Geco G-406-P09 User manual

SELF-DEPENDENT REGULATION
BLOCK USER’S MANUAL
G-406-P09
FOR CONTROL CENTRAL
HEATING SYSTEM BOILERS
WITH FEEDING SCREW AND FAN
ROTATION SMOOTH CONTROL
Program Version 00
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 between 8 a.m. and 16 p.m..
Note:
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. GENERAL CHARACTERISTICS........................................................................................3
2. TECHNICAL DATA...............................................................................................................3
3. WIRING SYSTEM AND RULES OF CONNECTION.......................................................4
4. SBR G-406-P09 OPERATION AND ADJUSTMENT METHODS....................................4
4.1. T EMPERATURE MEASUREMENT ............................................................................................4
4.2. C ONTROLLER INTERLOCK THROUGH THE ROOM THERMOSTAT ..............................................4
4.3. E XCEEDING THE ALLOWABLE TEMPERATURE OF THE FUEL IN THE FEEDING SCREW ..............5
4.4. P OWER FAILURE ...................................................................................................................5
5. G-406-P09 HANDLING..........................................................................................................6
5.1. S TARTING THE UNIT ..............................................................................................................6
5.2. M ANUAL CONTROL ..............................................................................................................6
5.3. A UTOMATIC OPERATION .......................................................................................................7
5.4. S USTAINING MODE OPERATION .............................................................................................8
5.5. A LARM MODES .....................................................................................................................8
6. USER PARAMETERS CONFIGURATION........................................................................9
6.1. T HE PRESET TEMPERATURE OF THE BOILER OUTLET WATER ..................................................9
6.2. T IME OF FEEDING THE COAL TO THE BOILER ( U 1)..................................................................9
6.3. T IME OF STOPPING THE FEEDING SCREW ( U 2) .....................................................................10
6.4. S USTAINING TIME ( U 3).......................................................................................................10
6.5. D ELAY IN FAN DEACTIVATION UNDER SUSTAINING MODE ( U 4)...........................................10
6.6. F AN EFFICIENCY ( U 5). ........................................................................................................10
7. MIXING PUMP HANDLING..............................................................................................11
8. UTILITY HOT WATER VESSEL HANDLING...............................................................11
8.1. A SSEMBLY AND CONNECTION ............................................................................................11
8.2. C ONFIGURATION OF THE PARAMETERS ...............................................................................12
9. METHOD OF CONNECTING THE EQUIPMENT TO THE G-406-P09
CONTROLLER...............................................................................................................................13
10. TROUBLESHOOTING GUIDE..........................................................................................14

USER’S MANUAL G-406-P09 STRONA 3
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
1. GENERAL CHARACTERISTICS
The self-dependent controller, hereafter called G-406-P09, 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-406-P09 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)
•one digital input:
1. to connect room thermostat which can force the controller to turn into sustaining mode
with water circulation pump operating (can be changed with Utility Hot Water pump)
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-406-P09 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.
2. 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;
-SBR type.
Important:
The total current consumed by the equipment must not exceed 10A !!!


USER’S MANUAL G-406-P09 STRONA 4
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
3. 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 16A rapid fuse and the residual current circuit breaker, with activation current 30 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!
4. SBR G-406-P09 OPERATION AND ADJUSTMENT METHODS
4.1. 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 temperature sensor has got broken,
AL3 symbol, if the utility hot water temperature sensor has got broken.
The occurrence of the temperature exactly equal to 100 degrees Celsius will cause the display to
show 00
o
.
4.2. Controller interlock through the room thermostat
If the external room thermostat is connected to the G-406-P09 unit (see figure 2), which will
be activated, i.e. will cause the output terminals to join, when the temperature preset for the heated
rooms is exceeded, the unit in question will enter the interlock status.
When the room panel of our manufacture is connected to the controller, the digital inputs of
the thermostat will remain inactive.

USER’S MANUAL G-406-P09 STRONA 5
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
This will cause the following changes to the operation of the unit, notably:
•in the sustaining mode, the controller will cause the central heating system pump to be
deactivated while the display will read “blo”;
•in the automatic operation mode, the controller will enter the sustaining mode, display the
“blo” text and deactivate the central heating system pump after four minutes;
•upon the expiry of the sustaining time, the controller will activate the feeding screw and fan
for the period of time predefined by the manufacturer, in spite of the thermostat operation.
The fan will operate five seconds longer than the feeding screw so that the added coal may get
fired up well;
•the central heating pump operation will be dependent on the value of the servicing parameter;
•the thermostat interlock will not cause the controller to abandon the controller programming
mode in the automatic or sustaining mode operation;
•during the interlock, the controller will activate the central heating system pump operate for
the period of 30 seconds, at the time intervals preset by the manufacturer so that the water in
the system may circulate.
4.3. 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.
Note:
The sensor of fuel ignition in the feeding screw may be deactivated if necessary.
Whenever the sensor in question is missing or has become damaged, the controller will act as
if the ignition of the fuel in the feeding screw has occurred and will control the feeding screw so that
the “burning fuel” be removed from the feeding screw and the furnace put down. This is due to the
safety reasons.
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.
If the fuel ignition sensor is not used in the boiler, the sensor may be deactivated.
4.4. 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.

USER’S MANUAL G-406-P09 STRONA 6
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
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.
5. G-406-P09 HANDLING
5.1. 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).
5.2. 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.

USER’S MANUAL G-406-P09 STRONA 7
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
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.
5.3. Automatic operation
When the pushbutton is pressed, the controller enters the automatic operation mode.
1. This operation mode is signaled 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.

USER’S MANUAL G-406-P09 STRONA 8
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
8. When the pushbutton is pressed, the controller enters the programming mode which
does not affect the automatic operation mode.
Remember!
If the temperature reaches value set by the user the controller will turn into sustaining mode.
5.4. 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, signaling the sustaining operation mode, is
on. The pump is on if the temperature is more or equal to the factory set value.
Following entering the sustaining mode, the fan will remain activated for the time, multiplied
by multiplication factor so that the fuel added can start burning, following which the fan will be
deactivated. 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.
If the temperature drops to the value that is equal to the value preset by the user minus
servicing parameter, the controller will resumed the automatic operation mode.
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.
5.5. 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 →
Damage to the utility hot water temperature sensor,
•
AL4 →
The outlet water has reached the temperature exceeding 85 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 85 degrees Centigrade.

USER’S MANUAL G-406-P09 STRONA 9
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
6. USER PARAMETERS CONFIGURATION
When the pushbutton is pressed, the controller will enter the programming mode which
will be signaled 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).
6.1. The preset temperature of the boiler outlet water
The following procedure allows to change the preset {T
zad
} 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.
6.2. 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.

USER’S MANUAL G-406-P09 STRONA 10
PPUH „GECO” Sp. z o.o. Edition II RELEASE DATE 2010-12-02
3. Set of the desired value by means of the pushbutton (down) and (up).
4. The allowable range of changes of the parameter is between 5 seconds and 250 seconds.
5. Press the pushbutton again so that the new value is stored.
At the same time the controller will switch to programming the subsequent u2 parameter.
6.3. Time of stopping the feeding screw (u2)
This parameter shows the time between the subsequent supplies of the coal to the boiler in the
automatic operation mode. The range of changes is between 5 seconds and 250 seconds.
The parameter in question may be modified in the same way as shown in item 6.1 and 6.2.
6.4. Sustaining time (u3)
This parameter will show the time after elapsing of which the controller will activated the
feeding screw and fan for the factory preset time, in the sustaining time, so as to present the furnace
from putting down. The range of changes is between 5 minutes and 250 minutes. The parameter in
question may be modified in the same way as shown in item 6.1 and 6.2.
6.5. Delay in fan deactivation under sustaining mode (u4)
This delay is aimed at allowing the added fuel to burn in the sustaining mode. The range of
changes is between 5 seconds and 250 seconds. The parameter in question may be modified in the
same way as shown in item 6.1 and 6.2.
6.6. Fan efficiency (u5).
The fan efficiency can be adjusted due to the quality of fuel and heating conditions. The range
of change is from 1 to 10 which refers to scale from 10% to 100%. The parameter in question may be
modified in the same way as shown in item 6.1 and 6.2.
The subsequent pressing of the pushbutton will cause the return to the mode from which the
programming mode was called for, as well as the deactivation
of the programming control diode.