KEY RK-2001TW4 User manual

OPERATING MANUAL
RK-2001TW4
SOLID FUEL FIRED BOILER
CONTROLLER
Version C112

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1. Application.
Controller RK-2001TW4 is intended for temperature control in the solid fuel fired
water boilers. The boiler temperature is maintained at the level programmed by the
user with blower rotational speed control. The temperature of the boiler water is
monitored continuously by the regulator and shown on the display as well as the unit
controls the central heating circulation pump. In order to ensure the proper control of
the inside temperature, the regulator has been equipped with the household
thermostat input. Also, the option of controlling the pump that refuels the domestic
hot water tank is available. The regulator is equipped with an additional programmed
multifunctional output that enables to switch the mixing valve, signaling device, an
additional (gas or oil fired) boiler, emergency chilling system or some other devices
turned on parallelly with the blower.
2. Connection.
Before connecting the controller to power supply, check if: power cords of the
controller, the blower, the central heating and domestic hot water pumps are properly
plugged in the appropriate slots at the back of the device. The temperature sensor
should be installed in a measurement opening of the boiler. The schematics of
connecting the regulator and additional devices are shown in pictures 2 and 3.
CAUTION! Before plugging in the controller first check if the wiring system is
properly grounded and if the screw terminals of the output connector are tightened.
CAUTION! The total power of the devices connected to the controller must not
exceed 450W.
The unused outputs may remain disconnected.
3. Operation.
Turning on the controller is signalized by a brief switching on all the light indicators
on the display to enable to check their status. After the regulator has been
connected to power supply, it returns to its most recent mode (before turning it off or
power failure).
The front panel of the controller (picture 1) includes:
1 – power switch
2 – boiler parameters and temperature indicator
3 – household thermostat indicator
4 – boiler thermostat knob
5 – central heating circulation pump indicator
6 – STOP button also used for parameters selection and alarm cancellation
7 – START button also used for parameters selection
8 – programming activation and parameters confirmation button
9 – domestic hot water pump indicator

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Picture 1. Front panel of the RK-2001TW4 controller.
The basic operation of the regulator depends on setting the desired temperature with
the thermostat knob; the remaining functions are carried out according to the
programmed parameters of the service mode. The change of thermostat parameters
is shown on the display for a few seconds, e.g. [C 55] and defines the value of the
boiler water temperature the regulator is going to reach. It is possible to take a brief
look at the value by pressing the OK button.
Pressing the START button activates both the blower and the possibility of its
control. The STOP button allows the user to stop the work of the blower, e.g. in order
to refuel the boiler. If the regulator is out of the service mode, the temperature of the
boiler water is shown on the display and the last symbol indicates the working mode
status:
e.g. [50°-] stands for the STOP mode
[50°C] is the WORK mode
[50°c] indicates maintaining the heating while in the WORK mode
4. Setting the user’s parameters.
When you press the OK button, the regulator enters the viewing and setting the
user’s parameters mode which is signalized with the household thermostat indicator
blinking at a fast rate. It is possible to view the parameters with buttons marked with
“<”, “>”. After the particular parameter has been selected, you can enter the
changing mode of the given parameter by simply pressing the OK button – this is
signalized with a blinking value of the parameter. Pressing the “-“ or “+” button will
introduce the change of the parameter. To confirm the newly set value, press the OK
button; then the regulator enables the user to select (<,>) the next parameter. If
there is no need to change values of the parameters, then select [End] and press the
OK button or wait about 1 minute – the regulator will exit the service mode and the
temperature of the boiler water will be shown.
CAUTION! If the domestic hot water pump working mode is off, then, when at the
user’s mode, pressing the OK button will make it possible to view the set
temperature value of the boiler thermostat only.

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Table 1. List of the user’s parameters.
Display Parameter Min Max Jump Prod.
settings
C 45 Programmed boiler temperature L45 H85 1°C L45
co C Central heating pump work while C (pump is off when ‘-‘) - C C
cu u Heating up u d u
50° Temperature of water in the domestic hot water tank
End Exiting the user’s mode
4.1. Temperature of boiler work.
The programmed boiler temperature [C 45] – is the value of temperature the
regulator is going to reach while in the WORK mode. It is set by turning the thermostat
knob manually and shown briefly on the display.
4.2. Central heating pump work [co C] – the WINTER/SUMMER mode – the central
heating pump work is indicated with the letter ‘C’. The heating can be turned off in
summer time by selecting the ‘-‘ value with the (-) button.
4.3. Bacteria eradication in the domestic hot water tank [cu u] – heating up – the
regulator enables to activate the process of bacteria eradication in the domestic hot
water tank manually. After selecting the ‘d’ value with the (+) button, the boiler is going
to reach the temperature of 75°C in the domestic hot water tank. At this stage the
boiler should be in the WORK mode (it is enough to press the START button to enter
the mode). A caption, for instance [70°d] will be displayed. Once the temperature of
75°C in the domestic hot water tank is obtained, the regulator returns to its previous
status.
CAUTION! To prevent the users from being scalded, the option of bacteria eradication
should be switched on at night time when the water is not taken from the domestic hot
water tank.
4.4. Reading the temperature of water in the domestic hot water tank [ 50°C] –
the parameter shows the value of the temperature measured in the domestic hot water
tank.
4.5. Exiting the user’s mode – selecting [End ] on the display and pressing the OK
button will cause the regulator to exit the parameter selection mode. Also, exiting the
mode will occur if for a period of 1 minute no buttons will be pressed at all.
5.Setting the parameters – service mode.
Holding the OK button for over 3 seconds will cause the regulator to enter the service
mode – then viewing and changing particular parameters is possible. Entering the
service mode is signalized with the blinking of the household thermostat indicator. To
view the parameters use the buttons marked with ‘<’, ‘>’. After you have selected the
particular parameter, it is possible to enter the mode of change by pressing the OK
button. This is signalized with the blinking of the set value. The change of the
parameter will occur after pressing the ‘-‘ or ‘+’ button. To confirm the set value press

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the OK button. Then the regulator enables the user to select (<,>) the next parameter.
If it is not our intention to change the parameter value with the < or > buttons, then
select [End ] and press the OK button or wait about 1 minute – the regulator will leave
the service mode and the temperature of the boiler water will be shown.
Table 2. List of the service parameters.
Display Parameter Min Max Jump Prod.
settings
Π100 Blower work capacity or maximum capacity when Xr 0
-10 50 100 10% 100
n 40 Blower minimum capacity 20 40 10% 40
Πh 2 Ratio of blower speed change 2 10 1 2
Πr 0 Automatic regulation of blower speed and ignition
duration --, 0 10 1 0
Πn15 Induced draught duration --, 5 60 1s 15
Πu 6 Draught interval duration 1 99 1min 6
r 50 Blower maximum speed at ignition 50 100 10% 50
rh 5 Hysteresis of ignition turn-off 1 45 1ºC 5
P 40 Temperature of central heating pump turn-on 30 70 1ºC 40
Ph 2 Hysteresis of central heating pump turn-on 1 10 1ºC 2
Pc 2 Mode of work and duration of central heating pump
check --, 1 99, F 1min 2
u 50 Domestic hot water programmed temperature 30 60 1ºC 50
uh 5 Hysteresis of domestic hot water heating 1 9 1ºC 5
ur 0
Domestic hot water pump working mode:
0 – no water
1 – priority of domestic water
2 – domestic water with no priority
3 – mixing pump
0 3 1 0
L 45 Boiler minimum temperature 30 65 1ºC 45
H 85 Boiler maximum temperature 80 90 1ºC 85
h 2 Hysteresis of boiler temperature 1 10 1ºC 2
A 99 Temperature of boiler overheating 90 99 1ºC 99
Fd2h Duration of fuel demand testing at ignition --, 1 99–4h 1min 2h
Fb2h Duration of fuel demand testing in the working mode
and at X --, 1 99–4h 1min 2h
Ar 0
Additional output working mode:
0 – additional boiler output
1 – alarm output
2 – output controlling the mixing valve
3 – pump or other boiler emergency chilling devices
output
4 – output controlling additional devices activated while
the blower operating
0 4 1 0
Prod Return to producer’s settings
outP Testing the central heating pump output outP out1
outΠ Testing the blower output outΠ out2
outr Testing the additional output outr out3
outu Testing the domestic hot water pump output outu out4
End Exiting the service mode

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5.1. Parameters of blower work.
Blower work capacity [Π100] – is the value of blower work capacity. When the „Πr”
parameter is set to ‘0-10’, then this is the maximum capacity that can be obtained
while automatic regulation.
Minimum capacity of the blower [n 40] – is the minimum value of capacity at
which the blower can work while the automatic regulation of rotational speed and
gradual increase of rotations during ignition are on.
Changing the rotational speed of the blower ratio [Πh 2] – the parameter
influences the way of decreasing the blower rotational speed when the temperature
of the boiler water approaches the programmed one. For instance, setting the 4
value indicates the blower will be working with the [Π100] maximum capacity, if the
regulator is in the WORK mode and the temperature of the boiler water is 4°C lower
than the programmed one. The increase in temperature will cause gradual slowdown
in blower rotational speed to the [n 40] minimum capacity.
Regulating the rotational speed automatically [Πr 0] – the option is on when the
parameter is set to ‘0-10’ and will induce the decrease in the blower rotational speed
automatically while the temperature of the boiler water approaches the programmed
one. If the parameter is set to ‘-‘, then the gradual regulation of rotational speed is
not available and the blower works with the capacity set with the ‘Π’ parameter.
Setting the parameter between 0 and 10 indicates period of time (counted in
minutes) during which the gradual increase in the blower rotational speed from the [n
40] minimum value to the [r 50] occurs. This is meant to make the ignition run
smoothly.
Induced draught duration [Πn 5] – is the period of temporary starting the blower in
order to remove the exhaust gases. Switching to ‘-‘ will cause the regulator to exit
the option. The draught function is available while in the WORK mode.
Duration of intervals between draughts [Πu 6] – is the period of time between
draughts.
Blower maximum rotational speed while ignition [r 50] – the parameter defines
the maximum capacity the blower can work while ignition. If the [Πr 0] parameter is
set to ‘0’, then the blower capacity during ignition is determined.
Ignition turn-off hysteresis [rh 5] – the parameter defines by how many degrees
the stage of ignition is turned off before the temperature of the boiler water reaches
the programmed value. Exiting the ignition mode will result in the regulator switching
to the working mode.

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5.2. Central heating circulation pump working parameters.
Temperature of central heating pump turn-on. [P 42] – is the value of the boiler
water temperature at which the central heating circulation pump is turned on. The
pump works regardless of the regulation process. Additionally, it is turned on in case
of boiler overheating.
Hysteresis of the central heating pump [Ph 2] – the parameter determines by
how many degrees the temperature of the boiler water must be decreased below the
temperature of turn-on so that the pump should be turned off.
Working mode and interval duration while starting the central heating pump
[Pc 2] – in case of the STOP mode or when the contacts of the household
thermostat are open, the central heating pump is turned on for the period of 30
seconds to mix water of the heating circulation. The parameter determines how often
the procedure will be repeated. Setting the ‘-‘ value results in turning off the option.
Some heating circuits are equipped with the central heating pumps that work
independently of the household thermostat. In such case the parameter should be
set to the ‘F’ value.
5.3. Preparing the domestic hot water.
Temperature of the domestic hot water [u 50] – is the value of temperature which
will be maintained in the domestic hot water tank.
Hysteresis of heating the domestic hot water [uh 5] – is the value by which the
temperature of the tank water must be decreased so that the domestic hot water pump
should be turned on to heat up the tank water.
Domestic hot water pump working mode [ur 0] – the parameter determines the
working mode of the output controlling the domestic hot water pump and the input of
the domestic water sensor:
[ur 0] value indicates lack of sensor and domestic hot water pump. The sensor is not
taken into account when checking failures, i.e. it may remain disconnected and while
in the user’s parameters mode the programmed temperature of the boiler thermostat is
displayed only,
[ur 1] means priority to work of the domestic hot water pump,
[ur 2] means the domestic water pump working with no priority,
[ur 3] return water mixing pump control at temperature of turn-on [u 50] and hysteresis
[uh 5].
5.4. Setting the range of boiler work temperature.
Boiler minimum temperature [L 40] – indicates the minimum temperature that can
be set with the thermostat knob.

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Boiler maximum temperature [H 85] – is the maximum value of temperature that can
be set with the thermostat knob.
Hysteresis of boiler temperature [h 2] – determines by how many degrees the
temperature of the boiler water must be decreased from the programmed with
thermostat so that the blower should be turned on.
5.5. Preventing the boiler from overheating.
The temperature of boiler overheating [A 99] – defines the value of temperature
which, when exceeded, causes the blower to turn-off permanently and to turn on the
central heating pump to prevent the boiler from overheating. The overheating is
indicated with the [E 2] caption on the display and after the temperature is decreased
below this value, you can exit the mode by pressing the STOP button. The blower will
also be turned off in case of boiler water temperature sensor failure which will be
shown [E 1] on the display.
STB – the regulator is equipped with an additional, independent of the processor
security against the overheating. When the temperature exceeds 95° C, the regulation
mode is stopped by the blower being turned off and central heating pump being turned
on. When the temperature is decreased below 89°C, then the blower and the pump
will be turned on to restore the regular work. Applying the STB system allows the user
to control the boiler work thoroughly and minimize the risk of overheating.
5.6. Fuel demand.
Duration of testing the fuel demand at ignition [Fd60] – if while in the WORK
mode the temperature of boiler water is not increased by 2°C during the
programmed period of time, the process of regulation will be interrupted and the
[FUEL] caption will be displayed. Press the STOP button to return to the regulation
mode.
Duration of testing the fuel demand in the working mode [Fb30] – if while in the
working mode the temperature of boiler water is decreased by the value of
hysteresis below the programmed with the thermostat and is not increased by 2°C
during the programmed period of time, then the regulation will be stopped and the
[FUEL] caption will be displayed. The alarm can be cancelled with the STOP button.
5.7. Additional output.
Additional multifunctional output working mode [Ar 0] – the regulator has been
equipped with an additional multifunctional output compatible with the modes given
below:
mode [Ar 0] indicates the control of an additional gas or oil boiler. After the regulator
has been turned on with the power switch, the additional boiler is turned off and
when the fuel demand in the solid fuel fired boiler occurs, it is turned on again. The

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option is useful in the heating systems where the solid fuel fired boiler is included in
order to decrease the costs of heating. After the fuel demand alarm has been
cancelled with the STOP button, the additional boiler is turned off again and the work
of the regulator is resumed.
mode [Ar 1] indicates that the additional output will be working as an alarm output to
which a signalling device can be connected. Boiler sensor failure, error of
overheating or fuel demand will cause the indicator to turn on.
mode [Ar 2] – the additional output controls the mixing valve. To control the mixing
valve, the household thermostat should be applied to the system. Closing contacts
of the thermostat will make the valve open, and opened contacts will cause the valve
to close. Additionally, the valve is opened to prevent the boiler when the error of
overheating or sensor failure occurs.
mode [Ar 3] – the additional output controls the boiler emergency chilling system
(e.g. a pump). In the mode, the additional output is turned on when the alarm of
boiler overheating or boiler sensor failure occurs.
mode [Ar 4] – the additional output controls the devices working simultaneously with
the blower.
CAUTION! The additional devices should be connected to the UM-1 unit.
Schematics of connections are shown in picture 3.
5.8. Testing the outputs.
To make checking the work of regulator easier it is possible to test the output
systems controlling the blower, pump and the additional boiler turn-on system. The
option is available in the service mode only when the regulating has been stopped,
i.e. the regulator had been in the STOP mode before it entered the service mode.
Selecting [outP] on the display allows with the OK button to turn on the central
heating pump temporarily, selecting [outΠ] will start the blower and choosing [outr]
will cause the additional multifunctional output to be turned on. To test the domestic
hot water pump output select [outu].
5.9. Producer’s settings.
The regulator enables the user to restore the standard settings introduced by the
producer. Select [Prod] on the display and press the OK button to confirm it. When
the option has been activated, the regulator enters the values of particular
parameters given in table 2.
5.10. Exiting the service mode.
To exit the parameters setting mode select [End] on the display and press the OK
button. Also, if no buttons will be pressed for 1 minute, exiting the mode occurs.

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6. Additional options.
To make the user feel more comfortable in the heated rooms, the regulator has been
equipped with the input that enables to connect any household thermostat provided
with a contact output. If the temperature in the room is lower than the desired one,
the turning on the central heating circulation pump and the household thermostat
light indicator will occur which means the temperature programmed with the
thermostat knob should be maintained by the boiler. When the desired room
temperature is reached, the central heating pump and the light indicator turn off and
the boiler will continue to burn the fuel at the minimum temperature.
CAUTION! When the household thermostat is unused, its input should remain
closed.
7. Regulator failures.
The regulator tests the inside systems and the boiler water temperature sensor
operating continuously. When a failure is detected, the blower is turned off and the
central heating pump is started. Also, the adequate description of a failure will be
shown on the display. In an emergency you should turn off the regulator, connect the
central heating circulation pump to the power supply permanently, ensure the proper
firing the fuel in the boiler and contact the technical staff.
The [E 1] caption when displayed indicates the boiler sensor failure has occurred or
the temperature has decreased below -9°C. The [E 2] caption indicates the boiler
overheating while the [E 3] means both the failure and the overheating have
occurred.
When after using the STOP button the [E 1] caption is displayed despite the
decrease in temperature below 90°C, the sensor might have been damaged
permanently (e.g. the boiler overheating above 150°C).
When the sensor and domestic hot water pump have been submitted to the service
mode, the regulator tests the domestic hot water sensor circuit. In case the [E 8]
error occurs, a failure or lack of the domestic hot water sensor has been detected.
8. Controller disassembly.
When disassembly of controller is necessary, you need to:
disconnect it from power supply with the power switch,
disconnect the boiler from the power supply,
remove the controller from the boiler chamber,
remove connectors and wiring from the regulator.

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9. Technical specification.
Power supply 230V + 10%, 50Hz
Power consumption (blower and pump not included) < 4VA
Temperature measurement range -9 - 109°C + 1°C
Boiler temperature adjustment range 30-90°C + 1°C
Boiler programmed overheating protection 90-99°C + 1°C
Boiler equipment overheating protection >95°C + 1°C
Pump turn-on temperature 30-70°C + 1°C
Total outputs rating max 2A/230V
Picture 2. Schematics of connecting the RK-2001TW4 unit.

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Picture 3. Schematics of connecting the UM-1 unit.

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DECLARATION OF CONFORMITY
Manufacturer:Przedsiębiorstwo Wielobranżowe KEY
11-200 Bartoszyce, ul. Bohaterów Warszawy 67
hereby declares that the product:
RK-2001TW4 Controller
is in conformity with provisions of the following directives:
73/23/EWG i 93/68/EWG (LVD 73/23/EEC + 93/68/EEC),
as superseded by Directive 2006/95/WE (EC Directive 2006/95/EEC);
89/336/EWG (Elektromagnetic Compatibility Directive 89/336/EEC),
as amended by Directive 93/68/EWG (EMC Directive 93/68/EEC)
on basis of compliance with the following harmonised directives:
PN-EN 55022:2006(U)
PN-EN 61000-4-2:1999+A2:2003
PN-EN 61000-4-3:2006(U)
PN-EN 61000-4-6:1999+A1:2003+IS1:2006
PN-EN 61000-4-4:2005(U)
PN-EN 61000-4-5:2006(U)
PN-EN 61000-4-11:2005(U)
PN-EN 60730-1:2002+A1:2006(U)A12:2004+A13:2005
PN-EN 60730-1:2005+A14:2006
PN-EN 60730-2-9:2006
PN-EN 61000-3-2:2006(U)
PN-EN 61000-3-3:1997+A1:2005+A2:2006+IS1:2006
Information on disposal
This appliance is marked according to the European Directive 2002/96/EC on Waste
Electrical and Electronic Equipment (WEEE).
The symbol on the product, or the documents accompanying the product, indicates that
his appliance may not be treated as household waste.
The appliance shall be handed over to the applicable collection point for used up
electrical and electronic equipment for recycling purpose.
Ultimate disposal of the appliance shall follow according to applicable local regulations
on waste utilization. For more information about disposal, utilization and recycling
please contact your local authorities, household waste disposal service or the shop
where you purchased the product.

Producent: P.W. KEY
11-200 Bartoszyce, ul. Bohaterów Warszawy 67
tel. [phone], fax. [phone]
www.pwkey.pl e-mail: [e-mail]