Ponast Sigmatek Operation manual

Workbook 4
Controller SIGMATEK - Boiler control
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MANUFACTURER:
PONAST spol. s r.o., Na Potůčkách 163, 757 01 Valašské Meziříčí, ČESKÁ REPUBLIKA
tel.:[phone] , fax [phone], e-mail: [e-mail]. www. ponast@cz
Associated regulations and instructions:
- Workbook 1 - Design - Installation - Service - Maintenance
- Workbook 2 - Controller RKP 12157 - Boiler control
- Workbook 3 - Controller IGNEO - Boiler control
- Workbook 4 - Controller SIGMATEK - Boiler control
- Workbook 5 - Technical parameters
For proper and safe operation of the product is necessary to follow:
- manufacturers instructions
- general principles of the operation and installation of the product
- standards, ordinances and regulations currently in force in the place of use of the product
The manufacturer reserves the right to innovative changes of product that may not be included in this
manual.
Boilers have been certified for operation in the Czech Republic and the EU countries by Engineering Test
Institute Brno, State testing laboratory n. 202
General information on CAA and smoke control
The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke
control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any fixed boiler if
located in a designated smoke control area. It is also an offence to acquire an "unauthorised fuel" for use within a smoke
control area unless it is used in an "exempt" appliance ("exempted" from the controls which generally apply in the smoke
control area).
The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise smokeless fuels or
exempt appliances for use in smoke control areas in England. In Scotland and Wales this power rests with Ministers in
the devolved administrations for those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981,
applies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have
been "authorised" in Regulations and that appliances used to burn solid fuel in those areas (other than "authorised"
fuels) have been exempted by an Order made and signed by the Secretary of State or Minister in the devolved
administrations.
The KPxxx boilers have been recommended as suitable for use in smoke control areas when burning wood pellet.
Further information on the requirements of the Clean Air Act can be found here: http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of
smoke control areas and you can contact them for details of Clean Air Act requirements.

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Controller SIGMATEK - Boiler control
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CONTENT
1USE AND ADVANTAGES....................................................................................................................................... 3
23. INSTALLATION INSTRUCTIONS ....................................................................................................................... 3
2.1 CONTROL UNIT............................................................................................................................................ 4
2.1.1 Boiler Function Module HZS 521-G ...................................................................................................... 5
2.1.1.1 Technical base data ........................................................................................................................ 7
2.1.2 Terminal HZS 555-S with USB ............................................................................................................. 8
2.1.2.1 Technical data ................................................................................................................................ 8
2.2 CONNECTION OF ELECTRICAL PARTS ......................................................................................................... 10
3CONTROL UNIT OPERATION ............................................................................................................................. 12
3.1 MAIN MENU ............................................................................................................................................... 12
3.2 OPERATING CONDITIONS – MAIN MENU..................................................................................................... 13
3.3 MAIN MENU ............................................................................................................................................... 14
3.3.1 Setting menu ................................................................................................................................... 14
3.3.1.1 Info menu .................................................................................................................................... 14
3.3.1.2 Menu users settings ...................................................................................................................... 15
3.3.1.3 Menu Service ................................................................................................................................ 18
3.3.2 Menu – heating circuits..................................................................................................................... 28
3.3.2.1 Tank ............................................................................................................................................ 29
3.3.2.2 Sanitary water .............................................................................................................................. 31
3.3.2.3 Heating circuit .............................................................................................................................. 33
4GUARANTEE AND LIABILITY FOR DEFECTS ........................................................................................................ 36
5DISPOSAL OF PRODUCT AFTER TEH END OF ITS SERVICE LIFE.......................................................................... 36
PICTURES
Picture No. 1 Control unit - configuration ................................................................................................... 4
Picture No. 2 HZS 521-G Connector and terminal electronics layout ......................................................... 5
Picture No. 3 Module HZS 532-1 ................................................................................................................. 6
Picture No. 4 Other modules ....................................................................................................................... 6
Picture No. 5 Terminal with USB ................................................................................................................. 8
Picture No. 6 Main menu – sample of visualisation .................................................................................. 12
Picture No. 7 Circuit diagram – control unit.............................................................................................. 37
Picture No. 8 Circuit diagram + module HZS 533 ..................................................................................... 38
Picture No. 9 Circuit diagram - HZS 533, HZS 535.................................................................................... 39

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IMPORTANT NOTES
This product may only be put into operation by an installation organization trained by the manufacturer.
This product may only be operated by adult persons, duly acquainted with the way the product is controlled and duly
acquainted also with these Instructions. If you adhere to the below mentioned principles, the product will serve you
reliably to your full satisfaction.
It is prohibited to intervene in any way in the structure or electrical installation of products. Having the equipment been
disconnected from the electric network, the power supply cord has to be plugged from the mains outlet.
1 USE AND ADVANTAGES
The main advantages of products:
CONTROL UNIT
• with modern design
• controls operation of the boiler
• ensures automatic operation
• high operational reliability
• long distance control
• Colour TFT display 5.7" with touch screen
• Remote control over TCP/IP
• USB
• User friendly controlling
• Operation modes: Equitherm, Modulation or Fixed power
• Two heating circuits and sanitary water in basic configuration
• Possibility to control accumulation tank or solar system – maximum 7 heating circuits
• Upgrading software over USB stick
• Possibility of control by thermostat or by optional number of sensors
• Possibility of setting time windows for heating circuits control
• Possibility of software update through the USB input or via TCP / IP
2 3. INSTALLATION INSTRUCTIONS
The control unit is supplied as part of equipment of boilers KP xxx.
Separately are control system´s spare parts supplied in the context of any claim or to order.

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2.1 CONTROL UNIT
Boiler is equipped with the control system with touch screen. This control system enables automatic boiler operation
through the control and regulation features (thermostats, sensors, etc.) in the requested modes. It also enables
Diagnostics mode of control, which can be used for instance for boiler commissioning.
The control system construction and its electrical shielding (IP 45) make safe and reliable operation possible even under
the demanding operational and climatic conditions common to boiler rooms.
Basic configuration Optional configuration
Picture No. 1 Control unit - configuration
Configuration:
Name Type Options Order code
Control unit - boiler function module HZS 521-G Standard
Terminal (touchscreen) HZS 555-S Standard
Module extension HZS 532-1 Standard
Module heating circuit / accumulation tank HZS533 Optional
Module solar HZS535 Optional
Type and number of circuit Type and number of module
HC1 SWT HZS 521-G HZS532-1
HC1 HC2 SWT HZS 521-G HZS532-1
HC1 HC2 HC3 SWT HZS 521-G HZS532-1 1 pc HZS 533
HC1 HC2 HC3 HC4 SWT HZS 521-G HZS532-1 2pcs HZS 533
HC1 HC2 HC3 HC4 HC5 SWT HZS 521-G HZS532-1 3pcs HZS 533
HC1 HC2 HC3 HC4 HC5 ACU HZS 521-G HZS532-1 3pcs HZS 533
HC1 HC2 HC3 HC4 ACU SOL HZS 521-G HZS532-1 2pcs HZS 533 HZS 535
HC – heating circuit
SWT – sanitary water tank
ACU – accumulation tank
SOL – solar system

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2.1.1 Boiler Function Module HZS 521-G
The heating system is modularly constructed. The HZS 521-G is a module for the boiler, which communicates with the
CPU module and executes the transmitted instructions. The HZS is a simple component that is used to control automated
processes in a heating system.
All interfaces and connections for controlling of the boiler are located on the control board.
Picture No. 2 HZS 521-G Connector and terminal electronics layout
Ambient temperature senso
r
HC1 mix temp
Backwater temp
Sanitary water temp
Exhaust temp
Sanitary water top
Sanitary water bottom
Room thermostat 3
Room thermostat 2
SWT thermostat
Room thermostat 1
Impulse sensor 2
Impulse sensor 1
Room thermostat 4
A
ntifrost protection
Servo open
Servo close
SWT pump
Bypass pump
I
g
nition
HC1 pump
Primary fan
Exhaust fan
Feeder 1
Feeder 2

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The control unit always contains modules HZS 521-G and HZS 532-1.
Picture No. 3 Module HZS 532-1
HZS533 HZS533 HZS535
Picture No. 4 Other modules

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2.1.1.1 Technical base data
HZS521-G
Supply voltage
230 V AC +/- 10 %
(Input voltage for the power transformer on the power board, input
voltage for the STB, phase for the phase angle, relays and Triac outputs)
Power supply fre-
quency
45 - 65 Hz
Total current consumption 200 mA + current consumption of the
connected loads (max. 16 A)
Power supply transformer
Supply for the power board and CPU electronics
Supply for Heater Lambda sensor: 200 mA
Current
consumption of
supply (230 V AC)
The power supply is switched of STB, L-STB
Loads connected over fuse F4 (3,15 AT): X11 primary fan: maximum
690 W/ maximum 3 A Loads connected over fuse F5 (10 AT): X14
Screw: maximum 690W/ maximum 3 A
Loads connected over fuse F6 (10 AT):
X9 Turbine: maximum 2300 W/ maximum 10 A
Loads connected over fuse F7 (10 AT):
X8 Ignition: maximum 2300 W/ maximum 10 A
Loads connected over fuse F8 (10 AT):
X5 heat exchange cleaner: maximum 690 W/ maximum 3 A
X6 grate open: maximum 690 W/ maximum 3 A
X7 grate closed: maximum 690 W/ maximum 3 A
The power supply not switched over STB, L Loads connected over fuse
F9 (10 AT):
X10 boiler circuit return flow pump: maximum 2300 W/ maximum 10 A
HZS532-1
Internal
electronics power
supply
+24 V (from HZS 511), must be connected to the expansion
controller
Relay power
supply
230 VAC
Fuse 10 A for relay outputs
+24 V current
consumption
HZS 532-1: maximum 60 mA (without relays) Maximum
120 mA (with relays) HZS 532-1 with 5 expansion modules,
maximum 350 mA
HZS533, HZS535
Internal
electronics power
supply
+24 V (from HZS 511), must be connected to the expansion
controller
Relay power
supply
230 VAC
Fuse 5 A for relay outputs and/or 3 A for solar module
+24V current
consumption
HZS 533 maximum 15 mA (without relays) Maximum 40
mA (with relays)

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2.1.2 Terminal HZS 555-S with USB
Picture No. 5 Terminal with USB
Description
The HZS 555-S is an intelligent terminal for programming and visualization of automated processes. Process
diagnosis as well as operating and monitoring automated procedures is simplified using this terminal.
A touch screen serves as the input medium for process data and parameters. The output is shown on a 5.7" SVGA
TFT color display.
Cleaning the Touch Screen
CAUTION!
Before cleaning the touch screen, the terminal must first be turned off to avoid unintentionally triggering
functions or commands!
The terminal's touch screen can only be cleaned with a soft, damp cloth. To dampen the cloth, a screen-cleaning
solution such as antistatic foam, water with detergent or alcohol should be used. First spray the cleaning fluid on the
cloth and not directly on the terminal. The cleaning solution should not be allowed to reach the terminal electronics, for
example, through the ventilation slots.
No erosive cleaning solutions, chemicals, abrasive cleansers or hard objects that can scratch or damage the touch screen
may be used.
If the terminal is soiled with toxic or acidic chemicals, quickly and carefully clean the terminal to prevent corrosion.
2.1.2.1 Technical data
Supply voltage Typically +24 V DC
MIN +18V DC MAX +30V DC
Current
consumption of
voltage supply
Typically 440 mA (pro + 24 V) ,
Maximum 650 mA
Standby Typically 0.56 W
Starting current Maximum 25 A for 20 µs

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Display
Type 5.7" LCD colour display
resolution VGA 640 x 480 Pixel
Colour depth 18-bit RGB (262K colours)
LCD Mode TN / normal white
LCD Polarizer Trans missive
Pixel size 0.18 mm x 0.18 mm
Active surface 115.2 mm x 86.4 mm
Background lighting LED
Contrast 600
Brightness Typically 350 cd/m²
Angle CR >= 10 Left, right, below 75°, above 60°
Environmental conditions
Storage temperature -10 – +85 °C
Operating temperature 0 – 50 °C
Humidity 10 - 90 %, uncondensed
EMV stability EN 61000-6-2: noise immunity
EN 61000-6-4: noise emission
Vibration - tolerance EN 600068-2-6 2 - 9 Hz: Amplitude 3.5 mm
9 – 200 Hz: 1 g (10 m/s²)
Shock resistance EN 60068-2-27 15 g (150 m/s²)
Protection Type EN 60529 Protected
through the housing
Front: IP54
Cover: IP20

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2.2 CONNECTION OF ELECTRICAL PARTS
The electric parts connections can be performed by qualified personnel only. Connect the particular appliances according
with connection diagram. During connecting the equipment must be shut down with the main switch or disconnected
from power supply by pulling the electric cord from the outlet.
1 Relay for electric ignition
2 Burner thermostat
3 Cover control unit
4 2x M4
5 Boiler thermostat
6 Control unit

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Connect: Connection terminal
Feeder motor F2 X14- L, N, PE
Impulse sensor F2 X45
Electric ignition spiral X4-L, N, PE
Primary Fan X11-L, N, PE
Flue Fan (if used) X12-L, N, PE
Feeder motor F1 X13- L, N, PE
Impulse sensor F1 X44
Flue thermometer X31
System pump X10-L, N, PE
Boiler pump X7-L, N, PE
Servo 3 (4) – way valve X5-L, N, PE, X6-L, N, PE
Room thermostat X46
Boiler thermostat X47
Outside temperature X34
Thermometer behind 3 (4) – way valve X28
Thermometer back water X29

Important note: Fan and flue fan are controlled proportionally.
With MENU Diagnostics -
direct control - to be checked by qualified personnel:
F1 feeder motor function and correct rotation direction
F2 feeder motor function and correct rotation direction
Correct functioning of F1 feeder impulse sensor and simultaneously
Correct functioning of F2 feeder impulse sensor
Functioning of fan and linearity of its regulation
Functioning of flue fan and linearity of his regulation (if used)
Functioning of system pump and its venting
Functioning of boiler pump and its venting
Functioning of motor and correct rotation direction of ash removal spiral screw
Functioning of exchange cleaning motor
Functioning and correct rotation direction of servomotor
Functioning and timing of servomotor between limit positions and agreement of timing with SW setting
Correct functioning of electric ignition spirals
Correct functioning of attached thermometers
Setting of a proper equithermal curve
Setting or changing servomotor timing

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3 CONTROL UNIT OPERATION
3.1 MAIN MENU
Description of the basic control panel screen
After switch on the main power switch, start program and after several minutes will show the main menu.
For easy operation are used:
- Buttons with names or pictograms
- Buttons with moving (setting of power and temperature)
- Boxes with information’s (text, numbers or pictograms)
- Date and time
The data are showed as numbers, diagrams or combination.
Picture No. 6 Main menu – sample of visualisation

Note: Changes important parameters for combustion quality and safety is allowed after insert
password according with table No.6 (In the end of this manual).
Button:
Information and
Service menu
Button:
Heating circuit
setting
Button:
Move to second
screen
Button
SELECTION
OF
OPERATING
MODE
A
ctual status Button:
START/STOP
Button:
Power setting
(required power)
Button:
Temperature setting
(required temperature)
Information space:
Boiler temperature - actual
Exhaust temperature - actual
Information:
Date
Time

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3.2 OPERATING CONDITIONS – MAIN MENU
SELECTION OF OPERATING MODE
User - before start operation of boiler, have to select operation mode – touch on the button is
automatically changed mode:
FIXED POWER
Operate boiler automatically on the fixed power. User can set value of power (% or kW) and temperature (°C).
MODULATION
Operate boiler automatically. User can set value temperature (°C). The power is adjusted automatically depend on
temperature. User cannot change the power.
EQUITHERM
Operate boiler automatically. The power and temperature is adjusted automatically depend on outside temperature and
setting of equitherm diagram. User cannot change the power and temperature.
This mode user cannot chose when the out temperature sensor is not use.
Selection – touch on button:
FIXED POWER »MODULATION »EQUITHERM
START
After touch on the button START boiler is working automatically. The display shows step by step actual
operation:
Ignition
Fuel is burn on by electric spiral.
Stabilisation
Stabilisation of fire
Operating
The fire was stabilised and boiler is normally working.
Stand-by
Quiet mode of the boiler, when the boiler is not burning actively. Boiler is ready on the basis of impulse from surrounding
equipment (thermostats, GSM Modem) to restore the supply of heat.

Note: Change –SELECTION OF OPERATING MODE – is possible to make at any time during operation.

Note: If boiler is working in -MODULATION or EQUITHERM - control unit automatically setting power in the range 0
– 10.

Note: After „START“ is activated automatic ignition. Auto ignition runs for several minutes.
The programme routine of Automatic Ignition has absolute priority to be carried out in full extent. If the routine is
activated, it is not possible to interrupt or stop it in any way. This fact is an important condition for reliable operation of
the boiler because it is then possible only to ascertain indirectly from further behaviour of the boiler whether it is burning
or not.
The on-going routine of Automatic Ignition may be terminated only by the operator by switching STOP. Service is than
responsible for the correct set up to a automatic operation.

Note: If the boiler is working in the mode FIXED POWER, MODULATION, EQUITHERM and power supply is
interrupted the boiler will start with the electric ignition routine after the power supply is resumed.

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3.3 MAIN MENU
3.3.1 Setting menu
3.3.1.1 Info menu
Button:
Back on the
previous screen
Button:
A
larm list
Software version
No. dated
Software version
visualisation No.
dated
Operating hours
Button:
Move to second
screen

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3.3.1.2 Menu users settings

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Time, date
Current time
HH:MM:SS
Current date
DD.MM.YY
Tine without
screensaver
Button:
Password
Showed:
„
Please insert your
password“
A
fter touch on the
box for password:
Insert password
and enter.
In the end confirm:
OK
If is password right
– button change on
green colour

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Cleaning an ash removing
Skin
Time window
setting

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IP Adress
3.3.1.3 Menu Service
Button:
Password
Showed:
„
Please insert your
password“
A
fter touch on the
box for password:
Insert password
and enter.
In the end confirm:
OK
If is password right
– button change on
green colour

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Diagnostics
Manual mode

Note: If you have empty feeders – you must fill fuel into the feeders before START:
The operator can directly control the startup fuel feeders. It is possibilities to fuel filling Feeder F1. Turn on Feeder F1
depend on Feeder F2.
Steps for turn on Feeders:
1. Feeder F2
2. Feeder F1
The rotation is signalized by two small red windows – blinking.
When fuel is falling down from Feeder F1 into Feeder F2 – immediately stop Feeders! Overfilling of fuel is dangerous!
Other functionality are used for diagnosing of functionality.
Button:
Password
Showed:
„
Please insert your
password“
A
fter touch on the box
for password: Insert
password and enter.
In the end confirm:
OK
If is password right –
button change on green
colour
Touch and start
functionality