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.

HAMWORTHY HEATING LTD 9 Merley Boiler Sequence Controller 500001210/D
2354Z06
061107B
000020RVS63.243/109
1PRVS63.243/109
S061107000020
Z
QX4 QX4
U
QX3
FX4 EX2
N
U
QX1 N
T
Y2 N Y1
S
Q2 N
R
Q3 N
Q
SK2 SK1
P
4 T2 T1 N S3 L1
L
S3 N L1 L
N
U
QX2 N
n
M UX
n
M BX4
n
M BX3
n
M H3
n
M BX2
n
M BX1
p
M B1
n
M H1
k
M B9
f
M B2 - G+
b
CL- CL+
b
CL- CL+
b
CL- CL+ X50
a
MB DB X60 X30 BSB LPB
h
M B3
2.4 Electrical Connections
IMPORTANT !
Please ensure that the mains voltage and low voltage cables are run in separate ducts/trunking, both within the
panel and outside of the panel.
Failure to observe this requirement will compromise the operation of the control.
• 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 a 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 (insulating) 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.
• Power to the controller may only be supplied when completely fitted. 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 when mounted and when ready to operate: 0..50°C.
• Power cables must be clearly segregated from low-voltage cables (sensors) observing a distance of at least
100 mm

HAMWORTHY HEATING LTD 10 Merley Boiler Sequence Controller 500001210/D
2.4.1 Terminal Markings - Mains Voltage
Use Slot Connector type
LLive AC 230 V basic unit N L 533511609
Protective earth
NNeutral conductor
L1 Live AC 230 V burner
S3 Output burner fault
NNeutral conductor R533901610
Protective earth
Q3 DHW charging pump / diverting valve
NNeutral conductor S533901611
Protective earth
Q2 1st heating circuit pump
Y1 1st heating circuit mixing valve opening T533901612
NNeutral conductor
Protective earth
Y2 1st heating circuit mixing valve closing
NNeutral conductor U533901613
Protective earth
QX1 Multifunctional output 1
NNeutral conductor U533901613
Protective earth
QX2 Multifunctional output 2
NNeutral conductor U533901613
Protective earth
QX3 Multifunctional output 3
The Merley control is supplied with screw type Rast 5 connectors for all electrical
connections. The following connectors are provided

HAMWORTHY HEATING LTD 11 Merley Boiler Sequence Controller 500001210/D
2.4.2 Terminal Markings - Low Voltage
Use Slot Connector type
BSB Service tool OCI700 - -
LPB Service tool OCI700 - -
X60 Radio module AVS71.390 - -
X30 Operator unit / boiler control panel - AVS82.491/109
DB LPB data 533901614
MB LPB ground
CL+ Room unit 1 data 533901615
CL- Room unit 1 ground b533901616
G+ Room unit power supply 12 V
B3 DHW sensor top 533901617
MGround h
B9 Outside sensor 533901618
MGround k
H1 Digital / DC 0...10 V input 533901619
MGround n
B1 Flow temperature sensor HK1 533901620
MGround p
BX1 Multifunctional sensor input 1 533901619
MGround n

HAMWORTHY HEATING LTD 12 Merley Boiler Sequence Controller 500001210/D
2.5 Pre-assembled Wall Mounted Panel
Figure 2.6.1 Wall Mounted Panel fixings
Note: the panel is supplied with 4 wall fixing
brackets, which can be adapted to provide
various fixing options, of which the detail
shown in Figure 2.6.1 is representative.
IMPORTANT !
In connecting the cables to the RVS logic control
(see 2.5 electrical connections and associated
tables), please ensure that the mains voltage and
low voltage cables are run in separate ducts/
trunking, both within the panel and outside of the
panel.
Failure to observe this requirement will
compromise the operation of the control.
See note:
2.6 Operator Unit - Fitting into panel door
The display panel providing the user interface, MUST be panel mounted and connected to terminal X50 on the
RVS63.243 with the 1m ribbon cable supplied.
Please ensure that the location of the display in the panel door allows the door to hinge open.
With the aperture cut into the door panel, carefully fit the ‘MERLEY’ label to the panel before fitting the display.
Removal
2358Z30
2358Z31
2358Z32
400
150
355
300
300
35
BRACKET FIXING
HOLES - 4 OFF
6 - 20mm CABLE
GLANDS SUPPLIED
LOOSE

HAMWORTHY HEATING LTD 13 Merley Boiler Sequence Controller 500001210/D
2358M03
144
96 90
27
42.4
17
(144)
0.5...3.0
92+0.8
0
138+1 0
2358M05 (96)
Dimensions
Panel cutout
2.7 Room Unit - QAA 55
• The room unit should be located in the main living room while giving consideration to the following points:
• The place of installation should be chosen so that the sensor can capture the room temperature as accu-
rately as possible without getting adversely affected by direct solar radiation or other heat or refrigeration
sources (about 1.5 meters above the floor)
• In the case of wall mounting, there must be sufficient clearance above the unit, enabling it to be fitted and
removed
 When the unit is removed from its base, power is
cut off so that the unit is out of operation.

HAMWORTHY HEATING LTD 14 Merley Boiler Sequence Controller 500001210/D
2284Z33a
2284Z34a
2.7.1 Mounting Location
• The controller must not be exposed to dripping water
2.7.2 Electrical Connections
1
34
56 2
2284Z40
1CL+ BSB data
2CL- BSB ground
2.7.3 Dimensions and Drilling
2282M02
96
96
91
47
12
2359Z27
4,2
56 60
56
60
2.8 Outside sensor - QAC34
The sensor must be installed on an outside, north facing wall, away from any air vents, pipes, illuminated signs or any other
device that could affect the ambient temperature local the sensor.
Note! Exposure of the sensor to direct sunlight at any time during the day will severely affect the performance of the compen-
sation and optimum start functions.
2359Z54
2359Z59
Outside Sensor

HAMWORTHY HEATING LTD 15 Merley Boiler Sequence Controller 500001210/D
2.9 Programmable Room Unit - QAA 75.611
• The room unit should be located in the main living room while giving consideration to the following points:
• The place of installation should be chosen so that the sensor can capture the room temperature as accu-
rately as possible without getting adversely affected by direct solar radiation or other heat or refrigeration
sources (about 1.5 meters above the floor)
• In the case of wall mounting, there must be sufficient clearance above the unit, enabling it to be fitted and
removed
 When the unit is removed from its base, power is
cut off so that the unit is out of operation.
Note: the device takes a 12V power supply from
the RVS to operate the back-lit lcd function.
2.9.1 Mounting Location
• The controller must not be exposed to dripping water
2359Z25
2359Z20
2359Z26
2359Z24
2359Z21
2.9.2 Electrical Connections
Terminal Name QAA75 611
1CL+ BSB data
2CL- BSB ground
3G+ Power supply DC 12 V
2359Z50
4,2
56 60
56
60
100
80
42
185
2359Z12
100
82
2.9.3 Dimensions and Drilling

HAMWORTHY HEATING LTD 16 Merley Boiler Sequence Controller 500001210/D
2.10 Wireless Components
The wireless components should be located such that transmission will be as interference-free as possible. The
following criteria must be observed:
Not in the vicinity of electrical cables, strong magnetic fields or equipment like PCs, TV sets, microwave ovens,
etc.
Not near larger metal structures or constructional elements with fine metal meshes such as special glass or
special concrete
The distance to the transmitter should not exceed 30 meters or 2 floors
2.10.1 Radio Module AVS71.390
The radio module extends the product range by introducing wireless communication. With this type of device, the
system components, such as room units, transmit data with no need for laying cables.
2.10.2 Mounting Location
Do not install the radio module inside metal casings (e.g. inside a boiler).
2359Z23
2359Z57
A
B
2.10.3 Electrical Connections
The prefabricated cable is to be connected to terminal X60 of the controller.
Prior to connecting the module, the basic unit must be disconnected from power!
2.10.4 Radio Connection
Establishment of the wireless connection is described in the following sections which cover the relevant radio-
controlled units.
2.10.5 Dimensions and Drilling
2354Z11
A-LED
B - Button

HAMWORTHY HEATING LTD 17 Merley Boiler Sequence Controller 500001210/D
2.11 Programmable Room Unit (Wireless) - QAA 78.611
• The room unit should be located in the main living room while giving consideration to the following points:
• The place of installation should be chosen so that the sensor can capture the room temperature as
accurately as possible without getting adversely affected by direct solar radiation or other heat or
refrigeration sources (about 1.5 meters above the floor)
• In the case of wall mounting, there must be sufficient clearance above the unit, enabling it to be fitted and
removed.
2.11.1 Mounting - with base
2359Z25
2359Z20
2359Z26
2359Z22
2359Z21
2.11.2 Mounting - without base
2359Z61
2.11.3 Power Supply
The room unit is powered by 3 off - 1.5 V alkaline batteries type AA (LR06).

HAMWORTHY HEATING LTD 18 Merley Boiler Sequence Controller 500001210/D
2.11.4 Radio Connection
Make the radio connection in the vicinity of the radio module prior to mounting so that all system are within
easy reach.
A prerequisite for the radio connection is that all components receive power, which means that the radio
module must be correctly connected to the basic unit and the batteries must be correctly installed in the
room unit & outside sensor.
Establishing the link
1Press the button on the installed radio module for at least 8 seconds until the LED on the radio module starts
flashing at high frequency.
2Press OK on the room unit to switch to programming.
3Press the info button for at least 3 seconds and select operating level “Commissioning“ with the setting knob. Then,
press OK.
4Select operating page “Operator section“ and press OK.
5Select operating section “Used as“ (operating line 40) and make the appropriate selection. Then, press OK. & Esc.
6Select operating page “Wireless“ and press OK.
7Select setting line “Wireless Binding Trigger“ (line 120). Then, press OK.
8Set the setting knob to “YES“ and press OK. Connection establishment is started.
9The display shows the progress of connection establishment in %. This process can take 2 to 120 seconds.
10 The connection is established when “Device ready” appears and the LED on the radio module extinguishes
Testing - The test is made to check the quality of the radio link.
The test can be aborted by pressing the ESC button.
While the radio link can be opened on the controller, the test should be made at the location where
the room unit will be installed.
On the room unit, as described above (points 2 through 4), select operating page “Radio“ and
activate the test mode on setting line “Test mode“ (line 121).
Example of a display during the test:
The digits on the left shows telegrams that have been sent, the
digits on the right telegrams that have been received. The test will
be ended after 24 telegrams. The test is considered successful
when at least 50 % of the telegrams sent have been received.
If the test was not successful, some other mounting location is to be
selected or the AVS14.390 radio repeater can be used.
Bedieneinheit
Testmode
42
185
2359Z12
100
82
2359Z50
4,2
9
56
60
100
80
11
39
67
2.11.5 Dimensions and Drilling