Compit R510 User manual

Str. 1
COMPIT, ul.Wielkoborska 77a, 42-200 Czêstochowa,tel./fax [phone] www.compit.eu
COAL FEED SYSTEM BOILER WITH DO-
MESTIC HOT WATER LOADING
Sensor type: T2001
Outputs: 230V/50Hz
Temperature setting range: 0 to +99°C
Resolution: 1°
R510
wersje u10 do u19
Operating Instructions
Pb

Str. 2
Safety Instructions
CAUTION!
- Before installation read the operating instructions and
warranty terms and conditions carefully. Faulty installa-
tion, maintenance and use of the controller will invali-
date the warranty.
Any installation work can be carried out only after power sup-
ply has been disconnected:
- In the case of RAPID controllers - after the power sup-
ply cord has been unplugged
- In others – after disconnecting power and making sure
that the voltage on the terminals is not hazardous.
- All wiring and mounting should be done by an author-
ized person in accordance with the regulations and stand-
ards in force.
- Do not install or use a controller if its housing has been
damaged. Electric shock hazard!
- The wiring system to which COMPIT controller is con-
nected should be protected with appropriate safety fuses.
- Before the controller is used for the first time, check if
the wiring is done in accordance with these instructions
and whether the controller's power supply conforms to
all the requirements.
- Any repairs to the controller can be done exclusively by
the manufacturer’s service. If the repairs are done by an
unauthorized person, the warranty shall not apply.
- This controller is not a safety device!
In systems liable to damage due to automatic control failure,
it is necessary to install an extra safety device with ap-
propriate certificates of approval. For systems that can-
not be switched off, the control system must be designed
in such a way that it can operate without the controller.
All EC Declarations of Conformity are available at
www.compit.pl
Disposal of Waste Electrical and Electronic Equipment (ap-
plies to private households only)
The symbol of the crossed-out wheeled bin
placed on COMPIT products or in the accompa-
nying operating instructions means that disposal
of waste electrical and electronic equipment
(WEEE) along with other waste is not allowed.
Equipment marked with this symbol that can be recycled, reused
or where subassemblies can be recovered should be returned to
a specialised collection facility free of charge. This product can be
returned to a local distributor on purchase of new equipment.
Appropriate recycling should be carried out so as to avoid
negative impact on the environment and human health. Inappro-
priate storage or treatment shall be subject to penalties as pro-
vided for in relevant regulations.

Str. 3
2OPERATION
R510 controller has been designed to maintain the boiler temperature and hot water tank temperature set by the user. The device
controls the feeder, the blower and both central heating and domestic hot water pumps. The blower speed, which controls the amount
of air used for combustion, can be freely adjusted.
1USE
The device has been designed for controlling central heating coal boiler with a feeding screw in order to maintain the tempera-
ture set by the user as well as for loading the domestic hot water tank. Additionally, it is possible to connect a room thermostat to
decrease the set temperature of the boiler and (optionally) to switch off the central heating circulation pump.
Fig. R510 controller operation diagram.
room
thermostat

Str. 4
F8
F7
2.1 Central heating boiler operation
START-UP mode
To proceed to the START-UP mode leave the SWITCH-OFF mode
by pressing “PRACA/STOP” [OPERATION/STOP] key. The
“PRACA” LED light begins to flash. The key is used to en-
able the feeder and the key is used to start the blower. After
the “?” key is pressed, the display shows the speed of the blower
– it is displayed as a number followed by letter “u”. The speed of
the blower can be adjusted by using the up/down arrow keys. Press
the “?” key again to proceed to the temperature display where the
arrow keys can again be used to start the blower and the feeder.
After starting-up the boiler, press “PRACA/STOP” key to enter the
OPERATION mode.
NOTE: YOU MUST NOT LEAVE THE BOILER IN THE START-
UP MODE UNATTENDED!!!
OPERATION mode
When in the OPERATION mode, the feeder engages cyclically in
order to feed in a new portion of coal for burning. The feeder oper-
ating time and feeding break time are determined in the controller
parameters: “F7” – feeder operating time and “F8” – feeding break
time.
The blower works throughout the whole cycle.
F7 - feeder operating time in the OPERATION mode
F8 - feeding break time in the OPERATION time
Once the boiler reaches the target temperature, the control-
ler engages the blower to blow through the boiler chamber for the
F12 time and then goes to the MAINTENANCE mode.
F7 F8
FEEDER
BLOWER
OPERATION MODE
ONE FULL OPERATING
CYCLE = 5 seconds+time t0+time t1

Str. 5
MAINTENANCE mode
In the MAINTENANCE mode the amount of the heat pro-
duced is reduced to a minimum necessary for maintaining com-
bustion. Feeder operating time as well as feeding break time are
determined in the control parameters: “F9” – feeder operating time
in the MAINTENANCE mode and “F10” – feeding break time in
the MAINTENANCE mode. Once the coal feed is finished, the
blower continues operating for the time specified in”F11” and then
it is switched off. The next cycle of the boiler blow-through and
coal feed is started after the time set in “F10” (feeding break time
in the MAINTENANCE mode). The controller will switch from the
MAINTENANCE mode to the OPERATION mode when the boiler
temperature falls below the set temperature of the boiler – minus
hysteresis.
F9 - feeder operating time in the MAINTENANCE mode
F10 - feeding break time in the MAINTENANCE mode
F11 - blower operating time
The BURN-OUT mode is enabled when boiler temperature
is lower than the manufacture’s design temperature for a period
exceeding the time set in F17 (boiler switch-off blocking time). In
the BURN-OUT mode both the feeder and the blower are switched
off, and the emergency relay is switched on.
F9 F10
F11
F9 F10
THE BOILER IS SWITCHED OFF when the user presses
the “PRACA/STOP” key and holds for over 3 seconds while in the
OPERATION or MAIINTENANCE mode.
MAINTENANCE MODE
ONE FULL OPERATING
CYCLE = 5 seconds+time t2+time t3
FEDDER
BLOWER

Str. 6
OPERATION WITH ROOM THERMOSTAT
Opening of the W terminal lowers the set temperature of the
boiler to minimum. The CH pump is also switched off after the
time set in F18 elapses – CH pump overrun time. If the value set
in this parameter is higher than 30 minutes (the display will read
OFF), then the pump will work while the thermostat output contact
is open. A dot appears after the last digit on the display when the
thermostat output contact is closed.
BOILER OPERATION FOR DHW LOADING (OPERATION IN
SUMMER MONTHS)
JWhen it is necessary to switch off the space heating and the
boiler is supposed to load the DHW tank, boiler target tempera-
ture should be reduced to a minimum. Instead of the set value the
display will read ”- -” , the CH pump will be switched off and the
controller will maintain the minimum temperature of the boiler.
2.2 Boiler pump operation
The boiler pump works when:
- the room thermostat terminal is closed,
- the boiler temperature exceeds the CH pump switch-on
temperature – manufacturer’s design temperature.
The boiler pump can be switched off when:
- the room thermostat terminal is opened and the time set
in “F18” parameter elapses – CH pump overrun time
- the boiler temperature falls below the CH pump switch-
on temperature - manufacturer’s design temperature.
- priority hot water is loaded
- the user switches off the CH circulation by setting the
target boiler temperature to a minimum.
2.3 DHW tank loading
The tank is loaded when its temperature falls below the set tem-
perature - DHW amplitude (“F3” – DHW set temperature). The
controller sets the target boiler temperature according to the value
in “F14” (set boiler temperature for loading the DHW tank). When
the boiler temperature exceeds the tank temperature, the pump
loading the tank is switched on. Loading is finished when the tank
reaches the set temperature + DHW amplitude. The set boiler
temperature returns to the temperature set by the user. The load-
ing pump continues to operate for the time determined by the
manufacturer and it is then switched off. The boiler pump is
switched off if a priority tank loading takes place.
2.4 Emergencies
The controller signals the following emergencies (they are
displayed alternately with the temperature reading):
A1 – boiler temperature exceeds 95°C – the EMERGENCY relay
is on and both CH and DHW pumps are enabled. This emer-
gency can be cancelled by pressing the “PRACA/STOP” key
when the temperature falls below 95°C. The “PRACA/STOP”
LEDs flash.
A2 – feeder is overheated – the EMERGENCY relay is on and the
controller feeds the coal for 10 minutes. The blower is switched
off. The “PRACA/STOP” LEDs flash. The emergency is can-
celled after the “PRACA/STOP” key has been pressed. How-
ever, with the temperature being 10°C lower than the emer-
gency threshold temperature, the controller tries to remove
the burning coal off the feeder – the feeding break time is
CAUTION: When the boiler temperature exceeds the maximum
value, the CH and DHW pumps are enabled in order to reduce the
boiler temperature.

Str. 7
3. CONTROLLER HANDLING
Four keys are used to operate the controller:
PRACA/STOP – press this key to switch between the
boiler operating modes.
press the “?” key to start editing the parameters.
press the “+” and “-” keys to view the param-
eter list and after enabling the editing mode by
pressing “?” – to change the parameter set-
tings.
In the START-UP mode the “+” key is used to start the feeder and
the “-” key is used to start the blower.
- boiler pump in operation
- DHW tank loading
- blower in operation
- feeder in operation
Output status is visualised through LEDs on the control panel:
The controller operates in one of the following modes:
SWITCH-OFF mode – the STOP LED is on. This mode is entered
manually from either the OPERATION or the MAINTENANCE
mode when the “PRACA/STOP” key has been pressed for 3
seconds. The blower and feeder are switched off.
START-UP mode – the STOP LED flashes. This mode is entered
manually from the SWITCH-OFF mode by pressing the
“PRACA/STOP” key. Both the blower and feeder can be
switched on manually by pressing the “+” and “-” keys. Press
the “PRACA/STOP” key to leave the START-UP mode and
the controller will switch to the MAINTENANCE mode.
OPERATION mode – the OPERATION LED is on. The controller
controls the feeder and blower in cycles as set in “F7”, “F8”
and “F11”. Having reached the set temperature the controller
automatically switches to the MAINTENANCE mode.
shorter by half and while in the MAINTENANCE mode the
coal feed time is doubled.
A3 – boiler burn-out - the EMERGENCY relay is switched on. The
LEDs are off. Boiler burn-out is signalled when the boiler tem-
perature falls below the manufacturer’s design temperature
and remains at that level for a time longer than in “F17”- the
boiler switch-off blocking time.przerwy pomiêdzy podaniami,
a w “podtrzymaniu” jednoczeœnie zwiêkszany jest dwukrotnie
czas podawania wêgla.

Str. 8
MAINTENANCE mode – the OPERATION LED flashes. This mode
allows for maintaining the combustion only. The controller
controls the feeder and blower in cycles as set in “F7”, “F8”
and “F11”. When the boiler temperature falls below the set
temperature, the controller automatically switches to the
OPERATION mode.
BURN-OUT mode – the “PRACA/STOP” LEDs are off. The con-
troller switches to BURN-OUT from the OPERATION mode
when for the time set in “F17” – “delay in switching off the
boiler” the boiler temperature is lower than the manufactur-
er’s design temperature. The burn-out is signalled by swtching
on the emergency relay and the EMERGENCY LED. Press
the “PRACA/STOP” key to switch to the OFF mode.
Setting the target boiler temperature
When the display reads the current temperature of the boiler,
press either the or key to display the set temperature of
the boiler.
Press the or key next to raise or lower the set tem-
perature of the boiler. When the required temperature has been
set and no key is pressed for 3 seconds, the controller automati-
cally displays the measured temperature of the boiler.
PARAMETER SETTING
To view and edit parameters press the and
keys.
Press the “?” key for the display to switch between the parameter
number and its value. When the parameter number is displayed,
you will see letter F in the initial position followed by number of the
parameter being adjusted (e.g. F12 – t5: blowing time). Change
from one parameter to another using the arrow buttons to choose
a higher or lower value next to the letter ”F” until you find the
required parameter. Press the “?” key again to switch to the pa-
rameter value display.
Changes in the parameter value are automatically saved in the
controller’s memory and they do not need to be accepted. The set
values are stored in the contoller’s memory for at least 10 years
(with a switched off controller).
To change a parameter value:
1. Press the “?” key. The display will read F1
1. Use the arrow buttons to choose parameter F6 – access
code for user parameters
2. Press the “?” key. The display will read: 100
3. Using the arrow buttons set the access code by selecting:
99
4. Press the “?” key. The display will read: F6
5. Using the arrow buttons select the number of the param-
eter to be changed
10. Press the “?” key. The display will read the value of the
currently chosen parameter.
11. Press the arrow keys to adjust the parameter value.
NOTE: The user can only access parameters F1 to F12.

Str. 9
5LIST OF PARAMETERS
F1 – Measured temperature of the boiler.
NOTE: Inappropriate parameter setting may result in faulty boiler
operation and in extreme situations in the boiler failure.
User parameters – accessible with 99 code
FACTORY DEFAULTS
If the controls unit operation is disturbed due to faulty set-
tings it is possible to set default parameters. To do this, set the
code to 70 and press both arrow buttons simultaneously. The con-
troller will remember the values given in the field next to param-
eter numbers.
F2 - Measured temperature of the DHW
tank.
F3 - Set temperature of the DHW tank, no
code necessary to access the parameter
(temperature setting range 0 to70°C in 1°C
steps).
F4 - Measured temperature of the feeder.
F5 - Operating speed of the blower; no ac-
cess code necessary (speed setting range
5 to 99 in 1 steps).
F6 - Access code for other controller param-
eters.
F7 - t0: feeder operating time in the OP-
ERATION mode (setting range 1 to 500s in
1s steps).
F8 - t1: feeding break time in the OPERA-
TION mode (setting range 1 to 500s in 1s
steps).
F9 - t2: feeder operating time in the MAIN-
TENANCE mode (setting range 1 to 500s
in 1s steps).
F10 - t3: feeding break time in the MAIN-
TENANCE mode (setting range 1 to 250m
in 1m steps).
F11 - t4: blower operating time after coal
feeding is complete in MAINTENANCE
mode (setting range 1 to 500s in 1s steps)
F12 - t5: blowing time – blower operating
time between the OPERATION and MAIN-
TENANCE modes (setting range 5 to 995s
in 5s steps).

Str. 10
F13 - DHW priority, 0 - off, 1 - on, CH pump
is off while loading the tank.
SERVICE parameters – accessible with the service code
F14 - set boiler temperature for loading the
DHW tank (setting range 0 to 90°C in 1°C
steps).
F15 - DHW loading amplitude (setting range
1 to 20°C in 1°C steps).
F16 - CH boiler hysteresis – the boiler
switches from the OPERATION to MAINTE-
NANCE mode after the set temperature has
been reached, and from the MAINTE-
NANCE to OPERATION mode after the cur-
rent boiler temperature drops below the set
temperature – hysteresis (setting range 1
to 30°C in 1°C steps).
F17 - delay in switching off the boiler – if for
the time set in F17 boiler temperature is
lower than the manufacture’s design
temerature, the boiler switches over to the
BURN-OUT mode (setting range 1 to
250min in 1min steps).
F18 - central heating pump overrun time
after the room thermostat input connection
is opened. “OFF” setting makes the pump
non-responsive to the thermostat signals
(setting range 0 to 30min, OFF, in 1min
steps).
F19 - feeder maximum temperature (setting
range 0 to 99°C in 1°C steps).

Str. 11
6WIRING DIAGRAMS
Fig. E510 Operating module connections.
INPUTS:
17, 18 -T3 sensor – DHW temperature
19, 20 -T2 sensor – feeder temperature
20, 21 -T1 sensor – CH boiler temperature
22, 23 -W input – room thermostat
6
5
4312 7
Pk1
9
810 12 11 13 15 14
Pk2 Pk3
1716 18 2019 21 2322
T1T2
T3 W
OUTPUTS:
1, 2 - 230 V~ power supply
3, 4 - main safety device (maximum 6,3 A fuse)
5 - strobe input
6, 7 - DHW pump
8, 9 - CH pump
10 - emergency output
11 - strobe input
12, 13 -blower
14, 15 -feeder

Str. 12
Fig. Controls unit connection diagram
display panel connection
6
5
4312 7
Pk1
9
810 12 11 13 1514
Pk2 Pk3
1716 18 2019 21 2322
T1T2
T3
W

Str. 13
7 MOUNTING
The controller consists of two modules: control panel and
E510 operating module. The operating module is placed in a hous-
ing to be mounted on the boiler. Dimensions as shown below:
The operating module takes the IP protection ratings of the
housing in which it is placed. The case does not protect against
dust and water so it is necessary to protect it duly.
46,6
88,1
112,4
100,0
75,0
The control panel is fitted to the boiler with four metal screws.
The size of the panel and the position of mounting holes is pre-
sented below:

Str. 14
In order to install the panel the following panel mounting hole
should be made:
The control panel is connected with the operating module by
means of a 20-wire cable included in the set.
8CONNECTING SENSORS AND ON/OFF IN-
PUTS
R510 controller works with three sensors. The boiler, feeder
and DHW tank sensors are T2001 series water immersion sen-
sors. It is possible to extend the sensor up to 30 cm using a 0.5mm2
to 1.5 mm2 cable. T2001 sensors cannot be replaced with T1001,
T1002 or T1006 sensors!
A minimum spacing of 30cm between the sensor cables and
parallel live network cables should be kept. A smaller spacing may
result in unstable temperature readings.
OTWÓR MONTAŻOWY
Temp.
[°C]
Rezyst.
[Ω]
Temp.
[°C]
Rezyst.
[Ω]
0 1630 60 2597
10 1772 70 2785
20 1922 80 2980
30 2080 90 3182
40 2245 100 3392
50 2417 110 3607
Examples of resistance value for T2001 sensor at different tem-
peratures:
Only no-voltage contacts may be connected to the on/off in-
put terminals (of the room thermostat). These could be contacts
of a relay, bimetal thermostat or electronic room thermostat. The
controller does not work with any systems sending voltage, cur-
rent or digital signals to their outputs.

Str. 15
TECHNICAL DATA
power supply: 230V~(+5, -10%) 50 Hz
according to PN-IEC60038:1999; 4VA
temperature measurement range:
0 to 100°C
1°C
accuracy: 1°C
display: 3 digit LED
control module case:
panel, dimensions as in Figures
operating module case:
attached to the boiler with screws, dimen-
sions as in the Figure
weight: 0.45 kg
output: screw joint terminals, maximum cable di-
ameter 1 x 1,5 mm2 or 2 x 0,75 mm2
operating temperature: from 0°C to 55°C
storage temperature: from 0°C to 55°C
When mounting the sensors it is important to ensure their
good contact with the surface. While fixing the boiler and DHW
tank sensors fill the pocket with silicon thermal grease, if possi-
ble. The sensor cannot come in contact with water! While mount-
ing the feeder sensor, apply thermal grease on the contact place
of the sensor and the snail. The sensor should be insulated if
possible.
INPUTS
- Tboiler, Tfeeder, Tdhw - T2001 sensor inputs, maximum length
complying with the electromagnetic compatibility require-
ments: 30m.
- 1 on/off no-voltage input, for further reduction and blocking
the CH pump
OUTPUTS
- two 230V~ output terminals (CH and DHW pump), resist-
ance capacity 2A/230V; induction capacity (cos=0,8) 0.6A/
230V.
- two 230V~ semiconductor outputs (feeder, blower), resist-
ance capacity 0,6A/230V; induction capacity (cos=0,8) 0.6A/
230V.
- one 230V~ voltage emergency output, resistance capacity
2A/230V; induction capacity (cos=0,8) 0.6A/230V.
REGULATION
- on/off adjustment for pumps and feeder , smooth regulation
for the blower.
THE SET INCLUDES:
1. R510 control panel – 1pcs.
2. E510 operating module– 1pcs.
3. 20-wire cable – 1pcs.
4. Boiler T2001 sensor – 1pcs.
5. Feeder T2001sensor – 1pcs.
6. Operating instructions.
7. Guarantee card.
NOTE: T2001 DHW tank sensor shall be purchased separately.

Str. 16
DECLARATION OF CONFORMITY
COMPIT Piotr Roszak
ul. Wielkoborska 77a
42-200 Czêstochowa
hereby declares that the product
R500 Microprocessor Controller
models : R510, R510B, R530, R550, R551,
E510, E550, E551
meets the following requirements:
Safety: PN – EN 60730 – 1;
EN 60730-2-9:2002 + A1:2003 + A11:2003,IDT
IEC 60730-2-9:2000 + A1:2002,MOD
Electromagnetic compatibility:
Emission - EN 55014-1
Immunity - EN 55014-2
Additional information:
This product complies with the following directives: Low Voltage Directive 73/
23/EEC (as amended 93/68/EEC) and EMC Directive 89/336/EEC (as amended
91/263/EEC, 92/31/EEC, 93/68/EEC) and bears the CE mark.