-on time After domestic hot water heating is completed, the D.H.W. pump continues to operate until the differential between the flow temperature and the domestic hot water temperatures reaches 3 °C. However, the run-on time is limited to the time period set in adjustment 4-3 (see section “6.3 Run-on time of domestic hot water pump (adjustment 4-3)”). 8.3 Boiler safety modes (adjustment 6-2) Depending on the safety mode selected here, given a sudden heat demand (from the heating circuits and/or domestic hot water heating) the heating load is immediately switched on or only after the flow temperature of the boiler (or the common flow temperature of the boilers) has reached the set minimum flow temperature TF MIN (see section “6.7 Minimum boiler temperature (adjustment 4-7)”). 27 rematic® 2945 C3 K In selecting the boiler safety mode, the functioning of the boiler circuit pump is determined at the same time as follows: Setting Safety mode Function of the boiler circuit pump Uw 0 U0 1 U1 Uw operates continuously during the heating season. 2 U3 3 U0 4 U1 5 U3 After the master boiler is switched off, Uw continues to operate for 15 minutes or (for communicating boilers) for the period set in the boiler control. Table 07 Safety mode U0 (settings 0 and 3) This mode ensures that the set minimum boiler temperature TF MIN (adjustment 4-7) is not undershot by using the maximum output of the boiler or boilers. If this set value is undershot, no heat load is switched off. Safety mode U1 (settings 1 and 4) This mode ensures that the minimum boiler temperature TF MIN (adjustment 4-7) is not undershot by using the maximum output of the boiler or boilers. Additionally, however, heat load is switched off if this set value is undershot. Safety mode U3 (settings 2 and 5) This mode ensures that, if the flow temperature of the boiler(s) drops below the set minimum return temperature TBR MIN (see section “7.4 Minimum boiler return temperature TBR MIN (adjustment 5-3)”), no heat load is switched off and no boilers are switched on. It is not before the flow temperature of the boiler(s) has dropped to the set point (according to the heating curve or external requirement) and heat production is necessary that the mixers are closed, the circuit pumps are switched off and the boilers are switched on with the required output. The heating circuits are enabled again once the flow temperature of the boiler(s) reaches the minimum temperature range. 8.4 Delayed cut-in of boiler stages 8.4.1 Delayed cut-in of 1st boiler (adjustment 6-3) A delayed cut-in may be programmed for the 1st boiler. The count down starts when the controller requests the first boiler, based on his internal PI calculation. 28 8.4.2 Delayed cut-in of subsequent boilers (adjustment 6-4) A second delayed cut-in may be programmed for the following boilers. The count down starts when the controller requests the next boiler. The programmed time is the same for all subsequent boilers. This time delay can prevent short-term switching on of boilers. 8.5 Blocking of boiler groups dependent on outside temperature Since a normal boiler installation does not need these adjustments, the adjustments 6-5 and 6-6 are ceased to be operative by the factory settings. 8.5.1 Blocking of boiler groups 3 and 4 dependent on outside temperature (adjustment 6-5) If the outside temperature exceeds the set value, the boilers associated with groups 3 and 4 are blocked. If the outside temperature drops by more than 2 °C below this value, the boilers in these groups are enabled again. 8.5.2 Blocking of boiler groups 1 and 2 dependent on outside temperature (adjustment 6-6) If the outside temperature undershoots the set value, the boilers associated with groups 1 and 2 are blocked. If the outside temperature rises by more than 2 °C above this value, the boilers in these groups are enabled again. This adjustment is important if air/water heat pumps are used in combination with boilers. 8.6 Neutral zone for the internal Pl-behaviour of the controller (adjustment 6-7) Variations in the (common) flow temperature within the neutral zone around the flow temperature set point, will not cause changes in the output of the boiler(s). 8.7 Ramp mode to limit the speed of changes in output If there are jumps in the set point (e.g. night/day changeover) or changes in load, this adjustment allows the speed of change in output to be limited. The ramp function may be adjusted separately for set temperature / /measured temperature deviations both outside and inside the proportional band. The maximum allowed change in output per minute is set as a percentage of the total boiler output. The higher the set value, the quicker the response in boiler output to a flow temperature change. The factory settings apply to 99% of the installations. - Adjustment 6-8: Ramp function outside the P-band - Adjustment 6-9: Ramp function inside the P-band For installation personnel only 29 rematic® 2945 C3 K 9 PUMP FUNCTIONS The system pumps run when: - heating is enabled and the outside temperature lies below the heating limit (see section “5.3.1 Summertime limit in heating mode (adjustment 3-3)”); - night set back is enabled and the outside temperature lies below the corresponding heating limit (see section “5.3.2 Summertime limit in night setback mode (adjustment 3-4)”); - frost protection is activated (outside temperature lies below 2°C) (see section “5.3.3 Frost protection”); - the heating program “manual operation” is selected. The 30-minute pump run-on time is effective when: - heating is enabled and the outside temperature rises above the heating limit (see section “5.3.1 Summertime limit in heating mode (adjustment 3-3)”); - night set back is enabled and the outside temperature rises above 4°C, or above the night set back heating limit (see section “5.3.2 Summertime limit in night setback mode (adjustment 3-4)”); - power is restored after an interruption (causes a reset) or following installation. The 5-second pump seizure protection operates: - daily at 24 hour intervals following the last time the power was switched on The boiler pump Uw runs: - during heating operation ( or ) according to the selected protection mode (see section “8.3 Boiler safety modes (adjustment 6-2)”) For installation personnel only 30 10 REMOTE CONTROL OPERATION Each heating circuit can be operated by its own remote control. See the corresponding instruction manual for more information. (ONLY ONE IN THE UK) The information in this chapter references the terminal numbers as they are marked on the controller. These numbers will not necessarily be the same if the controller has been built into a boiler control panel, control rack, etc. In this case, refer to the appropriate documentation. 10.1 Remote control FS 3611 10.1.1 Connecting the FS 3611 remote control (RED CIRCUIT NOT USED IN THE UK) Heating circuit “green” Connector P11 of rematic 2945 Terminal numbers of FS 3611 Heating circuit “red” Connector P12 of rematic 2945 Terminal numbers of FS 3611 Fig. 08 10.1.2 Operation with the FS 3611 remote control The controller display indicates whether a FS 3611 remote control is connected when the heating program “automatic operation” is selected. The remote control is automatically deactivated when the controller is not in the automatic time controlled mode. Select “Automatic operation” after the work has been completed. This reactivates the remote control. The heating program and temperature adjustment set on the remote control become visible in the controller display. 31 rematic® 2945 C3 K 10.2 Remote control FB 5240 (NOT USED IN THE UK) 10.2.1 Connecting the FB 5240 remote control Connector P11 of rematic 2945 Heating circuit “green” Terminal numbers of FB 5240 5 Heating circuit “red” Terminal numbers of FB 5240 6 5 6 FB 2 FB Fig. 09 FB 5240 remote controls may only be used for controllers which are programmed (with adjuster 3-7) as masters (and not as slaves). Also, when slaves are connected to a master, remote control FB 5240 can not be used. Allocation of the remote control FB 5240 to the “red” or “green” heating circuit is programmable on the rear of the remote control (see the remote control operating instructions). RED CIRCUIT NOT USED IN THE UK Allocation of FB 5240: Dipswitch position to the “green” heating circuit (and to the rematic® 2940 C3-s) OFF OFF to the “red” heating circuit ON OFF Dipswitch 1 Dipswitch 2 Table 08 10.2.2 Operation with the FB 5240 remote control The FB 5240 remote control connects to the controller data bus. Any change made on the remote control is mirrored at the controller, and vice versa. The program and settings on the remote control and the controller stay synchronised. The remote control must be assigned to the “red” or “green” heating circuit when the system is first put into operation (see the FB 5240 remote control operating instructions). 32 11 CONNECTOR PINOUTS The information in this chapter references the terminal numbers as they are marked on the controller. These numbers will not necessarily be the same if the controller has been built into a boiler control panel, control rack, etc. In this case, refer to the appropriate wiring diagrams. Unused sensor and signal inputs and outputs must not be connected. The associated symbols and temperatures are not displayed when checking the sensors. An unused heating circuit must have its heating curve set to 0, and its heating program must be set to “OFF” . It may be advisable to suppress inductive loads (circuit breakers, relays, mixer drives, etc.) by connecting RC snubber networks across the coils. (0.047µF, 100 W, rated 250 VAC recommended). For installation personnel only Warning: Before starting to wire up the system, ensure that all the conductors are disconnected from the electrical supply. Electricity must also be disconnected before plugging or unplugging the connectors. Never touch the controller wires or connections. Connections to sensors, remote controls, the data bus, etc. must be routed separately from high-power wiring. 11.1 Boiler control interface (in the UK the interface is supplied with the relevant controls package kit) An interface is required to exchange data with the boiler control. Depending on boiler execution, an interface might already be present in the boiler. The wiring of the interface, of the boiler control and of the sensors (outside -, DHW - and common flow -) must be carried out in accordance with the appropriate wiring diagrams, that come with the controls package kit. Anschluss- Connector steckerP11 P11 Interface Interface 9 10 11 12 Fig. 10 33 FeuerungsBoiler control automat rematic® 2945 C3 K 11.2 Connector layout (rear of controller) Fig. 11 11.3 Connector terminal pinouts The following diagrams show the full range of input and output connections. Depending on the controller version and application, not all of these may necessarily be in use. Always refer to the appropriate assembly instructions and for the correct terminal identification refer to the wiring diagrams, that come with the controller kits. 11.3.1 Live connections (230 Vac) Connector P1 Boiler Boiler 1 (on/off boiler) or Step 1 (high/low boiler) Boiler 2 (on/off boiler) or Step 2 (high/low boiler) not used Fig. 12 34 Connector P2 Mains supply, “green” heating circuit, D.H.W. production Mixer OPEN Mixer CLOSED D.H.W pump / diverter valve Circulation pump Live Neutral Connector P3 “Red” heating circuit, boiler circulation not used Boiler circulation pump Circulation pump Mixer OPEN Mixer CLOSED Fig. 13 35 rematic® 2945 C3 K 11.3.2 Sensor connections Connector P11 “Green” heating circuit, boiler, domestic hot water “Green” analogue remote control (on pins 1, 2 and 5) “Green” room sensor Set point input / output Outside sensor Sensor and set point ground Common flow sensor* “Green” mixer circuit flow sensor Domestic hot water sensor Return temperature sensor** Data bus signal Data bus ground not used * (or boiler sensor for on/off-high/low boilers) ** (see section “7.4 Minimum boiler return temperature TBR MIN (adjustment 5-3)”) Fig. 14 Connector P12 (RED CIRCUIT NOT USED IN THE UK) “Red” heating circuit “Red” analogue remote control (on pins 1, 2 and 4) “Red” room sensor not used Sensor ground “Red” mixer circuit flow sensor not used Fig. 15 36 12 FUNCTIONAL TESTS AND CHECKS 12.1 Service program The service program permits maintenance personnel to establish boiler conditions necessary for performing required measurements, without disturbing the controller’s normal operational parameters. The controller sets all boilers to full load and commands the installation load (i.e. mixing valves) in a way to reach a (boiler or common) flow temperature of 60°C as quick as possible and maintain this temperature as long as possible. To avoid overheating of the installation it may be necessary to manually switch off all boilers but the one that is measured. In on/off or high/low boilers with little water content the high limit thermostat may trigger, as well as in an installation where the boiler sensor is not fitted in the boiler but in the flow pipe work. However the Remeha communicating boilers will not be affected with this problem. 12.1.1 Starting the service program - Press the key. Instead of the current time, the display shows the elapsed time since the service program was started. P Fig. 16 12.1.2 Terminating the service program The service program terminates automatically when no controller key has been pressed for 30 minutes. The service program can also be terminated earlier by pressing the key again. The controller returns to normal programmed operation. 12.2 Test mode for controller output signals 12.2.1 Operation If the specialist levels are scrolled through with the key, after the 4th level and before the code-protected 5th level you will reach the test level for output signals. It is indicated on the display with “ “ (see also section “4.2.2 Performing 4th, 5th and 6th -level adjustments”). In this test level, the specialist may switch the outputs 37 rematic® 2945 C3 K on and off. With each push on one side of the key in the 3rd level, the status of the corresponding output signal toggles between “ON” and “OFF”. 12.2.2 Display The modes which are switched on or off are indicated in the display. - The modes which are allocated to the keys on the left-hand side (even numbers) are indicated with the corresponding symbol and the output number, e.g. and A-4. - The modes which are allocated to the keys on the right-hand side (odd numbers) are shown with the output number only, e.g. F-5. For each function the status indicator “ ” or “ ” also appears. 12.2.3 Closing the test mode The test mode is automatically interrupted if no key is pressed for 20 minutes. The display returns to normal. The functioning of the controller outputs is then determined once again by the controller. When switching to another specialist level, all output functions are switched off. 12.2.4 Meaning of keys and allocation to modes Adjustment key Push at – or + side of adjustment key 0 - 0 Display + 1 - 1 2 + - 2 + 3 - 3 4 + P11-10 Communication Boiler 2 P11-10 A-3 Mixer "opens", Green heating circuit A-4 Mixer "closes", Green heating circuit F-3 Communication Boiler 3 P11-10 P11-10 P2-1 P2-2 Communication Boiler 5 P11-10 F-6 Communication Boiler 6 P11-10 A-7 Mixer "opens", Red heating circuit A-8 Mixer "closes", Red heating circuit F-7 Communication Boiler 7 P11-10 + F-8 Communication Boiler 8 P11-10 A-9 Circulation pump, 38 Red heating circuit P3-3 + A-10 Boiler circulation pump P3-2 9 - Communication Boiler 1 F-2 F-5 7 - 8 F-1 Circulation pump, Green heating circuit + 8 P1-3 A-6 - 7 P1-1 Boiler step 2 (high/low) D.H.W. pump or diverter valve + 6 Boiler step 1 (on/off) A-2 Communication Boiler 4 5 - 6 A-1 F-4 + 5 Connection pinouts at back of controller A-5 - 4 Function --- Not used P2-3 P2-3 P3-4 P3-5 4 + 5 - 5 6 + - 6 + 7 - 7 8 + - 8 + 9 9 + A-6 Circulation pump, Green heating circuit F-5 Communication Boiler 5 P11-10 F-6 Communication Boiler 6 P11-10 A-7 Mixer "opens", Red heating circuit P3-4 A-8 Mixer "closes", Red heating circuit P3-5 F-7 Communication Boiler 7 P11-10 F-8 Communication Boiler 8 P11-10 A-9 Circulation pump, Red heating circuit P3-3 A-10 Boiler circulation pump P3-2 --- Not used --- Not used P2-3 Table 09 The test mode allows the specialist to test parts of the system for correct functioning. If proper procedures are not followed, this can lead to output statuses being enabled which place an abnormal load on the heating equipment (example: both directions of a mixer motor energised simultaneously). Modes which are switched on are only switched off if no key is pressed for 20 minutes or if the operating level is changed. Please, therefore, note the following: - after the function test, deactivate each output order. - never simultaneously enable an “ON” and an “OFF” order on the same mixer drive. - before leaving the system, ensure that the controller is no longer at the test level (change operating level or return to normal display using the key). 12.3 Checking the temperature sensors The temperature sensors can be checked without disconnecting the controller, or using special measurement or test equipment. (See section “12.5 Temperature sensor resistance values”) - Select the desired heating circuit using the toggle key. - Press the key. The measured temperatures appear in the display. If a temperature is displayed, this means that the corresponding sensor is properly connected and functional. Failure to display a temperature can have one of the following reasons: - The sensor is unnecessary for the heating system - Sensor or connection open-circuit - Sensor or connection short-circuit 12.4 Checking temperature settings For dual circuit controllers select the desired heating circuit using the toggle key. - Press and hold the key. The controller shows the measured temperature values in succession. After cycling through all the measured values, the controller shows the temperature settings in place of the regular display. 39 rematic® 2945 C3 K - Release the key. Single presses of this key display the Setpoints and sensor readings. - Press the key to return to the normal display. This also happens automatically if 1 minute elapses without pressing a key. 12.4.1 Displayed symbols and their meanings Symbol Display Unit Display shows set value °C Display shows measured value °C D.H.W. temperature (hot water) °C Common flow temperature °C Boiler flow temperature °C Boiler return temperature °C Room temperature °C Circuit flow water temperature °C Table 10 The outside temperature can be read as average temperature and as current temperature as follows: Symbol Display Unit Actual outside temperature °C Average outside temperature °C Table 11 On the master controller’s display, the total output and the output required by the individual boilers may be interrogated as well as the common flow set temperature. 40 Symbol Display Unit Common flow temperature measured °C Common flow temperature set °C Total load of all boilers kW Load per boiler % Table 12 The set output of the installation is understood to be the total output of all the required boilers in kW. The output of the individual boilers is shown as % of the nominal output of the boiler. 12.5 Temperature sensor resistance values The temperature sensors connected to the controller and those connected to the boiler control do have different characteristics. Resistance values are shown in the following table. Controller Boilercontrol Resistance Resistance °C Ω Ω -20 48.535 98.820 -15 36.475 75.940 -10 27.665 58.820 -5 21.165 45.910 0 16.325 36.100 5 12.695 28.590 10 9.950 22.790 15 7.855 18.290 20 6.245 14.770 25 5.000 12.000 30 4.029 9.805 40 2.663 6.653 50 1.802 4.609 60 1.244 3.253 70 876 2.337 80 628 1.707 Temperature 41 0 16.325 36.100 5 12.695 28.590 10 9.950 15 7.855 20 6.245 14.770 Temperature 25 Controller 5.000 Boilercontrol 12.000 30 Resistance 4.029 Resistance 9.805 °C 40 2.663 Ω 6.653 Ω 50 1.802 4.609 60 -20 1.244 48.535 3.253 98.820 70 -15 876 36.475 2.337 75.940 80 -10 628 27.665 1.707 58.820 90 -5 458 21.165 1.266 45.910 100 0 339 16.325 952 36.100 5 12.695 28.590 10 9.950 22.790 13 CONTROL 15 OF MODULATING BOILERS 7.855 18.290 Table 13 20 6.245 22.790 rematic®18.290 2945 C3 K 14.770 The rematic® controller communicates with all connected boilers over a two-wire 25 5.000 12.000 bus. Each boiler needs an interface for addressing and translation of the messages. 30send every 10 - 15 seconds. 4.029 9.805 Messages are The rematic®40 controller calculates a boiler flow temperature (or a common 2.663 6.653flow temperature in a multiple boiler installation) based on outside temperature, heating 50 1.802 4.609 curve, programmed over-temperature, room temperature etc. 1.244 3.253 - Without a 60 common flow sensor connected (i.e. in a single boiler installation), this flow temperature setpoint is sent to the boiler control, which in turn calculates the 70 876 2.337 necessary output to obtain the setpoint temperature. 80 flow sensor connected 628 1.707 the - With a common (i.e. in a multiple boiler installation), controller itself boilers and the output percentage 90 calculates the number of458 1.266 per boiler, necessary to obtain the setpoint temperature. 100 339 952 - With the DHW sensor and -pump connected to the controller (is standard configuration for single - and multiple boiler installations), the boilers are controlled as described above. (also during DHW production code 3 is displayed on the boiler(s)) DHW temperature, flow-over temperature and time program are as set in the controller. - In a multiple boiler installation, a DHW sensor and DHW pump or diverter valve can be connected to one or more boilers in which the rematic® controller is not mounted. The controller DHW-time program acts on all boilers. DHW temperature and over temperature are to be set in each boiler. 42 14 ERROR MESSAGES Display Left side Description of error Right side --- Communication error with boiler control 1….8 --- Communication error with slave 1…4 2) xxx* Lock-out of boiler 1…8 with error code 3) 1) Table 14 1) 2) 3) See also section “5.7 Nature of the controller (adjustment 3-8)”. Er1 can also mean: inverted or short-circuited bus wiring See also section “5.6 Number of slaves and their addressing (adjustment 3-7) NOT AVAILABLE IN UK” See the boiler documentation for the meaning of the displayed boiler error code. With more than one error , the sequence of the messages is as follows: - The message of a boiler control is displayed before that of a slave controller. - The message of the boiler control or slave with the lowest address comes first. Note 1: With the wires of the bus short circuited or connections crossed (boiler 1terminal 1 connected to boiler 2-terminal 2 etc) the message Er 1 will occur. Only one LED will blink on the boiler interface(s). With one interface disconnected or damaged, the corresponding message will be displayed, but the communication with other boilers and /or slaves will remain. Note 2: Every time the power to the controller is switched on, the microprocessor will initialise. During initialisation, the controller is exchanging date with the boiler control and a DHW temperature of 99 °C might be displayed. 43 rematic® 2945 C3 K 15 EXPLANATION OF TERMS Start of occupancy time: The start of occupancy time is the moment from which on the room temperature must be at comfort level. Occupancy time: The period of the day the room temperature must be at comfort level. Specialist levels: Adjustment levels controlled by engineers. They contain adjustment variables for matching the regulator to the heating system design parameters. Adaptive heating curve: Automatic modification of the heating curve to match the building characteristics. Measured value ( is displayed at the left): The present, measured temperature. The symbol underneath the displayed value indicates which sensor is read. Set point ( is displayed at the left): A temperature value calculated by the controller or specified by the specialist or end user. The controller regulates the measured value to match the set point. Pre-heat time: Automatic advancement of the heating start-up time according to the heating requirement, in order to obtain comfort temperature at start of occupancy time. 44 16 TECHNICAL DATA Supply voltage Power consumption Operational ambient temperature Sensor and Bus cable length and “ cross sectional area Bus Output switching capability Certification Protection category Protection level EMC EMC-emission 230 VAC ± 10%, 50 Hz 7W 0°C … 50°C max. 100 m min. 0.75 mm2 2 wire Bus 230V 6 (2) A, 50 Hz CE-compliant II EN 60730 IP 40 EN 60529 EN 50082-1 EN 50081-1 17 DIMENSIONS AND FITTING INSTRUCTIONS 17.1 Dimensions 96 144 B PROG B PROG - + 01 2 3 4 5 + t Comp. 8 9 B = securing latches * (69.3) Dimension when fitted with ZLS 203 or ZLS 204 sensor PCB Fig. 17 45 rematic® 2945 C3 K 17.2 Panel cut-out The panel cut-out is 92 x 138 mm according to DIN 43700. Panel thickness <5 mm Fig. 18 17.3 Fitting instructions (For UK see seperate fitting instructions) The recessed securing assemblies B to the left and right of the 2 nd -level keys are visible with the front cover removed (see Fig. 17). - After the electrical connectors have been plugged in, fit the controller into the panel cut-out. - 2. Use a screwdriver to push the securing latches gently inwards, then give them a quarter turn clockwise to secure the controller to the panel. Releasing the controller: turn both securing latches counter-clockwise to their endstops. 46 47 5 Summertime limit in heating mode Summertime limit in night set back mode Setting of time to reach design temp. Room temp. compensation 3-3 3-4 3-5 3-6 3-7 3 4 5 6 7 Use of adjustment 3-6 requires a remote control or a room sensor. Table 15 Slave: position of slave (F1…F4) Master: number of slaves (0…4) 20 Parallel shift of slope base point 3-2 2 M/S 75 0,0 180 30 1,2 Max. flow temp. 3-1 1 Red Compensation slope 0 0,0 180 5 20 30 75 1,2 Green Red Green Heating circuit Heating circuit 3-0 Commissioning settings Factory settings No. Description 0 Symbol Display No. Symbol + - Adjustment key °C /°C Min °C °C °C °C 18.1 level 3 controls Push several times on the button until “3--“ appears in the display. For adjustments 3-0 to 3-6 the heating circuit must be selected first with the toggle key in dual circuit systems (observe the display colour). The function(s) can be selected from the following table and set to the desired value if not protected (\). 18 ADJUSTMENT KEYS, BOILER DATA AND SYSTEM DATA 48 With the Table 16 9 P Symbol Minimum modulation percentage of boiler FA = controller for communicating boiler b2 = controller for high/low boiler b1 = controller for on/of boiler -- = mixing circuit controller without boiler control Nature of the controller : Factory settings Description 30 Fa 1 2 3 4 button the boiler can be selected, for which parameters must be set. 3-9 3-8 P No 8 typ Display No Symbol + - Adjustment key 5 6 7 8 % rematic® 2945 C3 K 49 4-0 4-1 4-2 4-3 4-4 4-5 1 2 3 4 5 No. 0 No. Symbol + - Symbol Adjustment key Display 9 = continuously at 60 °C 8 = daily 7 = Sundays 2 = Tuesdays 1 = Mondays Legionnaires' disease protection mode Legionnaires' disease protection temperature Run-on time of DHW pump Overtemperature of flow for DHW production diverter valve pump DHW production simultaneous priority DHW production Description Red 0 60,0 8,0 20,0 Green Heating circuit Factory settings Red Green Heating circuit Commissioning settings °C Min. °C 18.2 level 4 controls Push several times on the button until “4--“ appears in the display. For adjustments 4-6, 4-8 and 4-9 the heating circuit must be selected first with the toggle key in dual circuit systems (observe the display colour). The function(s) can be selected from the following table and set to the desired value if not protected (\). 50 4-7 4-8 M/S typ 7 8 = 0 (4-9=2) 2=direct heating circuit (no mixer displayed) (spring return) 1=2 point mixer motor 0=3 point mixer motor Adapting to the heating circuit - mixing circuit = 5 - direct circuit Overtemp. of common flow for heating Minimum boiler temperature active, automatic inactive Adaptive heating curve 0 = no Legionnaires' disease protection mode 9 = continuously at 60 °C 8 = daily 7 = Sundays 2 = Tuesdays 1 = Mondays Legionnaires' disease protection mode Legionnaires' disease protection temperature Table 17 Use of adjustment 4-6 requires a remote control or a room sensor. 4-9 4-6 6 P 4-5 5 9 4-4 4 0 5,0 0,0 0 60,0 0 5,0 °C °C °C rematic® 2945 C3 K 51 5-5 5-6 5 6 Table 18 5-4 4 Allocation of boilerrelay outputs: (options: ---, M, F1 till F4) Return control selection (option 0 till 6, see section 7.6) Min. fan speed in % --- 0 0,0 0,0 % °C Min. boiler return temperature 5-3 kW 3 1 Boiler output full load 60,0 % 8 Cut-in output for next 80,0 boiler in % 7 5-2 6 2 5 Grouping boilers (groups 1 till 4) 4 5-1 3 1 2 5-0 1 0 Factory settings Description No Symbol Display No Symbol + - Adjustment key 18.3 level 5 controls Push several times on the button until “codE” appears in the display. Use the button to enter the standard access code (000). Push the button once and the controller will display “Acc” for acceptance of the code. Now push several times on the button until “5--” appears in the display. The function(s) can be selected from the following table and set to the desired value if not protected (\). 52 Factory settings Integral proportion Proportional band continuous backward operation changeover after 10 - 990 run hours continuous forward operation Sequence changeover Description 6,0 6,0 100 Commissioning settings Min. °C h on/off No. Symbol 6-0 6-1 6-2 0 1 2 Display No. Symbol + - Adjustment key Boiler safety modes 1=temperature controlled 0=time controlled Run-on time of DHW pump Max common flow temperature Description 0 95,0 Factory settings Commission -ing settings °C 18.4 level 6 controls Enter the acces code as described in section 18.3. Push several times on the (94) button until “6--” appears in the display. The function(s) can be selected from the following table and set to the desired value if not protected (\). Table 19 5-9 5-8 typ 8 P 5-7 9 No. Symbol M/S 7 Display No. Symbol + - Adjustment key rematic® 2945 C3 K 53 Table 20 6-9 6-8 typ 8 P 6-7 M/S 7 9 6-6 6 6-3 3 6-5 6-2 2 5 6-1 1 6-4 6-0 0 4 No. Symbol No. Symbol -40,0 Blocking of boiler groups 1 and 2 at outside temperatures below Ramp mode inside P-band Ramp mode outsite P-band 1,0 5,0 1,0 40,0 Blocking of boiler groups 3 and 4 at outside temperatures over Neutral zone with PI behaviour 3,0 2,0 0 0 95,0 Delayed cut-in of subsequent boilers Delayed cut-in of 1rst boiler 5=U3 4=U1 Uw with run-on time 3=U0 2=U3 1=U1 Uw energised during heating season 0=U0 Boiler safety modes 1=temperature controlled 0=time controlled Run-on time of DHW pump Max common flow temperature Min. %/ Min. %/ °C °C °C Min. Min. °C rematic® 2945 C3 K 18.5 Data for Remeha modulating boilers in a single-boiler installation Remeha W 10/21/28 series, Quinta series, Gas 210 ECO series: For these applications the factory settings of the adjustments are adequate, except for those adjustments that are necessary to adapt the controller to the installation, such as heating curve, time program, D.H.W. temperature etc. 18.6 Data for Remeha modulating boilers in a multiple boiler installation In order to achieve proper operation of the boilers in a multiple boiler installation, the relevant adjustments must be set according to the tables below. Procedure for performing the adjustments in the table: - Select the adjustment. - If more than one boilers are connected, use the P key to invoke the boiler for which the adjustments are to apply. - Instead of the time bar, the points in the display indicate how many boilers are programmed. The point of the invoked boiler flashes. You can now perform the required adjustment. With adjustment 3-8 the number of boilers can be programmed by replacing on each position the given --- code by the correct FA code. Remeha Quinta Adjustment Setting for a single boiler installation Setting for a multiple boiler installation (for all boilers up to 8) 3-8 FA 3 FA 1 3-9 18 18 5-0 Table 21 The correct output of the boiler (in kW) can be read from the boiler identification plate. Remeha Quinta series Remeha Gas 210 ECO Adjustment Setting for a single boiler installation Setting for a multiple boiler installation (for all boilers up to 8) 3-8 FA 3 FA 1 3-9 10 10 5-0 Table 22 The correct output of the boiler (in kW) can be read from the boiler identification plate. Remeha Gas 210 ECO series 54 18.7 Installations with slave controllers rematic 2940 C3 S and/or 2945 C3 S In order to achieve communication between the master and the slave controllers, they must both correctly be programmed. In the master controller the number of slaves must be programmed. In each slave controller its address must be programmed according to the table below. Adjustment 3-7 Number of slave controllers Setting in master controller 1 1 F1 2 2 F1, F2 3 3 F1, F2, F3 4 4 F1, F2, F3, F4 Table 23 55 Setting in slave controllers rematic® 2945 C3 K Broag Ltd. Head office Remeha house Molly Millars Lane, Workingham, Berkshire RG 41 2QP. Tel: 0118 976977 Fax: 0118 9783434 © Copyright E-mail: boilers@broag.ltd.uk All technical information and drawings contained within this document are the Internet: http://www.broag.ltd.uk property of Broag - Remeha and shall not be copied without our prior consent in writing. Subject to alterations 56302/1000/0402/Ips. 56
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