SAS ST-550 zPID User Manual

User’s manual

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Tabel of contents

I. Safety ............................................................................................................................... 4

II. Description of the device ..................................................................................................... 5

III. Installation ...................................................................................................................... 5

IV. How to use the controller .................................................................................................. 8

IV.1. Principle of operation .................................................................................................. 8

IV.2. Stages of operation .................................................................................................... 8

IV.3. zPID control .............................................................................................................. 8

IV.4. Controller operation without zPID control ...................................................................... 9

IV.5. How to navigate ....................................................................................................... 10

V. Controller functions– main menu ........................................................................................ 10

V.1. Block diagram of the main menu. .................................................................................. 10

V. 2. Fire-up....................................................................................................................... 12

V. 3. Screen view ................................................................................................................ 12

V. 4. Fuel tank full .............................................................................................................. 12

V. 5. Temperature settings ................................................................................................... 12

V. 5.a) Pre-set CH temperature ......................................................................................... 12

V. 5.b) CH hysteresis ....................................................................................................... 12

V. 5.c) Pre-set DHW temperature ...................................................................................... 12

V. 5.d) DHW hysteresis .................................................................................................... 12

V. 5.e) Temperature of pump activation .............................................................................. 12

V. 5.f) Pre-set room temperature ...................................................................................... 13

V. 6. Manual mode .............................................................................................................. 13

V. 7. Operation settings ....................................................................................................... 13

V. 7.a) Feeding time ........................................................................................................ 13

V. 7.b) Pause time ........................................................................................................... 13

V. 7.c) Blow force ............................................................................................................ 13

V. 7.d) Operation in sustain mode ..................................................................................... 13

V. 7.e) Pause in sustain mode ........................................................................................... 13

V. 7.f) Fan in sustain mode .............................................................................................. 13

V.7.g) Fan speed in sustain mode ..................................................................................... 13

V. 8. Fuel granulation .......................................................................................................... 13

V. 9. Operation modes ......................................................................................................... 14

V. 9.a) House heating ...................................................................................................... 14

V. 9.b) Water tank priority ................................................................................................ 14

V. 9.c) Parallel pumps ...................................................................................................... 14

V. 9.d) Summer mode ...................................................................................................... 14

V. 10. Weekly control ......................................................................................................... 14

V. 11. Operation algorithm selection .................................................................................... 15

V. 12. Fitter’s menu ........................................................................................................... 15

V. 13. Service menu .......................................................................................................... 15

V. 14. Software version ...................................................................................................... 15

V. 14.a) Software update ................................................................................................ 16

V. 15. Factory settings ....................................................................................................... 16

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VI. Controller functions - Fitter’s menu................................................................................... 16

VI.1. PID coefficient ......................................................................................................... 18

VI.1.a) CH boiler power coefficient .................................................................................. 18

VI.1.b) Fan correction bottom / Fan correction top ............................................................ 18

VI.2. PID supervision ........................................................................................................ 18

VI.3. Buffer parameters .................................................................................................... 18

VI.3.a) Buffer ............................................................................................................... 18

VI.3.b) DHW function .................................................................................................... 18

VI.3.c) Pre-set temperature top...................................................................................... 19

VI.3.d) Pre-set temperature bottom ................................................................................ 19

VI.4. Valve settings .......................................................................................................... 19

VI.4.a) Built-in valve, Additional valve 1 and 2 ................................................................. 19

VI.5. Additional pump 1 / Additional pump 2 ....................................................................... 23

VI.5.a) Algorithm selection ............................................................................................ 23

VI.5.b) Short circuit pump ............................................................................................. 23

VI.5.c) Floor pump ....................................................................................................... 23

VI.5.d) Circulating pump................................................................................................ 23

VI.6. Time settings ........................................................................................................... 24

VI.7. Date settings ........................................................................................................... 24

VI.8. Internet module ....................................................................................................... 24

VI.9. Fuel level calibration ................................................................................................. 27

VI.10. Language ................................................................................................................ 28

VI.11. Room regulator ........................................................................................................ 28

VI.12. External temperature correction ................................................................................. 28

VI.13. GSM module ............................................................................................................ 28

VI.14. Factory settings ....................................................................................................... 29

VII. ST-66P pellet module ...................................................................................................... 29

VIII. Protections ................................................................................................................. 32

VIII.1. Temperature alarm ................................................................................................ 33

VIII.2. Thermal protection of CH boiler (STB) ..................................................................... 33

VIII.3. Automatic sensor control ....................................................................................... 33

VIII.4. Protection against boiling of water in the CH boiler .................................................... 33

VIII.5. Temperature protection .......................................................................................... 33

VIII.6. Fuel feeder protection ............................................................................................ 33

VIII.7. Limt switch in the fuel tank .................................................................................... 33

VIII.8. Fuse .................................................................................................................... 33

IX. Maintenance .................................................................................................................. 34

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I. Safety

Before using the device for the first time the user should read the following regulations carefully. Not
obeying the rules included in this manual may lead to personal injuries or controller damage. The user’s
manual should be stored in a safe place for further reference. In order to avoid accidents and errors it
should be ensured that every person using the device has familiarized themselves with the principle of
operation as well as security functions of the controller. If the device is to be sold or put in a different
place, make sure that the user’s manual is there with the device so that any potential user has access to
essential information about the device.
The manufacturer does not accept responsibility for any injuries or damage resulting from negligence;
therefore, users are obliged to take the necessary safety measures listed in this manual to protect their
lives and property.

WARNING

• High voltage! Make sure the regulator is disconnected from the mains before performing any

activities involving the power supply (plugging cables, installing the device etc.)

• The device should be installed by a qualified electrician.

• Before starting the controller, the user shoud measure earthing resistance of the electric motors

as well as the insulation resistance of the cables.

• The regulator should not be operated by children.

WARNING

• The device may be damaged if struck by a lightning. Make sure the plug is discon-

nected from the power supply during storm.

• Any use other than specified by the manufacturer is forbidden.

• Before and during the heating season, the controller should be checked for condition of its ca-

bles. The user should also check if the controller is properly mounted and clean it if dusty or

dirty.

Changes in the merchandise described in the manual may have been introduced subsequent to its
completion on August 25th 2016. The manufacturer retains the right to introduce changes to the
structure. The illustrations may include additional equipment. Print technology may result in differences
in colours shown..

We are committed to protecting the environment. Manufacturing electronic devices
imposes an obligation of providing for environmentally safe disposal of used electronic
components and devices. Hence, we have been entered into a register kept by the
Inspection For Environmental Protection. The crossed-out bin symbol on a product
means that the product may not be disposed of to household waste containers.
Recycling of wastes helps to protect the environment. The user is obliged to transfer
their used equipment to a collection point where all electric and electronic components
will be recycled.

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II. Description of the device

ST–550zPID temperature regulator is intended to control CH boiler with a screw feeder. Due to its
advanced software it offers a range of functions:

• Control of the fan and the feeder

• Control of CH pump

• Control of DHW pump

• Control of two additional pumps

• Control of two mixing valves actuators

• Possibility of connecting a room regulator with traditional or RS communication

• Possibility of connecting ST-65 GSM module

• Built-in Ethernet module enabling the user to view certain parameters and control

certain functions via the Internet

• Possibility of controlling two valves via additional modules (e.g. ST-431N)

Controller equipment:

• CH temperature sensor

• Feeder temperature sensor (protection)

• Floor temperature sensor

• DHW sensor

• Temperature protection (bimetallic mini sensor)

• Supply cable

• Pump supply cables

• Hall-sensor of the fan

• Feeder flap limit switch

III. Installation

The controller should be installed by a qualified person.

WARNING

Risk of fatal electric shock from touching live connections. Before working on the controller
switch off the power supply and prevent it from being accidentally switched on.

WARNING

Incorrect connection of the wires may lead to controller damage!

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ST-550 zPID

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IV. How to use the controller

IV.1. Principle of operation

The regulator controls the fan and the fuel feeder operation so that the pre-set temperature of the CH
boiler and the water tank is reached. Additionally, it controls CH and DHW pump operation activating
them once a pre-defined temperature of the CH boiler has been reached.

IV.2. Stages of operation

Fire-up – this phase is initiated when the flue gas temperature reaches a pre-set value and does not
drop below this value for 30seconds (default fire-up time).
Operation – when the fire-up phase has been completed, the controller enters operation mode and the
display shows the message ‘PID: OPERATION’. It is the primary mode of controller functioning when the
blow force and fuel feeding are regulated with PID algorithm, oscillating around the pre-set temperature
defined by the user. When the temperature increases unexpectedly by more than 5oC above the pre-set
value, the supervision mode is activated.
Supervision mode – this mode is activated automatically when the temperature exceeds the pre-set
value by more than 5oC in operation mode. In such a case, the controller disables PID control and uses
manual settings (according to parameters defined in the fitter's menu).The display shows the following
message: ‘PID: SUPERVISION’

IV.3. zPID control

ST-550zPID is a controller with continuous output signal, using zPID algorithm. This type of controller
calculates the blow force on the basis of CH boiler temperature and the flue gas temperature measured
at the CH boiler outlet. The fan operates continuously and the blow force depends on the CH boiler
temperature, the flue gas temperature as well as the difference between these parameters and their pre­set values. One of the greatest advantages of zPID regulators is their ability to maintain a stable pre-set
temperature without unnecessary overregulation and oscillations.

Apart from zPID control, the controller operation is adjusted on the basis of the the readings from

the air flow sensor mounted on the fan.

Using this type of regulator with a flue gas sensor helps to reduce fuel costs by up to several percent.
Moreover, it ensures stable temperature of output water thus prolonging the life of the heat exchanger
(of the CH boiler). Flue gas temperature control results in low emission of dust and environmentally
harmful gases. Flue gas heat is not disposed of through the chimney, but it is utilised for heating
purposes.

TEST RESULTS - TECH controller with PID control:

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TEST RESULTS - TECH controller without PID control:

IV.4. Controller operation without zPID control

zPID control may be disabled at any time using Operation algorithm selection parameter.
Additional submenu will appear in the controller menu, allowing the user to configure boiler operation
parameters.
Once zPID control is disabled, the principle of operation is changed - after the fire-up stage the
controller enters operation mode which is followed by sustain mode:
Operation – once the controller is switched on, it enters operation mode and OPERATION appears on
the display. It is the primary mode of controller operation in which the fan operates continuously and the
fuel feeder operation is adjusted according to user’s settings. The user defines both the operation time
and pause time.

Sustain mode – this mode is activated automatically if the temperature is equal or higher than the pre­set temperature value. Fuel feeding process slows down in order to smoothly reduce the temperature of
the circulating water. SUSTAIN appears on the display. In order for the temperature to decrease properly,
it is necessary to configure operation and pause time in sustain mode as well as the fan speed.

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IV.5. How to navigate

During standard operation of the controller, graphic display shows the main page.
By pressing MENU button the user enters the first level menu. In order to move on to the next option,
twist the pulser knob. Press the knob to select an option. Follow a similar procedure when adjusting
parameters. In order for the changes to be saved, use the pulser knob to select CONFIRM. In order not
to introduce any changes, use the pulser knob to select CANCEL. In order to leave the menu, use EXIT
button.

1. USB port

2. Panel showing current parameters of the sensors and the fan

3. CH boiler operation stage

4. Current time

5. Right parameter panel – use pulser knob to switch between CH boiler parameters and DHW or

valve parameters (if activated).

6. Operation status bar - it displays icons indicating all devices which are currently active:

- fan and its speed (%); if Hall sensor of the fan is active, letter H is displayed;

- feeder; if burning without feeder option is active, a crossed out feeder icon is displayed.

- CH pump

- DHW pump

- additional pump 1

- additional pump 2

7. Enter the controller menu. While viewing the controller functions use this button to return to the

main screen view.

8. Pulser knob. Twist the knob in the main screen view to change the parameter view or press it to

edit the selected parameter. While viewing the menu options use the knob to move on to the next

function or configure CH boiler operation parameters.

9. EXIT button

10. Active operation panel bar:

- CH boiler

- DHW

- built-in valve (if switched on)

- additional valves (if switched on; additional valve modules e.g. ST-431N are required).

V. Controller functions– main menu

V.1. Block diagram of the main menu.

Due to multiple functions offered by the controller, the menu is divided into Main Menu and Fitter’s Menu.
The main menu allows the user to set the basic controller options such as pre-set temperature values,
operation modes, screen view etc.

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7

5 4 3

2

1

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*Parameters available in the controller menu only if the additional valve module has been connected and
module registration process has been completed in the additional valve menu.
**Submenu available only if Operation without PID is selected.
***Parameter available only if TECH room regulator with RS communication has been connected and
activated.

Main menu

Fire-up

Screen view

Standard screen

Test screen

Fuel tank full

Temperature settings

Pre-set CH temperature

CH hysteresis

Pre-set DHW temperature

DHW hysteresis

Pump activation temperature

Pre-set room temperature***

Manual mode

Fan

Blow force

Feeder

CH pump

DHW pump

Additional pump 1

Additional pump 2

Built-in valve 1

Built-in valve 2

Additional valve 1*

Additional valve 2*

Operation settings**

Feeding time

Pause time

Blow force

Operation in sustain mode

Pause in sustain mode

Fan in sustain mode

Fan speed in sustain mode

Fuel granulation

Fine granulation

Coarse granulation

Operation modes

House heating

Water tank priority

Parallel pumps

Summer mode

Weekly control

Mode

Set mode 1

Set mode 2

Delete settings

Operation algorithm

PID

Operation without PID

Fitter’s menu

Service menu

Software version

Factory settings