Intiel INT0140 User manual

INTIEL
THE ELECTRONICS ON YOUR SIDE
Electrical boiler controller
INT0140
User’s Manual
Bulgara, Pomorie, tel:[phone]
str. “Peter Beron”, № 9 fax: [phone]
www.intiel.com e-e-mail: [email protected]

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I. Technical description
The present manual describe the operation principle and functionality of electrical boiler
controller, managing nominal capacities of up to 60kW, providing general control of the
parameters of one water heating installation in relation to environment conditions.
1. Operation
The Controller regulates the water heating system by affecting to the following components:
Electrical heating elements and
Circulation pump
In fact the main principle of the operation is based on a regulation of the capacity of the heating
elements in relation to the temperature in the heated premises (rooms). The control is provided
by step regulation of the heating element capacity of 2 kW (respectively 4 kW when the capacity
is bigger than 30 kW) by means of changing the number of switched on heating sections.
The controller is consisted of:
Basic control module (electrical boiler module) that is equipped with built-in weekly
programmer and boiler regulator. The boiler module can operate independently
without room thermo regulator.
Module for temperature measurement and assignation in the heated premises that in
fact is a room thermo regulator with or without outer weekly programmer.
The Boiler Controller operates as a proportional capacity regulator in compliance with
the temperature. In fact that allows using that part of the installed capacity, necessary for
keeping the desired temperature level without over-expenditure of the electrical energy surplus.
The previous mentioned principle avoids any water temperature fluctuations in the electrical
boiler during the fixed operation regime that extends the life expectancy of the water heating
components and increases its safety.
2. Regulation and signalization
2.1 Front panel –figure 1.
- The front panel is a LCD display with a resolution of 128x64 (position 1)
а) days of the week are indicated in
this field, as the current one is
underlined. The same field is being
used to show control indications about
emergency situations or about OFF
regime;
б)Present time. The same field is
being used to indicate the start of the
periods /operation and stop/ of the
boiler during setting of the weekly
program;
в)Menu;
г)Current operation capacity of the boiler;
д)Field to display icons

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- switched on circulation pump (1);
- switched on electrical heating elements (2);
- activated OFF regime (3);
- overheating thermostat (4);
- low water level in the boiler body (5);
- the boiler body temperature water is bellow 15°С (6).
е)Indication about equi-thermal curve, type of the room thermostat or selected manual mode for
adjustment of Tset.
- Button OFF/AUTO. It switches on the system (boiler) in heating or long stay mode.
-Button INCR. It changes the values and options in the menu.
-Button SET, for selection and confirmation.
-Light indication about week program (position 2). It is being indicated in case of active period
of the week program.
-Light indication about the state of the circulation pump (position 3). It is being indicated when
the circulation pump is switched on.
fig.1
2.2 Room thermoregulator
-Two positional digital display. It shows the current or assigned air temperature at the
place where it is mounted. The indication is in degrees centigrade.
-Button ASSAIGNED/CURRENT temperature. It shows the assigned temperature
which the system try to keep in the premises or the present one.
-Knob for defining of the desired temperature.

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Operation mode and functions
3.1 OFF regime. It is used during continual boiler stop. It can be chosen by the button
AUTO/OFF on the front panel. When the Controller is in OFF regime, the heating elements
are switched off. The room thermostat does not affect to the general operation, but it measures
and shows the real room temperature. Also, during that regime the circulation pump starts for
10 minutes a day in order to avoid its blocking, due to a fur accumulating. Generally the OFF
regime is appropriate during long stop boiler operation, even during the winter. There is no
risk of water freezing in the systems, due to all activated protections.
Going into OFF regime can be done by means of pressing and keeping the button (for about 3
sec.), then the button is to be released, as on the display at field “a” appears a notification about
the relevant operation mode. In case of switched on electrical elements during this mode, it starts
their smooth stopping. On the display appears symbol (3) after the last electrical element is
being switched off.
3.2 AUTO regime. It provides a regular heating operation and it can be selected by the front
panel button AUTO/OFF. The heating element operation is provided by the selected program,
by means of the weekly programmer or by a signal of the room thermostat.
3.3 Circulation PUMP. The pump is started when at least one heating section is switched on or
the boiler water exceeds 40 0C. The circulation pump goes on operation until the accumulated
energy in the boiler will be transmitted to the radiators (until boiler temperature reaches 40 0C).
The pump will be started by force, when the boiler temperature drops below 15 0C in order to
pass the whole water volume in the system through the boiler temperature sensor. The pump
operation is being indicated with symbol (1) at position 3 of the display.
3.4 ELECTRICAL HEATING ELEMENTS. The maximal number of heating element sections
is 15. Their in serial switching is provided by connection to the next power supply phase in
order to ensure an symmetrical electrical circuit loading. Switching of more than one section will
be performed consecutively and each next one will be connected with 3 sec. delay in relation to
the previous one. In this way it can be provided a smooth loading or unloading of the circuit,
avoiding any current rushes. In case of switched on at least one electrical heating section on the
display appears symbol (2).
3.5 REGULATION. The regulation of the heating capacity is fulfilled by room thermo
regulator, outdoor temperature and adjusted equi-thermal curve, or manually by fixing Tset. As
much as the real temperature becomes closer to the boiler one, more heating sections will be
switched off. In case both temperatures are equalized there will be kept the necessary number of
heating elements that is to provide the desired temperature level.
3.6 Weekly programmer. It defines the operation and stop time periods, according adjusted
program.
4. PROTECTIONS
4.1 Thermal protection of the boiler body. It is provided by electro-mechanical emergency
thermostat, which boundary temperature level is not adjustable and it is preliminary fixed by the
manufacturer.
REACTION. All heating elements will be switched off by force, in case its fixed boiler
temperature will be exceeded. The circulation pump will continue working
On the display appears symbol (4) OVERHEATING. The thermal protection cannot be restored
by itself. It has to be restored manually only after eliminating the reason about its activation.

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4.2 Protection against low volume of the water content in the boiler body.Due to different
reasons
the water volume in the boiler and whole heating system can be decreased, because of
evaporation, leakages and so on and the water level in the boiler body to be decreased bellow the
admissible level for boiler proper and safety operation.
REACTION. All heating elements and the circulation pump will be switched off after activating
of the above mentioned protection. As a result of that protection on the display appears symbol
(5) LOW WATER LEVEL. The protection waits for 40 seconds after restoring the
water volume and afterwards smoothly switches on the necessary heating elements.
4.3 Protection against freezing the water in the boiler, pipes and radiators. It is being activated
only in OFF regime.
REACTION: The circulation pump starts by force and constantly to operate if the boiler water
temperature drops below 15 0C. Symbol (6) appears on the display All heating elements will be
switched on smoothly(100%) if the boiler water is bellow 6 0C and that operation will continues
until the temperature exceeds 9 0C. Then the heating will be switched off smoothly, while the
water temperature is kept bellow 15 0C. When the protection against overheating is activated the
protection against freezing is blocked.
5. Equipment versions and operation characteristics
5.1 Equipped with a built-in weekly programmer and without a room thermostat.
The built-in weekly programmer defines the time intervals for the boiler operation and its
pause in relation to the selected program. During the operation interval the boiler assignation
is adjusted manually as the fixed temperature is constant. During the pause interval the controller
assignation is 20 0C that means switched off heating elements. Concerning the present
equipment version (with a built-in weekly programmer and without a room thermostat) it is
recommended the installation of thermostatic valves in each of the heated rooms, in order to
obtain an individual temperature regulation for each of them. The temperature of the boiler water
is to be defined manually by the costumer and it does not relate to the outdoor temperature, but
the thermostatic valves affect to the controller and the electrical capacity by fixing the dose of
the consumed heating capacity. During an operation interval the boiler keeps the water
temperature level permanent by variable capacity percentage. The main disadvantage of this
equipment version is that due to the manual setting, the water temperature can be not enough or
redundant high for following the room temperature assignation fixed by thermostatic valves. The
operation regime can be seen on the diagram on figure 2
fig.2

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5.2 With an outer programmable thermo regulator, like CM 51 (Honeywell) and built-in
weekly programmer.
The outer programmable thermo regulator is to be installed in the heated premises, defining the
time periods of operation and the pause of the boiler in relation to the temperature in the
premises. During the operation interval defined by build in weekly programmer the number of
switched on electrical sections respectively the boiler water temperature depends on the time in
which the room thermo regulator will be kept in ON or OFF, as in relation to that the switching
of the electrical heating elements is to be done in 3 min.(all heaters will be on only if the
difference between the present and max. assigned boiler water temperature is greater than 9 0C).
The status of the thermo regulator is being indicated on the display. During the pause interval the
boiler assignation is fixed at 20 0C. It can be fixed thermostatic valves in all rooms of the heated
premises, except this one where the weekly programmable thermostat is mounted. In case there
is installed thermostatic valve in this room also, it must be opened to its maximum level in order
to avoid the influence to the weekly programmable thermostat operation. The temperature of the
boiler water is to be fixed manually and it does not correspond to the room temperature. The
thermostatic valves affect to the Boiler Controller and the electrical capacity by fixing the dose
of the consumed heating capacity and the room temperature affects to the duration of the
operation boiler intervals. The advantage of this version is the convenient control of the boiler
directly from the room and the disadvantage is the frequent switching of the boiler, in order to
keep the room temperature in accordance with the assigned level. The operation of the heating
installation can be seen on the diagram bellow (figure 3)
5.3 With proportional room thermo regulator and built-in weekly programmer.
The proportional room thermo regulator is to be installed in one of the heated rooms and the
built-in weekly programmer located on the indication panel of the Controller assigns the weekly
program for a boiler starting and stopping. During the operation interval the assignation of the
Boiler Controller is variable. It is received by a signal of the room thermo regulator and depends
on the difference between the assigned and real boiler temperature. It can be fixed thermostatic
valves in all rooms of the heated premises, except this one where the room thermo regulator is
mounted. In case there is an installed thermostatic valve in this room, it must be opened to its
maximum level. During each of the operation intervals of the program, the boiler operates in the
fixed regime and a maximal adapted water temperature, in order to keep the assigned by the
room thermo regulator boiler temperature. The room temperature variation indirectly affects the
boiler temperature assignation as during autumn and spring there is no excessive heating as
tk,tkmax
Tkmax
fig.3
15С
t [s]
t [s]
18С
20С
25С
15С
tr,,trset
[С]

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during the winter it is enough. The over expenditure is eliminated and this version is the most
economical one, keeping the recourses of the installation. Its operation is shown on figure 4.
5.4 With equi-thermal regulation and built-in weekly programmer.
In this case the controller operates without a room thermo regulator. The water boiler
temperature is being adjusted according the outdoor temperature sensor.
The assignation of the water boiler temperature starts increasing with decreasing of the outdoor
temperature within defined range starting from +20°С. The water boiler temperature reaches its
max. level (Tkmax) at the lower boundary level of the equi-thermal range (Tout door-min. see
figure 5). The desired equi-thermal curve depends on premise insulation and it has to be selected
in relation to the curve number from
Table 2. The range from -20 up to +20 0C
is to be selected about premises with
small heating losses, where the hottest
temperature of the heating water is being
reached when the outdoor temperature
drops to -20 0C. Temperature ranges from
+5 up to +20 0C and 0 up to +20 0C are
being adjusted for premises with big heat
losses, as warehouses, halls, etc., where
highest temperature of the heating water
is being reached when the outdoor
temperature drops down to +5 or 0 0C. The default setting is from -20 up to +20 0C (curve 6).
The outdoor temperature sensor is to be mounted at the outer north part of the building, in a way
that it is not exposed to direct sun shine or other way of heating radiation, which can affect to the
correct measurement of the sensor.
5.5 The controller can be equipped with a domestic hot water temperature sensor, as it provides
domestic hot water preparation, as the control is being provided by the implemented thermostat
in the controller. In this case the number of switched on electrical heating elements depends on
the difference between the assigned Tbset and current water tank temperature Tb. The current
domestic hot water temperature is being indicated on the display at the place of Tset, as reaching
the assigned water tank temperature is with a higher priority than the heating.
fig.4
fig.5

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6. Programming
The controller adjustment and programming is to be fulfilled by means of buttons INC and SET.
B means of button INC is to be selected (see point 2.1 “в”):
Sett –adjustment of the assigned temperature in the water tank Tbset (when it is being
used a system with a domestic hot water preparation); Max. water temperature in the
boiler body Tkmax; Type of the room thermostat, selection of equi-thermal curve,
manual assignation of the necessary water temperature in the boiler body;
Time –adjustment of date and time;
Pr.N(Y) –switches the function –weekly programmer;
Pr.1 ÷ Pr.7 –adjustment of weekly program 1 to 7;
;
Press SET button (for at about 3 sec.) to start the adjustments, as the relevant value will
start blinking. The change of the values can be done by means of INC button, as the
confirmation of the desired one by pressing SET button.(note: date and time values do not
blink during their changes).
Order of setting within Sett menu :
1. Setting the water tank temperature Tbset. In case of need for domestic hot water
preparation;
2. Setting the max. level of the boiler water temperature Tkmax;
3. Selection of the regulation way:
-Equi-thermal regulation and selection of a curve (EQ Line, see Table 2)
-Type of the room thermo regulator (TR Type, see Table 3)
-Manual assignation of the boiler water temperature (Manual)
4. Adjustment of Tset, in case of manual assignation. In all the rest cases Tset is being
defined automatically.
Order for setting in Time menu
Adjustment of the present day of the month (DD), month (MM), year (YY), day of the week
(DOW). The symbol in “a” field starts blinking during entering the day of the week, as its
changing is to be done by means of INCR button.
Weekly programmer function –deactivation and activation
By means of keeping pressed SET button in menu Pr.N(Y), it starts blinking, as by means of
INCR button it is being changed respectively to Pr.N –as the function is deactivated and even
having an adjusted program it will not be fulfilled; Pr.Y –the function is activated. The
confirmation is to be done by means of SET button.
Way for setting the two week programs Pr.1 to Pr.7
Setting the starting time (beginning of the interval for a start of the boiler operation), setting the
stopping time (beginning of the pause interval), days of the week, during which the program will
be activated. It can be selected each day of the week, all days of the week, only working days,
holiday ones, as well without selected days –as in this case the program will not be activated. If
at one program the time for starting/stopping of the boiler coincided, then the stopping has a
priority. In case the time for starting regarding two programs is same then a valid one remains
the assignation of the first program.
For example:
P1 time ON= P1 time OFF –valid is P1 OFF
P1 time ON= P2 time ON –valid is P1 ON

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II. Electrical connection
1. Terminals (Figure 6)
1.1 Terminal about circulation pump connection –X14. It is being used for connection of
the circulation pump with operation supply voltage ~220V/50Hz and nominal current
up to 8A.
1.2 Terminal for connection of proportional room thermo regulator –X9.
-It is being used for connection of proportional room thermo regulator with three core
cable 3x0,75mm2
-X9.1 –current signal 0-20mA
-X9.2 –common terminal
-The power supply of the thermo regulator is being provided by terminal X7.2 for
+16V DC, as jumper J3 is to be fixed preliminary in position 2.
1.3 Terminal for a connection of a contact room thermo regulator –X12;
1.4 Terminal for domestic hot water preparation –X11;
1.5 Terminal for a connection of water tank temperature sensor –X10 (type Pt-1000 non
polar one);
1.6 Terminal for a connection of outdoor temperature sensor –X7 (type Pt-1000 non polar
one). Jumper J3 is to be fixed preliminary in position 1;
1.7 Terminal for a connection for boiler water temperature –X6 (type Pt-1000 non polar
one);
1.8 Terminal for a connection of water level sensor in the boiler body –X8;
1.9 Terminal for a connection of overheating (blocking thermostat) –X1(BT);
1.10 Terminal for a connection of operation power supply - 220V/50Hz - Х4;
1.11 Terminal for a connection of electrical heating elements –X2, X3 and X5. The phase
is to be connected to the heating elements through relays as the other terminals of the
heating elements are to be connected to neutral. The nominal current trough each of
those outputs is 16A.
1.12 Terminal J1 (figure 6)
This terminal is being used for connection of 20 core wire from the front panel.
2. Jumpers
2.1 Jumper J3. The position of this jumper defines if the boiler is to operate together with
room thermo regulator (placed in position 2), or with outdoor temperature sensor and
equi-thermal regulation (placed in position 1)(see figure 6)
2.2 Jumper J4. The protection against low water level of the boiler body is activated when
the jumper is placed in position 1, as when the jumper is in position 2, then this
protection is deactivated.

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Фиг. 6

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Table 1
Parameters and settings
Desribtion
Description
Range
Default settings
Customers’
settings
Tbset
Assigned temperature
in the water tank
30 ÷ 60°С
40° С
Tkmax
Max. water
temperature in the
boiler body
40 ÷ 90°С
90° С
Tк
Current temperature in
the boiler body
measuring
-
Tа
Outdoor temperature
measuring
-
Тset
Assigned temperature
in the boiler body.
Manual assignation
30 ÷ 90°С
30° С
Equi-thermal
regulation; Domestic
hot water
preparation;
Proportional thermo
regulator
Self
calculated
-
Тoutdoor
. min
During equi-thermal
regulation –the
outdoor temperature
corresponding to the
highest temperature of
the water in the boiler
body (heating
water)(see table 2)
5 ÷ -20°С
-10° С

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Table 2
T outdoor-min with equithermal regulation
Curve number
Range ° С
1
From +5 up to +20
2
From 0 up to +20
3
From - 5 up to +20
4
From -10 up to +20
5
From -15 up to +20
6
From -20 up to +20
Table 3
Room thermo regulator type
number
Type
1
Contact
2
Proportional
Notes:
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IIІ. Warranty
The warranty period is 24 months following the purchase date of the unit or its
installation by an authorized Engineering Company, but not exceeding 28 months after the
production date. The warranty is extended to the malfunctions that occur during the warranty
period and are result of the production reasons or defective used parts.
The warranty does not relate to malfunctions corresponding to not-qualified
installation, activities directed to the product body interference, not regular storage or transport.
The repairs during the warranty period can be done after correct filling of the
manufacturer warranty card
Warranty Card