KEY RK-2001W4 User manual

OPERATION MANUAL
RK-2001W4
SOLID FUEL FIRED
BOILER TEMPERATURE CONTROLLER
Wersja E128

Table of Contents.
Introduction ................................................................................................... 3
Operation ...................................................................................................... 3
Method of determining the set temperature of the boiler .............................. 4
Working in combination with exhaust gas sensor ......................................... 5
Working in combination with a room thermostat .......................................... 6
Alarms .......................................................................................................... 6
Setting up the user parameters. ..................................................................... 7
The desired boiler temperature [C 45] ............................................................. 7
Central heating pump work [co C] – WINTER/SUMMER ............................... 7
Total bacteria control in the hot water tank [cu u] ........................................... 8
The temperature measured by the additional sensor [u50 °] .......................... 8
The temperature measured emissions [150 °] ................................................ 8
Parameter setting – the service mode ............................................................ 8
Table 2. Service parameters list ...................................................................... 9
Pressure fan work parameters ........................................................................ 10
Central heating pump parameters .................................................................. 11
Settings of the sensor operation mode and additional pump .......................... 11
Setting the operating temperature range of the boiler .................................... 12
Boiler overheating protection .......................................................................... 13
No fuel ............................................................................................................. 13
Multifpurpose output ....................................................................................... 13
Setting the exhaust gas temperature control parameters ............................... 14
Testing of device's outputs .............................................................................. 14
Factory defaults .............................................................................................. 14
Exiting service mode ....................................................................................... 15
Device removal ............................................................................................... 15
Specifications .................................................................................................. 15
Connection diagram of the RK-2001W4 ......................................................... 16
Schemes of connecting additional devices ..................................................... 16

3
1. Application.
Controller RK-2001W4 is a device designed for temperature control in solid fuel fired
boilers equipped with:
- blower,
- central heating pump,
- domestic hot water pump, mixing pump or a pump charging the accumulative tank
(optional),
- household thermostat or exhaust gases temperature sensor (optional),
- signalling device or an additional boiler (optional).
2. Connection.
Before connecting the controller to the power supply, check if: power cords of the
controller, the blower and the central heating circulation pump are properly plugged
in the appropriate slots at the back of the device. The boiler water temperature and
the exhaust gases temperature sensors should be installed in a measurement
openings of the boiler. The schematics of connecting the regulator is shown in
picture 2.
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 700W.
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 the 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 temperature and parameters indicator,
3 – boiler thermostat knob,
4 – Ok button used for programming activation and parameters confirmation,
5 – STOP button also used for parameters selection and alarm cancellation,
6 – START button also used for parameters selection.

4
Picture 1. Front panel of the RK-2001W4 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 65] and defines the value of the
boiler water temperature the regulator is going to reach.
ressing the START (6) button activates both the blower and the possibility of its
control. The STOP (5) 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 user’s mode, the temperature
of the boiler water is shown on the display and the last symbol indicates the working
mode status:
[50°-] - stands for the STOP mode
[50°C] is the WORK mode
[50°c] indicates maintaining the heating while in the WORK mode
[50°U] means heating the domestic hot water in SUMMER mode
[50°u] is maintaining the heating while in SUMMER mode
.[70°d] indicates the bacteria eradication mode – heating the domestic
hot water up to 75°C
3.1. The method of determining the desired temperature of boiler water.
The temperature maintained in the boiler (the programmed one) depends on the
working mode of the household thermostat input (the exhaust gases sensor) as well
as on the additional pump working mode. Table 1 contains the list of all parameters
values possible to set.

5
If the circulation system is equipped with the accumulative tank, the desired boiler
water temperature equals the value set with the thermostat knob (3).
If the heating system is equipped with the domestic hot water tank, the higher of two
component temperatures is accepted as the desired boiler water temperature –
either the temperature needed by the central heating circulation or the boiler water
temperature necessary to heat up the domestic hot water tank.
In all other cases (no additional pump and when the mixing pump is installed) the
desired boiler water temperature is the same as the temperature needed by the
central heating circulation.
The temperature necessary to heat up the tank is taken into account when the
domestic water temperature is too low only and it equals the total of the programmed
hot water temperature [u 50] and the value of its increase [uP 5].
The temperature needed by the central heating circulation is determined on the
basis of the value set with the thermostat knob (3) and the household thermostat
input status. If the exhaust gases sensor is connected, then the central heating
temperature equals the value set with the knob. If the household thermostat is
connected and its contacts are opened, the central heating temperature is the same
as the minimum boiler temperature [L 45], and if its contacts are opened, the central
heating temperature equals the value set with the knob.
Table 1. Methods of establishing the desired temperature of boiler water.
Thermostat
input
Additional pump working mode
None
[ur 0]
Domestic hot water
[ur 1] lub [ur 2] Mixing pump
[ur 3] Accumulator [ur 4]
Exhaust gases
sensor Set with knob Of which higher:
– Set with knob
– Domestic water
heating temperature
Set with knob Set with knob
Thermostat
contacts
opened Minimum Domestic water
heating temperature Minimum Set with knob
Thermostat
contacts closed Set with knob Of which higher:
– Set with knob
Domestic water
heating temperature
Setpoint knob Set with knob
3.2. System with the exhaust gases sensor operation.
If the heating system has been equipped with the exhaust gases temperature sensor
and the temperature of the boiler water approaches the desired value, the regulator
will switch into the mode of stabilizing the boiler water temperature.

6
3.3. System with the household thermostat operation.
If the heating system is equipped with the household thermostat, the desired
temperature of the boiler water depends on the status of its contacts (3.1.). As an
addition the central heating pump work may, depending on the service settings, be
influenced by the household thermostat.
4. Alarms.
The correctness of the inside circuits and the temperature sensors work is tested
continuously. When a failure is detected, the information of the errors that has
appeared is displayed and the adequate action is undertaken.
The [FUEL] caption when displayed indicates fuel demand alarm. After the boiler has
been refuelled, the alarm can be cancelled with the STOP button.
The [Hot] caption is displayed alternately with the exhaust gases temperature e.g.
[°410] means the temperature of 400°C has been exceeded by the exhaust gases. In
such case the blower is turned off by the regulator (it is turned on during draught cycle
only). The regular work is resumed after the temperature of the exhaust gases has
decreased below 250°C.
The [E 1] error indicates that a failure in the boiler sensor circuit has occurred. The
error will induce the blower to turn off and the central heating pump to turn on. After
the reason for the alarm has been removed, it can be cancelled with the STOP button.
The [E 2] error indicates that the boiler overheating has occurred. The error will
induce the blower to turn off and the central heating pump to turn on. The alarm can
be cancelled with the STOP button after the boiler water temperature has decreased.
The [E 8] indicates that a failure of the additional sensor circuit has occurred. If the
additional output operates in the domestic hot water pump working mode, then the
topping up the hot water tank is ceased. When the output works as a mixing pump, the
protection of the return temperature is turned off. If the additional pump is intended to
charge the accumulative tank, then it is turned on permanently. It is not necessary to
cancel the alarm manually (it is cancelled automatically after the reason for failure has
been removed).
The [E128] indicates that a failure of the exhaust gases temperature sensor has
occurred. In case of the alarm, the regulator operation is continued in the stabilizing
the boiler temperature mode. The alarm does not need cancelling manually (it is
cancelled automatically after the reason for failure has been removed).
When several errors occur at the same time, the total of their codes is shown on the
display, e.g. the [E 3] caption indicates both failure of the boiler temperature sensor
and boiler overheating have occurred.

7
5.Setting the user’s parameters.
When you press the OK button briefly, the regulator enters the viewing and setting
the user’s parameters mode. 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 user’s mode and the
temperature of the boiler water will be shown.
Table 2. List of the user’s parameters.
Display Parameter Min Max Jump Producer’s
settings
C 45 Programmed boiler temperature L65 H90 1°C -
co C Central heating pump working mode (‘C’ –
WINTER, ‘-‘ – SUMMER) C - C
cu u Domestic hot water pump working mode (‘u’ – regular work, ‘d’ – bacteria
eradication program) u d u
u50° Temperature measured with the
additional sensor
150° The measured temperature of the
exhaust gases
End Exiting the user’s mode
The first column of the table shows the exemplary indications of the display, the next
columns: description of a parameter, the minimum and maximum values that may be
set as well as the jump of the value during its setting. The last column includes values
preprogrammed by the producer – one can return to them by selecting the [Prod]
service function.
The programmed boiler temperature [C 45] – is the value of boiler water
temperature the regulator is going to reach while in the WORK mode. It is set by
turning the thermostat knob manually (3) and shown briefly on the display.
CAUTION! The value of the desired boiler temperature may be different from the one
set with the thermostat knob. The detailed description has been included in 3.1.
differ from the value set by the knob. A detailed description is included in section 3.1.
5.2. Central heating pump work [co C] – the WINTER/SUMMER mode – the
WINTER mode is indicated with the letter ‘C’ – then the rooms are heated by
appropriate central heating pump control. Selecting the ‘-‘ value means the SUMMER
mode has been introduced. Then the central heating pump is turned off and the

8
domestic hot water system or the accumulative tank only are supported by the
regulator. If the additional pump is turned off or it works as the mixing pump, then there
is no possibility of changing the WINTER/SUMMER mode (the parameter is not
available).
CAUTION!!! If the heating system is not equipped with accumulative tank, then when
a failure of the boiler sensor occurs, the temperature of the boiler water exceeds the
maximum value or the boiler overheating takes place, the central heating pump will be
turned on regardless of the working mode.
5.3. Domestic hot water tank working mode (bacteria eradication program) [cu u]
–the regulator enables to activate the process of bacteria eradication in the domestic
hot water tank manually. After selecting the ‘d’ value, the boiler is going to reach the
temperature of 75°C in the domestic hot water tank. Once the temperature of 75°C in
the domestic hot water tank is obtained, the bacteria eradication programme will be
turned off automatically. The parameter is not available if the additional pump works in
a mode other than the domestic hot water mode.
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.
5.4. The temperature measured with the additional sensor [u50°] – the parameter
presents the temperature of the accumulative tank or the domestic hot water tank tem-
perature. If the additional pump is turned off or operates in the mixing pump mode,
then the parameter is not available.
5.5. The measured temperature of the exhaust gases [150°] – the parameter is
available when the household thermostat input is switched to measurement of the ex-
haust gases temperature. In such case the above mentioned temperature is displayed.
6. Setting the parameters – service mode.
Holding the OK button for over 3 seconds will cause the regulator to enter the
viewing and setting parameters of the service mode. 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 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.

9
Table 2. Service parameters list.
Disp. Parameter Min Max Step Factory
default.
Π100 Blower work capacity or maximum capacity when
Πr 1. 1 100 1% 100
n 40 Blower minimum capacity. 1 100 1% 40
Πh 5 Ratio of blower speed change. 2 20 1 5
Πr 0 Automatic regulation of blower speed. -, 0 10 1 0
Πn 5 Induced draught duration. --, 5 60 1s 5
Πu 6 Draught interval duration. 1 99 1min 6
r 50 Blower maximum speed at ignition. 1 100 1% 50
rh 5 Hysteresis of ignition turn-off. 1 45 1°C 5
P 40 Temperature of central heating pump turn-on. --, 20 70 1°C 40
Ph 2 Hysteresis of central heating pump turn-on. 1 40 1°C 2
Pc 2 30 second interval while turning on central heating
pump . --, 1 99 1min 2
ur 0 Sensor and additional pump working mode. 0 4 1 0
u 50 Additional pump operating temperature. 30 60 1°C 50
uh 5 Hysteresis of additional pump work. 1 30 1°C 5
uP 5 Increase in boiler temperature while heating
domestic water. 1 20 1°C 5
L 45 Boiler minimum temperature. 30 65 1°C 45
H 85 Boiler maximum temperature. 80 95 1°C 85
h 2 Hysteresis of boiler temperature. 1 10 1°C 2
A 99 Hysteresis of boiler temperature. 90 99 1°C 99
Fd2h Fuel shortage testing time with burning. --, 1 99-4h 1min 2h
Fb2h Duration of fuel demand testing in working mode. --, 1 99-4h 1min 2h
Ar 0 Additional output: 0-FUEL, 1-ALARM. 0 1 1 0
c--- Temperature of exhaust gases/exhaust gases
sensor turn-off. ---, 50 250 1°C ---
ch10 Hysteresis of exhaust gases temperature. 1 99 1°C 5
ct 5 Time constant of exhaust gases temperature
stabilization. 1 99 1 min 5
cF10 Blower speed jump while stabilizing exhaust gases
temperature. 1 20 1% 10
c90 Temperature of exhaust gases while detecting fuel
demand. 30 150 1°C 90
Prod Restoring producer’s settings after pressing OK
button.
outΠ Testing blower output. outΠ out1
outP Testing central heating pump output. outP out2
outu Testing additional pump output. outu out3
outr Testing additional output. outr out4
End Exiting service mode after pressing OK button.
Examples of display indications are shown in the first column. The next columns
contain: description of a parameter, the minimum and maximum values that may be
programmed as well as the jump of a value while setting. The values
preprogrammed by the producer can be found in the last column – it is possible to
restore them by selecting the [Prod] option.

10
6.1. Parameters of blower work.
Blower maximum capacity [Π100] – is the maximum value of capacity at which the
blower can operate.
Blower minimum capacity [n 40] – is the minimum value of capacity at which the
blower can work.
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 stabilizing the boiler water temperature mode or in the WORK
mode (while the exhaust gases sensor is turned off) 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.
Automatic regulation of the rotational speed [Πr 0] – setting the parameter
between ‘0-10’ 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 makes the ignition run smoothly.
Induced draught duration [Πn 5] – is the period of starting the blower temporarily
in order to remove the exhaust gases. Switching to ‘--‘ will cause the regulator to exit
the option.
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 or (when the exhaust gases sensor is turned on) before the
exhaust gases temperature reaches the programmed value. Exiting the ignition
mode will result in the regulator switching to the working mode.