Regulus BIO 55 MIX W-PWM 1F TRS6K User manual

www.regulus.eu
BIO 55 MIX W–PWM 1F TRS6K
BIO 55 MIX W–PWM 1F TRS6K
EN
Installation and Operation Manual
BIO 55 MIX W–PWM 1F TRS6K
LOAD UNIT

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Contents
1. Introduction ......................................................................................................... 3
2. Description .......................................................................................................... 3
3. Load Unit Data .................................................................................................... 4
4. Load Unit Components ....................................................................................... 6
4.1. Pumps for Boiler and Heating Circuits ...................................................... 7
4.2. LK840 Actuated Mixing Valve .................................................................... 8
4.3. TSV3BM Load Valve ................................................................................. 8
4.4. Ball Valves ................................................................................................. 9
4.5. Ball Valve with Check Valve ...................................................................... 10
5. Load Unit Installation ........................................................................................... 11
6. Hydraulic Variants, Position of Sensors .............................................................. 13
7. Controller - Operation and Settings ..................................................................... 16
7.1. Safety Instructions - Controller Settings .................................................... 16
7.2. Display and Input ...................................................................................... 17
7.3. Controller Settings (Load Unit without Accessories) ................................. 18
8. Optional Accessories ........................................................................................... 21
8.1. Auxiliary Electric DHW Heating Element Wiring (code 15169) ................. 22
8.2. Room Temperature Sensor Wiring (code 16167) ................................... 22
8.3. RC Caleon Room Unit Wiring (code 17150) ............................................. 23
8.4. DHW Recirculation Pump Wiring (code 15181) ........................................ 24
8.5. Wiring of an Electric Heating Element for Heating
(code 14996,14998,14999) ....................................................................... 25
9. Controller Settings (Load Unit with Accessories) ................................................ 26
9.1. Room Temperature Sensor Settings (code 16167) ................................... 26
9.2. DHW Recirculation Pump Settings (code 15181) ..................................... 26
9.3. Auxiliary Electric DHW Heating Element Settings (code 15169) .............. 26
9.4. RC Caleon Room Unit Settings (code 17150) .......................................... 26
Attachment – Load Unit Rearrangement Procedure ..................................................... 27

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1. INTRODUCTION
BIO 55 MIX W–PWM 1F TRS6K Load Unit includes a complete hydraulic and electrical
connections for the installation of a heating system with a solid fuel boiler.
The load unit has a complete electrical installation and is tted with a power cord with a plug.
All you need to do is connect the boiler, the heating system, the thermal store with DHW,
then place the sensors and plug the load unit into a socket. Then select the corresponding
hydraulic variant in the controller using the setup wizard and set other required parameters.
It is possible to connect the Caleon room unit with colour touch screen and easy operation to
the controller. Room unit is not included, shall be ordered separately.
2. DESCRIPTION
Main Features
Description The Load Unit includes:
● TRS6 BIOMIX controller with hydraulic variant selection for smart
control of the entire system
● two Wilo Para 25/8 iPWM1 circulation pumps with continuous
performance control via PWM signal for boiler circuit and heating
system
● TSV3BM load valve with automatic bypass balancing to protect
the boiler against low temperature corrosion by keeping return water
temperature at 55 °C minimum
● motorised three-way mixing valve including actuator to maintain the
required temperature in the heating circuit
● two ball valves and a drain valve for shutting off and draining the
heating system
● check valve integrated in the ball valve body located at the outlet
from the heating system
● two ball valves and a drain valve to shut off the boiler circuit
● two ball valves permitting to shut off the thermal store circuit
(included in supply)
● lever for ball valves
● 3m power cord, 1.5 mm2cable cross section
● Pt 1000 outdoor temperature sensor with 10 m cable
● four Pt 1000 temperature sensors with 4 m cable
● four thermometers
● outlets to connect a thermal store or a combination one and
alternative outlets to connect optional accessories
Working uid water, antifreeze uid for heating systems
Installation vertically on a wall using the installation kit
Connections 2 x G 1“ F to connect a heating system
2 x G 1“ F to connect a boiler circuit
2 x G 1“ F to connect a thermal store
2 x G 1/2“ F alternative outlets to connect optional accessories (if you
do not need to use the outputs, they can be plugged with the enclosed
plugs)
Code 17499

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3. LOAD UNIT DATA
Technical Data
Fluid working temperature 5-95 °C
Max. working pressure 6 bar
Ambient temperature 5-40 °C
Max. relative humidity 95%, non condensing
Load unit max. power input 155 W
Load unit power supply * 230 V, 50 Hz (power supply cord)
Max. boiler output 40 kW at ∆t 20 °C
Heating system max. heat output 20 kW at ∆t 10 °C
Insulation material EPP RG 60 g/l
Overall dimensions 640 x 250 x 350 mm
Total weight 16.7 kg
* the power cord serves to power supply the TRS6 BIOMIX controller and Wilo Para 25/8 iPWM1 circulation pumps.
The three-way mixing valve actuator is powered from the controller.

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2 1 2 1 4 3 2 1 4 3 2 1
CAN CAN VFS2 VFS1
+ S6 V2 V1 S5 S4 S3 S2 S1 - PELV R3 R3I R2 R1 L N
N N N N N N
PŘIPOJENÍ
NAPÁJENÍ
230 VAC 50-60Hz
NAPÁJENÍ
umístěno na horním víku u desky plošných spojů
Pt1000
SVORKA
PŘIPOJENÍSVORKA
NA DESCE PLOŠNÝCH SPOJŮ
–
S1
S2
S3
S4
S5
S6
V1
V2
+
propojka GND pro čidla, výstupy V1,V2 a napájení
teplotní čidlo 1
teplotní čidlo 2
teplotní čidlo 3
teplotní čidlo 4
teplotní čidlo 5
teplotní čidlo 6 (venkovní)
výstup PWM pro čerpadla Wilo Para
výstup PWM pro čerpadla Wilo Para
24V napájení (např. pro pokojové jednotky Caleon)
N
L
R1
R2
R3I
R3
nulový vodič N
vnější fázový vodič L
relé 1 pro pohon směšovacího ventilu AVC
relé 2 pro pohon směšovacího ventilu AVC
relé 3 (rozpínací kontakt NC)
relé 3 (spínací kontakt NO)
M
CAN1
CAN2
připoj. sběrnice CAN (1=vysoký, 2=nízký) pro pokoj. jednotky Caleon nebo další příslušenství
připoj. sběrnice CAN (1=vysoký, 2=nízký) pro pokoj. jednotky Caleon nebo další příslušenství
v systémech Regulus není použito
v systémech Regulus není použito
VFS1
VFS2
MALÉ NAPĚTÍ
max. 24 VDC
MALÉ NAPĚTÍ
Pt1000 Pt1000 Pt1000
Pt1000
EXTRA LOW VOLTAGE (ELV)
TERMINAL CONNECTION
- GND bridge for sensors, V1 and V2 outputs, power supply
S1 Temperature Sensor 1
S2 Temperature Sensor 2
S2 Temperature Sensor 3
S4 Temperature Sensor 4
S5 Temperature Sensor 5
S6 Temperature Sensor 6 (outdoor)
V1 PWM signal output for Wilo Para pumps
V2 PWM signal output for Wilo Para pumps
+ 24V Power supply (e.g. for Caleon Room Units)
POWER SUPPLY
TERMINAL CONNECTION
N neutral conductor N
L network outer conductor L
R1 relay 1 for AVC mixing valve actuator
R2 relay 2 for AVC mixing valve actuator
R3l relay 3 (normally closed contact NC)
R3 relay 3 (normally open contact NO)
ON PCB
CAN1 CAN bus connection (1=high, 2=low) for Caleon room units or other accessories
CAN2 CAN bus connection (1=high, 2=low) for Caleon room units or other accessories
VFS1 not used in Regulus systems
VFS2 not used in Regulus systems
EXTRA LOW VOLTAGE
max. 24 VDC
POWER SUPPLY
230 VAC 50-60 HZ
located on the top cover of the printed circuit board

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4. LOAD UNIT COMPONENTS
9
10
11
2
12
13
14 15 16
17
7
18
20
TRS 6
TRS 6
1
4
3
2
5
6
7
6
8
6
19
21
21
1 – Heating water thermometer, inlet to boiler circuit
2 – Wilo Para 25/8 iPWM1 pump in boiler circuit
3 – TRS6 BIOMIXK Controller
4 – Heating water thermometer, outlet from heating circuit
5 – Heating water thermometer, inlet to heating circuit
6 – Wilo Para 25/8 iPWM1 pump in heating circuit
7 – Mixing valve actuator
8 – Heating water thermometer, outlet from boiler circuit
9 – G 1“ Fu × G 1“ F × G 1/2 “ F ball valve w. sheath for temperature sensor*
10 – G 1“ F thermal store lower connection
11 – G 1“ F thermal store upper connection
12 – TSV3BM load valve
13 – G 1/2“ M drain valve with hose tail
14 – G 6/4“ Fu × G 1“ F × G 1/2“ F ball valve w. check valve and sheath for temperature
sensor
15 – Handle for ball valves
16 – G 6/4 “ Fu × G 1“ F × G 1/2“ F ball valve w. sheath for temperature sensor
17 – G 1/2“ M drain valve with hose tail
18 – LK 840 mixing valve
19 – Drain plugs
20 – G 1“ Fu × G 1“ F × G 1/2 “ F ball valve w. sheath for temperature sensor*
21 – DN 20 ball valves to be mounted on connection points 10 and 11 (enclosed)
* The G 1/2 “F free outlets at ball valves at positions 9 and 20 can be used to connect additional accessories. If you do not need to
connect any, the output remains closed by a plug.

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4.1. PUMPS FOR BOILER AND HEATING CIRCUITS
Wilo Para 25/8 iPWM1 boiler and heating circuit pumps are wet running circulation pumps.
The pump speed is controlled by the PWM signal. Operating status and possible pump faults
are indicated by LEDs on the pump.
Technical Data
Power supply 230 V, 50 Hz from TRS6 BIOMIX
Power input (min./max) 2 / 75 W
Current (min./max) 0.03 – 0.66 A
Max. speed 4800 rpm
Speed control frequency converter
Energy Efciency Index (EEI) ≤ 0.21
IP rating IPX4D
Motor protection integrated
Min. pressure at the suction port
to avoid cavitation
0.5 mH2O at 50 °C
4.5 mH2O at 95 °C
LED signals status description and possible fault reasons
green is lit 1 – pump is running in trouble-free operation
red is lit 1 – rotor is blocked
2 – electric motor winding defect
ashing red
1 – power supply voltage lower/higher than permitted
2 – electric short circuit in pump
3 – pump overheated
ashing red and green
1 – unforced uid circulation through the pump
2 – pump speed lower than desired
3 – air in pump
Performance curves of Wilo Para 25/8 iPWM1

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4.2. LK840 ACTUATED MIXING VALVE
LK 840 mixing valve is controlled by AVC actuator with 3-point control. The valve position is
indicated by a LED on the actuator.
Technical Data of AVC Actuator
Torque 5 Nm
Angle of rotation 90°
Shift time 120 s
Max. power input 2.5 VA
IP rating IP42
Protection class II
Technical Data of LK 840 Mixing Valve
Max. pressure difference 5 mH2O
Leak rate 1 % Kvsat 5 mH2O
Valve Kvs6.3 m3/h
LK840 Mixing Valve Pressure Drop Diagram
4.3. TSV3BM LOAD VALVE
Thermostatic mixing valve with automatic bypass balancing protects the boiler against low-
temperature corrosion. It keeps the water in the boiler circuit at such a temperature that
the condensation of water vapours contained in the ue gas does not occur in the boiler
combustion chamber. It has a built-in thermostatic element that closes the inlet from the
heating system if the temperature of the return water to the boiler is lower than the opening
temperature. After reaching the opening temperature, the thermostatic element slowly opens
the return water inlet from the heating system so that after mixing with the hot water coming
from the boiler, the opening temperature of the return water to the boiler is reached. At the
same time, it also closes inlet from the boiler, limiting the hot water ow from the bypass until
it is completely closed.
Technical Data of TSV3BM Load Valve
Opening temperature 55 °C
Kvsvalue Direction from A to AB: 9.8 m3/h
Direction from B to AB: 5.3 m3/h

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Load Valve Pressure Drop Diagram
4.4. BALL VALVES
The ball valves are operated by a lever that is not placed on the valve during operation. The
open / closed position on the ball valve is indicated by a groove. If the groove is perpendicular
to the direction of ow, the ball valve is closed, if it is in the direction of ow, the ball valve is
open, see g. The groove position is marked in red in the gure.
During normal operation, all ball valves shall be in the open position. If necessary, the ball valve
can be closed from the open position by turning the lever 90° to the right. When maintenance
is complete, turn the lever to the left to open it. Before closing / opening the ball valve, the top
section of the insulation shall be removed rst. As a result, unintentional closure of the system
by an unauthorized person is not possible.
The ball valves are tted with a packing with two O-rings of 8.7 x 1.8 mm that can be easily
replaced by removing the control element with end stops and loosening the packing nut with
# 21 spanner.
drážka kolmo na směr
proudění
poloha
zavřeno
poloha
otevřeno
drážka ve směru
proudění
open closed
groove in the ow
direction
groove perpendicular
to the ow direction
During mixing, the
pressuredropofthevalve
moves between the two
curves depending on the
mixing ratio.
Technical Data
Kv value 20,2 m3/h

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4.5. BALL VALVE W. CHECK VALVE
Pos. 12, see Chap. 4.
Pressure Drop Diagram

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5. LOAD UNIT INSTALLATION
The pump station is designed for wall mounting. In the rear section of the insulation there are
two mounting holes for xing the metal plate to the wall, see picture.
In the basic version, the thermal store is supposed to be connected on the left side of the
pump station. If necessary, the pump station can be converted to be connected to a thermal
store on the right side, as described at the end of the instructions in the appendix. Insulation
passage points are prepared for both variants of thermal store position.
The pump station is xed to the intended location using the mounting kit supplied. Select the
pump station mounting height on the wall so that you can operate the controller without any
problems.
Two DN 20 ball valves are also included in supply (see pump station components, pos. 21).
The ball valves are installed at the outlets at positions 10 and 11 (see chapter 4). If necessary,
they serve for closing and isolating the thermal store circuit from other parts of the system.
The mounting kit and the ball valves are included in the pump station supply. A detailed list of
the contents of the package is shown on the next page.
horní otvor
pro uchycení čerpadlové skupiny
spodní otvor
pro uchycení čerpadlové skupiny
404
výstup z
kotlového okruhu
vstup do
kotlového okruhu
vstup do
otopného okruhu
výstup z
otopného okruhu
připojení akumulační nádrže
horní
spodní
outlet from
heating circuit
inlet to
heating circuit
inet to
boiler circuit
outlet from
boiler circuit
thermal store
connection points
upper
lower
upper opening
to mount the pump station
lower opening
to mount the pump station

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PACKAGE CONTENTS
Mounting kit
Screw 5x50, round head 2 pcs
6.4 stainless steel washer, DIN 9021/A2 2 pcs
Wall plug 8mm TX 2 pcs
Other
G 1 “Fu x G 1“ F ball valves with union nut 2 pcs
Pt1000 outdoor temperature sensor 1 pc
INSTALLATION PROCEDURE
1. Connect the pipes
2. Fill the system, air bleed
3. Perform a pressure test
4. Place the sensors according to the following chapter

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6. HYDRAULIC VARIANTS, POSITION OF SENSORS
The pump station is intended for installation in the following systems:
A. systems with solid fuel boiler with manual stoking, one heating circuit and combination
thermal store
B. systems with solid fuel boiler with manual stoking, one heating circuit, combination
thermal store and additional basic thermal store to increase the total system heat
storage volume
SENSOR IDENTIFICATION
VARIANT 2A
The sensor S2 is installed in the combination thermal store under the separating metal sheet,
the number S3 is installed in the lower part of the combination thermal store. Sensor S4 is
installed in the solid fuel boiler or on its outlet piping as close as possible to the boiler, sensor
S5 is installed directly in the pump station and outdoor sensor S6 shall be installed on a
northern wall of the building at a height of about 1.5 - 3 m.
VARIANT 2B
The sensor S2 is installed in the combination thermal store under the separating metal sheet,
the number S3 is installed in the lower part of the other basic thermal store. Sensor S4 is
installed in the solid fuel boiler or on its outlet piping as close as possible to the boiler, sensor
S5 is installed directly in the pump station and outdoor sensor S6 shall be installed on a
northern wall of the building at a height of about 1.5 - 3 m.
The diagrams are shown on the following pages.
S5 temperature sensor located inside
S6 temperature sensor
S2, S3, S4 temperature sensors

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S2 – čidlo teploty kombinované akumulační nádrže (horní) S3 – čidlo teploty kombinované akumulační nádrže (dolní) S4 – čidlo teploty na výstupu z kotle na pevná paliva
S5 – čidlo teploty otopné vody (v jímce v čerpadlové skupině) S6 – čidlo venkovní teploty
S4
230 V AC, 50 Hz
S2
S3
TRS 6
TRS 6 S6
S5
VARIANT 2A
The diagram is only a simplied graphical representation and does not claim to be complete.
temperature sensor in the combination thermal store (upper) temperature sensor in the combination thermal store (lower) temperature sensor at the solid fuel boiler outlet heating water temperature sensor (sheath in pump station) outdoor temperature sensor

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S4
230 V AC, 50 Hz
S2
TRS 6
TRS 6 S6
S3
S5
S2 – čidlo teploty kombinované akumulační nádrže (horní) S3 – čidlo teploty kombinované akumulační nádrže (dolní) S4 – čidlo teploty na výstupu z kotle na pevná paliva
S5 – čidlo teploty otopné vody (v jímce v čerpadlové skupině) S6 – čidlo venkovní teploty
VARIANT 2B
The diagram is only a simplied graphical representation and does not claim to be complete.
temperature sensor in the combination thermal store (upper) temperature sensor in the combination thermal store (lower) temperature sensor at the solid fuel boiler outlet heating water temperature sensor (sheath in pump station) outdoor temperature sensor

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7. CONTROLLER - OPERATION AND SETTINGS
7.1. SAFETY INSTRUCTIONS - CONTROLLER SETTINGS
• The installation must be carried out by a qualied professional who is trained to an
appropriate level and is authorized to install electrical equipment.
•The installation must be carried out in accordance with applicable standards and
regulations.
• All adjustments shall be done in compliance with this Manual and with the dedicated
Manual for TRS6 BIOMIX Controller.
• Changes, additions to or conversion of the unit are not permitted without a written
permission from the Manufacturer.
• It is forbidden to install any additional components into the controller that has not been
tested together with the controller.
• The Controller does not under any circumstances replace safety elements in a heating
circuit, boiler, DHW heating and electric devices in a heating system!
• Any equipment or accessories that are not in perfect condition must be replaced
immediately.
• When it is obvious that safe operation of the controller is not possible any more, e.g. due
to a casing damage, it shall be switched off immediately.
• Use original spare parts and accessories only.
• Marking of the Manufacturer and Distributor shall not be altered or removed.
• When installing accessories, follow the instructions in this manual and in the accessories
manual.

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7.2. DISPLAY AND INPUT
Display and LED light
The display (a) shows in text and graphical mode the hydraulic variant, desired and measured
values and other text information.
the LED light (b) is used to indicate the status:
• is lit green – when a relay is switched on and the Controller works correctly
• is lit red - when Auto mode is set and all relays are off
• ashes slowly red – when Manual mode is set
• ashes fast red - when an error is present
Keys
Entries are made using 4 keys (c, d), to which contextual functions are assigned.
The „esc“ key (c) is used to cancel an entry or to exit a menu.
The keys (d) - their actual function is shown in the display right above the keys; the right-hand
key generally has a conrmation and selection function. Possible functions of keys (d):
+/- increase / decrease values
▼/▲ scroll down / up menu
Yes / No conrm / reject
Info further information
Back to previous
OK conrm selection
The graphics mode appears if no key is pressed for 2 minutes or after exiting the main
menu with „esc“ (c). The temperature overview appears when you press the left button (d).
Tapping the button again leads back to the graphic overview. Pressing the „esc“(c) key in the
graphics mode takes you directly to the main menu.

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7.3. CONTROLLER SETTINGS (LOAD UNIT WITHOUT ACCESSORIES)
Having nished the complete installation of the entire heating system, lled it with heating
water and performed pressure test, install the controller sensors in the dedicated places of
the system according to chapter 6. If any optional accessories are to be used, connect it
according to chapter 8.
Before connecting the pump station for the rst time, make sure that:
• the entire heating system is completely pressurized and air bled
• all safety elements of the system are installed and put into operation, especially the
safety valves on the boiler and the thermal store, the expansion vessel is connected and
properly pressurized, the boiler thermal safety relief valve is properly connected and put
into operation
• all temperature sensors are installed in their installation positions
• all valves and stopcocks are open that shall be opened during operation of the heating
system
STEP 1 – PROGRAM SELECTION
When the pump station is switched on, the TRS6 BIOMIX controller automatically starts in the
mode of language, date and time settings.
You will then be asked to run the setup wizard - conrm with OK. Using the setup wizard,
follow the steps below to select a hydraulic variant.
1.1. Using the up/down keys to set the hydraulic
variant 1. DUO+HC+solid fuel boiler“ and press
Info.
1.2. The selected program 2 appears on the display;
conrm it by pressing the OK key (bottom right).
Conrm all the following settings (S/W day, S/W night, heating curve) by pressing OK.
STEP 2 – ADJUSTING A HEATING CURVE DEPENDING ON A SPECIFIC
HEATING SYSTEM TYPE
Now it is necessary to enter the heating curve parameters according to the type of your
heating system and its calculated maximum temperature. The maximum design temperature
of the heating system can be obtained from your installer or from your heating system design.
As an example, here are typical values for:
A - oor heating B– low-temperature radiators C- high-temperature radiators

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! Choose only one of the examples shown above!
A B C
COURSE OF ACTIONS FLOOR HEATING
(design temperature 42 °C / 35 °C
LOW-TEMP. RADIATORS
(design temperature 55 °C / 45 °C)
HIGH-TEMP. RADIATORS
(design temperature 70 °C / 55 °C)
2.1. Use - / + keys to set the curve break point to 10 °C and press OK. 2.2. Using the - / + keys, set the slope of the curve’s rst section to the value: 0.9 for A – oor heating 1.6 for B – low-temperature radiators 2.4 for C – high-temperature radiators and press OK. 2.3. Using the - / + keys, set the slope of the curve’s second section to the value: 0.6 for A – oor heating 0.9 for B – low-temperature radiators 1.2 for C – high-temperature radiators and press OK.

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STEP 3 – COMPLETING THE CONTROLLER BASIC SETTINGS
Having nished the previous steps, keep pressing the OK button until
you reach setting the maximum heating circuit temperature. Follow the
instructions below to set up.
3.1.
Using the - / + keys, set the Max. temperature of the
heating circuit. The maximum temperature of your
heating system can be obtained from your installer or
from your heating system design. The typical value
for oor heating is 45 °C, for low-temperature radiators
55 °C and for high-temperature radiators it is 70 °C.
Then press OK.
Continue by pressing the OK button until the display
asks you to save the changes. Press the YES key to
save the set values.