P.W. KEY RK-2001AT2 User manual

OPERATION MANUAL
SOLID FUEL FIRED
BOILER TEMPERATURE CONTROLLER
RK-2001AT2
Version AC22

Product history:
Date Version Changes
2010-08-03 A803 Exhaust gas thermostat is used solely for „no fuel” detection.
2010-09-13 A913 Exhaust gas temperature drop below value set with
thermostat knob will stop the fan and central heating pump.
This will not work if boiler temperature is below minimum
temperature.
2010-12-10 AC10 After pressing STOP, STARTagain the controller starts in
HEATING UP mode. This mode turns off influence of exhaust
gas thermostat on the fan and central heating pump.
HEATING UP is active until exhaust gas temperature achieves
temperature set with thermostat knob. Protection against too
high exhaust gas temperature has been added.
2010-12-20 AC20 In FC1 mode central heating pump is turned off after FUEL
alarm.
2010-12-22 AC22 If boiler temperature is less than set temperature and is within
hysteresis, then after pressing STOP, START again the
controller starts in WORK mode (it was SUSTAIN mode in
previous versions).

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1. Application.
RK-2001AT2 controller is a device designed for temperature control of solid fuel
fired boilers. The temperature of the boiler is kept on level set by user, by controlling
the speed of the pressure fan. The controller monitors temperature of water in the
boiler, displays it on the display, and controlls circulating pump. The controller has
been equipped with additional thermostat and sensor input. This thermostat can be
used to set room temperature or desired exhaust gas temperature. Depending on
chosen solution, room temperature sensor or exhaust gas temperature sensor should
be connected to the additional sensor input. The device also design allows for
connecting external contact thermostat instead of room temperature sensor.
2. Connection.
Before turning on the device by master switch, connect controller, pressure fan and
circulating pump power cords to appropriate sockets in the rear of the controller.
Temperature sensor should be placed in measurement hole in the boiler. Picture 2
shows diagram of electrical connection of the device.
WARNING! Before plugging the device to the power source check if it is proprerly
grounded and if the screws of the connector are properly screwed.
CAUTION! The maximum total power of devices connected to the controller mustn't
exceed 450W.
CAUTION! As additional option you can connect the UM-1 module to the controller
that allows controlling the additional boiler or the hot water loading pump. It is
necessary to protect the power supply of these devices with suitable cut-outs.
Not used power outs of the controller may remain unconnected.
3. Operation.
After turning the device on, all the elements of the display are lit for a while to check
if they are working properly. The controller, when power appears, returns to its last
state before turning off or power loss.
Front of the device (Picture 1) consist of:
1 - Master switch,
2 - Display, indicating boiler temperature and parameters,
3 - Room thermostat or exhaust gas thermostat indicator,
4 - Boiler thermostat knob,
5 - Additional thermostat knob,
6 - STOP/choose parameters/erase alarms button,
7 - START/choose parameters button,
8 - Start programming in service mode/confirm settings button,
9 - Circulating pump indicator,

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Picture 1. Front of the device.
Basic operation of the device is done by setting desired temperature with boiler
thermostat knob, other functions are realized according to parameters programmed in
service mode. While changing boiler temperature settings with the knob, the change is
displayed on the display for a few seconds (for example [C 75]) and this value means
the temperature, which the controller will be trying to achieve. This value can be
checked in temperature viewing mode. Depending on heating installation type and
service settings, additional thermostat can be used to set desired room temperature,
or desired exhaust gas temperature. Additional thermostat knob position change is
signaled for several seconds on the display e.g.: [ 20°]. Current value of this setting
can also be viewed in temperature viewing mode.
After pressing START button, the fan starts to work and the control process begins.
STOP button stops the fan, for example allowing to add fuel to the boiler.
If the controller isn't in service mode, the display shows water temperature of the boiler
and the last sign on the display defines mode, which controller currently is in:
for example: [70º-] - STOP mode
[70ºC] - WORK mode
[70ºc] - keeping fire in WORK mode
When the device displays boiler temperature, the function of indicator (3) depends on
function performed by additional thermostat. If the thermostat is used to set room
temperature, indicator (3) is continuously lit when room temperature is too low. If the
thermostat is used to set desired exhaust gas temperature, the indicator (3) signals
low exhaust gas temperature with quick blinking. If exhaust gas temperature is too
high, the controller turns off the fan and shows [Hot ] on the display.
4. Manual fan operation.
During boiler operation user may need to turn on the fan manually (for example, to
remove gases from the boiler before removing the fuel). Pressing START button and
holding it down for 3 seconds will turn the fan on. The fan will keep working for time set
by the service or until STOP button is pressed.

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5. Temperature viewing mode.
To enter temperature viewing mode press OK. Entering this mode will be signaled
by fast blinking of room thermostat indicator. Use < and > buttons to move between
viewing different temperatures. To exit temperature viewing mode select [End ] option
and press OK button or wait for 1 min.
Table 1. List of temperatures available in temperature viewing mode.
Display Parameter
C 45 Boiler desired temperature.
20cTemperature set with additional thermostat knob.
18° Current room or exhaust gas temperature.
End Exit temperature viewing mode.
The desired boiler temperature [C 45] – is the temperature which the controller will
try to achieve in WORK mode. It is set by direct turning of the knob and is indicated by
a short display.
Temperature set with additional thermostat knob [ 20c]- this parameter displays
temperature set with additional thermostat knob.
Current room or exhaust gas temperature [ 18°] - this parameter displays current
measured room or exhaust gas temperature.
6. Setting up the parameters - service mode.
Holding OK button for more than 3 seconds causes change to service mode, where
you can view and change programmed parameters. Service mode is indicated by
flashing of the room thermostat indicator. You can look through parameters with
+ and - buttons. After choosing desired parameter, you can switch to change mode of
the parameter by pressing OK button - this mode is indicated by value of the
parameter flashing. Change of the parameter is possible by pressing - or + buttons.
You can confirm new settings by OK button and after that there is possible to choose
another parameter (with +,- buttons). If you want to quit service mode , choose [End ]
option with + and - buttons and press OK; or wait 1 minute. The device will exit service
mode and will start to indicate boiler temperature.
In the table the first column represents example display indications, in the next
columns there are: parameter description, minimal amount, maximum amount allowed
to set, step of the parameter during the setup, factory defaults, to which you can return
by choosing [Prod] option.

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Table 2. Service parameter's list
Disp. Parameter Min Max Step Factory
default
Π100 Fan max work power or max power when Πr
0-10. 50 100 1% 100
n 40 Minimum fan power. 20 40 1% 40
Πh10 Fan speed decrease coefficient. 2 10 1 10
Πr 1 Automatic fan speed control and time of fan
start. --, 0 10 1 1
Πn 5 Fan work time. --, 5 60 1s 5
Πu 6 Fan pause time. 1 99 1min 6
Πd 3 Fan work time in manual mode --, 1 99 1min 3
P 65 Central heating pump launch temperature. 60 70 1ºC 65
Ph 5 Central heating pump hysteresis. 1 10 1ºC 5
Pr 1
Central heating pump work mode:
0- automatic,
1- the pump work depends on room
temperature or room thermostat contacts,
2- the pump work depends on controller work
mode.
0 2 1 1
Pc-- Central heating pump pause time. --, 1 99 1min --
Pd 2 Central heating pump turn off delay. --, 1 99 1min 2
L 65 Minimum boiler temperature. 60 65 1ºC 65
H 90 Maximum boiler temperature. 80 95 1ºC 90
h 5 Boiler temperature hysteresis. 1 10 1ºC 5
A105 Boiler overheating temperature. 95 105 1ºC 105
Fc 1 Additional thermostat work mode: 0 - room thermostat,
1 - exhaust gas thermostat. 0 1 1 1
F300 Maximum exhaust gas temperature. ---,
250 320 1ºC 300
Fh20 Maximum exhaust gas temperature hysteresis. 5 50 1ºC 20
Fd60 Fuel shortage testing time during boiler start. --, 1 99, 4h 1min 60
Fb30 Fuel shortage testing time in work mode. --, 1 99, 4h 1min 30
Ar 0
Work mode of extra output:
0- output turning on extra boiler,
1- alarm output,
2- output controlling emergency cooling
system,
3- output controlling extra devices turning on
during work of blow-in fan.
0 3 1 0
Prod Return to factory defaults.
outP Central heating pump testing. outP out1
outΠ Fan output testing. outΠ out2
outr Additional output testing. outr out3
End Exit the service mode.

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6.1. Pressure fan work parameters.
Fan power [Π100] - this value defines power of the fan. When „Πr” parameter is set to
„0-10” this is the maximum power of the fanwhich can be achieved during automatic
fan control.
Minimum fan power [n 40] - lowest fan power which can be used when automatic
fan speed control is on and when fan speed is gradually increased during boiler start.
Fan speed decrease coefficient [Πh10] - this parameter influences the way fan
speed is reduced when boiler tremperature is approaching its desired value. E.g.
setting this parameter to 2 means that when the controller is in WORK mode and
boiler temperature is 2°C lower than desired boiler temperature the fan will work with
its maximum power [Π100]. Further increase of boiler temperature will cause fan
speed to be reduced gradually to its minimum power [n 40].
Automatic fan speed control [Πr 1] - it is on, when this parameteris set to „0-10” and
causes automatic fan speed decrease when temperature of water in the boiler reaches
desired temperature.If this parameter is set to „-”, the fan automatic smooth speed
control is disabled and the fan can work with power set by „Π” parameter. Setting
parameter value in range from 0 to 10 means time in minutes of the smooth fan speed
increase from 40% to value of „Π” for smooth boiler start.
Fan work time [Πn 5] - time of turning the fan on for a while, to remove accumulated
gases. Setting the parameter to „-” turns this function off. This function can be active in
WORK mode.
Fan pause time [Πu 6] - time between fan work periods
Fan work time in manual mode [Πd 3] – this parameter defines how long the fan will
work when started manually. Setting this parameter to „--” will disable manual fan
operation.
6.2. Central heating pump parameters.
Central heating pump launch temperature [P 65] - temperature of water in the
boiler, which causes start of the circulating pump. Circulating pump works
independently from the control process and is launched additionally in case of boiler
overheat.
Central heating pump hysteresis [Ph 5] - this parameter defines what value should
temperature decrease by, below circulating pump launch temperature, to turn the
pump off.
Central heating pump work mode [Pr 1] - central heating pump, independently of
work mode, is always turned off when boiler temperature drops below temperature set
with [P 65] parameter and is always turned when boiler temperature exceeds 90°C,
boiler is overheated or boiler temperature sensor is damaged. In remaining cases,
central heating pump works in mode set with [Pr ] parameter:

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- mode [Pr 0] – continuous work.
- mode [Pr 1] - pomp work depends on additional thermostat work mode. In
[Fc 0] mode central heating pump is turned on when room temperature is too low
(additional thermostat connection shorted or room temperature lower than temperature
set with additional thermostat knob). The pump is turned off when room temperature
reaches desired value. In [Fc 1] mode central heating pump is turned on when
measured exhaust gas temperature is higher than temperature set with additional
thermostat knob. The pump is turned off when exhaust gas temperature drops below
the set temperature.
- mode [Pr 2] – in this mode the central heating pump will turn on only when the
controller is in WORK mode.
Central heating pump pause time [Pc--] – when boiler temperature exceeds
temperature set with [P 65] parameter and pump work mode doesn't allow turning the
pump off (e.g. thermostat contacts open) the pump can be periodically turned on for 30
seconds in order to move water in heating installation. This parameter sets pause time
in minutes between pump work periods. Setting this parameter to „--” disables this
function.
Central heating pump turn off delay [Pd 2] – central heating pump stopping too
early can cause temperature rise in the boiler and cause its overheating. This
parameter allows setting central heating pump turn off delay. Setting this parameter to
„--” means that the pump will be stopping without delay.
6.3. Boiler work temperature setting.
Minimal boiler temperature [L 65] - minimal temperature, which you can set with the
boiler thermostat knob.
Maximum boiler temperature [H 90] - maximum temperature, which you can set with
the boiler thermostat knob.
Boiler temperature hysteresis [h 5] - this parameter defines what value should
temperature of water in the boiler decrease by, below temperature set with the
thermostat knob, to turn the pressure fan on.
6.4. Boiler overheating protection.
Boiler overheating temperature [A105] - value, exceeding which causes permanent
turn off of the pressure fan and launch of the circulating pump, to prevent boiler
overheating. Overheating mode is indicated by boiler overheating indicator and by
displaying error [E 2] on the display. It can be turned off by pressing STOP button, but
only when temperature decreases below boiler overheating temperature. Pressure fan
turning off occurs also in case of damage of the boiler temperature sensor, which is
displayed on the display by error [E 1].

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STB - the controller has also additional protection from overheating, which is
independent from the processor, . In case of temperature increase over 95°C, the
control process is turned off by turning the fan off and launching the circulating pump.
The fan and the pump are joined to the control process again, when temperature
reaches 89°C. STB circuit enables more precise boiler work control and reduces
overheating possibility.
6.5. Additional thermostat work mode.
Additional thermostat work mode [Fc 1] - the controller is equipped with additional
thermostat and temperature sensor connection. This parameter selects work mode of
the additional thermostat and additional sensor connection.
- mode [Fc 0] - means that room temperature sensor is connected to the
additional sensor connection. RK-2001AT2 will compare measured room temperature
with temperature set with additional thermostat knob. When room temperature is lower
than the desired temperature, room thermostat indicator will be lit meaning that boiler
should keep temperature set with boiler thermostat knob. When room temperature
reaches desired temperature, room thermostat indicator will be switched off and boiler
enters fire keeping mode at minimum boiler temperature. Device design allows for
connecting any external contact thermostat in place of room temperature sensor.
Shorting the contacts when temperature is low will start the heating procedure
described above. When contacts are open, the controller will keep minimum boiler
temperature. Attention! When external thermostat is connected in place of room
temperature sensor, the temperature set with room thermostat knob on the device will
not affect the controlling process and room temperature will depend solely on
temperature set on external contact thermostat.
- mode [Fc 1] - means that exhaust gas temperature sensor is connected to the
additional sensor connection. In this case the value set with additional thermostat knob
specifies desired exhaust gas temperature. If the controller is in WORK mode and
boiler water temperature has reached value set with [P 65] parameter, then exhaust
gas temperature drop below temperature set with additional thermostat knob will stop
the fan. If central heating pump is in [Pr 1] mode, the pump will also stop in this case.
Additionally, if exhaust gas temperature is below desired temperature, this will also be
signaled with quick blinking of thermostat indicator.
6.6. High exhaust gas temperature protection .
If exhaust gas temperature sensor is connected to additional input ([Fc 1]), the
controller can protect from too high exhaust gas temperature. Next two parameters
control this function.
Maximum exhaust gas temperature [F300] – this parameter controls maximum
temperature which exhaust gas is allowed to achieve. If exhaust gas temperature is
higher than programmed value, the controller displays [Hot ] and turns off the fan.
Normal work resumes after the temperature drops by value of hysteresis. Setting this
parameter to „---” turns off high exhaust gas temperature protection.

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Maximum exhaust gas temperature hysteresis [Fh20] – this parameter describes
how much exhaust gas temperature should drop in relation to maximum temperature
for the controller to stop [Hot ] alarm and resume normal work.
6.7. Fuel shortage testing.
If central heating installation is equipped with exhaust gas temperature sensor
([Fc 1]), then fuel shortage testing starts when exhaust gas temperature falls below
temperature set with additional thermostat knob. If there is no exhaust gas
temperature sensor ([Fc 0]), then fuel shortage testing starts when boiler water
temperature falls below value of [L 65]. If temperature tested during fuel shortage
testing stays below threshold for specified time, the controller will stop regulation
process and will show [FUEL] message on the display. This alarm can be erased with
STOP button.
Fuel shortage testing time during boiler start [Fd60] – time set with this parameter
is used when testing fuel shortage during boiler start. Boiler is considered starting from
the time when the controller is switched from STOP mode to WORK mode and ends
when boiler temperature reaches minimum temperature (set with [L 65] parameter).
Setting [Fd60] parameter to „--” disables fuel shortage checking during boiler start.
Fuel shortage testing time in work mode [Fb30] – time set with this parameter is
used when testing fuel shortage after boiler has started. Setting this parameter to „--”
disables fuel shortage checking in WORK mode.
6.8. Additional output.
Additional output work mode [Ar 0] - the controller is equipped with a multipurpose
output that can work in one of following modes:
-[Ar 0] mode - output may control oil or gas boiler if such boiler exists in the
heating circuit. After switching the controller on with the main power switch, the
additional boiler is turned off and it turnes on again when there is no fuel in the solid
fuel boiler. This function is useful in heating systems where the solid fuel boiler is used
to cut heating costs. After erasing no fuel alarm by pressing STOP button, the
additional boiler is again turned off and the controller works again.
-[Ar 1] mode - output may control additional alarm signaling system. Boiler
temperature sensor malfunction, overheating or no fuel alarm will turn on the
additional alarm.
-[Ar 2] mode - output may control boiler emergency cooling system (e.g. pump).
In this mode the additional output is turned on in case of boiler overheating or boiler
temperature sensor error alarm.
-[Ar 3] mode - output may control devices working together with blow-in fan.
CAUTION. Equipment should be connected to additional output using UM-1module.
Connection schemes are shown on picture 3.

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6.9. Testing of device's outputs.
To make checking the controller work easier, it is possible to test output circuits
which control the fan and the pump, and the circuit which controls additional boiler. By
choosing [outP] on the display and pressing OK button you can turn on the circulating
pump for a while, by choosing [outΠ] and pressing OK you can turn on the pressure
fan and by choosing [outr] and pressing OK you can turn the additional boiler, the
alarm signaling system or the mixing valve servo-motor on (if the additional module is
connected).
6.10. Factory defaults.
You can return to standard settings, set by the producer, by choosing [Prod] option
in service mode and pressing OK button. After activating this function, the device sets
each parameter showed in the table to default.
6.11. Exiting service mode.
By choosing [End ] option on the display and pressing OK button you can quit
service mode. The device also quits service mode, when no buttons are pressed for 1
minute.
7. Device failures.
The controller is constantly testing if its internal circuits and temperature sensor are
working correctly. After detection of fault, it stops the pressure fan, turns on the
circulating pump and shows proper error message on the display. In case of failure
please turn off the controller, plug the circulating pump to the power source, bypassing
the controller, ensure appropriate fuel firing in the boiler and contact the service.
When [E 1] error appears on the display, it means fault (short-circuit) in the boiler
sensor circuit or temperature below -9°C. [E 2] is displayed if boiler overheats. [E 3]
error means fault and overheating at the same time. Appearing of [E 1] error on the
display without ability to cancel it by pressing STOP button, in spite of temperature
below 90°C, may mean permanent damage of boiler temperature sensor (e.g. if the
boiler overheated above 150°C). [E 8] error on the display indicated malfunction in
exhaust gas sensor circuit. In this case the controller disables exhaust gas thermostat
(it will behave as if exhaust gas temperature was always higher than temperature set
with additional thermostat knob).
8. Device removal.
In case of need to remove the controller from the system:
- turn the master switch off,
- disconnect the power of the boiler,
- remove the controller from the slot in the boiler,
- disconnect all connectors with cords from the controller.

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9. Specifications.
Voltage: 230V ± 10%, 50Hz
Power consumption: <4VA
Temperature measurement range: -9–109°C ± 1°C
Boiler temperature adjustment range: 30–90°C ± 1°C
Programmable boiler overheating protection: 90 –99°C ± 1°C
Hardware boiler overheating protection: >95°C ± 1°C
Circulating pump launch temperature: 30–70°C ± 1°C
Fan out: total max 2A/230V
Dimensions: 80 x 170 x 100 mm

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Picture 2. RK-2001AT2 connection scheme
Picture 3. UM-1 module connection scheme.

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10. Notes.
Disp. Parameter User
Π100 Fan max work power or max power when Πr 0-10.
n 40 Minimum fan power.
Πh10 Fan speed decrease coefficient.
Πr 1 Automatic fan speed control and time of fan start.
Πn 5 Fan work time.
Πu 6 Fan pause time.
Πd 3 Fan work time in manual mode
P 65 Central heating pump launch temperature.
Ph 5 Central heating pump hysteresis.
Pr 1
Central heating pump work mode:
0- automatic,
1- the pump work depends on room temperature or room
thermostat contacts,
2- the pump work depends on controller work mode.
Pc-- Central heating pump pause time.
Pd 2 Central heating pump turn off delay.
L 65 Minimum boiler temperature.
H 90 Maximum boiler temperature.
h 5 Boiler temperature hysteresis.
A105 Boiler overheating temperature.
Fc 1 Additional thermostat work mode: 0 - room thermostat,
1 - exhaust gas thermostat.
F300 Maximum exhaust gas temperature.
Fh20 Maximum exhaust gas temperature hysteresis.
Fd60 Fuel shortage testing time during boiler start.
Fb30 Fuel shortage testing time in work mode.
Ar 0
Work mode of extra output:
0- output turning on extra boiler,
1- alarm output,
2- output controlling emergency cooling system,
3- output controlling extra devices turning on during work of
blow-in fan.

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