Hamworthy Merley Guide

MERLEY BOILER
SEQUENCE CONTROLLER
For Modular Boiler Installations
Installation, Commissioning
and Operating Instructions
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT

HAMWORTHY HEATING LTD 1 Merley Boiler Sequence Controller 500001210/D
MERLEY BOILER
SEQUENCE CONTROLLER
For Modular Boiler Installations
Installation, Commissioning
and Operating Instructions
NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE
ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT
PUBLICATION NO. 500001210
ISSUE ‘D’
June 2022

HAMWORTHY HEATING LTD 2 Merley Boiler Sequence Controller 500001210/D
CONTENTS
PAGE
1.0 General Overview ……………………………………………………………………………..3
1.1 Description
1.2 Abbreviations
1.3 Product Range
1.4 System Configurations
2.0 Mounting and Installation…...……………………………………………………………………..…….……7
2.1 Electrical Installation
2.2 General Requirements
2.3 Mounting Location
2.4 Electrical Connections
2.5 Pre-Assembled Wall Mounted Panel
2.6 Operator Unit
2.7 Room Unit
2.8 Outside Sensor
2.9 Programmable Room Unit
2.10 Wireless Components
2.11 Programmable Room Unit (wireless)
2.12 Outside Sensor (wireless)
2.13 Radio Repeater
3.0 Commissioning…....………………………………………………………………………………………........22
4.0 Operation………………………………...……………………………………….…………...23
4.1 Function
4.2 Display
5.0 Programming ........................................………………………………………………………..………30
5.1 User Levels
5.2 Overview of Settings
5.3 QAA55
6.0 Settings in Detail ..................................................…………………………………………..……46
6.1 Time of Day & Date
6.2 Operator Unit
6.3 List of Wireless Devices
6.4 Time Programs
6.5 Holidays
6.6 Heating Circuits
6.7 DHW
6.8 Primary Controller / System Pump
6.9 Cascade
6.10 DHW Storage Tank
6.11 Configuration
6.12 LPB
6.13 Faults
6.14 Maintenance / Special Modes
6.15 Input / Output Tests
6.16 State
6.17 Diagnostics heat generation
6.18 Diagnostics consumer
6.19 List of Displays
7.0 Plant Diagrams ...........................................................................................................84
7.1 Basic Diagrams
7.2 Extra Functions - DHW
- Low Loss Header

HAMWORTHY HEATING LTD 3 Merley Boiler Sequence Controller 500001210/D
8.0 Technical Data ...........................................................................................………….…...88
8.1 RVS
8.2 Operator & Room Units
8.3 Power Supply
8.4 Radio Module
8.5 Wireless Outside Sensor
8.6 Radio Repeater
8.7 Sensor Characteristics
Appendix A: ............................................................................................……………...………...97
Figure A1 Cascade with primary circuit pump
Figure A2 Cascade with primary circuit pump
Appendix B: Wiring Schematics ………....…………………………………………………………………...99
Figure B1 RVS Wiring
Figure B2 Wireless Configuration
Appendix C: Programming Parameters .…………………………...……………….………101
Appendix D: Wiring for Primary Pump when using Cascade Controller ...............….104

HAMWORTHY HEATING LTD 4 Merley Boiler Sequence Controller 500001210/D
Hamworthy offer a pre-assembled wall mounted panel version incorporating the sequence control and user
display, mounted in a robust painted steel cabinet, complete with lockable hinged door, mounting brackets, DIN
rail, cable trunking and cable glands.
Alternatively, the Merley is suitable for incorporating into a local control panel (not HHL supply), requiring a Din rail
to mount the plc logic control and a cutout in the panel door to accommodate the user display screen.
Boiler
• Optimum start control with minimum limitation of
the boiler temperature
• Minimum and maximum limitation of the boiler
temperature
• Protective boiler startup
• Protection against boiler over temperatures
(pump overrun)
• Burner cycling protection by observing a
minimum burner running time
• Frost protection boiler
Heating Circuit Control
• Pure weather compensation
• Weather compensation with room influence
• Pure room temperature compensation
• 1st mixing / pump heating circuit with 7-day
program
• The building’s thermal dynamics are taken into
consideration (building time constant)
• Automatic adaptation of heating curve
• Automatic summer / winter changeover
• Automatic 24-hour heating limit
• Holiday program
• Quick setback and boost heating
• Optimum start / stop control
• Raising the reduced temperature level
depending on the outside temperature
• Frost protection flow, building and plant
• Primary controller
DHW Control
• DHW storage tank charging with 7-day program
• DHW charging with charging pump or diverting
valve
• DHW charging with sensor
• DHW charging with a thermostat
• Selectable priority (absolute / shifting / none)
• Selectable DHW program (according to DHW
program, according to heating programs, 24
hours)
• DHW push, manually or automatically
• Legionella function
• DHW discharging protection
• Control of DHW circulating pump
• electric immersion heater for DHW
• Overtemperature protection DHW storage tank
• Frost protection DHW
General
• Automatic summertime/wintertime changeover
• Automatic identification of sensors
• Input and output test
• Service and error messages
• Status display for partial plant diagram
• Parameter reset
• Read/write parameters with operator units
• Multifunctional inputs and outputs
• Connection facility radio receiver
• Connection facility service tool (via OCI700)
• Connection facility for remote monitoring (via
OCI611)
1.0 General Overview:
1.1 Merley Boiler Sequence Controller
Brief Description
Controls up to 16 boilers using Siemens LMU controls. May be independently enabled by a 0-10v signal from a
BMS or start/stop signal from a time clock. It also has a built in clock & uses an LPB Bus to communicate with the
boilers. Each boiler control requires an extra module to communicate with the cascade controller. Operating from
a BMS temperature signal or with the dedicated flow temperature sensor, cascade systems can be designed to
operate up to 90°C. Dependant on application the control can offer additional features as detailed below.
Note: the control offers system functionality which is not detailed in this manual. For more complex systems
refer to HHL Technical.

HAMWORTHY HEATING LTD 5 Merley Boiler Sequence Controller 500001210/D
1.3 Product Range
The following Merley Boiler Sequence Controller kits and accessories are designed for use with the Hamworthy
Range of boilers using Siemens LMU controls
** Note:
This kit is designed to install the RVS control into an existing local panel (not HHL supply).
Hamworthy strongly recommend the use of an outside sensor to optimise the performance of the
equipment. The use of wireless or wired configuration will determine the outside sensor supplied with the
product as standard.
The options provide suitability for hard wired or wireless applications.
Wireless applications must be subject to a site survey by a competent person to establish site suitability.
Care must be taken in ordering the correct options suitable for hard wired or wireless applications.
The kits include the cascade control (incl wiring connectors), an insertion flow sensor & immersion pocket & 2
OCI LPB relays.
Additional sensors (room or external) must be specified, at the point of ordering.
1.4 Product liability
• The products may only be used in building services plant and applications as described above
• All requirements specified in chapters "Handling" and "Technical data" must be satisfied
• The local regulations for installation must be complied with.
HHL Reference Description Option
563605 603 RVS63.243 Cascade Control kit - pre-assembled panel
563605 602 RVS63.243 Cascade Control kit - loose
533901589 QAA55.110 Adjustable Offset room temperature sensor - hard wired ✓
533901587 QAA75.611 Multifunctional programmable room thermostat - hard wired ✓
533901588 QAA78.611 Multifunctional programmable room thermostat - wireless ✓
533901457 QAC34 Outside sensor - hard wired ✓
533901592 AVS13.399 Outside sensor - wireless ✓
533901590 AVS71.390 Radio Module - wireless ✓
533901591 AVS14.390 Radio repeater - wireless ✓
533901594 QAD36 Strap on flow sensor ✓
1.2 Abbreviations
The following list contains the abbreviations used in this document, including their meaning;
BX - Sensor X Tagem - Composite Outside Temperature
QX - Relay X TAged - Attenuated Outside Temperature
BR - Burner TK - Boiler Temperature
Comp - Compressor TRL - Return Temperature
dT - Temperature Differential TVL - Flow Temperature
SD - Switching Differential
SP - Switching Point (on/off) DHW - DHW Temperature
St - Stage TR - Temperature Regulator
T - Temperature TW - Temperature Limiter
t - time of day x - Actual Value
TA - Outside Temperature w - Nominal Value
**

HAMWORTHY HEATING LTD 6 Merley Boiler Sequence Controller 500001210/D
1.4 System Configurations
1.4.1 Wired
1.4.2 Wireless
Remote
Service Tool
Mobile, SMS, Pager, Fax,
WEB,
Telephone
Network
Telephone
SMS
OCI611
OCI700
ACS700
BSB : Boiler System Bus
Room
Unit
Service Unit
(RU)
HMI
HMI
(RU)
wired
wired
wired
Basic Unit
RVSxx
Extension
mod. AVS75…
(max. 2)
BSB-W
LPB : Local Process Bus
Basic Unit
RVS...
LPB
Remote
Service Tool
Mobile, SMS, Pager, Fax,
WEB,
Telephone
Network
Telephone
SMS
OCI611
OCI700
RF
module
ACS700
BSB : Boiler System Bus
Room
Unit
RF
Repeater
RF
Toutside
BSB-RF
Service Unit
(RU)
HMI
(RU)
wireless wireless wireless
Basic Unit
RVSxx
Extension
mod. AVS75…
(max. 2)
BSB-W
LPB : Local Process Bus
Basic Unit
RVS...
LPB

HAMWORTHY HEATING LTD 7 Merley Boiler Sequence Controller 500001210/D
B
A
B
A
EB
A
B
A
E
ABasic unit RVS…
CRoom unit QAA75… / 78… / QAA55..
DOutside sensor AVS13…
EOperator unit AVS37.294 (clear-text)
FRadio module AVS71…
Wired Wireless
1.4.3 - Operating Options
Operation with room unit
Operation with “clear-text” operator unit
(optional with additional room unit)
2.0 Mounting and Installation
2.1 Electrical installation
• Prior to installing the Merley Boiler Sequence Controller, the power supply must be turned off
• The connections for mains and low-voltage must be separated
• The wiring must be made in compliance with the requirements of safety class II. This means that sensor
and mains cables must not be run in the same duct
• The panel must be earthed in accordance with IEE regulations
• Wiring must be completed in heat resistant cable size 1.0mm2 csa.
• The electrical isolator must have a contact separation of minimum 3mm in all poles
• The electrical isolator must be installed in a readily accessible location
• Any pump must be powered through a suitably rated contactor

HAMWORTHY HEATING LTD 8 Merley Boiler Sequence Controller 500001210/D
2.2 General requirements
• Air circulation around the controller must be ensured, allowing the unit to emit the heat produced by it.
A clearance of at least 10 mm must be provided for the controller's cooling slots which are situated on the
top and bottom of the housing.
The space should not be accessible and no objects should be placed there. If the controller is enclosed in
another (insulated) casing, a clearance of up to 100 mm must be observed around the cooling slots
The controller is designed conforming to the directives for safety class II mounted in compliance with these
regulations.
• Electrical supply to the controller may only be switched on when the installation is completed. If this is not
observed, there is a risk of electric shock hazard near the terminals and through the cooling slots.
• The controller may not be exposed to dripping water.
• Permissible ambient temperature range when mounted 0.. - 50°C.
• Power cables must be clearly segregated from low-voltage cables (sensors) observing a distance of at least
100 mm
2.3 Mounting Location
It is recommended that the control is mounted in a dedicated control panel capable of providing the necessary
power supply, electrical connections and electrical safety.
The control may be screw mounted to the electrical panel or alternatively (and preferred for convenience) onto a
suitable DIN rail.
Screwed On DIN rail
2359Z09
A1
A2
B1
B2 2359Z11
A mounting B removal
Note: to mount the controller on a
DIN, a clip is required.
L
B
L1
B1
2358M01
2359Z10
x
(dimensions in mm) LBXL1 B1
RVS63…281 121 70 270 110
2.3.1 Pre-assembled wall mounted panel
Should the Merley be supplied in the pre-assembled HHL panel, the panel should be located in a readily
accessible position and the following requirements observed;
• External fuses should be rated for 10A
• The panel must have individual means of isolation to provide complete electrical isolation
• Power cables must be clearly segregated from low-voltage cables (sensors) observing a distance of at least
100 mm, using the cable 20mm glands supplied in the kit.