Romotop DIRECT User manual

en
ROMOTOPspol. s r.o.
Komenského 325
742 01 SuchdolnadOdrou
CzechRepublic
tel.:[phone]
fax:[phone]
e
-
mail:
[e-mail]

en GeneralInstallationand OperationManualfortheRomotop
DIRECTAutomatic CombustionRegulator
TheRomotopDIRECTautomaticregulatormustbeoperatedincompliance withthis manualonly!
UnauthorizedmodificationoftheRomotopDIRECTautomaticregulatoris notpermitted!
All localregulations, includingregulationsrelatingtonationalandEuropeanstandardsforthistypeof
device,mustbeobservedduringinstallationoftheRomotopDIRECTautomaticregulator.
Keepthis manualina safeplace so thatyoucanrefer to itatthebeginning ofeachheating season.
1. Introduction
2. Generalprovisions
3. Romotop DIRECT automaticregulatorparameters
4. Description oftheregulation process
5. Safetyregulations
6. Variants ofthe RomotopDIRECT automaticregulatorand assignmentto fireplaceinserts
7. Listof RomotopDIRECTautomaticregulatorcomponents
8. Servomotorassembly
9. Temperaturesensorassembly
10. Doorswitch assembly
11. Assemblyand description ofthe RomotopDIRECTcontrolunit
12. Doorswitch assembly
13. Electricalwiringdiagram
14. Description ofthefrontpanelofthe RomotopDIRECTcontrolunit
15. Description ofsignalization and settingLEDbrightness
16. Description oftheregulation process
17. Description and selection ofthecombustion mode
18. Tableoffurnaces (defaultconfiguration)
19. Outageof~230Vsupply
20. Warrantycertificate
21. Deliveryprotocol
1. Introduction
The RomotopDIRECT automaticregulatorisastate-of-the-artelectronicdevice that,together withyour
fireplaceinsert(orfireplace stove),maximizestheefficiencyofthecombustion process. The Romotop
DIRECT automaticregulatorisspecificallydesignedand configuredforyourconcretefireplaceinserton the
basisofourextensiveexperience and measurementsofthecombustion process usingstate-of-the-artHoriba
technology, used byleadingEuropean laboratories, directlyin theRomotoptestingroom.
The RomotopDIRECT automaticregulatoroptimizescombustion inthefurnaceand thusensures
economicaland ecologicalfuelcombustion. Atthesametime,it ensuresmore even, longer heatingofthearea
after each stoking. This also has apositiveeffecton thehygieneoftheheated area.
The RomotopDIRECT automaticregulatorthus increases personalcomfort.
The RomotopDIRECT automaticregulatorreducestherisk ofoverheatingthefireplace insertand
consequentlyoverheatingtheheatedarea.Thismeans saferoperation ofthefireplaceinsert,especiallyinlow-
energyhousesand increases theservicelife ofthefireplaceinsert.
The RomotopDIRECT automaticregulatoriscontrolledbyacontrolunit,whichcomparescurrent
combustion withthecombustion optimization programand basedon thisassessmentdirectlyregulatesthe
amountofairsupplied to thecombustion process in thecombustion chamber ofthefireplace insert.
Advantages oftheautomaticcombustionregulator
•regulates and optimizes thecombustion process
•prolongs thecombustion process and stokingintervals
•reducesfuelconsumption
•prevents overheatingofthefireplace stove
•improves areahygiene
•improves heatcomfortofthearea
•increases heatingsafety
•prolongs theservice lifeofthefireplace stove
•increases theefficiencyofthefireplace stove
•provides an acousticand opticalsignalofthesuitablemomentforstoking.
Functions oftheautomaticcombustionregulator
•regulates theamountofairsupplied to thefurnace dependingon thefurnacetemperature
•providesanacousticandopticalsignalattheendofactivecombustion andthebeginningoftheheat
radiation process
•theuser is thus informedofthesuitabletimeforfurther stoking
•allows regulation ofcombustion in thefurnace tobeset
•provides an acousticand opticalsignalifthefire dies after starting
•improves heatcomfortofthearea
•increases heatingsafety
•prolongs theservice lifeofthefireplace stove

2. Generalprovisions
•Thismanualispartoftheproductand mustbestorednearthedevice toallowquickand easyaccess
to information.
•Thedevice is notintended foruseforpurposes other than thosedescribed in this manual.
•Thedevice mayonlybeusedforthepurposesforwhichit hasbeendesignedand inaccordancewith
theconditions stipulated bythemanufacturer.
•Theproductmustnotbeused as asafetydevice.
•Before use,check therangeofconditions forthegiven application.
•Theoperatormustregularlyconductavisualcheck ofthedevice and ensurebasicmaintenance.
3. RomotopDIRECTautomaticregulatorparameters
Technicalparameters
•Power supply:230VAC+/-15%
•Consumption:1.4 Wwhen theservomotoris running
•Consumption:1.2 Wwhen theservomotoris notrunning
•Ingress protection:IP20
•Noiselevel: <42 dB
•Inputs:1 analog– temperature sensor
1 logiccommand -doorswitch
1 power supply(230VAC+/-15%)
•Outputs:1 servomotorcontrol(24VAV/DC, 1VA)
1 acoustic– signals whenstokingis required
1 optical– LEDsignalization oftemperature (1xgreen, 3x yellow, 1xred)
•Theelectricaldevicewastested in accordancewith thefollowingstandards: SNEN60730-1, SN
EN55022 and SNEN61000-6-1.
•Theelectricaldevicecomplies with thefollowingstandards: SNEN55014-1 ed.3:2007, SNEN
55014-2:1998, SNEN62233:2008, SNEN61000-3-2 ed.3:2006, SNEN61000-3-3 ed.2:2009,
SNEN60335-1 ed.2:2003, SNEN60335-2-102:2007
Parameters ofthecentralunit
•Frontpaneldimensions:125x95 mm
•Recess depth:80mm
•Weight: 200 g
•Installation:theunit is designed to beinstalled in awall, alternativelyon the
fireplacestovebody, in theplace designated bythestovemanufacturer
•Degreeoffouling:1 /dry, non-conducting/
•Operatingtemperature:0 to 50°C
•Storagetemperature:-10 to +60°C
•230 Vconnection cablenotincluded in thedelivery!!!
•Rated pulsevoltage:categoryII
•Forconnection ofindividualconductors referto thewiringdiagram
Accessories included:
•1x RomotopDirect regulationunit
•1xrecess box(forwall installation)
•1xtemperature sensorwith screwfitting
•1xservomotorwith installation accessories, includingcables
•!230Vconnection cablenotincluded in thedelivery!
Additionalaccessories:
•doorswitchwithconnection cable-theassemblydiagramforthedoorswitchisincludedinthe
delivery
4. Descriptionoftheregulationprocess
Whenstartingafire inthefireplacestove,the RomotopDirect automaticregulation unit willbeginthe
process ofregulatingcombustion byeither manuallypressingthestartbutton orthedoorswitch.Thesystem
assessesthetemperatureinthecombustion chamber fromthebeginningofthecombustion process. Basedon
thisvalue,the RomotopDirect automaticregulation unit evaluatesthestateofcombustion inthecombustion
chamber and optimizestheamountofairand place it issuppliedinthecombustion process. Theamountofair
suppliedisrealizeddirectlythroughthefireplaceinsert(fireplace stove) fixer,whichistheonlyregulatory
componentdesignatedand allowedbythemanufacturer.The RomotopDirect automaticregulation unit also
optimizesthecombustionprocess basedon information whether thefireisbeingstarted, heatingisinprogress
orit istheend ofthecombustion process. Everytimethestartbutton ispressed, orthefeedingdoorwithadoor
switch is opened during thecombustion process, the RomotopDirect automaticregulationunit re-evaluatesand
re-optimizesthecombustion process basedon thecurrentstateoftheinterruptedcombustion cycle.Attheend
ofthecombustion cycle,anacousticsignalsounds and thegreenLEDstartstoflash to informtheuser thestove
shouldbestokedand anewcombustion cyclestarted. Theprogress ofthecombustion cycleismonitoredby
LEDs installedundertheglass ofthefrontpanelofthe RomotopDirect automaticregulation unit (forthecolor
spectrum,seethe Operation section).Attheendofheatingand blowingthroughthecombustion chamber,the
airintaketothechamber iscompletelyclosed. Theregulatorswitchesto STANDBY modeuntil thenextfire is
started.
Graphofthedependenceoftemperatureand timeinregulated and non-regulated combustion
non-regulated burningcurve
regulated burning curve
time
temperature

5
4
3
1
2
5. Safety regulations
•Thedevice mustnotbeused in rooms thatare exposed to chemicals, dust,gases orvapors with arisk
offire orexplosion.
•The RomotopDirect automaticregulation unit can onlybeconnected to an alternatingcurrentpower
pointwith voltageof230V/50Hz.
•All electricalwork forconnection and installation mustbeexecuted in accordance with relevantvalid
nationaland regionalstandards and regulations, and in compliance with theprovisions ofthelocal
electricitysupplier.
•Electricalinstallation, placementinto operation, maintenance and repairsofelectricalcomponents
mayonlybecarried outbyaqualified specialistaccordingto this manual.
•Ifaplugis used, onlyastandardized plugfor230VACpower supplymaybeused.
•Thepower supplycable,ifinstalled, mayonlybereplaced bythemanufacturer, its servicetechnician
oraperson with similar qualifications.
•Theconnectingpower supplyconductormusthaveasuitablediameter.
•Thepower supplycablemayonlybereplaced usingacablewith thesametypeofinsulation, i.e. with
thesameorahigher heatresistance and correspondingconductordiameter.
•Incaseofafixed connection, ameans fordisconnectingthedevice fromthemains mustbeinstalled
with contactdisconnection atall poles and agap betweencontacts ofatleast3 mm.
•Avoid contactofelectricalwires with theliningand flue.
•Theelectricaldeviceis delivered asan accessoryto Romotop fireplace inserts and stoves and must
notbedamaged in anyway.
•Duringinstallation ofthe RomotopDirect automaticregulation unit, duringrepairorexchangeofits
electricparts, thedevicemustbedisconnected fromthepower supplynetwork.
•Voltagefluctuations ofmore than 10%maydamagetheelectricalcomponents ofthefireplace insert
(stove), thereforewerecommend theinstallation ofsuitablevoltagesurgeprotection.
•WARNING!Alwaysuseonetypeofvoltageonoutputterminalsofthecontrolunit onlyand never
connectsafe and lowvoltagesidebyside!
•Before connectingthedevice, doublecheck thesupplyvoltage.
•Avoidanycontactofthedevicewithwaterorhumidityand alwaysusethedeviceunderthe
prescribedoperatingconditions. Protectthedevice fromtheeffectsofsignificantfluctuationsin
surroundingtemperature athighatmospherichumidityinorder topreventcondensation ofwater
vaporin thedevice.
•Before anymaintenancework, disconnectall power supplies!
•Maintaintheprescribedmaximumcurrentloadofoutputs-see Technicalparameters -electrical
data.
•Ensure thatsupplytotheprobe,theloadand power suppliesare placedseparatelywithsufficient
distance between them,withoutmutualcrossoverand parallelconduction.
•Whenusedinanenvironmentwithincreasedindustrialinterference,useanetworkfilter and voltage
surgeprotection.
•This device is notdesigned forusebypersons (incl. children)whosephysical, sensoryormental
disabilityorlack ofexperience and knowledgeprevents themfromusingtheequipmentsafely, unless
theyare under supervision orunless theyhavebeen instructed in howto usethedevicesafelybythe
person responsiblefortheirsafety.
•Children mustbekeptunder supervision to ensure theydo notplaywith thedevice.
•Incaseofadefectorincorrectfunction, send thedevice backtothedistributor,together witha
detailed description ofthedefect.
•Defects causedby incorrect connectionto themains are notcoveredby thewarranty.
6. Variants oftheRomotopDIRECTautomaticregulatorand assignmentto fireplace inserts
Regulator model-trade
identification Variants ofservomotor fixtures Color ofthefrontpanel
REG01 Short Black
REG02 Short White
REG03 Long Black
REG04 Long White
Regulator model REG01, REG02 REG03, REG04
KV productseries KV DYNAMIC2G KV 6.6.3
KV productseries KV 025LN KV 025LN*
KV productseries KV 025W KV ANGLE 2G88.51.44.
KV productseries KV ANGLE 2G66.44.44.
KV productseries KV ANGLE 2G66.51.44.
KV productseries
KV productseries
* alongservomotorfixture maybeused fortheKV025 LNifthefireplace insertis lifted byatleast3 cmusing
screwed footings.
7. ListofRomotopDirectautomaticregulatorcomponents
1. Romotop Direct regulationunit 1x
2. servomotorassembly1x
3. temperaturesensorscrewfitting1x
4. temperaturesensor1x
5. servomotorcables1x
frontpanelvariant-black
frontpanelvariant-white
shortfixture
longfixture

8. Servomotorassembly
8.1 Descriptionofservomotorcomponents
Note: Before installing theservomotorremovethebackstopfromservo!
8.2 Dimensionaldrawing oftheservomotorassembly
8.3 Installationofservomotorassembly
1) Unscrewthe3x M6 screws pos.1 fromthebottomofthefireplace insertand removethe lidpos.2.
1
2
2) Movetheairintakecontrollever tothefar rightposition and mounttheservomotorassemblyon the
bottomofthecontrollever axis, see picture. The magnetickeypos.1mustremainmountedon the
servomotorduringinstallation. Therecommendedposition oftheservomotorrotating componentis
depicted in thefigurebelow, defined bytheposition ofthe M4 screwpos.2.
1
2
fixture(short-long)
axis
teflonwasher
spring
3xwasher
M4x30screw
2xforthelongvariant
M4self-tappingscrew
plasticservomotorfixture
Magnetickey
servomotor
backstopfromservo2x

3
5
2
4
1
Servomotorbackstop-fromtheleft
Servomotorbackstop -fromtheright
Indicatorofservomotopposition
Note: After installing theservomotorre-mounttheservomotorbackstops defining theoperation
oftheservomotor.
Procedure:
3) Aircontroll setintothezeroposition (fullyclosed),press lightlyand hold. Withtheother hand snapthe
backstop oftheservomotorfrombellow, fromtheleftofrotaryposition indicatoroftheservomotor.
4) Aircontroll setintothemaximalposition(fullyopened),press lightlyandhold. Withtheother hand snap
thebackstop oftheservomotorfrombellow, fromtherightofrotaryposition indicatoroftheservomotor.
Note: Before thefirststartup oftheautomaticcontroldonotforget toremovethemagnetickeyfrom
servomotor.
9. Temperaturesensorassembly
9.1 Descriptionoftemperature sensorcomponents
Description ofpositions according tothe
installation manual
pos.2 -screwfitting
pos.3 -temperature sensor
pos.4 -swivelnut
pos.5 -loop
9.2 Installationofthetemperature sensorinto thedome
1).Unscrewthe M10 screw fromthesideofthe dome pos.1.
2).Install screw fitting pos.2 into thecreated opening.
3).Usingamarker, mark a distance of17.5 cm fromthetip ofthe temperaturesensorpos.3.
4).Slidethe swivelnutpos.4 and looppos.5 onto the temperature sensorpos.3 up to themarked distance.
5).Insertthetemperature sensorthrough the screwfitting pos.2 into the domepos.1 up to the looppos.5
and secureusingthe swivelnutpos.4.
6). Adjustthetemperature sensorto ensure thatthegreen cableis nottouchinganypartofthefireplace
insertbody.
9.3 Installationofthetemperature sensoronthetopplate.
1).Unscrewthe M10 screw fromthe topplate pipepos.1.
2).Install screw fitting pos.2 into thecreated opening.
3).Usingamarker, mark a distance of20 cm fromthetip ofthe temperaturesensorpos.3.
4).Slidethe swivelnutpos.4 and looppos.5 onto the temperature sensorpos.3 up to themarked distance.
5).Insertthetemperature sensorthrough the screwfitting pos.2 into the topplate pipepos.1 up to the loop
pos.5 and secure usingtheswivel nutpos.4.
6). Adjustthetemperature sensorto ensure thatthegreen cableis nottouchinganypartofthefireplace
insertbody.
3
5
2
4
3
5
2
4
1

9.4 Installationofthetemperature sensorontheKV6.6.3
1).Unscrewthe M10 screw fromthe ceiling oftheKV6.6.3 pos.1.
2).Install screw fitting pos.2 into thecreated opening.
3).Usingamarker, mark a distance of6 cm fromthetip ofthe temperature sensorpos.3.
4).Slidethe swivelnutpos.4 and looppos.5 onto the temperature sensorpos.3 up to themarked distance.
5).Insertthetemperature sensorthrough the screwfitting pos.2 into the ceiling oftheKV6.6.3 pos.1 up to
the looppos.5 and secureusingtheswivel nutpos.4.
6). Adjustthetemperature sensorto ensure thatthegreen cableis nottouchinganypartofthefireplace
insertbody.
9.5 Installationofthetemperature sensorontheKV025W
1).Unscrewthe M10 screw fromthepipein the ceiling oftheKV025W pos.1.
2).Install screw fitting pos.2 into thecreated opening.
3).Usingamarker, mark a distance of10 cm fromthetip ofthe temperaturesensorpos.3.
4).Slidethe swivelnutpos.4 and looppos.5 onto the temperature sensorpos.3 up to themarked distance.
5).Insertthetemperature sensorthrough the screwfitting pos.2 into thepipein the ceiling oftheKV025W
pos.1 up to the looppos.5 and secureusingtheswivel nutpos.4.
6). Adjustthetemperature sensorto ensure thatthegreen cableis nottouchinganypartofthefireplace
insertbody.
3
5
24
1
10. Doorswitchassembly
Note:
Theassemblyandconfigurationmanualfor thedoor switcharepartofthepackageddeliveredbythe
manufacturer.
Before installation ofthedoorswitch, it isnecessarytoopenthefeedingdoorand removethecover ofthe
doorswitch holeatthebottomoftheframe, which is secured bytwo M4x8 hexkeyscrews.
11. ssembly and descriptionoftheRomotopDIRECTcontrolunit.
I. Place therecess boxinto thewall in aplacewherethetemperaturewill notexceed 50 °Cand
secure it in place.
II. Conducta230Vpower supplycableto thebox.
III. Conducttheservomotor,temperaturesensorand possiblythedoorswitch cableto thebox.
IV. Connectthecables to the RomotopDIRECT controlunit board in accordance with themanual,
see section 12. ElectricalwiringdiagramfortheRomotopDirect controlunitboard.
V. Usetheswitch on theback ofthefrontpanelto selectthecorrectfireplaceinsertfurnace in
accordancewith themanual, see section 14. Configurationoffireplace insert furnaces.
VI. Mountthefrontpanelontherecess box.
VII. Connectthe230Vpower supplycableto theelectricitynetwork.
coverofholeforthedoorswitch
3
5
2
4
1

11.1 Instructions forinstallationoftherecess box
1. Place therecessboxintoapre-preparedholeinsuchawaythatitsouter edgeisalignedwiththe
renderingofthewall and secure it inplace usingappropriatecement,plaster,etc.Thenfinish and clean
theopeningup to theedgeofthebox.
2. Usethe4screwstoattachthereduction frametotherecess boxwiththewhitedotfacingupwards.
Before tighteningthescrews, rotatetheframetoalignit inahorizontalposition. Thentightenthe
screws.
3. Before installation ofthecontrolunit,connectall cables, includingthetemperaturesensor.Mountthe
controlunit with thefrontpanelon theframebyplacingthehooks into theholes and pullingdownward.
11.2 DescriptionofRomotopDIRECTcontrolunitcomponents
11.3 Dimensionaldrawing oftheRomotopDIRECTcontrolunit
125
front panel
119
recessbox
89
recess box
79,7
recessbox
95
front panel
78,5
frontpanelwithcontrolunit
RomotopDirect
recess box
Recess box
Reduction frame 4 securingscrews

Central
unit
Temperat
ure
sensor
Door
switch
Servomotor Mechanical
fixer
230 V
12. Doorswitchassembly
12.1 Basicinformation
Thedoorswitchisusedforunmannedcontroloftheautomaticcombustion regulatororforcontrolof
externalequipment/fumehood, fan, etc.Thedoorswitchisintendedforswitchingtosafe lowvoltageand
ensurestheconnection and disconnection oftheelectriccircuit betweenthebottomswitchsection and the
switch body. Thedoorswitch maybeused up toatemperature of350 °C.
12.2 Installationmethod:
1 -distance d between thedoorand theframeexceeds 13 mm (additionalinstallation possible) -seeFig.1
2 -install thesection oftheconnection cablewithglass fibrebraidingto thedoorswitch, thesection with silicon
to thecontrolunit
3 -connecttheconductors in accordance with Fig.2;when earthing, it is importantto ensure correct
polarization:thedoorswitch bodyis connected toaconductorwith apositivepole(brown), theframe(plate)
mustbeconnected to aconductorwith anegativepole(blue).
12.3 Maintenance ofthedoorswitch
Keepthedoorswitchandespeciallymovablecontactsurfacesclean.Ifmovementbecomesstiff,cleanwitha
vacuum.Iftheswitchisnotworkingduetofouling,it maybetakenapartand cleaned. To takethedoorswitch
apart, unscrewthebottomswitch section. Do notuseanypreservatives orlubricants on thedoorswitch.
12.4 Contents ofthepackage
-doorswitch, top plate, tighteningnut
-1.5 mm hexkey
-screw ø3.9 x13 mm, 2 pieces
-two-wire cable:-0.5mglass fibrebraiding+2.5msilicon
Fig.1
Fig. 3
13. Electricalwiring diagram
13.1 Blockdiagram
13.2 Electricalwiring diagramfortheRomotopDirect controlunitboard
black
white
red
blue
brown
white
green
Descriptionofelectricalconnection:
S1 Servomotor
DSDoorswitch
TS Temperaturesensor
CONFIGURATION Switch forselection offireplaceinsert
LPhase
NZero conductor
Note:
Thesupplycablefromtheservomotor and thecablefromthedoor switchareequipped with corresponding
connectors.
Door
Frame
Secure
withscrew Negative
pole-blue
Positive
pole-brown

colorLEDstrip1xgreen,3xyellow, 1xred
rightcapacitybutton
leftcapacitybutton
13.3 Electricalwiring fortheservomotorwithregulator
14. DescriptionofthefrontpaneloftheRomotopDirect controlunit
15. Descriptionofsignalizationand setting LEDbrightness
15.1 Descriptionofsignalization
Lightsignalization consistsof5LEDdiodes, i.e.1xgreen, 3xyellowand1xred. Thisdivision simulatesa
trafficlight, where:
greenlight means go -in this case, startorstoke
yellowlight means wait orgetready-inthiscaseheatingup orcoolingdown. There arethree yellowLEDs
installedthatturnon and off dependingon thetemperature ofthefurnace.Whenall three lights
are on, thecombustion process is in optimalmode.
redlight means stop -inthiscaseit informstheuser thattherecommended(orpermitted)combustion
temperatureoftheconcretefurnaceand outputhasbeenexceeded. Itthereforeindicates
overheating, i.e.an excessiveamountoffuelfed into thefurnace.
Ifthegreen lightflashesevery2 sec, it means it is timeto stokethefire.
Ifthegreen lightflashesevery5 sec,it signalsthatthefurnace isburning outand thatit isswitching toStand
Bymode.Atthismomentit isstillpossibletorestartand continuethecombustion process bystokingwithout
theneed to restartthefire.
Ifbothredand greenlightsare flashing every5sec,it means thatthefire didnotbegin burningafter thestart
phase.
Ifonlythered lightflashes every5 sec, it signals adefectin thetemperaturesensor.
All thisinformation issummarizedinaclear tablebelowwithadescription oftheoperation ofthe Romotop
DIRECT controlunit.
15.2 Setting LEDbrightness
You cansetthebrightness oftheLEDstosuit yourneeds.You canchoosethreebrightness levelsbybriefly,
repeatedlypressingtheleftcapacitybutton. Whenyouarehappywiththesetting,saveyourselection bybriefly
pressingtherightcapacitybutton, as indicated in the RegulatorOperation-configuration tablebelow.
Standardservomotor
Key
S1
TS
DS
230V
-servomotorofmechanicalfixer
-fluegastemperaturesensor
–doorswitch
–supplyvoltage
s
c
h
w
a
r
z
w
e
i
ß
r
o
t
a
n
g
e
s
c
h
l
o
s
s
e
black
white
red
blue
brown
white
green
b
l
a
c
k
w
h
i
t
e
r
e
d
n
o
t
c
o
n
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e
c
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e
d