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ZAB–07, ZAB–07 REVERS, ZAB–07 REVERS RR
ZAB–12, ZAB–12RR
Boiler regulator
FOR SOLID FUEL-FIRED BOILERS WITH FEEDING SCREW
* - functions available instead Mixer 1
** - functions available with additional extension module MX.01
*** - room panel ecoSTER200 (not included)
SERVICE AND ASSEMBLY MANUAL
1.1
ISSUE: 1.6
2014-12-10
1
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Table of Contents
Related Manuals for Plum ZAB-07
Summary of Contents for Plum ZAB-07
- Page 1 ZAB–07, ZAB–07 REVERS, ZAB–07 REVERS RR ZAB–12, ZAB–12RR Boiler regulator FOR SOLID FUEL-FIRED BOILERS WITH FEEDING SCREW * - functions available instead Mixer 1 ** - functions available with additional extension module MX.01 *** - room panel ecoSTER200 (not included) SERVICE AND ASSEMBLY MANUAL ISSUE: 1.6 2014-12-10...
- Page 3 GENERAL PRINCIPLES OF A PROPER WORK BOILER WITH INDIVIDUAL FUZZY LOGIC: The controller must be programmed individually for each type of boiler and fuel point. 19.1! There shall be no change in type of operator, and other type of fan gear changes affecting boiler combustion process.
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Page 4: Table Of Contents
Table of contents RECOMMENDATIONS REGARDING SAFETY ..6 7.26 DIAGRAM 2 ............25 GENERAL INFORMATION ........7 7.27 DIAGRAM 3 ............26 INFORMATION ABOUT DOCUMENTATION ..7 TECHNICAL DATA ..........28 STORAGE OF DOCUMENTATION ......7 CONDITIONS OF STORAGE AND TRANSPORT ..29 APPLIED SYMBOLS .......... - Page 5 11.13 FEED TIME SUPERVISION ........45 RESTORING SERVICE SETTINGS ......49 11.14 AIRFLOW OPER.EXTEND........45 DESCRIPTION OF ALARMSBŁĄD! ZDEFINIOWANO ZAKŁADKI. 11.15 MAXIMUM FEEDER TEMPERATURE ....45 15.1 NO FUEL ............. 50 11.16 MIN. RETURN TEMPERATURE ......45 15.2 MAXIMUM BOILER TEMPERATURE EXCEEDED. 50 11.17 RETURN TEMPERATURE HYSTERESIS ....
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Page 6: Recommendations Regarding Safety
which means that in the case of RECOMMENDATIONS REGARDING malfunction it can be the source SAFETY of a spark or high temperature, Requirements concerning safety which presence described detail flammable dusts or liquids can cause fire or explosion. Thus, individual chapters this regulator... -
Page 7: General Information
Information about documentation General information The regulator manual is a supplement for the The ecoMAX 800R1 boiler regulator, model boiler manual. In particular, except for this R1, version ec, is a modern electronic device manual, the boiler manual should also be the purpose of which is to control operation observed. -
Page 9: Regulator Instruction Manual
REGULATOR INSTRUCTION MANUAL ecoMAX 800, model R1... -
Page 10: Operating The Regulator
Operating the regulator 3. measured boiler temperature, This section briefly describes 4. field of values which influence the preset regulator should be operated. In order to boiler temperature: ,,T” – symbol of start using a boiler with the regulator, you decrease in the preset boiler temperature must fire the boiler up using the regulator disconnection... -
Page 11: Start-Up Of The Regulator
regulator skips preset boiler Hot water window on the main screen, you temperature. parameter when the preset can also change the view of the fuel level by boiler temperature is determined in relation turning the knob TOUCH and PLAY if the weather. -
Page 12: Operation - Mode Standard
Shall the user forget to switch the regulator into OPERATION mode, the regulator will continue to heat the boiler until reaching the preset temperature Fig. 5 Manual start-up of the feeder Then, it will automatically switch into the OPERATION mode, and, as Pressing the „TOUCH and PLAY”... -
Page 13: Operation - Mode Fuzzy Logic
be changed, the details in section 11.23 THE MANUFACTURER’S SETTINGS DO NOT ALWAYS MATCH THE GIVEN BOILER TYPE, THUS THEY MUST BE ADJUSTED TO THE GIVEN TYPE OF BOILER AND FUEL Fig. 9 View of the main window in the OPERATION mode Administration time and break The regulator can be switched into the WORK administration should be... -
Page 14: Supervision
same type. Please note that the fuzzy logic program is selected individually for the given type of the It is recommended that before switching fuzzy logic to control the boiler and fuel, and it can work properly only fire the boiler using FIRE UP mode with this boiler and fuel. -
Page 15: Fuel Type
hysteresis relation preset temperature. Recommended settings SUPERVISION mode: -Feed Interval supervision = 15 minutes - Feed time supervision = 12s, - Airflow oper.extend supervision = 1s. 8.10 Fuel type The fuel type menu is intended only for the FUZZY LOGIC regulation mode. Choose the Fig. -
Page 16: Enabling The Summer Function
the HUW pump is turned off, and the boiler The preset domestic hot water temperature resumes normal operation. The disinfection can be also set at the main window. Press function should not be activated if the HUW the „TOUCH and PLAY” knob in the main support is disabled. -
Page 17: Weather Control
Then, set the value Reduce preset mixer the greater the correction preset boiler temperature to thermostat parameter, for temperature. When set to a value, 0 " Preset example. the value of 2 °C. After contact mixer temperature is not corrected. Note: To opening set temperature thermostat mixer set the values too high room temperature circuit is reduced, as the proper choice of the... -
Page 18: Description Of Setting Night-Time
Tips for selecting appropriate heating curve: - if the temperature inside rises while the temperature outside drops, selected heating curve is too high, - if the temperature inside drops while the temperature outside drops well, the selected heating curve is too low. Fig. -
Page 19: Control Of Circulation Pump
preset CH temperature by 5°C. Between 15:00 and 22:00, the regulator will keep the Settings are located in: preset CH temperature unchanged. Between Menu → Night time decrease→ 22:00 and 23:59, the regulator will lower the CIRCULATION. pump preset boiler temperature by 3°C. The time period is skipped if its Menu →... -
Page 20: Off Fan
This option is not intended for boilers with an additional grate, where the air is regulated with a 8.23 Restoring user settings draught regulator or manually by In order to restore default user settings, the user. Operation with active fan place the cursor on the „YES”... - Page 21 Calibration Cover with fuel container to a level which corresponds to the full loading, then set the value of the parameter calibration level of 100%. parameter MENU Level Cal. Fuel level. →Fuel → In the main window pointer is set to 100%. indication duration Fig.
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Page 23: Regulator Installation And Service Settings Manual
REGULATOR INSTALLATION AND SERVICE SETTINGS MANUAL ecoMAX 800, model R1... -
Page 24: Diagram 1
Hydraulic diagrams 8.25 Diagram 1 Fig. 21 Diagram with four-way valve controlling the central heating cycle ,where: 1- boiler with retort feeder, 2 – ecoMAX regulator – executive module, 3 – ecoMAX regulator – control panel, 4 - Fan, 5 – feeder temperature sensor, 6 –... -
Page 25: Diagram 3
stage at which the temperature at sensor (9) will be equal to the preset mixer temperature. When the temperature measured by sensor (8) drops below the preset HUW temperature, the HUW pump (12) is enabled. The HUW pump (12) will be disabled after the HUW container (15) is filled, i.e. - Page 26 pump (11). The thermostatic valve (28) opens after the temperature returning to the boiler increases, directing the boiler water to the central heating system. When the temperature measured by sensor (8) drops below the preset HUW temperature, the HUW pump (12) is enabled.
- Page 27 SUGGESTED SETTINGS: Parameter Setting MENU Return protection Valve 3D term. service settings -> boiler settings Mixer support 1 on, floor service settings -> mixer 1 settings 50C Max. pre-set mixer temp. 1 service settings -> mixer 1 settings menu mixer settings 1,2,3 Mixer weather control 1, 2, 3, 4 Mixer heating curve 1 0.2 –...
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Page 28: Technical Data
Grate ON (without feeder) up to six (6) 3(2,6) A Grate OFF 3(2,6) A Mixer pump 2 3(2,6) A ZAB-07 REVERS RR: Mixer motor 2 ON Maximum rated current: 3(2,6) A Mixer motor 2 OFF Regulator protection rating IP20 CH pump... -
Page 29: Conditions Of Storage And Transport
The set includes: - boiler temperature sensor 1 piece 1 piece - feeder temperature sensor 1 piece - HUW temperature sensor, 1 piece - executive module 1 piece - control panel - connecting cable - panel lid 1 piece - panel hole plugs 4 pcs. -
Page 30: Ambient Temperature
three core (with protective wire), accordance with applicable regulations. Caution: After regulator turned using keyboard, dangerous voltage can occur on the terminals. Before starting assembly works, must Fig. 29 The range of diameters cables installed in cable disconnect the mains supply and glands make sure... - Page 31 Fig. 24 ZAB-07 diagram for electric connections with external devices.
- Page 32 Fig. 25 ZAB-12 diagram for electric connections with external devices.
- Page 33 Fig. 26 ZAB-07 REVERS diagram for electric connections with external devices.
- Page 34 Fig. 27 ZAB-07 REVERS RR diagram for electric connections with external devices.
- Page 35 Fig. 28 ZAB-12 RR diagram for electric connections with external devices.
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Page 36: Connecting Temperature Sensors
Connect the sensor using cable of 0,5 mm 10.7 Connecting temperature cross-section, up to 25 m long. Bias of the sensors leads is insignificant. Connect the other end of the cable to the regulator, as shown in The regulator cooperates only CT4 sensors. Figure 32. -
Page 37: Connecting Room Thermostat
CT4-P (weather ) Temp. Min. Nom. Max. ,,T” °C Ω Ω Ω Fig. 31 View of the main window after activation of thermostat Setting any value other than „0” will cause activation of the room thermostat. When the temperature in the room where the room thermostat is installed reaches the preset value, the regulator will decrease the Table Values of resistance of temperature sensors CT4-P... -
Page 38: Connecting Room Thermostat Of Mmixer
10.11 Connecting room thermostat of In a standard version, the regulator is not mmixer equipped with the U3 module. Components necessary for assembly of the U3 module can Room thermostats connected to executive be purchased from the manufacturer of the module influences mixer 1 and boiler. -
Page 39: Connection Of Alarm Signalling
Mixer is operative when a reserve boiler is enabled. Thanks to this, if the retort boiler runs out of fuel, the mixer cycle is still fed. It recommended switch ecoMAX regulator into the STOP mode if the retort boiler malfunctions and it is necessary to operate on the reserve boiler. -
Page 40: Connecting Mixer
Fig. 37 Connecting an external alarming device, where: 1 – ecoMAX800 regulator, 2 – external alarming device, 3 – U3 Module, consisting of relay RM 84-2012-35-1006 AL 1 AL 2 AL 3 AL 4 AL 5 RELPOL and base GZT80 RELPOL. If the regulator is to control an Example: value... -
Page 41: Connecting The Circulation Pump
signalled in the MENU Information – mixer spaces in which the pump is not running. info by sign “CAL”. It is recommended to connect a circulator to purchase additional controller - make sure that the servo opens in the ecoMAX800S MX.01 type, it retains the correct direction. - Page 42 Four-conductor connection: Fig. 38 Electric connections diagram (four-conductor), ecoSTER200 room panel, 2 - ecoMAX800T1 regulator, 3 - connection cable, 4 room sensor thermostat 2 type CT7, 5 - room sensor thermostat 3 type CT7. Two-conductor connection: The two-conductor connection requires a 5V DC power supply with rated current of at least 200 mA.
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Page 43: 11 Boiler Service Settings
11 BOILER SERVICE SETTINGS 11.1 Return protection 11.2 Room thermostat of the boiler Caution: return protection function This parameter allows to determine decrease protects the boiler against operation with in the preset boiler temperature due to cold return water. This function will not work disconnection of room thermostat contacts. -
Page 44: Curve Shift
Additionally, the regulator will accept this temperature instead of the preset boiler temperature which results from decreases on account of time periods, or room thermostat. Set the value in accordance with the boiler manufacturer’s recommendations Fig. 40 Selection of the boiler’s heating curve, where: 1.4 –... -
Page 45: Fuel Detection Time
If the boiler cannot reach the preset 11.15 Maximum feeder temperature temperature due to reducing the fan This is the temperature at which the function revolutions, value which prevents the flame from going back to parameter Minimum airflow output the fuel feeder is activated. This function is should be increased. -
Page 46: Boiler Cooling Temperature
Increasing its value speeds up 11.25 Revers time increment in the boiler output. The higher the value, the faster Applies only to ZAB-07 REVERS and ZAB-12. Specifies the reversing time of feeder after a the boiler reaches the pre-set Parameter dose of fuel. -
Page 47: Pump Standstill Time
Disabling the CH pump on its own it impossible to channel excessive heat to the does not guarantee protecting the HUW container if the boiler overheats. boiler against retting, resulting corrosion of the boiler. Use When designing the domestic hot additional automatics, e.g. -
Page 48: Circul.standstill Time
operation of the HUW pump can be extended 13 MIXER SERVICE SETTINGS by the time of Extend HUW time. 13.1 Mixer support It is not recommended to set the The following options are available: time of Extend HUW time to a value OFF –... -
Page 49: Max. Preset Mixer Temperature
If the ecoSTER200 is not connected, the longer standstills of the servo. Too high a regulator cooperates with a standard room value extends the time by which the servo thermostat. can find the preset temperature. Setting too low values can cause over-regulation of 13.3 Max. -
Page 50: Fuel
14 RESTORING SERVICE SETTINGS regulator identifies fuel In order to restore default service settings, shortage incorrectly, increase the place the cursor on the „YES” option and parameter no fuel detection time press the “TOUCH and PLAY” knob. point 11.12, decrease difference between the measured boiler temperature and preset CH temp. -
Page 51: Maximum Feeder Temperature Exceeded
15.4 Damage to boiler temp. sensor This alarm will be produced in the case of damage to the boiler sensor, and after exceeding its measuring range. The alarm activates the CH and HUW pumps, as well as the mixer pump, in order to cool the boiler down. -
Page 52: Filled Pommel
16 EXTRA FUNCTIONS Except for the functions described above, the regulator offers number other functions. 16.1 Power supply decay In the cases of power supply failure, the regulator will resume the operation mode in Fig. 45 View of alarm „feeder sensor failure which it was before the failure. -
Page 53: Replacing Mains Fuse
The regulator serial number can be Examples of software numbers: found on a rating plate of the executive module. The number of Control panel Executive module control panel serial 06.10.010. 06.11.026.W0 number. 17.1 Replacing mains fuse The software numbers can be read Bezpi The mains fuse is situated in the rating plates... -
Page 54: Description Of Possible Faults
Description of possible faults Signs of a fault Hints Check: 1. The display blank if the main fuse is burnt-out, replace if so, despite connection if the lead connecting the panel with the module is properly power supply. plugged in, and if it’s not damaged Check: ... - Page 55 Increase airflow adjustment Fuzzy logic point. 7.8, Check that the unburned fuel comes from working in supervision - adjust mode SUPERVISION, by. point. 7.9, Check that the unburned fuel transition is caused by frequent OPERATION SUPERVISION point. 11.23, →...
- Page 56 The reason may be activity of the return protection function, point 11.1. If the return protection function is active, check if the sensor for water returning to the boiler is thermally insulated from its surroundings, and improve contact with the pipe by applying thermally conductive paste.
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Page 57: Regulator Settings By Boiler
Whereas in the menu available to users and fitters, options for a 15kW MK boiler will appear: Fig. 50 Selection of fuel for the boiler user Includes only boilers and fuels which were tested in Plum Ltd laboratory. -
Page 58: Registration Temperatures And Alarms
Settings for individual boilers require arrangements between the boiler manufacturer and the PLUM sp. z o.o. company. In order to apply the changes, disable and enable mains supply to the regulator. 19.2 Registration temperatures and alarms The regulator has another hidden menu for boiler manufacturers, which allows to read recorded parameters of boiler operation. -
Page 59: 20 Changes In Documentation Records
alarm name No fuel Boiler overheated Flame recessed to retort Boiler temperature sensor damage Feeder temperature sensor damage Caution: A temperature record of about 108°C is an evidence that the sensor was disconnected. Values recorded for a given day are stored in the memory at 00.00. 20 Changes in documentation records 1.6 –... - Page 64 Wspólna 19, Ignatki 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...
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