P.W. KEY RK-2001U User manual

OPERATION MANUAL
SOLID FUEL FIRED
BOILER TEMPERATURE CONTROLLER
RK-2001U
Version 9A15

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1. Application.
RK-2001U 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. To enable more precise
temperature control of heated rooms, the controller is equipped with input for room
thermostat. The controller is equipped with extra programmable multi-functional
output, which allows connecting mixing valve, alarm signal, extra boiler (gas or
oil-fueled), emergency cooling system or other devices turned on simultaneously with
blow-in fan.
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 mixing valve and 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 indicator
4 – Boiler thermostat knob
5 – Circulating pump indicator
6 – STOP/choose parameters/erase alarms button
7 – START/choose parameters button
8 – Start programming in service mode/confirm settings button

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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 55]) and this value means
the temperature, which the controller will be trying to achieve. You can check this
value by pressing OK button. 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: [50º-] – STOP mode
[50ºC] – WORK mode
[50ºc] – keeping fire in WORK mode
4. 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.

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Table 1. 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 10% 100
n 40 Minimum fan power. 20 40 10% 40
Πh 2 Fan speed decrease coefficient. 2 10 1 2
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
P 42 Central heating pump launch temperature. 30 70 1ºC 42
Ph 2 Central heating pump hysteresis. 1 10 1ºC 2
Pc 2 The work mode and pause time of CH pump. --, 1 99, F 1min 2
L 40 Minimum boiler temperature. 30 65 1ºC 40
H 85 Maximum boiler temperature. 80 90 1ºC 85
h 2 Boiler temperature hysteresis. 1 10 1ºC 2
A 99 Boiler overheating temperature. 90 99 1ºC 99
Fd60 Fuel shortage testing time with burning. --, 1 99, 4h 1min 60
Fb30 Fuel shortage testing time in WORK mode and
burning out. --, 1 99, 4h 1min 30
Ar 0
Work mode of extra output:
0– output turning on extra boiler,
1– alarm output,
2– output controlling mixing valve,
3– output controlling emergency cooling system,
4– output controlling extra devices turning on during
work of blow-in fan.
0 4 1 0
Prod Return to factory defaults after pressing OK
outP Central heating pump testing, press OK - launch outP out1
outΠ Fan output testing, press OK - launch outΠ out2
outr Additional output testing, press OK - launch outr out3
End Exit the service mode after pressing OK
In the table above, 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.
4.1. 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 [Πh 2] – 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

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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 0] – it is on, when this parameteris set to „0-10” and
causes automatic fan speed decrease whentemperature of water in the boiler reaches
desired temperature.If this parameter is set to „-”, the fan automatic smooth
speedcontrol is disabled and the fan can work with power set by „Π” parameter.
Setting parameter value in range from 0 to 10 meanstime in minutes of the smooth fan
speed increase from 40% tovalue 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.
4.2. Circulating pump parameters.
Circulating pump launch temperature [P 42] – 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.
Circulating pump launch hysteresis [Ph 2] – this parameter defines what value
should temperature decrease by, below circulating pump launch temperature, to turn
the pump off.
The work mode and pause time of CH pump [Pc 2] – in STOP mode or when the
room thermostat circuit is not shorted, CO pump is turned on for 30 seconds to move
water in the heating system. This parameter controls the repeat time. Setting this
parameter to „--” turns this function off. In case of some heating systems the pump
should work independently of room thermostat. In such case the parameter should be
set to value „F”.
4.3. Boiler work temperature setting.
Minimal boiler temperature [L 40] – minimal temperature, which you can set with the
boiler thermostat knob.
Maximum boiler temperature [H 85] – maximum temperature, which you can set
with the boiler thermostat knob.
Boiler temperature hysteresis [h 2] – 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.

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4.4. Boiler overheating protection.
Boiler overheating temperature [A 99] – 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].
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.
4.5. No fuel.
No-fuel testing time during fuel firing start [Fd60] – after switching to WORK mode,
if water temperature does not increase by 2°C in programmed time, the control
process will be turned off and the display will show the message: [FUEL]. You can
return to previous mode by pressing STOP button. No fuel testing time during fuel
firing is finished after the set temperature is achieved.
No-fuel testing time during work mode [Fb30] – in WORK mode, if temperature of
water in the boiler decreases below temperature set with the thermostat, by hysteresis
value, and does not increase by 2°C in the programmed time, the control process will
be turned off and the display will show the message: [FUEL]. You can cancel the
alarm by pressing STOP button.
4.6. 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.

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[Ar 2] mode – output may control mixing valve servo-motor. Controlling the mixing
valve requires room thermostat to be connected to the controller. The mixing valve is
being opened and closed depending on the room thermostat input. Additionally, mixing
valve is opened in case of overheating or boiler temperature sensor malfunction.
[Ar 3] 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 4] 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.
4.7. 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. This
function is available in service mode, only if the control process is off, i.e. the controller
was in STOP mode before switching to service mode. 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).
4.8. 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.
4.9. 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.
5. Additional functions.
To improve comfort in heated rooms, the device is equipped with input allowing to
connect any kind of room thermostat with contact output. When temperature in the
room is below desired temperature, the circulating pump is turned on and the room
thermostat indicator is lit. It means that the boiler should keep temperature set by the
room thermostat. After reaching desired temperature in the room, the room thermostat
indicator turns off, the circulating pump is turned off and the boiler switches to mode, in
which it's keeping minimal temperature.
CAUTION. In case of not having room thermostat in the system, the room thermostat
input contacts must be short-circuited.
6. 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

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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).
7. 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.
8. 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-2001U connection scheme.
Picture 3. UM-1 module connection scheme.