Plum ZAB-14 Service And Assembly Manual Download

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14. Structure – service menu

Service settings

Boiler setting

Grate

CH and HUW settings

*Buffer settings

*Mixer 1-4 settings

Restore service settings

Boiler settings

Firing-up

Putting out

Cleaning

Supervision

Return protection

Thermostat selection

Min. boiler temp

Max.boiler temp

Min. airflow output

Fuel detection time

Ex. temp. w. no fuel

Poker cycle time

Feeder 2-extended operation

Additional feeder-operation

Reserve boiler

Alarms

Boiler cooling temp.

*Parameter A FL

*Parametr B FL

*Parameter C FL

*Grate

Pump off by therm.

Firing-up

Ignition test time

Feeding time

Firing-up airflow

Firing-up time

Ex. temp delta

Ex. temp for fired-up

Air flush intensity

Air flush delay

Igniter period

Worktime with minimal power

Putting out

Putting out time

Putting out airflow

Cleaning

Poker period before inflame

Poker period after bufning off

Cleaning airflow

Ash removal working period

Ash removal interval

Supervision

Supervision time

Supervision feeding time

Supervision feeder interwal

Blow-in SUPERV

Return protection

Operation mode

Min. return temp.

Return temp. hysteresis

Valve closing

Summary of Contents for ZAB-14

Page 1: ... ecoSTER200 is not part of standard equipment SERVICE AND ASSEMBLY MANUAL EDITION v1 2 APPLICABLE TO SOFTWARE MODULE A PANEL v08 30 xx v08 13 xx Boiler regulator ZAB 14 FOR BIOMASS BOILERS WITH TWO FEEDERS 11 2015 ...

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Page 3: ...e other changes in the boiler fittings which can influence the burning process The fittings should correspond to the components installed by the manufacturer pkt 23 It is recommended to operate boiler with maximally opened fan flap Activation of the fuzzy logic mode does not eliminate the necessity of regulating the SUPERVISION parameters p 8 9 In some cases the fuzzy logic mode may require additi...

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Page 5: ...Enclosure conditions 31 12 3 Ambient temperature 31 12 4 Protective connection 31 12 5 Control module disassembly 31 12 6 Exchanging parts and subassemblies31 12 7 Replacing mains fuse 31 12 8 Control panel replacement 32 12 9 Executive module replacement 32 12 10 Other requirements 32 13 Connecting electrical installation 32 13 1 Current carrying capacity of the regulator 33 13 2 Connecting HV an...

Page 6: ... mixer temperature 50 19 4 Max preset mixer temperature 50 19 5 Range of proportionality 50 19 6 Integration time constant 50 It is recommended to set this parameter within the range of 80 140 by default 110 50 19 7 Valve opening time 50 19 8 Pump deactivation by thermostat 51 20 RESTORING SERVICE SETTINGS 51 21 DESCRIPTION OF ALARMS 51 21 1 Exhaust temperature sensor damage51 21 2 Exceeding max b...

Page 7: ...ng any connection works please make sure that the mains power supply is disconnected and that terminals and electric wires are devoid of voltage Any work within the electrical installation should be done by a qualified staff with appropriate permissions After the regulator is turned off using the keyboard dangerous voltage still can occur on its terminals The regulator cannot be used at variance w...

Page 8: ...egulator A and B module and STB temperature limiter manual We are not responsible for any damages caused by failure to observe these instructions 4 Storage of documentation This assembly and operation manual as well as any other applicable documentation should be stored diligently so that it was available at any time 5 Applied symbols In this manual the following graphic symbols are used useful in...

Page 9: ...REGULATOR INSTRUCTION MANUAL ZAB 14 ...

Page 10: ...Auto detect SUMMER Activ temp SUMMER Deactiv temp SUMMER HUW operations mode Off Priority No priori ty Summer Mixer settings Preset mixer temp Mixer room therm Weather contr mixer Heating curve mixer Curve translation Room temperature coefficient Menu for all mixer cycles is identical Night time decrease Boiler Mixer 1 4 HUW tank Circ Pump Regulation mode Standard FuzzyLogic Manual control Fan Fee...

Page 11: ...bol of increasing the preset boiler temperature to fulfill mixer circuit demands P weather control for boiler cycle is active B increase in preset temperature in order to fill the buffer 5 fan operation symbol 6 fuel feeder operation symbol 7 central heating pump operation symbol 8 domestic hot water pump operation symbol 9 measured temperature of domestic hot water tank 10 preset temperature of d...

Page 12: ...o activate the boiler press encoder knob and select setting or to set its operation parameters MENU button without the need for turning it on After making sure that there is fuel in the bin and that the bin flap is closed you can turn the boiler on 8 4 Setting preset boiler temperature Preset boiler temperature just like the preset mixer circuit temperature can be set in the menu possible settings...

Page 13: ...ring up Furnace is cleaned with the use of a fan A blow is activated on a time defined by Fir clean time parameter During this time the fan works with a power set in Cleaning blow parameter In some instances the regulator extends cleaning time before firing up in order to make sure that no smouldering fuel particles are present e g after a blackout It is done in order to minimize the risk of fuel ...

Page 14: ...s environmental protection savings of consumed fuel and in most cases releases the user from the necessity of adjusting regulator parameters During operation with Individual Fuzzy Logic algorithm there is no need to set up the feeder operation parameters feeding times feeding intervals and airflow power for the each boiler output level 3 phase modulation is inactive the regulator automatically and...

Page 15: ...e controller uses an output modulation algorithm The currently selected output level one of three available is presented on the display in the form of a three bar indicator on the left side of the boiler icon Fig 10 Output level indicator in the main window Parameters for all output levels are available in the menu Boiler settings Output modulation Each of the levels referred to as 100 50 and 30 r...

Page 16: ... ignite fuel after feeding thereof is set in Supervision Airflow operation extend Parameters should be selected in such a way that boiler temperature would gradually decrease when this mode is active Improper settings can cause the boiler to overheat Airflow in the SUPERVISION mode operates with power set in the power modulation parameter 30 Airflow power The regulator returns to the OPERATION mod...

Page 17: ... to cool the boiler down during operation on a grid During this period a DAMP REQ Damping on request message is displayed on a screen Do not deactivate the regulator when there is a burning fuel inside the boiler due to a risk of boiler overheat 8 13 Hot utility water settings HUW The device controls temperature of the hot utility water HUW tank provided that a HUW temperature sensor is connected ...

Page 18: ...onal thermostat no nc or room panel ecoSTER200 Upon activation of the thermostat the preset mixer circuit temperature will be decreased which if proper decrease value is selected will stop growth of temperature in the heated room Settings for mixer with weather sensor without room thermostat ecoSTER200 Set parameter Weather contr mixer to on Select weather curve as per point 8 19 Using parameter C...

Page 19: ... automatically If proper heating curve is selected the temperature of the circuits is calculated automatically depending on the outdoor temperature Thus if the selected heating curve is appropriate for the given building the room temperature stays more or less the same regardless of the temperature outside Note during trial and error selection of appropriate heating curve it is necessary to exclud...

Page 20: ...eekdays Saturdays and Sundays Fig 14 Interval selection window It is necessary to specify beginning and end of the given interval as well as the value by which the preset temperature is to be decreased Three intervals per day are available Fig 15 Editing intervals Below is an example of night time decrease in preset room temperature lasting from 22 00 till 06 00 as well as another decrease between...

Page 21: ...e fuel bin to the required level press and hold the knob while in the main window to open the prompt Fig 19 Fuel level service Select and confirm YES to set the fuel level to 100 Caution The fuel can be replenished at any time i e you do not have to wait until the fuel bin becomes empty Nonetheless the fuel should always be replenished to the level equal 100 and conform by press holding the knob D...

Page 22: ...hance conditions of combusting lower quality fuel and removing ashes from the furnace The furnace is cleaned by a mobile grid in WORK mode In case when the boiler operates in WORK or SUPERVISION mode for a long time it is possible to clean the boiler automatically with the use of the parameter Service settings Boiler settings Furnace cleaning Pt 16 includes service parameters concerning the mobile...

Page 23: ...er can be deactivated in time intervals which are predefined in Menu Work acc to a schedule Note Work acc to a schedule position can be unavailable if the boiler manufacturer has not included this function in a particular boiler 8 30 Restoring user settings It is possible to restore default parameter of settings which are available in the main menu Fig 21 Restoring user settings Note service param...

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Page 25: ...REGULATOR INSTALLATION AND SERVICE SETTINGS MANUAL ZAB 14 ...

Page 26: ...ly from the surroundings and improve thermal contact with the pipe by using thermal grease The boiler pre set temperature must be high enough to provide thermal power for the mixer circuit while heating the water which returns to the boiler SUGGESTED SETTINGS Parameter Setting MENU Return protection on service settings boiler settings Min return temp 42 C service settings boiler settings Return te...

Page 27: ...t of exceeding the Max mixer temp Return protection is available only for mixer 1 circuit 9 2 Scheme 2 Fig 23 Diagram with thermostatic three way valve which protects the temperature of return water3 where 1 boiler with feeder 2 ZAB 14 regulator 3 regulator control panel 4 boiler temperature sensor 5 return temperature sensor 6 central heating cycle pump 7 thermostatic three way valve 8 throttle p...

Page 28: ... coupling eliminates necessity of balancing the pumps flows 11 domestic hot water temperature sensor 12 domestic hot water pump 13 mixer servo 1 14 mixer pump 1 15 external thermostat protecting floor heating 55 ºC it cuts off electricity supply for mixer pump after exceeding maximum temperature the thermostat is not included in the regulator 16 room thermostat of mixer 1 17 mixer temperature sens...

Page 29: ...heating curve 2 0 2 0 6 service settings mixer 2 settings Mixer support 3 on floor service settings mixer 3 settings Max pre set mixer temp 3 50 C service settings mixer 3 settings Mixer heating curve 3 0 2 0 6 service settings mixer 3 settings Mixer support 4 CH on service settings mixer 4 settings Max pre set mixer temp 4 80 C service settings mixer 4 settings Mixer heating curve 4 0 8 1 4 servi...

Page 30: ...onnected to the regulator PG13 5 6 12mm cable Control PG07 4 6mm cable Display Graphic 128x64 External dimensions Control panel 164x90x40 mm Execution module 495x400x205 mm Total weight of the set 10 3kg Standards PN EN 60730 2 9 PN EN 60730 1 Protection rating To be built in devices of I class Rated surge voltage 2500Vrms 50Hz 11 Conditions of storage and transport The regulator cannot be exposed...

Page 31: ...tended for enclosing the regulator 12 4 Protective connection Connect the boiler enclosure PE cables on peripherals and other available connective parts to terminals marked on a HV plate as inside the enclosure 12 5 Control module disassembly To disassemble the control module 3 shift latches 1 with the use of z flat screwdriver 2 Fig 27 Enclosure conditions 12 6 Exchanging parts and subassemblies ...

Page 32: ...tible with the executive module 12 9 Executive module replacement The requirements are the same as those for replacement of the control panel 12 10 Other requirements Before using the regulator in the boiler verify whether the regulator meets the boiler requirements defined in valid regulations Check whether the regulator can properly and safely cooperate with particular boiler type 13 Connecting ...

Page 33: ...ld be connected in accordance with information on plates fixed next to terminals Tighten gland nuts and pull the cable in order to make sure that it does not come out Cables with dangerous voltages can be led only through appropriate glands They cannot be led directly net to each other It is forbidden to mix cables with dangerous voltages 230 400V with LV cables e g from sensors Wires of connected...

Page 34: ...emp sensor 101 102 HUW temp sensor 103 104 Weather sensor 105 106 Exhaust temp sensor 107 108 Room thermostat 1 109 110 Mixer temp sensor 111 112 GND Capacity sensor 113 OUT 114 5V 115 Buffer temp up 116 117 Buffer temp down 118 119 Fuel level sensor ceramic head 120 121 Room thermostat 2 122 Additional functional description of terminals for mobile grate and mixer servo Terminal PE N L Function 7...

Page 35: ...35 Fig 29 ZAB 14 Diagram for electric connections MOUNTING PLATE ...

Page 36: ...cations can be incorrect Minimum distance between these leads should be at least 10 cm The sensor leads cannot have contact with hot elements of the boiler and heating system The temperature sensors leads are resistant to temperature up to 100 C 13 5 Connecting weather sensor The regulator cooperates only with a weather sensor of the CT4 P type The sensor should be installed on the coldest wall of...

Page 37: ...r circuit all room thermostat settings for boiler should be disabled After opening of the contacts the room thermostat decreases the preset mixer circuit temperature by the value of preset mixer temperature decrease from thermostat This parameter can be found in Mixer 1 settings Mixer room therm The value of this parameter should be chosen in such a way that after activation of room thermostat ope...

Page 38: ... the U3 module relay coil and its contacts will be disconnected After the boiler temperature drops below the parameter auxiliary boiler off temperature the regulator ceases to supply voltage to the terminalsi 87 88 which will activate the reserve boiler Switching the ZAB 14 regulator into OFF mode causes activation of reserve boiler It is recommended to switch the ZAB 14 regulator in the OFF mode ...

Page 39: ...tings Alarms Selecting a value of 127 will cause occurrence of voltage between terminals 30 31 alarm output activation if any alarm occurs Setting this value to 0 will prevent the boiler from activating the output in the case of alarm It is also possible to set up the alarm output in such a way that it was activated when one or several selected alarms occur The value to which this parameter should...

Page 40: ...make sure that the servo opens in the correct direction to do so open menu Information and go to tab info mixer or enable manual control of devices connected to the regulator 13 11 Connecting circulating pump The circulating pump can be connected to the ZAB 14 boiler regulator only after purchasing an extension executive module 13 12 Connecting temperature limiter STB In order to prevent the boile...

Page 41: ...0 supply points connect GND and V to external power supply The power supply is not included with the regulator Connect lines D and D as shown in the diagram Maximum length of leads to the additional panel should not exceed 30 m whereas their gauge should be at least 0 5 mm2 13 14 Internet connection ZAB 14 regulator can be connecter with the Internet via an additional ecoNET300 module Detailed inf...

Page 42: ...r cooling temp Parameter A FL Parametr B FL Parameter C FL Grate Pump off by therm Firing up Ignition test time Feeding time Firing up airflow Firing up time Ex temp delta Ex temp for fired up Air flush intensity Air flush delay Igniter period Worktime with minimal power Putting out Putting out time Putting out airflow Cleaning Poker period before inflame Poker period after bufning off Cleaning ai...

Page 43: ...culation pump operation time Boiler pump Pump hysteresis Buffer settings Activate operations Loading start temperature Loading start temperature Mixer 1 4 settings Mixer support Thermostat selection Min mixer temp Max mixer temp Proportionality range Integration time constant Valve opening time Pump deact by time Mixer input dead zone Menu for mixer cycles is identical Note some menu elements can ...

Page 44: ...ator will go directly from operation mode into putting out mode 15 5 SUPERVISION feeding time This is the time of feeding fuel and airflow operation in the SUPERVISION mode point 8 9 Setting the parameter value to 0 will cause only the airflow to be activated during supervision The value of this parameter cannot be too high as it can cause the boiler to overheat in the SUPERVISION mode In the SUPE...

Page 45: ...r returning to the boiler below which the four way valve servo is closed After the return temperature exceeds the value of this parameter return temperature hysteresis the servo resumes normal operation 15 10 Return temperature hysteresis This parameter defines the return temperature hysteresis 15 11 Valve closing This parameter specifies percentage of closing the four way valve after drop in temp...

Page 46: ...ur After setting a value of e g 20 the user will not be able to set fan speed lower than 20 15 16 Fuel detection time The regulator can detect lack of fuel in the main tank of the boiler on the basis of exhaust gases temperature If for a time exceeding one programmed in parameter Service settings Boiler settings Fuel detection time the emission temperature is lower than one set in parameter Servic...

Page 47: ...zy Logic mode as this is controlled automatically It is not recommended to change these parameters if the rate of boiler power change is at the required level Parameter A Increasing its value speeds up increment in the boiler output The higher the value the faster the boiler reaches the pre set temperature Value too high can destabilize maintenance of the pre set boiler temperature Settings range ...

Page 48: ... can put the users at risk of being scalded with the utility water Too low a value thereof will make it impossible to carry excessive heat away to the HUW tank if the boiler overheats When designing the hot utility water system it is necessary to provide for the possibility of regulator failure As a result of the regulator failure the water in the hot utility water tank can overheat to a dangerous...

Page 49: ...he value defined in parameter Buffer filling stop temperature 19 MIXER SERVICE SETTINGS 19 1 MIXER OPERATION The following options are available OFF mixer servo and mixer pump are inoperative CH ON choose this option if the mixer circuit feeds radiator system of central heating The maximum temperature of mixer circuit is unlimited the mixer is fully opened during alarms e g boiler overheat Caution...

Page 50: ...nally the limit temperature of the mixer circuit at which the mixer pump is disabled For floor heating set the value within the range of 45 C 50 C unless the manufacturer of the floor materials or the designer of the CH system specified otherwise 19 5 Range of proportionality Caution it is recommended not to modify this parameter This is the mixer step value Increasing its value will speed up reac...

Page 51: ...ace it if necessary See how to check the temperature sensor in point 13 6 21 2 Exceeding max boiler temperature Protection against boiler overheating is twofold First after exceeding the boiler cooling temp the regulator tries to decrease the boiler temperature by dropping the excessive heat to the HUW tank and by opening the mixer servo only if mixer cycle on CH If the temperature measured by the...

Page 52: ...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 Cancel the alarm by pressing the TOUCH and PLAY button or by restarting the regulator Check the sensor and possibly replace it The method of checking the temperature sensor is described in point 13 6 21 5 Feeder temperature sensor damage This alarm will occur in the cas...

Page 53: ...ve module via digital communication link RS485 If this link is damaged the following alarm will be displayed Caution No communication The regulator does not disable regulation and operates as usual with the pre programmed parameters If any other alarm occur it will take action in accordance with the given alarm Check the connection the control panel and repair or replace it respectively 21 9 Unsuc...

Page 54: ...ual return to its initial position unlock it by removing the lid and pushing the button in accordance with the documentation provided by the boiler manufacturer check the fan and replace it if necessary Fuel feeder inoperative fails to feed Check if the feeder leads are properly connected to terminals If temperature limiter STB is connected to terminals 90 91 check if the circuit is not cut off du...

Page 55: ...ystem is properly made i e after closing the valve the return temperature must be able to exceed the parameter Min return temp value The reason can be that the HUW tank is being filled with HUW priority enabled Wait until the HUW is filled or disable the HUW priority The reason can be active SUMMER function The reason can be an on going calibration of the mixer valve wait until the calibration is ...

Page 56: ...s tested in PLUM sp z o o laboratory are available in the regulator Caution selecting an incorrect boiler type which was not examined in the PLUM laboratories can damage the boiler during its operation Settings for individual boilers require arrangements between the boiler manufacturer and the PLUM sp z o o company In order to apply the changes it is necessary to disconnect and reconnect the regul...

Page 57: ...57 Register of changes V1 1 general proofread V1 2 changing the type of sensors in the table with a description of the terminals page 34 clamps 106 107 119 120 ...

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Page 60: ...ul 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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