Hamworthy Merley Installation, Commissioning And Operating Instructions Download Page 1

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MERLEY BOILER

SEQUENCE CONTROLLER

For Modular Boiler Installations

Installation, Commissioning

and Operating Instructions

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE

INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT

Summary of Contents for Merley

Page 1: ...ONTROLLER For Modular Boiler Installations Installation Commissioning and Operating Instructions IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING...

Page 2: ......

Page 3: ...EY BOILER SEQUENCE CONTROLLER For Modular Boiler Installations Installation Commissioning and Operating Instructions NOTE THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO INSTALL...

Page 4: ...it wireless 2 12 Outside Sensor wireless 2 13 Radio Repeater 3 0 Commissioning 22 4 0 Operation 23 4 1 Function 4 2 Display 5 0 Programming 30 5 1 User Levels 5 2 Overview of Settings 5 3 QAA55 6 0 Se...

Page 5: ...ireless Outside Sensor 8 6 Radio Repeater 8 7 Sensor Characteristics Appendix A 97 Figure A1 Cascade with primary circuit pump Figure A2 Cascade with primary circuit pump Appendix B Wiring Schematics...

Page 6: ...storage tank charging with 7 day program DHW charging with charging pump or diverting valve DHW charging with sensor DHW charging with a thermostat Selectable priority absolute shifting none Selectabl...

Page 7: ...ces plant and applications as described above All requirements specified in chapters Handling and Technical data must be satisfied The local regulations for installation must be complied with HHL Refe...

Page 8: ...nit Service Unit RU HMI HMI RU wired wired wired Basic Unit RVSxx Extension mod AVS75 max 2 BSB W LPB Local Process Bus Basic Unit RVS LPB Remote Service Tool Mobile SMS Pager Fax WEB Telephone Networ...

Page 9: ...the Merley Boiler Sequence Controller the power supply must be turned off The connections for mains and low voltage must be separated The wiring must be made in compliance with the requirements of sa...

Page 10: ...nge when mounted 0 50 C Power cables must be clearly segregated from low voltage cables sensors observing a distance of at least 100 mm 2 3 Mounting Location It is recommended that the control is moun...

Page 11: ...emit the heat produced by it A clearance of at least 10 mm must be provided for the controller s cooling slots which are situated a the top and bottom of the housing The space should not be accessibl...

Page 12: ...S 533901611 Protective earth Q2 1st heating circuit pump Y1 1st heating circuit mixing valve opening T 533901612 N Neutral conductor Protective earth Y2 1st heating circuit mixing valve closing N Neu...

Page 13: ...perator unit boiler control panel AVS82 491 109 DB LPB data 533901614 MB LPB ground CL Room unit 1 data 533901615 CL Room unit 1 ground b 533901616 G Room unit power supply 12 V B3 DHW sensor top 5339...

Page 14: ...are run in separate ducts trunking both within the panel and outside of the panel Failure to observe this requirement will compromise the operation of the control See note 2 6 Operator Unit Fitting i...

Page 15: ...lowing points The place of installation should be chosen so that the sensor can capture the room temperature as accu rately as possible without getting adversely affected by direct solar radiation or...

Page 16: ...nd Drilling 2282M02 96 96 91 47 1 2 2359Z27 4 2 56 60 56 60 2 8 Outside sensor QAC34 The sensor must be installed on an outside north facing wall away from any air vents pipes illuminated signs or any...

Page 17: ...bout 1 5 meters above the floor In the case of wall mounting there must be sufficient clearance above the unit enabling it to be fitted and removed When the unit is removed from its base power is cut...

Page 18: ...r 2 floors 2 10 1 Radio Module AVS71 390 The radio module extends the product range by introducing wireless communication With this type of device the system components such as room units transmit dat...

Page 19: ...ture the room temperature as accurately as possible without getting adversely affected by direct solar radiation or other heat or refrigeration sources about 1 5 meters above the floor In the case of...

Page 20: ...ng Trigger line 120 Then press OK 8 Set the setting knob to YES and press OK Connection establishment is started 9 The display shows the progress of connection establishment in This process can take 2...

Page 21: ...should be chosen such that batteries can be easily changed 2 12 1 Mounting 2359Z30 2359Z33 2359Z32 2359Z31 2359Z54 2359Z59 2359Z55 AAA AAA 2359Z53 RF Transmitter Outside Sensor Battery transit tab Bat...

Page 22: ...n is established when the LED on the radio module extinguishes 4 Press the button on the transmitter of the wireless outside sensor briefly again until the LED extinguishes 2359Z58 AAA AAA LED Button...

Page 23: ...nstalled in the room unit Establishing the link 1 Press the button on the radio module for at least 8 seconds until the LED on the radio module starts flashing at high frequency 2 Press the button on...

Page 24: ...Configuration For that purpose the relevant operating level is to be selected as follows If the programmable room unit is used press OK on the room unit to switch to programming Press the info button...

Page 25: ...of DHW heating mode Quitting the setting Confirmation of setting Adjustment of room Comfort setpoint Presence button Displaying information 4 1 2 Operator unit Selection of DHW heating mode Selection...

Page 26: ...e displayed by pressing the info button Possible displays Depending on the type of unit configuration and operating state some of the info lines listed below may not appear Display Possible error mess...

Page 27: ...as operator unit 1 operating line 40 acting on all heating circuits operating line 42 and can only be readjusted on operating lines 44 46 and 48 Operating line 40 42 44 46 48 54 Room unit 1 Heating c...

Page 28: ...t room sensor Room sensor The temperature display can be readjusted Line no Operating line 70 Software version Device data The display shows the current version of the room unit 4 1 3 Radio Line no Op...

Page 29: ...re the maintenance special mode symbol appears Press the info button to switch to info display Manual mode where the setpoint can be adjusted Chimney sweep function The chimney sweep function is activ...

Page 30: ...h between the different operating modes The selection made is indicated by a bar which appears below the respective symbol Automatic mode Automatic mode controls the room temperature according to the...

Page 31: ...r which ap pears below the respective symbol DHW heating mode On The DHW is heated according to the selected switching program Off No DHW heating but the protective function is active DHW push Trigger...

Page 32: ...e and the user level Operation Display example Description 1 0 4 8 12 16 20 24 AUTO 2359Z140 Roomtemperature Basic display If the basic display is not shown press the ESC button to return to it Press...

Page 33: ...to do this manually By changing the setting the respective periods of time will be shortened or extended Increase Winter operation will start earlier Summer operation will start later Decrease Winter...

Page 34: ...later Decrease Heating mode will start later changeover to ECO earlier The function is not active in operating mode Continuously Comfort temperature The display shows ECO To give consideration to the...

Page 35: ...rcuit 2 Time program heatingcircuit P Holidays heating circuit 1 Diagnosticsof consumers Hours minutes Month day Year Start of summer time End of summer time Hours 1 24 h Minutes 0 60 min Example of M...

Page 36: ...9Z139 OEM Time of day and date Operator section Wireless Time program heatingcircuit 1 Time program heatingcircuit 2 Time program heatingcircuit P Holidays heating circuit 1 Diagnosticsofconsumers Hou...

Page 37: ...Temporarily Permanently Temporarily 26 F Operation lock Off On Off 27 F Programming lock Off On Off 28 I Direct adjustment Automatic storage Save with acknowledgment Save with acknowledgment 401 I Us...

Page 38: ...Period 3 Period 4 Period 5 Period 6 Period 7 Period 8 Period 1 642 E Start 01 01 31 12 dd mm 643 E End 01 01 31 12 dd mm 648 E operating level Frost protection Reduced frost protection Heating Circui...

Page 39: ...24h day Time programs HCs Time program 4 DHW Time programs HCs 1630 I charging priority Absolute Shifting None MC shifting PC absolute MC shifting PC absolute 1640 F Legionella function Off Periodical...

Page 40: ...speed HC1 Q21 H pump Q18 System pump Q14 Heat generator shutoff valve Y4 Time program 5 K13 H3 pump Q19 Flue gas relay K17 Assisted firing fan K30 Cascade pump Q25 DHW mixing pump Q35 DHW internal cir...

Page 41: ...Electric immersion heater DHW K6 H1 pump Q15 Boiler pump Q1 Bypass pump Q12 Alarm output K10 2nd pump speed HC1 Q21 H2 pump Q18 System pump Q14 Heat generator shutoff valve Y4 Time program 5 K13 H3 pu...

Page 42: ...W charging alarm 1 48 h 6800 F History 1 6801 F Error code 1 0 255 6802 F History 2 6803 F Error code 2 0 255 6804 F History 3 6805 F Error code 3 0 255 6806 F History 4 6807 F Error code 4 0 255 6808...

Page 43: ...I Boiler temp B2 0 140 C 7820 I Sensor temp BX1 28 350 C 7840 I Voltage signal H1 0 10 Volt 7841 I Contact state H1 Open Closed open State 8000 I State of heating circuit 1 8003 I State of DHW 8005 I...

Page 44: ...0 8831 I DHW temp setpoint 80 C 8 8832 I DHW temp 2 140 C 0 8835 I DHW circulation temp 140 C 0 8836 I DHW charging temp 0 140 C 0 8850 I DHW primary controller temperature 0 140 C 0 8851 I DHW prima...

Page 45: ...ls and segments Example of basic display 2354Z09 2354Z09 Display Selection of space heating mode This setting is used to switch between the different operating modes The selection made is indicated by...

Page 46: ...mmer winter changeover ECO functions and automatic 24 hour heating limit active Heating to Comfort setpoint Heating to Reduced setpoint Adjusting the room temperature setpoint Turn the setting knob to...

Page 47: ...g press on the presence button enables the service level to be accessed Configuration P1 1 factory setting Automatic storage A setpoint readjustment with the knob is adopt ed either by pressing the op...

Page 48: ...c display is made after a maximum of 8 minutes or by pressing the operating mode button with the QAA78 only 2 minutes Continuously After pressing the info button a change back to the new basic display...

Page 49: ...o reception Change battery 138 Service unit Missing Ready No reception Change battery 140 Delete all devices 6 4 Time programs Entering the switching times For the heating circuits and DHW heating a n...

Page 50: ...42 Start 643 End 648 Operating level Frost protection Reduced The holiday program is used to switch the heating circuits to a selectable operating lev el according to calendar dates The holiday progra...

Page 51: ...ive depending on the selected operating mode thus producing different temperature levels in the rooms The ranges of adjustable setpoints result from the interdependencies as this is shown in the follo...

Page 52: ...the flow temperature especially when outside temperatures are low The programmed heating curve is based on a room setpoint of 20 C If the room setpoint is adjusted the heating curve automatically ada...

Page 53: ...n can be activated although the heat generation lock is switched on Line no Operating line 5950 Function input H1 Operating mode changeover HCs DHW Operating mode changeover HC1 Heat generation lock E...

Page 54: ...controller Central effect LPB When using LPB device address 1 excessive heat dissipation also acts on the consumers connected to the other controllers in the same segment The distribution of excessive...

Page 55: ...nnections Mixing valve group 1 Q2 Y1 Y2 B1 Heating circuit 1 For this application the respective settings of operating page Heating circuit 1 can be adapted Return temp controller For this application...

Page 56: ...ture control The authority of deviation is set as a percentage figure The better the reference room correct room temperature correct mounting location etc the higher the value can be set Example Appro...

Page 57: ...tation does not work in the case of pure weather compensation OFF ON P C TRx TRw SDR 2371D02 TRw t TRx Actual value room temp TRw Room temperature setpoint SDR Room switching differential P Pump t Tim...

Page 58: ...fort setpoint 20 C and Reduced setpoint 18 C Outside temperature composite Building time constant 0 2 5 10 15 20 50 15 C 0 3 1 7 7 15 3 23 30 6 76 6 10 C 0 1 3 3 3 6 7 10 13 4 33 5 5 C 0 0 9 2 1 4 3 6...

Page 59: ...is used primarily in connection with heating systems with only little spare capacity e g low energy houses In such cases the heating up time would be too long at low outside temperatures When the Redu...

Page 60: ...4 Actuator running time Actuator type The selection of the type of actuator determines the control behavior for the type of mixing valve actuator used Switching differential 2 pos For the 2 position a...

Page 61: ...system pump depending on the type of plant Speed controlled pump Line no Operating line HC1 882 Pump speed min 883 Pump speed max Pump speed min The minimum speed of the heating circuit pump can be d...

Page 62: ...oiler is used primarily for DHW Absolute priority The mixing and pump heating circuit stay locked until DHW heating is finished Shifting priority If the capacity of the heat source is not sufficient t...

Page 63: ...ating line 1642 When using this setting heating up to the legionella setpoint takes place on the selected weekday independent of previous storage tank temperatures During the time the legionella funct...

Page 64: ...the switch on delay ensures that plant operating conditions will be stable This prevents too frequent switching actions of the boilers cycling In the case of a DHW request the delay time is fixed at 1...

Page 65: ...n the first and or the last boiler can be exempted from automatic changeover None The order of switching on the boilers changes when the number of hours set is reached operating line 3540 First The fi...

Page 66: ...lectric immersion heater is only used if the boiler delivers a fault status message or has been shut down via boiler lock This means that in normal situations the DHW is always heated by the boiler Su...

Page 67: ...6 Electric immersion heater control External thermostat The storage tank is charged with an external thermostat without setpoint compensation of the controller DHW sensor The storage tank is charged w...

Page 68: ...he first 10 seconds 6 11 Configuration Heating circuits Line no Operating line HC1 5710 Heating circuit 1 Using this setting the heating circuit can be switched on and off Use of mixing valve 1 DHW se...

Page 69: ...an the setpoint adjustment on the thermostat thermostat calibrated at switch off point The flow temperature setpoint for DHW must be set to a minimum of 10 C has an impact on the charging time In that...

Page 70: ...5060 of the electric immersion heater s operating mode must be appropriately set Pump H1 Q15 Pump H1 can be used for an additional consumer Together with an external request for heat at input H1 it i...

Page 71: ...ll be deactivated followed by overrun Cascade pump Q25 Common boiler pump for all boilers in a cascade DHW mixing pump Q35 Separate pump for storage tank circulation during the time the legionella fun...

Page 72: ...ervice operating line 7139 In Economy mode the heat source K27 with QX or output UX operates as follows Off Remains locked Only DHW Released for DHW charging On Always released Heat required in econom...

Page 73: ...currently active At the moment the controller supplies some of the power required by the bus Parameter reset Line no Operating line 6205 Reset to default parameters All parameters can be reset to the...

Page 74: ...perating line Action changeover functions either the heating circuits in the segment or those of the entire system are switched based on operating line 730 Line no Operating line 6620 Action changeove...

Page 75: ...e temperature sensor is required in the LPB plant This sensor is connected to a freely selectable controller and delivers via LPB the signal to the controllers without sensor The first numeral to appe...

Page 76: ...propriately configured This setting can be used to reset the alarm relay Temperature alarms Line no Operating line 6740 Flow temp 1 alarm 6741 Flow temp 2 alarm 6743 Boiler temp alarm 6745 DHW chargin...

Page 77: ...er of burner operating hours or the selected number of burner starts has elapsed a service message will be displayed Counted for the message are the number of operating hours and the number of starts...

Page 78: ...by setting on this operating line or automatically after a timeout of 1 hour Name relay State DHW Charging pump Q3 On Diverting valve Q3 Off Mixing pump Q32 Off Intermediate circuit pump Q33 On Mixing...

Page 79: ...d the temperatures are available again when simulation is completed The function is deactivated by setting on this operating line or automatically after a timeout of 1 hour Telephone customer service...

Page 80: ...ive Manual control active 4 Heating mode restricted 106 Forced discharging DHW 108 Forced heat release 110 Overrun active 17 Forced heat release 110 Opt start control boost heating 111 Optimum start c...

Page 81: ...harging electric legionella setpoint 87 Charging electric nominal setpoint 88 Charging electric Red setpoint 89 Charging electric frost setpoint 90 Electric immersion heater released 91 Charging elect...

Page 82: ...ion active Minimum limitation active 22 Protective start up 11 Protective startup low fire 12 Return limitation 13 Return temperature limitation low fire 14 In operation 18 In operation for HC DHW In...

Page 83: ...mperature primary controller sensor error 6 40 Return temperature 1 sensor error 6 46 Return temperature cascade sensor error 6 47 Common return temperature sensor error 6 50 DHW temperature 1 sensor...

Page 84: ...sage 3 171 Alarm contact 1 H1 active 6 172 Alarm contact 2 H2 active 6 173 Alarm contact 3 EX2 230VAC active 6 174 Alarm contact 4 H3 active 6 178 Temperature limiter heating circuit 1 3 217 Sensor er...

Page 85: ...Maintenance interval exceeded 6 10 Replace battery of outside sensor 6 21 Maximum flue gas temperature exceeded 6 22 Water pressure 3 heating circuit too low dropped below lower pressure limit 3 9 6 1...

Page 86: ...e pump Q33 DHW intermediate circuit pump Y1 1st Heating circuit mixing valve Y4 Heat source shutoff valve Y7 Maintained boiler return temperature Y19 Primary controller Y31 DHW primary controller mixi...

Page 87: ...7 1 1 Basic diagram RVS63 243 Standard diagram cascade pump Combined DHW heating with pump valve cascade pump B9 T T T T BX1 Q25 Q3 Boiler 1 Boiler 2 Boiler 3 Low loss header Q2 Rg1 B3 B9 T T T T T BX...

Page 88: ...e and number of extra functions that can be applied depend on the multifunctional outputs and inputs QX or BX Depending on the type of application the use of extra functions necessitates a number of a...

Page 89: ...y Boiler Sequence Controller 500001210 D 7 2 1 DHW storage tank DHW 7 2 2 Low Loss Header Common flow sensor B10 2358A25 Q3 DHW circulating pump DHW electric immersion heater Q4 Q3 Electric immersion...

Page 90: ...operation to EN 60 730 1 B automatic Inputs Digital inputs H1 and H2 safety extra low voltage for potential free low voltage contacts voltage with contact open DC 12 V current with contact closed DC 3...

Page 91: ...l area 2 wire connection not interchangeable 200 m 400 m max cable capacitance 60 nF 0 5 mm2 LPB with bus power supply via controller per controller With central bus power supply Bus loading number co...

Page 92: ...on of housing to EN 60 529 IP20 for QAA7 QAA55 IP40 for AVS37 IP20 when mounted Normal pollution Safety class to EN 60 730 low voltage carrying parts meet the require ments of safety class III if corr...

Page 93: ...class III if correctly in stalled Degree of pollution to EN 60 730 Normal pollution Standards safety EMC etc CE conformity to EMC directive Immunity Emissions Low voltage directive Electrical safety R...

Page 94: ...ine size AAA LR03 Battery life approx 2 years Interfaces RF transmitter BSB RF frequency band 868 MHz Degree of protection and safety class Degree of protection of housing to EN 60 529 IP20 Safety cla...

Page 95: ...50 C non condensing Outside temperature acquisition Outside Sensor QAC34 101 Measuring range 50 70 C cable length max 5 m Weight Without packaging Radio transmitter 160 g Outside sensor QAC34 73 g Ca...

Page 96: ...ctive Electrical safety Radio 89 336 EEC EN 61000 6 2 EN 61000 6 3 73 23 EEC EN 60730 1 EN 50090 2 2 EN 300 220 1 25 1000MHz Climatic conditions Storage to IEC721 3 1 class 1K3 temp 20 65 C Transport...

Page 97: ...86 9 0 1 920 39 0 595 20 0 7 578 10 0 1 840 40 0 575 19 0 7 193 11 0 1 763 41 0 555 18 0 6 831 12 0 1 690 42 0 536 17 0 6 489 13 0 1 621 43 0 517 16 0 6 166 14 0 1 555 44 0 500 15 0 5 861 15 0 1 492 4...

Page 98: ...6 185 0 85 30 0 8059 110 0 508 190 0 77 35 0 6535 115 0 443 195 0 70 40 0 5330 120 0 387 200 0 64 45 0 4372 125 0 339 8 7 2 NTC 10 k 8 7 3 PT1000 T C R Ohm T C R Ohm T C R Ohm 30 882 2 50 1194 0 130 1...

Page 99: ...HAMWORTHY HEATING LTD 97 Merley Boiler Sequence Controller 500001210 D APPENDIX A System Schematics Figure A1 Cascade with primary circuit pump...

Page 100: ...mp Boiler 1 Boiler 2 Boiler 3 Low loss header Mixing Valve Heating Pump Heating circuit flow sensor Room sensor Immersion heater DHW temperature sensor or thermostat 1 1 1 2 2 2 Supply 230V 50Hz Remot...

Page 101: ...unication to boilers ground signal Radio module for use with wireless programmable room sensor or external air sensor Supply 230V 1 phase 50Hz Fused 10 Amps DHW primary pump relay contactor required 2...

Page 102: ...Sequence Controller 500001210 D Figure B2 Wireless configuration Programmable Room Sensor 30m Max 30m Max 30m Max Power Supply 230V Radio Repeater Module Radio Module Sequence Controller BUS Boiler 1...

Page 103: ...the boilers are ever powered down it automatically resets the time and you don t end up with it constantly flashing on the display Internal Clock sensors required common flow sensor and outside tempe...

Page 104: ...summer winter heating limit switches off the heating when the outside temperature gets to this level function can be switched off set to if required 8 DHW note if the dhw time program is to be the sam...

Page 105: ...t The set point for 10V can be set using parameter 5952 in the range 0 90 C The maximum setting of 90 C is a result of the application with the boiler LMU control which has a maximum setting of 90 C a...

Page 106: ...HAMWORTHY HEATING LTD 104 Merley Boiler Sequence Controller 500001210 D APPENDIX D Wiring for Primary Pump when using Cascade Controller...

Page 107: ......

Page 108: ...12 Ireland tel 00 353 141 91919 fax 00 353 145 84806 email info hevac ie Scotland Sales Service McDowall Modular Services 2 Penson Road Queenslie Industrial Estate Glasgow G33 4AG tel 0141 336 8795 fa...

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