Geco G-403-P02 User manual

SELF-CONTAINED
CONTROL UNIT (SCCU)
USER’S MANUAL
G-403-P02
FOR CONTROLLING CENTRAL HEATING
SYSTEM BOILERS WITH FEEDING SCREW
Program Version 11
NOTE
In the G-403-P02 controller starting from v.11 the points of wiring from the
fuel feeder and DHW pump have been switched over.
/See: fig. 2 page 15/
Please consult the information mentioned above and pay special attention when
connecting the fuel feeder.
You are politely requested for the familiarization with the manual prior to making the
connection and activating any of our machines. Should you have any doubts, please do not
hesitate to contact our firm from Monday to Friday between 8 a.m. and 16 p.m..
The most recent update release date is provided at the bottom of each following page.
Please, always use the most recent version of the manual, which can be obtained by mail free of
charge after the previous order.

Table of contents
1. INTRODUCTION....................................................................................................................3
1.1. GRAPHICAL SYMBOLS ...........................................................................................................3
1.2. KEYBOARD AND FUNCTION BUTTONS....................................................................................3
2. GENERAL CHARACTERISTICS ........................................................................................4
3. TECHNICAL DATA ...............................................................................................................4
4. WIRING SYSTEM AND RULES OF CONNECTION .......................................................5
5. G-403-P02 OPERATION AND ADJUSTMENT METHODS.............................................5
5.1. TEMPERATURE MEASUREMENT .............................................................................................5
5.2. EXCEEDING THE ALLOWABLE TEMPERATURE OF THE FUEL IN THE FEEDING SCREW...............5
5.3. POWER FAILURE....................................................................................................................6
6. STB FUNCTION MANUAL REACTIVATION ..................................................................6
WHEN THE STB TEMPERATURE LIMITER HAS BEEN TRIGGERS AND FAN
DEACTIVATED, ITS OPERATION MUST UNCONDITIONALLY BE RESTORED IN
ORDER TO ENSURE THE PROPER FUNCTIONING OF THE G-406-P02
CONTROLLER. ................................................................................................................................6
IN ORDER FOR THE UNIT TO BE REACTIVATED, PROCEED AS FOLLOWS: ..............6
7. G-403-P02 HANDLING...........................................................................................................7
7.1. STARTING THE UNIT ..............................................................................................................7
7.2. MANUAL CONTROL ...............................................................................................................7
7.3. AUTOMATIC OPERATION .......................................................................................................7
7.4. SUSTAINING MODE OPERATION .............................................................................................9
7.5. ALARM MODES .....................................................................................................................9
8. USER PARAMETERS CONFIGURATION ......................................................................10
8.1. THE PRESET TEMPERATURE OF THE BOILER OUTLET WATER ................................................10
8.2. TIME OF FEEDING THE COAL TO THE BOILER (U1) ................................................................10
8.3. TIME OF STOPPING THE FEEDING SCREW (U2) ......................................................................11
8.4. SUSTAINING TIME (U3)........................................................................................................11
8.5. DELAY IN FAN DEACTIVATION UNDER SUSTAINING MODE (U4) ...........................................11
9. MIXING PUMP HANDLING...............................................................................................11
10. UTILITY HOT WATER VESSEL HANDLING................................................................12
10.1. ASSEMBLY AND CONNECTION..........................................................................................12
10.2. CONFIGURATION OF THE PARAMETERS ............................................................................13
11. ROOM PANEL ......................................................................................................................13
12. METHOD OF CONNECTING THE EQUIPMENT TO THE G-403-P02
CONTROLLER ...............................................................................................................................14
13. TROUBLESHOOTING GUIDE ..........................................................................................15

G-403-P02 USER’S MANUAL PAGE 3
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2006-09-04
1. INTRODUCTION
1.1. Graphical symbols
Below symbols are used to signal and underline meaning of very important information. They refer
to safe usage of equipment.
Be aware!
This symbol is used when sequence of taken actions is important. In case of
mistake or procedure inadequate to the description the equipment can be
damaged.
Important!
This symbol refers to information of the special meaning.

Reference!
This symbol informs of additional information somewhere else in the manual.
1.2. Keyboard and function buttons
PROGRAMMING
POWER
TURN
ON/OFF
MANUAL
AUTOMATIC
MODE OPERATION
SIGNAL
MANUAL ACTIVATION
OF FAN
/ PARAMETERS VALUE
CHANGE, UP
AUTOMAT
SUSTAIN MODE
OPERATION SIGNAL
MANUAL ACTIVATION
OF FEEDING SCREW
/ PARAMETERS VALUE
CHANGE, DOWN

G-403-P02 SERVICE’S MANUAL PAGE 4
PPUH „GECO” Sp. z o.o. Edition I RELEASE DATE 2009-08-18
2. GENERAL CHARACTERISTICS
The self-dependent controller, hereafter called G-403-P02, is a convenient, modern and
easy-to-use equipment. It has been made in microprocessor based techniques, with the application
of the automatic surface assembly.
Depending on the installation method, the two-part casing provides the possibility of
installing the control panel operating under safe voltage practically everywhere, without the
necessity of running power supply cables far away from the equipment controlled.
The G-403-P02 controller has been equipped with:
temperature sensors
1. For measuring the temperature of water leaving the boiler;
2. For measuring the temperature of fuel feed - (note: this sensor may be deactivated);
3. For measuring the temperature of water in the utility hot water vessel (option)
two digital inputs:
1. To connect the thermostat which may force the controller to change for temperature
marinating status, with the controlled water circulation pump;
2. To connect the feeding screw cotter pins breaking sensor.
The controller is equipped with 4 outputs allowing the direct connection of equipment
operating under the voltage of 230 V, such as fan, fuel feeding unit, central heating system and
utility hot water circulating pumps.
If the unit is to act as the central heating system boiler controller, the G-403-P02 stabilizes
the temperature of water and controls the process of fuel combustion in the boiler, preventing
damping a fire. The regulation parameters may be adjusted to current conditions of operation and
kinds of the boiler. The boiler has been equipped with the system of protection from the power
failure or several kinds of interference.
The controller does not require any maintenance, and the keyboard has been made from the
special kind of a film resistant to high-level temperatures and the majority of chemicals. The
keyboard, however, must not be cleaned with sharp edge objects. Instead, a humid cloth should be
used for cleaning the front panel.
In summertime, the controller should be kept connected to the power supply system,
however, it should be disconnected from the power for the period of storms.
3. TECHNICAL DATA
Operating voltage

230V +10% -15%
Temperature

+5 degrees Celsius - + 40 degrees Celsius
Relative humidity

od 20% do 80%
Protection degree

IP65 on the control panel front
NOTE!!!
The label can be found on each casing, meaning:
-serial number;
-description of inputs, including their load capacity;
-SDRB type.
Important:
The total current consumed by the equipment must not exceed 10A !!!


G-403-P02 USER’S MANUAL PAGE 5
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2006-09-04
4. WIRING SYSTEM AND RULES OF CONNECTION
1. The boiler house should be equipped with the 230V/50Hz wiring system, in accordance
with applicable regulations.
2. Irrespective of the wiring system kind, the plug-in sockets should be equipped with the
protective terminal. The application of the socket without the protective terminal
connected is a shock hazard!
3. The controller should be connected to the separate power supply line, protected by means of
the 2-4A rapid fuse and the residual current circuit breaker, with activation current 20 mA
maximum. The connection of any other equipment to this line is not allowed!
4. The clamp conductor joints used are certified for continuous load of 16 A. As the fine
thread and special metal sheets preventing conductors cutting have been applied, a perfect
contact is achieved with slight screwing of the conductor. Applying larger force may lead to
breaking the thread.
5. The power supply cables must be firmly attached along their entire length and should not
catch the water coat or the outlet to the chimney.
6. Following the connection of the unit to the power supply, the unit may be energized
irrespective of switching on or off by means of the pushbutton, therefore any repairs
may be performed only when the voltage is disconnected from the fuse!
5. G-403-P02 OPERATION AND ADJUSTMENT METHODS
5.1. Temperature measurement
The controller measures the temperature within the range of 0 degree Centigrade to 100 degree
Centigrade. The temperature is displayed with the delay of one second. Where the malfunction
occurs to the temperature sensor, or temperature value is found beyond the above-mentioned range
and the equipment is not found in the mode of 60 second-waiting for power supply voltage
stabilization following power failure, the controller reports the malfunction to the sensor. This
causes both the deactivation of all activated equipment, i.e. fan, feeding screw and pump, and
switching to the manual operation mode, the following symbols being then displayed:
AL1 symbol, if the flow water temperature sensor has got broken,
AL2 symbol, if the feeding screw sensor has got broken,
AL3 symbol, if the malfunction has occurred to the boiler inlet water temperature sensor or the
feeding screw coupling cotter pin has got broken.
The occurrence of the temperature exactly equal to 100 degrees Celsius will cause the display to
show 00o.
5.2. Exceeding the allowable temperature of the fuel in the feeding screw
The controller has been equipped with the sensor reporting that the allowable temperature of
fuel in the feeding screw has been exceeded. The controller operates owing to the measurement of
the feeding screw pipe temperature. If the temperature in question reaches the level of 98 degrees
Centigrade, the controller reports the AL6 alarm, deactivating the fan and activating the continuous
operation of the feeding screw for the period of 10 minutes so that the burning fuel may be removed
from the feeder and the furnace may be put down.
When the manual operation mode is activated, the feeding screw temperature is not checked,
therefore the malfunction to the feeding screw temperature sensor launches the AL2 alarms.

G-403-P02 SERVICE’S MANUAL PAGE 6
PPUH „GECO” Sp. z o.o. Edition I RELEASE DATE 2009-08-18
5.3. Power failure
Following power failure, the controller will start operations depending on its status prior to
the occurrence of the power failure. The controller will wait for the period of one minute so that the
electric grid can stabilize, after which the operation with the previously programmed values of
parameters will be resumed.
During the standby mode, the display shows the time remaining to the standby mode end, as
well as the denotation of the mode in which the controller operated prior to the power failure:
blinking A letter means the automatic operation mode;
P letter means sustaining mode;
r letter means the manual operation mode.
Also the corresponding controls of automatic operation or sustaining mode will blink
together with the letters. If the controller was under the manual operation mode, it will resume
operating in this status with deactivated equipment, and if the controller was under the automatic
operation mode, it will also resume the automatic operation.
If the controller was in the sustaining mode, the sustaining mode will be resumed after
which the feeding screw and the fan will be activated for the limited period of time so as to prevent
the furnace from putting down.
6. STB FUNCTION MANUAL REACTIVATION
When the STB temperature limiter has been triggers and fan deactivated, its operation must
unconditionally be restored in order to ensure the proper functioning of the G-406-P02 controller.
In order for the unit to be reactivated, proceed as follows:
Damage or breaking to the capillary tube means the leaks of the
temperature limiter filled with liquid, which leads to the G-406-
P02 performance.
Should such fault be found, the temperature limiter should be
disconnected from the G-406-P02 controller, dismantled and
replaced with the brand new one.
1. Unscrew the black protective nut
(1).
2. Press RESET pushbutton
(2) to unblock.
3. Apply and secure
protective nut (1).

G-403-P02 SERVICE’S MANUAL PAGE 7
PPUH „GECO” Sp. z o.o. Edition I RELEASE DATE 2009-08-18
7. G-403-P02 HANDLING
7.1. Starting the unit
1. Connect the unit to the power supply network (insert the plug to the plug-in socket).
The display will show four horizontal dashes. All functions, in particular, the equipment
controlling the boiler operation, i.e. pump, fan and feeding screw, are deactivated.
The unit will ignore pressing all pushbuttons except for the pushbutton.
2. Turn the controller on by pressing the pushbutton.
When this pushbutton is pressed, the controller enters the status of manual controlling of
the central heating system boiler and reads the most recent user-defined settings of the
boiler operation parameters (see item 6).
7.2. Manual control
Following pressing the pushbutton, the controller enters the manual mode of central
heating system boiler control. All equipment connected to the controller is deactivated, and the
display shows the central heating system boiler water temperature, measured by means of the
sensor.
This mode allows activating the following equipment, notably:
1. Fuel feeding screw.
Pressing the pushbutton causes the activation of the feeding screw connected to the
controller, as well as the illumination of the bottom control diode found on the
pushbutton. When the pushbutton is pressed again, the feeding screw is deactivated and the
control diode goes off.
2. The fan.
When the pushbutton is pressed, the fan connected to the controller is activated, and
the corresponding top control diode goes on. When the pushbutton is pressed again, the fan
is deactivated and the control diode goes off.
In this operation mode, the feeding screw and the fan may be activated and deactivated irrespective
of one another.
Pressing the pushbutton causes the controller to abandon the automatic operation mode
(heating and sustaining) and to enter the manual operation mode, involving the immediate stop of
the operation of the fan, feeding screw and pump.
7.3. Automatic operation
When the pushbutton is pressed, the controller enters the automatic operation mode.

G-403-P02 SERVICE’S MANUAL PAGE 8
PPUH „GECO” Sp. z o.o. Edition I RELEASE DATE 2009-08-18
1. This operation mode is signalled through the top control diode going on. The automatic
operation in false controlling the coal feeding screw and fan so that the temperature of the
water in the boiler is maintained at the level preset by the user.
2. In this operation mode, the controller will additionally show whether the feeding screw
and/or fan is activated through the activation of the corresponding control diodes arranged
on the pushbutton.
3. When the automatic operation mode is activated, the controller will start the central heating
system circulation pump, if the boiler water temperature is more or equal to the factory set
value. Also the pump operation control diode (the vertical dash on the left hand side of the
display) goes on.
4. The controller will stop the pump if the temperature of water drops to the temperature of
pump activation minus 4 degrees Centigrade.
5. When the feeding screw stop time set has elapsed, the controller causes the feeding screw to
start operation for the preset loading time, after which the feeding screw is deactivated, etc.
(the cycle is repeated).
6. The method in which the controller finds out that the furnace has put down:
if, in the automatic mode of operation, the boiler water temperature reduces by 10
degrees Celsius, the growth by more than 4 degrees Celsius not occurring in the course
of temperature value reduction, the pump is deactivated. The controller will store the
temperature and wait for the period of time factory set, after which will check whether
the temperature has risen. If not, this means that the furnace has put down;
if the controller enters the automatic operation mode in the course of the thermostat
interlock, the procedure of checking whether the furnace has put down is not activated.
7. The display will show the temperature of water measured. When the pushbutton is
pressed, all the equipment is deactivated and the manual operation mode resumed.

G-403-P02 USER’S MANUAL PAGE 9
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2006-09-04
8. When the pushbutton is pressed, the controller enters the programming mode which
does not affect the automatic operation mode.
7.4. Sustaining mode operation
When this mode is activated, the display shows the boiler water temperature measured, as
well as the bottom control diode on the pushbutton, signalling the sustaining operation mode,
is on. The pump is on if the temperature is more or equal to the factory set value.
After the sustaining time has elapsed (u3 user parameter), the controller will start the feeding
screw and the fan for the factory set time, in spite of the thermostat operation. The fan will operate
correspondingly longer (u4 parameter) than the feeding screw so that the added fuel can start
burning.
When the pushbutton is pressed, the programming mode is entered, similarly to the
automatic operation mode.
When the pushbutton is pressed, all the equipment is deactivated and the manual
control operation mode is resumed.
7.5. Alarm modes
Five alarm modes are recognized by the controller. Except for AL4, the number of alarm
will be shown, as well as the acoustic alarm output will be activated for the period of two seconds.
Then this output will be deactivated for the period of two seconds, to be activated again, etc..
Except for the AL4, the abandonment of the alarm modes is possible only when the
pushbutton is pressed.
Kinds of alarms:

AL1

Damage to the boiler outlet water temperature sensor;

AL2

Damage to the feeding screw temperature sensor;

AL3

Failure of the return temperature sensor or DHW temperature sensor or breaking
the feeder roller (reed relay failure)

AL4

The outlet water has reached the temperature exceeding 95 degrees Centigrade;

AL5

The furnace has put down;

AL6

The maximum temperature in the feeding screw has been exceeded or the feeding
screw temperature sensor has broken down.
Where the AL4 alarm has occurred, the temperature measured and the alarm message (AL4
text) is displayed alternately. If the controller detected the alarm in the course of manual operation
mode, the central heating system circulation pump will be activated. This alarm will automatically
go off when the temperature in the boiler drops below 95 degrees Centigrade.

G-403-P02 USER’S MANUAL PAGE 10
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2006-09-04
8. USER PARAMETERS CONFIGURATION
When the pushbutton is pressed, the controller will enter the programming mode which
will be signalled by the activation of the control diode on the pushbutton. The programming
does not affect the current operation of the controller. While in the programming mode, the
controller cannot change between the manual and automatic operation modes (the controller does
not response to pressing the and pushbuttons).
8.1. The preset temperature of the boiler outlet water
The following procedure allows to change the preset {Tzad} temperature of the boiler outlet water:
1. Press the pushbutton.
The illumination of the diode on the pushbutton signals commencing the temperature
setting. The display shows the temperature set to date.
2. Set the desired temperature by means of the pushbutton (down) and (up).
The allowable range of changes is programmed by the boiler manufacturer. When this level
of temperature is reached, the controller will enter from the automatic operation mode to the
sustaining mode.
3. Press the pushbutton again so that the new level of temperature is stored.
At the same time, the controller will enter the programming mode of the subsequent u1
parameter.
Comments:
if the pushbutton is not pressed again, the changes will be discarded;
if, in the course of setting the new temperature, any of the , , , is not pressed
for the period of 20 seconds, the new temperature will not be stored and the controller will
abandon the programming mode.
8.2. Time of feeding the coal to the boiler (u1)
This parameter shows the time for which the feeding screw will be activated in the
automatic operation mode. The value of these parameters may be modified in the same way as is the
case for the u0 parameter.
1. Press the pushbutton. The controller with display the u0 parameter value.
2. Press the pushbutton again. The controller will store of the value of the u0 parameter
and will switch to u1.