Ponast Sigmatek Instructions For Use And Installation

Workbook 4
Controller SIGMATEK - Boiler control
MANUFACTURER: PONAST spol. s r.o., Na Potůčkách 163, 757 01 Valašské Meziříčí, ČESKÁ REPUBLIKA tel.:+420 571 688 180 , fax +420 571 688 115, e-mail: obchod@ponast.cz. www. ponast@cz
Associated regulations and instructions:
- Workbook 1 - Design - Installation - Service - Maintenance
- Workbook 2 - Controller RKP 12157 - Boiler control
- Workbook 3 - Controller IGNEO - Boiler control
- Workbook 4 - Controller SIGMATEK - Boiler control
- Workbook 5 - Technical parameters
For proper and safe operation of the product is necessary to follow:
- manufacturers instructions
- general principles of the operation and installation of the product
- standards, ordinances and regulations currently in force in the place of use of the product
The manufacturer reserves the right to innovative changes of product that may not be included in this manual.
Boilers have been certified for operation in the Czech Republic and the EU countries by Engineering Test Institute Brno, State testing laboratory n. 202
General information on CAA and smoke control
The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any fixed boiler if located in a designated smoke control area. It is also an offence to acquire an "unauthorised fuel" for use within a smoke control area unless it is used in an "exempt" appliance ("exempted" from the controls which generally apply in the smoke control area).
The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise smokeless fuels or exempt appliances for use in smoke control areas in England. In Scotland and Wales this power rests with Ministers in the devolved administrations for those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been "authorised" in Regulations and that appliances used to burn solid fuel in those areas (other than "authorised" fuels) have been exempted by an Order made and signed by the Secretary of State or Minister in the devolved administrations.
The KPxxx boilers have been recommended as suitable for use in smoke control areas when burning wood pellet.
Further information on the requirements of the Clean Air Act can be found here: http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of smoke control areas and you can contact them for details of Clean Air Act requirements.
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CONTENT
1 USE AND ADVANTAGES....................................................................................................................................... 3
2 3. INSTALLATION INSTRUCTIONS ....................................................................................................................... 3
2.1 CONTROL UNIT............................................................................................................................................ 4
2.1.1 Boiler Function Module HZS 521-G ...................................................................................................... 5
2.1.1.1 Technical base data ........................................................................................................................ 7
2.1.2 Terminal HZS 555-S with USB ............................................................................................................. 8
2.1.2.1 Technical data ................................................................................................................................ 8
2.2 CONNECTION OF ELECTRICAL PARTS ......................................................................................................... 10
3 CONTROL UNIT OPERATION ............................................................................................................................. 12
3.1 MAIN MENU ............................................................................................................................................... 12
3.2 OPERATING CONDITIONS – MAIN MENU..................................................................................................... 13
3.3 MAIN MENU ............................................................................................................................................... 14
3.3.1 Setting menu ................................................................................................................................... 14
3.3.1.1 Info menu .................................................................................................................................... 14
3.3.1.2 Menu users settings ...................................................................................................................... 15
3.3.1.3 Menu Service ................................................................................................................................ 18
3.3.2 Menu – heating circuits..................................................................................................................... 28
3.3.2.1 Tank ............................................................................................................................................ 29
3.3.2.2 Sanitary water .............................................................................................................................. 31
3.3.2.3 Heating circuit .............................................................................................................................. 33
4 GUARANTEE AND LIABILITY FOR DEFECTS ........................................................................................................ 36
5 DISPOSAL OF PRODUCT AFTER TEH END OF ITS SERVICE LIFE.......................................................................... 36
PICTURES
Picture No. 1 Control unit - configuration ................................................................................................... 4
Picture No. 2 HZS 521-G Connector and terminal electronics layout ......................................................... 5
Picture No. 3 Module HZS 532-1 ................................................................................................................. 6
Picture No. 4 Other modules ....................................................................................................................... 6
Picture No. 5 Terminal with USB ................................................................................................................. 8
Picture No. 6 Main menu – sample of visualisation .................................................................................. 12
Picture No. 7 Circuit diagram – control unit.............................................................................................. 37
Picture No. 8 Circuit diagram + module HZS 533 ..................................................................................... 38
Picture No. 9 Circuit diagram - HZS 533, HZS 535 .................................................................................... 39
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IMPORTANT NOTES
This product may only be put into operation by an installation organization trained by the manufacturer.
This product may only be operated by adult persons, duly acquainted with the way the product is controlled and duly acquainted also with these Instructions. If you adhere to the below mentioned principles, the product will serve you reliably to your full satisfaction.
It is prohibited to intervene in any way in the structure or electrical installation of products. Having the equipment been disconnected from the electric network, the power supply cord has to be plugged from the mains outlet.
1 USE AND ADVANTAGES
The main advantages of products:
CONTROL UNIT
with modern design
controls operation of the boiler
ensures automatic operation
high operational reliability
long distance control
Colour TFT display 5.7" with touch screen
Remote control over TCP/IP
USB
User friendly controlling
Operation modes: Equitherm, Modulation or Fixed power
Two heating circuits and sanitary water in basic configuration
Possibility to control accumulation tank or solar system – maximum 7 heating circuits
Upgrading software over USB stick
Possibility of control by thermostat or by optional number of sensors
Possibility of setting time windows for heating circuits control
Possibility of software update through the USB input or via TCP / IP
2 3. INSTALLATION INSTRUCTIONS
The control unit is supplied as part of equipment of boilers KP xxx.
Separately are control system´s spare parts supplied in the context of any claim or to order.
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2.1 CONTROL UNIT
Boiler is equipped with the control system with touch screen. This control system enables automatic boiler operation through the control and regulation features (thermostats, sensors, etc.) in the requested modes. It also enables Diagnostics mode of control, which can be used for instance for boiler commissioning.
The control system construction and its electrical shielding (IP 45) make safe and reliable operation possible even under the demanding operational and climatic conditions common to boiler rooms.
Basic configuration Optional configuration
Picture No. 1 Control unit - configuration
Configuration:
Name Type Options Order code
Control unit - boiler function module HZS 521-G Standard Terminal (touchscreen) HZS 555-S Standard
Module extension HZS 532-1 Standard Module heating circuit / accumulation tank HZS533 Optional Module solar HZS535 Optional
Type and number of circuit Type and number of module
HC1 SWT HZS 521-G HZS532-1
HC1 HC2 SWT HZS 521-G HZS532-1
HC1 HC2 HC3 SWT HZS 521-G HZS532-1 1 pc HZS 533
HC1 HC2 HC3 HC4 SWT HZS 521-G HZS532-1 2pcs HZS 533
HC1 HC2 HC3 HC4 HC5 SWT HZS 521-G HZS532-1 3pcs HZS 533
HC1 HC2 HC3 HC4 HC5 ACU HZS 521-G HZS532-1 3pcs HZS 533
HC1 HC2 HC3 HC4 ACU SOL HZS 521-G HZS532-1 2pcs HZS 533 HZS 535
HC – heating circuit SWT – sanitary water tank ACU – accumulation tank SOL – solar system
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2.1.1 Boiler Function Module HZS 521-G
The heating system is modularly constructed. The HZS 521-G is a module for the boiler, which communicates with the CPU module and executes the transmitted instructions. The HZS is a simple component that is used to control automated processes in a heating system.
All interfaces and connections for controlling of the boiler are located on the control board.
Ambient temperature senso
HC1 mix temp
Backwater temp
Sanitary water temp
Exhaust temp
Sanitary water top
Sanitary water bottom
Room thermostat 3
Room thermostat 2
Room thermostat 1
Room thermostat 4
SWT thermostat
Impulse sensor 2
Impulse sensor 1
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ntifrost protection
Servo open
Servo close
SWT pump
Bypass pump
Ignition
HC1 pump
Primary fan
Exhaust fan
Feeder 1
Feeder 2
Picture No. 2 HZS 521-G Connector and terminal electronics layout
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The control unit always contains modules HZS 521-G and HZS 532-1.
Picture No. 3 Module HZS 532-1
HZS533 HZS533 HZS535
Picture No. 4 Other modules
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2.1.1.1 Technical base data
HZS521-G
Supply voltage
(Input voltage for the power transformer on the power board, input
voltage for the STB, phase for the phase angle, relays and Triac outputs) Power supply fre­quency
Current consumption of supply (230 V AC)
45 - 65 Hz
Total current consumption 200 mA + current consumption of the
Supply for the power board and CPU electronics
Supply for Heater Lambda sensor: 200 mA
The power supply is switched of STB, L-STB
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230 V AC +/- 10 %
connected loads (max. 16 A)
Power supply transformer
Loads connected over fuse F4 (3,15 AT):
690 W/ maximum 3 A Screw: maximum 690W/ maximum 3 A
Loads connected over fuse F5 (10 AT):
X11 primary fan: maximum
Loads connected over fuse F6 (10 AT):
X9 Turbine: maximum 2300 W/ maximum 10 A
Loads connected over fuse F7 (10 AT):
X8 Ignition: maximum 2300 W/ maximum 10 A
Loads connected over fuse F8 (10 AT):
X5 heat exchange cleaner: maximum 690 W/ maximum 3 A X6 grate open: maximum 690 W/ maximum 3 A
HZS532-1
Internal electronics power supply Relay power supply
Fuse 10 A for relay outputs
X7 grate closed: maximum 690 W/ maximum 3 A
The power supply not switched over STB, L
F9 (10 AT):
X10 boiler circuit return flow pump: maximum 2300 W/ maximum 10 A
+24 V (from HZS 511), must be connected to the expansion controller
230 VAC
X14
Loads connected over fuse
+24 V current consumption
HZS533, HZS535
Internal electronics power supply Relay power supply
Fuse 5 A for relay outputs and/or 3 A for solar module
+24V current consumption
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+24 V (from HZS 511), must be connected to the expansion controller
HZS 533 maximum 15 mA (without relays) Maximum 40
HZS 532-1: maximum 60 mA (without relays) Maximum 120 mA (with relays) HZS 532-1 with 5 expansion modules, maximum 350 mA
230 VAC
mA (with relays)
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2.1.2 Terminal HZS 555-S with USB
Picture No. 5 Terminal with USB
Description
The HZS 555-S is an intelligent terminal for programming and visualization of automated processes. Process diagnosis as well as operating and monitoring automated procedures is simplified using this terminal.
A touch screen serves as the input medium for process data and parameters. The output is shown on a 5.7" SVGA TFT color display.
Cleaning the Touch Screen
CAUTION! Before cleaning the touch screen, the terminal must first be turned off to avoid unintentionally triggering functions or commands!
The terminal's touch screen can only be cleaned with a soft, damp cloth. To dampen the cloth, a screen-cleaning solution such as antistatic foam, water with detergent or alcohol should be used. First spray the cleaning fluid on the cloth and not directly on the terminal. The cleaning solution should not be allowed to reach the terminal electronics, for example, through the ventilation slots.
No erosive cleaning solutions, chemicals, abrasive cleansers or hard objects that can scratch or damage the touch screen may be used.
If the terminal is soiled with toxic or acidic chemicals, quickly and carefully clean the terminal to prevent corrosion.
2.1.2.1 Technical data
Supply voltage Typically +24 V DC
MIN +18V DC MAX +30V DC Current consumption of voltage supply
Standby
Starting current
8
Typically 440 mA (pro + 24 V) ,
Maximum 650 mA
Typically 0.56 W
Maximum 25 A for 20 µs
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Display
Type 5.7" LCD colour display
resolution VGA 640 x 480 Pixel
Colour depth 18-bit RGB (262K colours)
LCD Mode TN / normal white
LCD Polarizer Trans missive
Pixel size 0.18 mm x 0.18 mm
Active surface 115.2 mm x 86.4 mm
Background lighting LED
Contrast 600
Brightness Typically 350 cd/m²
Angle CR >= 10 Left, right, below 75°, above 60°
Environmental conditions
Storage temperature -10 – +85 °C
Operating temperature 0 – 50 °C
Humidity 10 - 90 %, uncondensed
EMV stability EN 61000-6-2: noise immunity
EN 61000-6-4: noise emission
Vibration - tolerance EN 600068-2-6 2 - 9 Hz: Amplitude 3.5 mm
9 – 200 Hz: 1 g (10 m/s²)
Shock resistance EN 60068-2-27 15 g (150 m/s²)
Protection Type EN 60529 Protected
through the housing
Front: IP54
Cover: IP20
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2.2 CONNECTION OF ELECTRICAL PARTS
The electric parts connections can be performed by qualified personnel only. Connect the particular appliances according with connection diagram. During connecting the equipment must be shut down with the main switch or disconnected from power supply by pulling the electric cord from the outlet.
1 Relay for electric ignition 2 Burner thermostat 3 Cover control unit 4 2x M4 5 Boiler thermostat 6 Control unit
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Connect: Connection terminal
Feeder motor F2 X14- L, N, PE Impulse sensor F2 X45 Electric ignition spiral X4-L, N, PE Primary Fan X11-L, N, PE Flue Fan (if used) X12-L, N, PE Feeder motor F1 X13- L, N, PE Impulse sensor F1 X44 Flue thermometer X31 System pump X10-L, N, PE Boiler pump X7-L, N, PE Servo 3 (4) – way valve X5-L, N, PE, X6-L, N, PE Room thermostat X46 Boiler thermostat X47 Outside temperature X34 Thermometer behind 3 (4) – way valve X28 Thermometer back water X29
Important note:
Fan and flue fan are controlled proportionally.
With MENU Diagnostics -
F1 feeder motor function and correct rotation direction F2 feeder motor function and correct rotation direction Correct functioning of F1 feeder impulse sensor and simultaneously Correct functioning of F2 feeder impulse sensor Functioning of fan and linearity of its regulation Functioning of flue fan and linearity of his regulation (if used) Functioning of system pump and its venting Functioning of boiler pump and its venting Functioning of motor and correct rotation direction of ash removal spiral screw Functioning of exchange cleaning motor Functioning and correct rotation direction of servomotor Functioning and timing of servomotor between limit positions and agreement of timing with SW setting Correct functioning of electric ignition spirals Correct functioning of attached thermometers Setting of a proper equithermal curve Setting or changing servomotor timing
direct control
- to be checked by qualified personnel:
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3 CONTROL UNIT OPERATION
3.1 MAIN MENU
Description of the basic control panel screen
After switch on the main power switch, start program and after several minutes will show the main menu.
For easy operation are used:
- Buttons with names or pictograms
- Buttons with moving (setting of power and temperature)
- Boxes with information’s (text, numbers or pictograms)
- Date and time
The data are showed as numbers, diagrams or combination.
Button SELECTION OF OPERATING MODE
ctual status
Button: START/STOP
Information:
Date Time
Button: Information and Service menu
Button: Heating circuit setting
Button: Move to second screen
Button:
Picture No. 6 Main menu – sample of visualisation
Power setting (required power)
Note: Changes important parameters for combustion quality and safety is allowed after insert
Button:
Temperature setting (required temperature)
password according with table No.6 (In the end of this manual).
Information space: Boiler temperature - actual Exhaust temperature - actual
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3.2 OPERATING CONDITIONS – MAIN MENU
SELECTION OF OPERATING MODE
User - before start operation of boiler, have to select operation mode – touch on the button is automatically changed mode:
FIXED POWER
Operate boiler automatically on the fixed power. User can set value of power (% or kW) and temperature (°C).
MODULATION
Operate boiler automatically. User can set value temperature (°C). The power is adjusted automatically depend on temperature. User cannot change the power.
EQUITHERM
Operate boiler automatically. The power and temperature is adjusted automatically depend on outside temperature and setting of equitherm diagram. User cannot change the power and temperature. This mode user cannot chose when the out temperature sensor is not use.
Selection – touch on button:
FIXED POWER » MODULATION » EQUITHERM
START
After touch on the button START boiler is working automatically. The display shows step by step actual operation:
Ignition
Fuel is burn on by electric spiral.
Stabilisation
Stabilisation of fire
Operating
The fire was stabilised and boiler is normally working.
Stand-by
Quiet mode of the boiler, when the boiler is not burning actively. Boiler is ready on the basis of impulse from surrounding equipment (thermostats, GSM Modem) to restore the supply of heat.
Note:
 
– 10.
The programme routine of Automatic Ignition has absolute priority to be carried out in full extent. If the routine is activated, it is not possible to interrupt or stop it in any way. This fact is an important condition for reliable operation of the boiler because it is then possible only to ascertain indirectly from further behaviour of the boiler whether it is burning or not. The on-going routine of Automatic Ignition may be terminated only by the operator by switching STOP. Service is than responsible for the correct set up to a automatic operation.
interrupted the boiler will start with the electric ignition routine after the power supply is resumed.
Change –SELECTION OF OPERATING MODE – is possible to make at any time during operation.
Note:
If boiler is working in -MODULATION or EQUITHERM - control unit automatically setting power in the range 0
Note:
After „START“ is activated automatic ignition. Auto ignition runs for several minutes.
Note:
If the boiler is working in the mode FIXED POWER, MODULATION, EQUITHERM and power supply is
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3.3 MAIN MENU
3.3.1 Setting menu
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3.3.1.1 Info menu
Button:
larm list
Button: Back on the previous screen
Software version No. dated
Software version visualisation No. dated
Operating hours
Button: Move to second screen
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3.3.1.2 Menu users settings
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Time, date
Current time HH:MM:SS
Current date DD.MM.YY
Tine without screensaver
Button: Password
Showed:
Please insert your
password“
fter touch on the box for password: Insert password and enter. In the end confirm: OK
If is password right – button change on green colour
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Cleaning an ash removing
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Time window setting
Skin
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A
IP Adress
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Button: Password
Showed:
Please insert your
password“
fter touch on the box for password: Insert password and enter. In the end confirm: OK
If is password right – button change on green colour
3.3.1.3 Menu Service
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Diagnostics
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Manual mode
Touch and start functionality
Button: Password
Showed:
Please insert your
password“
fter touch on the box for password: Insert password and enter. In the end confirm: OK
If is password right – button change on green colour
Note:
The operator can directly control the startup fuel feeders. It is possibilities to fuel filling Feeder F1. Turn on Feeder F1 depend on Feeder F2. Steps for turn on Feeders:
The rotation is signalized by two small red windows – blinking. When fuel is falling down from Feeder F1 into Feeder F2 – immediately stop Feeders! Overfilling of fuel is dangerous!
If you have empty feeders – you must fill fuel into the feeders before START:
1. Feeder F2
2. Feeder F1
Other functionality are used for diagnosing of functionality.
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Actual values
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Configuration
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Parameters The setting value of parameters is important for combustion quality, correct function and safety. The producer saves changes of parameters by password. Is prohibited to make unqualified changes. .
Important note:
Actual setting depend on the type of boiler! Producer
The value of parameters on the pictures below is ONLY SAMPLES!
and qualified service can make changes only!
Next page
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Previous page
Temperatures
Maximum boiler temperature
Minimum exhaust temperature for heating
Maximum exhaust temperature
Temperature for activate pump
Temperature for activate bypass pump
Button for activate electric heating
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Ignition
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Button for activate electric ignition. Boiler is operating in Stand-by and keeps the fire
Fuel for ignition
Time for pre heating of ignition spiral (without fan)
Fan revolution
Control temperature
Note:
Control temperature is important for fire control
Time limit for ignition
Time for stabilisation of fire
Time for prolong of stabilisation of fire
Fuel for stabilisation of fire
Time spiral activation - during stabilisation of fire
Time feeder F1 during burn on ­fuel
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A
T
T
Standby mode
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Time period, in which automatic boiler is not actively burning
ime – fire life
Setting temperature
ime -
Programs
Button to select programs for settings
Parameters for chosen program above
ctual program for fix
power
:
Note
Is possible to set here but main settings is on the main menu
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:
T
A
Modulation
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PID regulation ­recommended
Parameters for regulations
Feeders
ime count impulses
Note
If it is set „0“ then there is no control of the motor
llowed errors
On time feeder F2 before F1
Off time feeder F2 of F2
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Cleaning, Ash removing
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Time window setting
USB
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Load from USB
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Save on USB
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Controller SIGMATEK - Boiler control
3.3.2 Menu – heating circuits
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Button for open window for addition heating circuits
Button for confirmation
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After confirmation:
V
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3.3.2.1 Tank
Demand for heating
Time window setting
Button for settings menu
Button for manual functionality
isualisation of
29
pump status Green - On Grey – Off
Controller SIGMATEK - Boiler control
Function for settings of parameters
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Function for manual control of pump
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3.3.2.2 Sanitary water
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Demand for heating Blue – heating Red – not heating
Time window setting
Button for settings menu
Button for manual functionality
isualisation of pump status Green - On Grey – Off
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3.3.2.3 Heating circuit
Demand for heating Blue – heating Red – not heating
Time window setting
Button for settings menu
Button for ekviterm parameters
Button for manual functionality
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Servo control: White: Off Green: On
Servo location: White: closed Black: opened
isualisation of pump status Green - On Grey – Off
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4 GUARANTEE AND LIABILITY FOR DEFECTS
The manufacturer provides guarantee:
- for the boiler on a period of 24 months from the date of putting into operation, however, no longer than 30 months from the date of shipment from the manufacturing plant
- for the boiler body on a period of 60 months from the date of putting into operation
- ceramic parts are not covered by the warranty. Its durability is dependent on the way of operation of boiler and their guaranteed durability is 12 months.
GUARANTEE CONDITIONS
1) User is obliged to ensure installation of the boiler and putting it into operation only by an authorized servicing organization which has the manufacturer's accreditation and the user is also obliged to send the after the product has been put into operation.
2) The boiler has to be operated only within these Instructions for operation and only prescribed fuel may be used (wood pellets - φ6-8.5 mm), free from any admixtures and foreign object. Alternative fuel must be approved by the boiler manufacturer.
3) If the user wants to claim any form of guarantee, he/she has to submit duly filled in letter of
letter of guarantee number 1 to the manufacturer's address immediately
guarantee number 2
4) The user is obliged to demonstrate that the product was maintained in regular intervals which are described in the chapter "MAINTENANCE". Regular annual maintenance has to be done by trained person who is also responsible for the record of it within 14 days (list is part of manual) / service intervention or repaired has to be correctly recorded and sanded to a manufacturer.
5) Every notification of defect has to be done in writing to the address of the manufacturer immediately after having been ascertained.
The manufacturer reserves the right of product innovations, which may not be part of this manual.
Important:
.
Recommended hydraulic connections are principled diagrams created by manufacturer on the basis of practical experience in the operation of boilers KP.
The user can use the application unchanged as well as in particular modification to the best solution of heating system.
This is primary responsibility of the designer and implementer of the heating system ­Ponast company cannot take over the guarantee for the functionality of a particular solution of heating system.
which is why the
5 DISPOSAL OF PRODUCT AFTER TEH END OF ITS SERVICE LIFE
Disposing of the Product is done in accordance with the generally applicable regulations.
The following main kinds of waste will be generated after the end of the product´s service life: Control unit with sensing and control elements – waste code 200136, category O.
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Picture No. 7 Circuit diagram – control unit
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Picture No. 8 Circuit diagram + module HZS 533
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Picture No. 9 Circuit diagram - HZS 533, HZS 53
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