DK System Master 500 User manual

The Master 500 controller is designed to
control the boiler operation with
automatic feeding of fuel, CH pump and
DHW pump in central heating systems.
Operating instructions
for screw feeder or piston feeder
maintaining the set temperature of the boiler by controlling the blower and the
feeder
ability to operate a boiler with an emergency grate
infinitely adjustable blower operation and adjustable power
programmable boiler blow
adjustable damping time and automatic disabling of control when boiler no fuel
is available
controlling the central heating circulating pump operation
ability to switch hot water priority on and off
control of the domestic hot water heater charging pump depending on the
required temperature
ability to operate the boiler and the DHW pump under one of several weekly
programs installed in the Master 500 controller
COMFORT SYSTEM function, which protects the pump against limescale
protection system – TERMIK thermal fuse
function protecting the system against freezing and overheating of the boiler
temperature sensor failure alarm
adjustable display brightness – increased during adjustment of settings
ability to connect remote control with a sound alarm system
ability to connect a room thermostat
1

Description of the controller components1
1 2 3 4 5
6
2
Operating screen description
Current temperature
of the boiler
Operation mode
Current time
Day of the week
DHW parameters
1.
2. Signal LEDs:
FEEDER
FAN
CH PUMP
DHW PUMP
3. The back button
4. Adjust setting UP button (+)
5. MENU button
6. Adjust setting DOWN button (-)
Display
Fig.1 Description of the controller components
Fig.2 Description of the operating screen

Installation Recommendations2
The controller is designed for use with boilers with automatic feeding of fuel.
The controller must be installed by an authorized person.
The controller must be connected to a socket with a protective contact.
It is required that the boiler had its own safeguards against excessive
temperature rise of the boiler caused e.g. boiler controller or related equipment
malfunction.
The controller should be placed in a location that prevents its heating to a
temperature higher than 40°C.
The controller must not be exposed to water and conditions causing
condensation (e.g. sudden changes in ambient temperature).
The device should be installed and operated as described in the assembly
description and rules for electrical equipment.
A blown fuse due to bad wiring or a short circuit in the electrical system does not
constitute grounds for a warranty repair.
Before starting the controller, you should check the electrical connections.
The controller is protected with two 5Afuses.
Connection of the power cord and fuse replacement should be made with the
controller powered off (the controller power plug must be disconnected from the
mains). Connection of the receiving devices and replacement of fuses with the
mains plug of the controller plugged in creates an electric shock hazard.
The connection cables of the controller can be replaced only by the
manufacturer or their authorized service establishment.
You must not use a damaged controller.
3

Electrical connection and sensors diagram3
control
fuse 5 A fuse 5 A
L N PE L N L N PE L N
Room thermostat
DHW sensor
Reed relay
PE PE
M
Fun
1~
M
Feeder
1~
M
CH Pump
1~
Power supply
~230 V
Thermal
fuse
CH boiler sensor
Feeder sensor
L N PE
M
DHW Pump
1~
Fig.3 Wiring diagram to connect power cables
Fig.4 Wiring diagram to connect sensors
Controller installation4
1. The controller is designed to be mounted on the boiler.
2. Using the provided template for positioning of the controller.
3. Install a screw in the boiler housing in the place indicated on the template.
4. Decide on the method of routing the cable from the controller (rear, bottom) and
remove the corresponding caps from the housing.
5. Slide the controller onto the fixed screw, use the other two screws to fasten it to
the boiler housing.
6. Install the optional cables at the appropriate connectors and put them through
the holes in the housing.
7. Protect the installed cables against pulling out, fixing then to the housing in
special sockets using the provided brackets and screws.
8. Install the controller door.
4

Note: If after the controller is switched on, the display is not lit up, check
whether there is voltage in the mains socket, then check the fuses and
replace if damaged with new ones 2 x 5 A. If, after the replacement of
fuses the display remains dark, please contact the maintenance provider.
!
Note: Always replace fuses with the unit switched off and the plug
removed from the socket.
!
Connection of the controller to the electrical system
1. Connect the fan, pump and feeder with the appropriate power cables (see -
Figure 3).
2. Install all necessary sensors (and reed relay for the piston feeder) acc. to Fig.4
and Fig.6.
3. Put the plug of the controller power supply cable in a ~ 230 V socket.
4. Switch the controller on, using the power switch.
Fan, feeder and pumps wiring diagrams5
5
M
N
L
blue wire N
brown wire L
yellow-green wire
M
Fig.5 Power supply cable wiring diagrams for the fan, feeder, pump, etc. (Depending on the version of the
controller).

~ 230 V
1. Master 500 controller
2. Feeder motor
3. Reed relay
4. Feeder temperature sensor
5.
6. TERMIK thermal fuse
7. CH boiler temperature sensor
8. Central heating pump
9. DHW pump
10. DHW heater sensor
11. Remote control
12. Room thermostat
CH boiler fan
Controller to hydraulic system connection diagram6
1
6
8
10
9
7
11 12
Fig.6 Master 500 wiring diagram
2
4
5
First start7
To set the correct time and date, press , and then use the "+", “-" keys to set the
desired day of the week and approve .
Proceed in the same way by setting the current time, and then the minute.
When you first run the controller, the display flashes the clock and day of the week.
3
6

Starting the boiler and setting the operating parameters 8
When the boiler temperature rises to the level specified by the "dt" parameter, the
controller switches to HEATING mode.
After finishing the settings and double-pressing of , you will be taken to the main
screen.
After reaching the required temperature, the controller will switch to the
MAINTAINING mode, until the temperature drops below the hysteresis – to find out
more, see Operating parameters - HYSTERESIS.
When you press the or button, the SETT symbol will show to inform about the
currently set temperature. Set the required value, using the same buttons: to
increase the setting or to reduce it.
Setting the parameters of the boiler
1. Open the ash pit door.
2. Start the feeder manually (see Manual operation - Testing outputs) and wait
until coal shows at the level of the blow holes.
3. Turn off the feeder and then ignite the coal in the furnace chamber.
4. After obtaining a stable flame, start automatic operation of the controller by
holding down for three seconds the , the display shows START, the controller
will start regular dosing fuel and will control the fan in order to obtain the desired
temperature in the boiler.
7

DHW heater operating parameters setting9
During operation of the controller press the button ; the HOT WATER display will
be shown.
Setting the temperature of the domestic hot water heater.
Pressing again will take you to the desired temperature setting for the boiler. Set
the required temperature, using the buttons: to increase the setting or to reduce
it. Change range: from 40 °C to 70 °C.
The parameter that specifies the minimum measured temperature difference
between the boiler and the domestic hot water heater that must occur for the heating
of domestic hot water to be cost effective and the domestic hot water pump to be
turned on. If this difference is less than the set point, the DHW pump will not switch
on (regardless of whether priority of hot water is turned on or not). Change range:
from 2 °C to 20 °C.
The temperature difference between the boiler and heater
8

A parameter that specifies the number of degrees Celsius by which the temperature
must fall on the domestic hot water heater below the set point for the domestic hot
water pump to turn on. Change range: from 2 °C to 9 °C.
Hysteresis of the DHW pump
Selecting or changing the CH and DHW operating mode10
To access the controller operation mode selection menu, press the ; the display
will show HOT WATER. Then use the or button to select the OPER. MODE
option and confirm with .
You can choose the mode in which the controller operates. The mode determines
whether the DHW pump is to be operated and whether it must run in the DHW priority
mode.
Selecting the desired mode using the or buttons. : only CH /
CH&DHW / DHW Priority / SUMM.
Change range
9

Note: SUMMER mode, indicated by the symbol on the screen means
that outside of the heating season the heating pump will not operate and
all the heat generated by the boiler is designed to heat domestic hot water.
!
ON / OFF. Operation of room thermostat11
You can connect a room thermostat (see Fig. 4) that controls the operation of the
central heating pump, depending on the room temperature. In order to operate the
pump the boiler must also reach its corresponding minimum temperature.
To access the room thermostat menu, press the button ; the display will show HOT
WATER. Then use the or button to select the ROOM THERMOSTAT and
confirm with .
Use the or buttons to select the desired setting. Change range: no / yes
In order to improve thermal comfort, the controller will periodically run the CH pump
when the room temperature is at a preset level.
In order to determine the conditions of this operation, set the operation time and
pause time for the central heating pump.
Pressing again takes you to the next setting.
10
The activated room thermostat function is indicated with the symbol on the display.

Pressing again takes you to the next setting.
Central heating pump - break time
This parameter specifies the time interval in the operation of the CH PUMP (calculated
in minutes) when interoperability with the room thermostat. Change range: from 5 min
to 60 min.
Shutting down the boiler 12
When the boiler is operating in HEATING or MAINTAINING mode, you can switch it to
the DAMPING mode - during which the fan and the feeder is not working.
DAMPING mode
The boiler may be shut down due to lack of fuel, the completion of the damping
process or manually switching to the STOP mode.
When there is no fuel, EMPTY BUNK will be displayed.
11
Central heating pump - operation time
A parameter that specifies the CH pump operation time (calculated in seconds) when
interoperability with the room thermostat. Change range: from 0 s to 240 s.

You can manually shut down the boiler and go to STOP mode.
To do this, press and hold for a few seconds the - the display will show STOP. If
the message is different (e.g. START / HEATING / MAINTAINING), then repeat the
action until STOP is displayed.
STOP mode
Operating parameters13
The OPERATING PARAMETERS functionality makes it possible to set the operating
parameters for the boiler, feeder, fan and CH pump.
To enter the operating parameters menu, press the button ; the display will show
HOT WATER. Then use the or buttons, select the OPER.PARAM. options and
confirm with .
When the temperature in the boiler drops below "dt damp", countdown to damping
will start (see - Adjustment of damping time), and then the boiler will shut down -
which will be indicated by the STOP message.
To switch on the DAMPING mode, press and hold for a few seconds the - the
screen will show DAMP.
12

The parameter defines the number of degrees Celsius by which the temperature
must fall below the setpoint, at which the controller will resume the HEATING mode –
at this point the feeder will start regular operation as set by the parameters Operating
parameters - HEATING - feeder operation and Operating parameters - HEATING
- feeder pause) ,fan will be switch on and will keep running until the boiler reaches the
required temperature. Change range: from 1 °C to 9 °C.
Operating parameters - HYSTERESIS
Operating parameters - HEATING - feeder operation
The parameter defines the time (in seconds) of the duration of fuel feeding (feeder
operation) in the START and HEATING mode. Change range: from 1 s to 250 s.
Operating parameters - HEATING- feeder pause
This parameter specifies the time (in seconds) of the interval between cyclic fuel
delivery (feeder operation) in START and HEATING mode.
250 s.
Change range: from 1s to
Pressing again takes you to the next setting.
Pressing again takes you to the next setting.
Pressing again takes you to the next setting.
If a piston feeder is used, feeding of fuel into the furnace will be performed in cycles
(i.e. stroke of the fuel drawer and its return). Change range: from 1 to 20.
13

Operating parameters - HEATING - blowing power
This parameter allows you to set the maximum power at which the fan will operate
during HEATING mode. Change range: from 1 % to 100 % of maximum fan power, set
in the maintenance menu - see Adjusting the maximum fan power.
Pressing again takes you to the next setting.
In the case of the piston feeder the scope and factory setting is changed. Change
range: from 10 s to 900 s.
14
Operating parameters - FAN - run-out
This parameter allows you to set the time (in seconds) of earlier switching on of the
fan relative to the switching on of the feeder.
Pressing again takes you to the next setting.
Operating parameters - FAN - delayed switch-off of the fan
This parameter allows you to set the time (in seconds) to delay the switching off of the
fan until the feeder is switched off.
Pressing again takes you to the next setting.

Pressing again takes you to the next setting.
This parameter specifies the time (in seconds) of the interval between cyclic fuel
delivery (feeder operation) in the MAINTAINING mode. Change range: from 1 min to
240 min.
Operating parameters - MAINTAINING - feeder pause
Pressing again takes you to the next setting.
This parameter specifies the time (in seconds) of the interval between cyclic fuel
delivery (feeder operation) in the MAINTAINING mode during summer. Change
range: from 5 min to 240 min.
Operating parameters - MAINT. SUMMER - feeder pause
15
Pressing again takes you to the next setting.
If the piston feeder is used, its time of operation in maintaining mode will be defined by
the number of cycles and not by seconds. Change range: from 1 to 20.
Operating parameters - MAINTAINING - feeder operation
This parameter specifies the time (in seconds) of the duration fuel feeding (feeder
operation) in the MAINTAINING mode. Change range: from 1s to 250 s.

Pressing again takes you to the next setting.
This parameter defines the time of interval in the operation of the fan (in seconds) in
the MAINTAINING mode. Change range: from 5 min to 240 min.
Operating parameters - MAINTAINING - fan pause
Pressing again takes you to the next setting.
Operating parameters - MAINTAINING - blowing power
This parameter allows you to set the power at which the fan will operate during the
MAINTAINING mode. Change range: from 1 % to 100 % of maximum fan power, set
in the maintenance menu - see Adjusting the maximum fan power.
16
Operating parameters - MAINTAINING - fan operation
This parameter defines the time of operation of the fan (in seconds) in the
MAINTAINING mode. Change range: from 0 s to 90 s.
Pressing again takes you to the next setting.
Note: In the MAINTAINING mode the fan starts at the same time as the
feeder.
!

A parameter that specifies the temperature above which the central heating pump
turns on and operates continuously. If the temperature of the boiler falls below this
setting, the pump is switched off. Change range: from 30 °C to 70 °C.
Operating parameters - CH pump oper. threshold control
Emergency grate14
The controller allows you to control the boiler also when it is burning fuel using the
emergency grate instead of the retort furnace. Boiler operation in this mode is
indicated by the GRATE message, displayed on the screen.
To access the menu of the emergency grate, press the ; the display will show HOT
WATER. Then use the or button to select the EMER. GRATE option and confirm
with .
17
The parameter enabling or disabling smooth operation of the fan. The principle of
smooth operation is that the fan progressively reduces its speed when the
temperature of the boiler approaches the desired setpoint. Change range: yes / no.
Fan - smooth operation
Pressing again takes you to the next setting.

Emergency grate - blowing power
This parameter allows you to set the maximum power at which the fan will operate
when the emergency grate is used. Change range: from 1 % to 100 % of maximum
fan power, set in the maintenance menu - see Adjusting the maximum fan power.
This parameter defines the time of interval in the operation of the fan (in seconds) in
the MAINTAINING mode. Change range: from 1 min to 60 min.
Emergency grate - MAINTAINING - fan pause
Emergency grate - MAINTAINING - fan operation
This parameter defines the time of operation of the fan (in seconds) in the
MAINTAINING mode. Change range: from 0 s to 90 s.
Pressing again takes you to the next setting.
18
Use the or buttons to select the desired setting. Change range: no / yes
Pressing again takes you to the next setting.

This parameter allows you to set the power at which the fan is to operate in manual
mode (testing). Change range: from 1% to 100% of maximum fan power, set in the
maintenance menu - see Adjusting the maximum fan power.
Manual operation - blowing power
Pressing again takes you to the next setting.
A window allowing testing the correctness of operation of individual outputs (feeder,
fan, CH pump, DHW pump).
Select the tested output with the button , and to enable/disable it press the or
button. The output currently being checked is indicated by a blinking symbol on the
screen and lighting up the appropriate LED.
.
Manual operation - testing outputs
A window indicating the currently measured temperature of the boiler (temperature),
the hot water heater (DHW), the feeder (Feed).
Temperatures16
19
Manual operation15
This function is used testing the correctness of the connected equipment. To enter the
manual operation menu, press the button ; the display will show HOT WATER.
Then use the or buttons to select the MANUAL OPERATION option and confirm
with .

In order to enter the temperatures window, press the button the display will show
HOT WATER. Then use the or button to select the TEMPERATURES option and
confirm .
No temperature rise17
Use the or buttons to set the desired value and confirm with . :
from 10 min to 240 min.
Change range
Clock18
The CLOCK function allows you to change the set time and day of the week, as
described in the Section Getting Started. To enter the time setting menu, press and
hold the button , the display will show HOT WATER Then use the or buttons
to select the CLOCK and confirm with .
This parameter defines the time (calculated in seconds), during which it is expected
that the temperature will rise during operation in the HEATING mode. To access the
no temperature rise menu, press the button ; the display will show HOT WATER.
Then use the or button and select the T NOT RISING option and confirm . If
the after specified time the temperature does not increase by 2 °C, then the message
EMPTY BUNKER will be displayed.
20