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.