DK System MASTER 600 User manual

Boiler temperature
controller with a feeder
Service Manual
INS-023-003 130x184,5
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MASTER 600

Safety instructions and notes on installation
Boiler temperature controller with a feeder
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qThe controller is designed for use with boilers with automatic feeding of fuel.
qThe controller must be installed by an authorized person.
qThe controller must be connected to a socket with a protective contact.
qIt 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.
qThe controller should be placed in a location that prevents its heating to a
temperature higher than 40°C.
qThe controller must not be exposed to water and conditions causing
condensation (e.g. sudden changes in ambient temperature).
qThe device should be installed and operated as described in the assembly
description and rules for electrical equipment.
qA blown fuse due to bad wiring or a short circuit in the electrical system does
not constitute grounds for a warranty repair.
qBefore starting the controller, you should check the electrical connections.
qThe controller is protected with two 5 A fuses.
qConnection 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.
qThe connection cables of the controller can be replaced only by the manu-
facturer or their authorized service establishment.
qYou must not use a damaged controller.
qAny damage caused by lightning, improper power surges in the power grid or
random events are not eligible for warranty repair (please refer to the
warranty terms and conditions).
Notice: Fuses should be replaced only with the controller powered
off and the plug disconnected from the mains.
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Table of Contents
1. Description of a controller...................................................................
1.1 Description of a controller - functions.................................................
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2. Controller components description
3. Operating panel description
4. Connection panel - components and connections
4.1 Connection panel - version with external power delivery
5. Controller installation...........................................................................
6. Diagrams of connections to the heating installation
7. Main menu - description
8. Main menu - structure......................
9. Service menu - structure
10. Settings table - Main menu......................
11. Settings table - Service menu..............
12. First start. Clock settings...................................
13. Control mode settings
14. Starting the bolier and setting the operating parameters...
15. Shutting down the boiler
15.1 Shutting down the boiler - Stop mode
16. Description of controller functions
17. Main menu - Operating parameters
17.1 Operating parameters - Boiler hysteresis
17.2 Operating parameters - Heating - feeder operation
17.3 Operating parameters - Heating - piston feeder operation.........
17.4 Operating parameters - Heating - feeder pause
17.5 Operating parameters - Heating - blowing power
17.6 Operating parameters - Fan run-out
17.7 Operating parameters - FAN - delayed switch-off of the fan
17.8 Operating parameters - Hold-up - feeder operation
17.9 Operating parameters - Hold-up - feeder pause
17.10 Operating parameters - Hold-up Summer - feeder pause.............
17.11 Operating parameters - Hold-up - fan operation
17.12 Operating parameters - Hold-up - fan pause
17.13 Operating parameters - Hold-up - blowing power
17.14 Operating parameters - Fan slow start
17.15 Operating parameters - CH pump oper. threshold control
18. Main menu - Summer
19. Main menu - Clock
20. Main menu - Weekly program
20.1 Weekly program - Reduction of boiler temperature
20.2 Weekly program - Operation program selection
20.3 Weekly program - Custom
21. Main menu - Technical inspection
22. Main menu - Factory settings
23. Main menu - Party mode
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Boiler temperature controller with a feeder

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24. Main menu - Circulation
24.1 Other application of circulation pump...............
25. Main menu - Hot water (DHW)
26. Main menu - Manual operation
27. Main menu - Emergency grate
27.1 Emergency grate - blowing power
27.2 Emergency grate - Hold-up - fan operation
27.3 Emergency grate - Hold-up - fan pause
28. Main menu - Temperatures
29. Main menu - 1. circuit
30. Main menu - 2. circuit
31. Service menu
32. Service menu - Parameters 1. Circuit
32.1 Parameters 1. Circuit - Control type
32.2 Parameters 1. Circuit - Max. temperature
32.3 Parameters 1. Circuit - Min. temperature
33. Service menu - Pumps turning off temperatures
33.1 Pumps turning off temperatures - 2. Circuit pump
33.2 Pumps turning off temperatures - Circulation pump - DHW temp....
33.3 Pumps turning off temperatures - Circulation pump - Boiler temp...
34. Service menu - Boiler return protection
35. Service menu - Valve
36. Service menu - Heating curves
36.1 Heating curves - 1. Circuit - Slope
36.2 Heating curves - 1. Circuit 1 - Level
36.3 Heating curves - 2. Circuit - Slope
36.4 Heating curves - 2. Circuit - Level
37. Service menu - Circulation
38. Service menu - Service parameters
38.1 Service parameters - Feeder type
38.2 Service parameters - Setting maximum fan power.................
38.3 Service parameters - Initiation of DAMPING process (dt)
38.4 Service parameters - Damping time adjustment
39. Service menu - DHW - service
39.1 DHW service - Pump Summer
39.2 DHW service - Protection against Legionella
39.3 DHW service - Temp. difference between a boiler and heater
39.4 DHW Maintenance - Hysteresis of the DHW pump
40. Service menu - Alarms and protections
40.1 Alarms and protections - Pumps turning on temperature
40.2 Alarms and protections - Boiler temperature
40.3 Alarms and protections - Feeder temperature
40.4 Alarms and protections - No temperature rise
40.5 Alarms and protections - No temperature rise - time
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Boiler temperature controller with a feeder

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58. Information about recycling...............................................................
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40.6 Alarms and protections - DHW temperature.
40.7 Alarms and protections - 2. Circuit temperature
40.8 Alarms and protections - Sound
40.9 Alarms and protections - Valve protection
40.10 Alarms and protections - Emergency stop of piston feeder............
40.11 Alarms and protections - Feed. and fan block. in HOLD. mode.....
40.12 Alarms and protections - Fuel outburst to a furn. in critic. situat....
41. Service menu - INIT
42. Service menu - Technical inspection
43. Service menu - Language
44. Service menu - Room thermostat
44.1 Room thermostat - CH pump - operation time
44.2 Room thermostat - CH pump - pause time
44.3 Room thermostat - 2. Circuit
45. Service menu - Operation mode
46. Service menu - Parameters 2. Circuit2
46.1 Parameters 2. Circuit - Control mode
46.2 Parameters 2. Circuit - Maximum temperature
46.3 Parameters 2. Circuit - Minimum temperature
47. COMFORT SYSTEM function
48. Protection against freezing
49. Alarms - description
49.1 Over temperature on the boiler
49.2 Over temperature on the feeder
49.3 Damaged boiler temperature sensor
49.4 Damaged feeder temperature sensor
49.5 Damage to the outside temperature sensor
49.6 Damaged DHW temperature sensor..............
49.7 Damaged temperature sensor 2. Circuit .............
49.8 Thermal fuse
49.9 Piston feeder drawer fault
49.10 Return temperature sensor fault
49.11 Circulation temperature sensor fault
50. Weather control as per the heating curves......................
51. Heating curves - introduction
52. Heating curves - tracing............................
53. Heating curves - description
54. Correction of the heating curves' settings...........
55. Heating curve - guides
56. Temperature sensors characteristics.........................
57. Technical data
59. Appendix
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Boiler temperature controller with a feeder

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Boiler temperature controller with a feeder
1. Description of a controller
Controller is designed for an automatic fuel feeding system boiler operation
control, domestic hot water pump control, 2. circuit pump, circulation pump, 3- or
4-way valve control depending on the external temperature in central heating
installations. The controller has the following features:
qmaintaining the preset temperature of a boiler by controlling the air blow-in and the
feeder operation
qpossibility of operating the boiler with an emergency grate
qadjustment of the heating temperature of two circuits on the basis of the outside
temperature acc. to the selected heating curve
qpossibility of choosing an independent heating curve for the boiler and a circuit with the
mixing valve
qfunction of moving the curve up or down to better match the thermal characteristics of
the building
qhigh-temperature silicone cables of temperature sensors
qprotection of floor heating systems against overheating
qsmooth operation of a fan and preset power
qfunction of supporting the combustion process by the so-called blow-bys
qadjustable damping time and automatic turn off during fuel shortage
qcontrol of the central heating circulation pump
qcontrol of the 3- or 4-way valve
qoption of enabling or disabling the DHW priority
qcontrol of the domestic hot water heater charging pump depending on the required
temperature
qcontrol of the 3rd circuit pump working as a circulation pump, a pump protecting the
boiler from cold return or a floor heating pump
qcontrol of the boiler operation and domestic hot water pump acc. to one of several
weekly programs
qprotection of domestic hot water heater against Legionella
qoption to work in the SUMMER mode
qCOMFORT SYSTEM function, which protects the pump and mixing valve against
scaling
qprotection system - a thermal fuse as an additional, mechanical protection of the boiler
against uncontrolled temperature increase
qcooperation with liquid STB protection
qdetection and sound and optical alarm of the STB protection activation
qfunction of protecting the system against freezing and overheating of the boiler
qdamage indication of the temperature sensors
qadjustable display brightness - increased during settings modification
qpossibility of connecting a room thermostat
qlarge, readable, alphanumeric LCD display with 4x16 characters

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Boiler temperature controller with a feeder
1.1 Description of a controller - functions
REED RELAY ALARMS
4W VALVE
NUMBER OF PUMPS
CONTROLLING
OUTPUTS
4
CENTRAL
HEATING PUMP DHW PUMP
CIRCULATION
PUMP
2ND CIRCUIT
PUMP
FAN FEEDER 3W VALVE
FAN
MODULATION
DHW
DISINFECTION
RETURN
PROTECTION
PUMP
WEEKLY
PROGRAM
DHW
PRIORITY
PRIORYTET
EMERGENCY
GRID
COLD RETURN
PROTECTION
FROST
PROTECTION
SUMMER
MODE
THERMAL
FUSE
ROOM
THERMOSTAT
CONTROL
THE WEATHER
COMFORT
SYSTEM

Boiler temperature controller with a feeder
2. Controller components description
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indication lights operating screen function buttons
feeder
fan
central heating pump
DHW pump
2. circuit pump
3D/4D valve opening
3D/4D valve closing
alarm
Indication lights - description Function buttons - description
- one level up in Menu, operating mode
change
- moving between Menu categories,
settings change - values increase
- entering Menu category, confirming,
entering “TEMPERATURE” screen,
operating mode change,
- moving between Menu categories,
settings change - values decrease
- entering Main and Service Menu
Fig.1 Control panel - front
Fig.2 Control panel - back
COMX3 communication socket
to contect with operating panel
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COMX 3

Boiler temperature controller with a feeder
3. Operating panel description
9
service socket sensors connecting
socket
two sockets
5A fuses
mains
off/on
switch
mains
socket 230V
Fig.3 Operating panel - front
Fig. 4 Operating panel - side and back
PE
STB
STB
N
8
9
6
5
11
7
10
12
X50
Operating panel - back
sensors connecting socket
Operating panel - side
connecting socket to
connect with connection
panel
COMX2 communication
socket to connect with
control panel
COMX 2
CZ. 7
CZ.
POD
IN
2
T
IN
3
IN
1
+5
V
+5
V
+5
V
T T
CZ.
KOT.
TER
MIK
X30
X40
O
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Boiler temperature controller with a feeder
4. Connection panel – components and connections
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Fig. 5 Connection panel wiring diagram
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10
9
8
6
5
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12
central heating pump
DWH pump
3D/4D valve opening
3D/4D valve closing
2. circuit pump
circulation pump
feeder
fan
Operating panel
(side view)
connection
panel
PE
STB
STB
N
8
9
6
5
11
7
10
12
X50
L – central heating pump (outp.12)
L – DHW pump (outp.11)
L – valve open (outp.10)
L – valve closed (outp.9)
L – 2. circuit pump (outp.8)
L – circulation pump (outp.7)
L – feeder (outp.6)
L – fan (outp.5)
N – shared power capble
STB – temperature protection
STB – temperature protection
PE – grounding point
L - brown wire
N - blue wire
PE - yellow-green wire
Notice: If STB sensor has not been connected, the
outputs (marked STB) must be bridged.
PE
STB STB
N
8 9
6
5
11
7
10
12
X50
85
379
6
11 10
12