Tech Controllers EL480zPID User manual

User manual
EL480zPID

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Declaration of Conformity No. 60/2010
Hereby, we declare under sole responsibility that the ST-480
230V 50Hz thermoregulator manufactured by TECH,
headquartered in Wieprz 1047A, 34-122 Wieprz, is compliant with
the Regulation by the Ministry of Economy. (Journal of Laws Dz.U.
155 Item 1089) of July 21, 2007 implementing provisions of the
Low Voltage Directive (LVD) 2006/95/EC of January 16, 2007.
The ST-480 controller has been tested for electromagnetic
compatibility (EMC) with optimal loads applied.
For compliance assessment, harmonized standards were used:
PN-EN 60730-2-9:2006.

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I. Description
EL–480 temperature controller is intended for use with central heating boilers equipped with
feeding screw. It controls water circulation pump, domestic hot water pump, floor heating
pump, circulation pump, blower (fan) and fuel feeder. It incorporates a valve control module
and can operate with two mixing valves (via additional ST-61 modules), conventional (two-
state) room controller or RS-port communication, GSM module or Ethernet module.
The advantage of the controller is the ease of use. The user can change all parameters
using the pulser knob. Another advantage is the large and easy-to-read display where the
current boiler operation parameters are shown.
Exemplary view of the main screen:
Any remarks regarding the programme should be reported to the boiler manufacturer. Each
driver should be adjusted according to individual needs depending on the fuel type used and
the boiler type. TECH shall not be held liable for wrong adjustment of the controller.
The EL480zPID controller is a unit with a continuous output signal using a modified PID control
algorithm. In this type of controller the blowing power is calculated by measuring the boiler
temperature and the flue gas temperature as measured at the outlet of the boiler. The fan is
run continuously and the blowing power depends directly on the measured temperature of the
boiler, the flue gas temperature and the difference between these parameters and their set-
points. The advantages of a modified PID controller include the ability to maintain a stable set-
point temperature without any unnecessary overshoot or oscillations.
When using this type of controller equipped with a flue gas outlet sensor fuel savings can
be achieved from a few percent up to around 15 percent with the output water temperature
kept at a very stable label, resulting in longer life of the exchanger (boiler). As the flue gas
temperature at the boiler outlet is controlled this results in low emissions of dust and gases
that are harmful to the environment. The thermal energy of the flue gas is not wasted and
released into the chimney, but is instead used for heating.
Below we present the results of tests conducted with the use of the Tech controller with PID
control:

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and the same controller without PID control:
Basic terms
Operation–once activated the controllers enters the operation mode and a "WORKING"
message appears on the display. It is the basic state of the controller where the blower is
operating continuously and the feeder operation time is set by the user (both operation time
and pause time can be set).
Sustain mode–the mode is entered automatically if the temperature is higher than or equal
to the preset temperature. In such a case the controller feeds the fuel slowly to reduce the
temperature smoothly and a "SUSTAIN" message appears on the display. Both pause time and
operation time in sustain mode have to be configured for the temperature to be reduced
properly.
II. Functions of the controller
This chapter describes the controller functions, methods of changing the settings and use of
the menu with the pulser (knob). The main controller screen displays boiler operating
parameters. Operation mode and a number of other settings can be selected by the user
according to the individual needs.
II.a) Main page
Main page is displayed on the graphic display during normal operation of the controller. Other
main screens are displayed according the operation mode.
Once the pulser knob is pressed the first level menu appears. The display shows three initial
menu options. Further options are available after turning the knob. An option can be selected

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by pressing the knob. Similar procedure is followed when changing the parameters. In order
for the changes to be input they need to be confirmed by pressing the pulser after the
"CONFIRM" message appears. If the user does not intend to make any changes in a function
the pulser should be pressed after the "CANCEL" message is displayed. Select "EXIT" in the
menu or use EXIT button to exit the menu.
Stand-by mode button located on the controller housing allows disabling all operating units
quickly, if necessary. It serves as an additional emergency protection to cut-off power supply
to all operating units of the controller (feeder, fan, pumps).
ATTENTION: Power supply to the controller is not cut-off in the stand-by mode.
II.b) Screen view
The user can select one of three main screens of the temperature controller operation using
that function. They include:
central heating screen (displays current boiler operation mode) valve (displays working
parameters of the valve)
valve 1 (displays working parameters of the first valve).
valve 2 (displays working parameters of the second valve).
NOTE The valve parameter views are available only if the valves have been properly preinstalled
and configured by a technician.
II.c) Preset temperature of the central heating system
The option is used to set the boiler temperature. The user can change the boiler temperature
within the range of 45OC to 80OC. The preset central heating system temperature can also be
changed directly in the main screen of the controller by turning the pulser knob.
Additionally, the preset central heating system temperature can be adjusted using the room
temperature reduction function (see Item II.15) and the weekly control function. The preset
temperature is a sum of all those values but it may not exceed the range of 45OC to 80OC.

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II.d) Preset temperature of hot domestic water
The option is used to set the temperature of hot domestic water. The temperature is adjustable
within the range between 40°C and 75°C.
II.e) Manual operation
For your convenience the controller is equipped with a Manual operation module. When this
function is active each actuator (blowing, central heating pump, hot water pump, additional
circulating or valve pump) can be switched on or off independently and each active mixing valve
can be closed, opened or stopped.
You can start the motor of your selected device by pressing the pulser. The device will remain
activated until the pulser is pressed again.
Additionally, an option to control the blowing power is available where you can set any
fan speed in manual mode.
II.f) Pump operation modes
This function allows you to select one of the following four boiler operation modes:

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II.f.1) House heating
When you select this option the controller switches over to a mode where heating is provided
only to heat the central heating circuit. The central heating pump begins to run above the pump
activation temperature (factory set at 38OC - see Section III.g). The pump will turn off below
this temperature (minus a hysteresis of 2°C).
II.f.2) Boiler tank priority
In this mode, the boiler tank (hot water) pump will be switched on first to run until the set-
point temperature is reached (see Section II.e), after which the pump will be turned off and the
CH circulating pump will be enabled.
The central heating pump will run all the time until the boiler tank temperature drops below its
set-point by the hot water hysteresis value. At that moment the CH pump will turn off and the
HW pump will turn on (both pumps operating alternately).
In this mode the fan and the feeder are run only up to 62OC as measured at the boiler
(instantaneous set-point) so as to prevent overheating of the boiler.
NOTE: The boiler must be fitted with check valves on the central heating and hot water pump
circuits. The valve mounted on the hot water pump is to prevent drawing hot water from the
boiler tank.
II.f.3) Pumps in parallel
In this mode both pumps begin to run together (in parallel) above the pump activation
temperature. However, these temperatures may vary for each pump, depending on your
settings (see Sections III.g-h). When this is so one of the pumps will switch on earlier than the
other one, but after both thresholds are crossed both pumps will run together. The central
heating pump will run all the time while the hot water pump will turn off when the boiler tank
set-point temperature is reached. It will turn on again when the temperature drops by the
preset HW hysteresis value below its set-point.

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II.f.4) Summer mode
Once this function is activated the central heating pump will be off and the DHW pump will turn
on above the preset activation temperature (see Section III.h) and will work continuously until
the temperature drops below the activation temperature by the hot water hysteresis value or
until the following conditions are met:
(boiler temperature) + 2°C ≤ (boiler tank temperature)
In summer mode you only enter the set-point temperature of the boiler, which is also
understood to mean the set-point temperature of the boiler tank.
II.g) Weekly control
The function is used to programme daily changes in the boiler temperature. The preset
temperature deviations are within the range of +/-100C.
Step #1:
The user needs to set current time and date first (Installer menu > Clock).
Step #2:
The user sets temperature values for individual days of the week (Set mode 1):
Monday–Sunday
Select specific hours and required deviations from the preset temperature (how many degrees
the temperature should rise or drop) for each day of the week. Additionally, the preset values
can be copied to facilitate the operation.
Example
Monday
preset: 3 00 , temp. -10°C (temperature change– 10°C)
preset: 4 00 , temp. -10°C (temperature change – 10°C)
preset: 5 00 , temp. -10°C (temperature change – 10°C)
In such a case, if the temperature preset on the boiler is 60ºC, it will drop 10ºC to
50ºC between 3 a.m. and 6 a.m. on Monday.
As an alternative to the temperatures being preset separately for individual days, the
temperatures can also be set collectively, in the second mode, for the working days (from
Monday to Friday) and the weekend (Saturday and Sunday) separately - Set mode 2.
Monday - Friday; Saturday - Sunday
Similarly to the previous mode it is necessary to select specific times and required deviations
from the temperature preset for the working days (Monday - Friday) and the weekend

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(Saturday, Sunday).
Example
Monday - Friday
preset: 3 00 , temp. -10°C (temperature change – 10°C)
preset: 4 00 , temp. -10°C (temperature change – 10°C)
preset: 5 00 , temp. -10°C (temperature change – 10°C)
Saturday - Sunday
preset: 16 00 , temp. 5°C (temperature change +5°C)
preset: 17 00 , temp. 5°C (temperature change +5°C)
preset: 18 00 , temp. 5°C (temperature change +5°C)
In this case, if the preset boiler temperature is 60ºC, the temperature will drop 10ºC to 50ºC
between 3 a.m. and 6 a.m. on each day from Monday to Friday. However, the temperature
will rise 5ºC to 65ºC during weekend (Saturday, Sunday) between 4 p.m. and 7 p.m.
Step #3:
The user enables one of two preset modes (Mode1, Mode2) or disables the weekly control
option.
Once the mode is enabled the value of the deviation currently set is displayed on the main
page of the controller next to the preset central heating system temperature. This,
additionally, indicates that the weekly control is active.
Data deletion function is a simple method to remove all previously saved weekly
programme settings to enter new settings.
II.i) Fuel selection
This function is used to choose one of two fuel: coal or lignite. For each fuel there is suitable
blow force and fuel feeding frequency programmed.
II.j) Room temperature reduction
After the room controller reaches the preset temperature, the preset boiler temperature
(set in the installer menu - see Item III.16) will drop by the value set there. The reduced
temperature will not be lower however than the minimum preset central heating temperature.
Example: Temperature preset on the boiler: 55ºC
Room temperature reduction: 15ºC
Minimum temperature set on the boiler: 45ºC (factory setting)
Once the preset room temperature is reached (signalled by the room controller) the
temperature preset on the boiler will drop to 45ºC i.e. only by 10ºC although the room
temperature reduction is 15ºC. At the same time a message reading "!-10º" will be shown in
the main display next to the preset boiler temperature.
II.k) Factory settings
The controller is pre-configured for operation. However, it should be adapted to individual
needs. Factory settings can be restored at any time. Selection of “factory settings” option will
result in all boiler settings (saved in user’s menu) being lost and reset to boiler manufacturer’s
settings. Individual boiler parameters can be set at that point again.
ATTENTION: Restoration of factory settings will not cause the changes in service settings to be
deleted.

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II.l) Information about the programme
This function allows the user to check the controller programme version.
III. Installation menu
The functions of the installation menu should be set by the person installing the boiler or service
personnel of the manufacturer.
III.a) Fan coefficient
This function is used to adjust the fan power. If the blow force is too low/high, the coefficient
should be adequately increased/decreased in order to ensure efficiency.
The most common cause of inadequate fan operation is the considerable difference in voltage
supply for different recipients which has a significant impact on the fan functioning.
III.b) CH boiler power coefficient
CH boiler power coefficient serves to optimize the feeder operation so that it supplies an
appropriate amount of fuel. With this function the user may increase or decrease the amount
of fuel fed to the CH boiler (the amount is given in percentages).
After the CH boiler power is defined initially in the main menu, the CH boiler coefficient
enables the user to choose precisely the optimum amount of fuel, on the basis of the calorific
value of a given fuel type.
III.c) Room regulator
A room controller can be connected to ST-480 controller. This function allows to configure the
controller by selecting “ON” option. Additionally, the user may check the programme version of
the room controller.
After connection of TECH controller the user may check and change the preset
temperature of the central heating system, hot domestic water and the mixing valve.
Additionally all boiler controller alarms are displayed. When the operation involves the mixing
valve the user may preview the current external temperature while viewing the main screen
with the valve parameters .
After TECH Controller option is enabled a letter "P" appears in the upper part of the
display in the main screen of the controller. A flashing letter "P" indicates that the temperature
in the room is too low. As soon as the required room temperature is reached the letter "P" stops
flashing and stays on.
ATTENTION: No external voltage can be connected to the room controller output.

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III.d Main valve
III.a.1 Switch on
This feature allows you to temporarily make the valve inactive.
III.a.2) Set-point valve temperature
This setting is used to set the circuit temperature to be maintained by the mixing valve. This is
the main temperature based on which the room thermostat reduction function is to be run (see
Section III.a.10). The room thermostat reduction function is set separately for the CH system
(setting in the user menu) and separately for each of the valves.
III.a.3) Temperature control
This parameter determines the sampling (control) frequency of the water temperature
downstream of the valve for the central heating or hot water system. If the sensor indicates a
change in temperature (deviation from set-point), then the solenoid will open or close partially
by a preset step to restore the set-point temperature.
III.a.4) Opening time
You can use this function to set the time for the full opening of the valve, that is to say, how
long it takes to open the valve to 100%. This time should be selected according to your valve
actuator (shown on the nameplate).

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III.a.5) Single step
You can use this function to set a percentage value for a single step in the operation of valve
opening, that is to say the maximum percentage value of opening or closing that the valve can
move in a single step (maximum movement of the valve in one measurement cycle).
III.a.6) Minimum opening
Use this function to set the minimum value for valve opening. Below this value, the valve will
not close shut.
III.a.7) Type of valve
You can use this option to select the type of valve: central heating or floor type.
III.a.8) Weather program (weekly valve program)
In order to enable the weather function an outdoor sensor should be installed in a place not
exposed directly to sunlight or weather conditions. After installing and connecting the sensor
the Weather program function must be enabled in the controller menu.
For the valve to work properly enter set-point temperatures (downstream of the valve)
for the following four intermediate outside temperatures:
TEMP. FOR -20
TEMP. FOR -10
TEMP. FOR 0
TEMP. FOR 10
Heating curve - curve which is used to determine the set-point temperature of the controller
based on the outside temperature. In our controller this curve is established based on four
temperature set-points selected for their respective outside temperatures. Set-point
temperatures must be provided for the following outside temperatures: -20ºC, -10ºC, 0ºC and
10ºC.

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The more points there are available for constructing the curve, the greater is its accuracy, which
allows you to determine its shape in a flexible way. In our case, four points seem to be a very
good compromise between accuracy and ease of setting its shape.
Where in our controller:
XA= -20ºC, XC= 0ºC,
XB= -10ºC, XD= 10ºC,
YA, YB, YC, YD–set-point valve temperatures for their corresponding outside temperatures: XA,
XB, XC, XD
After weather control is enabled the valve set-point parameter is calculated based on the
heating curve. By changing this parameter you can decrease or increase all the weather control
settings.
III.a.9) Return protection
This feature allows you to enable protection for the boiler from excessively cold water returning
from the main circuit, which could cause the boiler to suffer from low-temperature corrosion.
The return protection function works to ensure that when the temperature is too low the valve
will close partially until the short circuit of the boiler reaches the desired temperature. This
feature also protects the boiler from a dangerously high return temperature to prevent water
from boiling.
When this function is enabled you need to set the minimum and maximum return temperatures.
III.a.10) Room thermostat reduction
This function is active only when the unit is operated with a (standard or TECH) room
thermostat. When the room thermostat reaches the desired temperature in the house/flat
(reports heated up condition), the valve will close to such an extent so that the temperature
downstream of the valve drops by the <room thermostat reduction> temperature.

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NOTE: If the installation includes a TECH room thermostat with RS communication (four-wire
cable), you may choose an option providing dynamic control for the mixing valve (see Section
III.a.11)
III.a.11) Operation of TECH thermostat
This setting is active only if the controller is connected with a TECH room thermostat (with RS
communication) and allows a choice in how the thermostat is to work together with the mixing
valve:
temperature reduction –when you select this mode after heating up the house/flat to
your required temperature set-point temperature the TECH room thermostat will lower the set-
point temperature of the valve by the pre-set room thermostat reduction value (see Section
II.a.10);
dynamic changes - when you select this mode after heating up the house/flat to the
set-point temperature the TECH room thermostat will work as per the following settings:
Change in valve set-point. This setting determines by how many degrees the valve
temperature is to increase or decrease with a single unit change in room temperature. This
function is closely related to the Room temperature difference parameter.
Room temperature difference. This setting is used to define the single unit change in the
current room temperature (accurate to 0.1°C) at which there is to occur a specific change in
the set-point temperature of the valve.
Example:
setting: Room temperature difference 0.5ºC
setting: Change in set-point valve temperature 1ºC
setting: Set-point valve temperature 40ºC
setting: Set-point room thermostat temperature 23ºC
Case 1. If the room temperature rises to 23.5ºC (by 0.5ºC) the valve will close to such an
extent as to have 39ºC as a set-point (by 1ºC).
Case 2. If the room temperature drops to 22ºC (by 1ºC) the valve will open to such an extent
as to have 42ºC as a set-point (by 2ºC).
III.a.12) Factory settings
This parameter allows you to restore the mixing valve settings saved by the manufacturer. By
restoring the factory settings you will not change the valve type setting (central heating or floor
type).

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III.b) Valve 1
NOTE: Control with an additional valve (1 or 2) is only possible after you purchase and connect
the controller to an additional control module (ST-61), which is not provided as standard
equipment with the controller. In order to control two valves you need to connect two ST-61
modules.
The options presented in this chapter are used to adjust the operating settings of an additional
mixing valve. In order for the valve to work properly and meet your expectations it should be
configured with its parameters set like in the case of the main valve.
III.b.1)Registration.
To register an additional valve enter the serial number of the control module of the ST-61 mixing
valve servo (look for the five-digit number on the cover of this module). Without this number
the valve cannot be activated.
III.b.2) Switch on (setting as for the main valve - see Section III.a.1).
III.b.3) Set-point valve temperature (setting as for the main valve –see Section
II.a.2)
III.b.4)Room thermostat
If the valve is to be operated with a room thermostat, you should select its type:
module controller (traditional two-state type –“from the module”),
standard or TECH controller (traditional two-state type –“from the controller”),
TECH algorithm controller (RS communication),
room temperature difference (setting as for the main valve –see Section III.a.11),
set-point change (setting as for the main valve –see Section III.a.11).
III.b.5) Temperature control (Setting as for the main valve –see Section III.a.3).
III.b.6) Opening time (Setting as for the main valve –see Section III.a.4)

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III.b.7) Single step (Setting as for the main valve –see Section III.a.5).
III.b.8) Minimum opening (Setting as for the main valve –see Section III.a.6).
III.b.9) Type of valve (Setting as for the main valve –see Section III.a.7).
III.b.10) Weather program (weather control) (Setting as for the main valve –see
Section III.a.8).
III.b.11) Return protection - (Setting as for the main valve –see Section III.a.9).
III.b.12) Additional sensors
When two mixing valves are used and you select this function you will be able to select the
sensors from which temperature data are to be retrieved for a valve (for return and outside
temperature sensors). Temperatures can be retrieved from the sensors of the valve being set
(Own) or as per the controller sensors (Main controller).
III.b.13) Room thermostat reduction (Setting as for the main valve –see Section
III.a.10).
III.b.14) External sensor adjustment
The external sensor is to be adjusted during installation or after prolonged use of the thermostat
if the outside temperature displayed deviates from the actual one. Adjustment range: -10 to
+10 OC with an accuracy of 1OC
III.b.15) Factory settings (Settings as for the main valve –see Section III.a.12)
III.b.16) Valve removal
This function is used to completely remove a valve from the controller memory. Valve removal
is used for example when removing or replacing a module (the new module requires to be
registered again).

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III.b.17) About the program
When this option is selected the display will show the software version of the active valve
module.
III.c)Valve 2
All settings for valve 2 are made in the same way as in the case of valve 1.
III.d) GSM module
NOTE: Controlling of this type is possible after purchasing and connecting, to the controller,
the additional control module ST-65 which is not attached to the regulator as a standard
feature.
The GSM module is an optional device cooperating with the boiler controller, enabling remote
control of the boiler operation with the use of a mobile phone. The User is notified with a text
message on each alert of the boiler controller, and by sending an appropriate text message at
any time, he or she receives a return message with the information on the current temperature
of all sensors. After entering an authentication code it is also possible to remotely change the
set temperatures.
The GSM module can also operate independently from the boiler controller. It has two
inputs with temperature sensors, single contact input for use in any configuration (detecting
short circuit/opening of contacts) and one controlled output (e.g. possibility to connect
additional contactor to control any electrical circuit).
When any temperature sensor reaches the preset deactivation temperature, maximum
or minimum, the module will automatically send a text message with such information. It is
similar in the case of a short-circuit or opening of contact input, which may be used e.g. for
simple protection of property.
III.e) Internet module
NOTE: Controlling of this type is possible after purchasing and connecting, to the controller,
the additional control module ST-500 which is not attached to the regulator as a standard
feature.
The Internet module is a device enabling remote control of the boiler over the Internet or local
network . On the home computer screen the user controls the condition of all boiler system
devices and the operation of each device is presented in the animated form.
Apart from the possibility to view the temperature of every sensor, the user has the possibility
of introducing changes of the set temperatures for both the pumps and the mixing valves.
After activating the Internet module and selecting the DHCP option, the controller will
automatically download such parameters from the local network as: IP address, IP Mask,
Gateway address and DNS Address. In the case of any problems with downloading network
parameters of the existing network, there is a possibility of setting these parameters manually.
The method of obtaining local network parameters has been described in the instructions for
the Internet module.
The function Reset module password may be used when the User, on the login page, has
changed the factory user's password to his or her password. When a new password is lost, it is
possible to return to the factory password after resetting the module password.

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III.f) Pump activation temperature
The option is used to set the activation temperature for central heating and domestic hot water
pumps (the temperature is measured on the boiler). None of the pumps will operate if the
temperature is lower than the preset one. If the actual temperature is higher than the preset
one the pumps are working but they operate depending on the operation mode (see: pump
operation modes)
III.g) HUW hysteresis
This option is used to set the hysteresis of the set temperature in the reboiler. It is the
maximum difference between the set temperature (that is required in the reboiler) and the
current temperature in the reboiler at which the HUW pump will activate. (for example: when
the set temperature has the value of 55oC and the hysteresis is 5oC. After reaching the set
temperature, that is 55oC, the HUW shuts down and causes activation of the CH pump. Re-
activation of the HUW pump will proceed when the temperature decreases to 50oC).
III.h) Feeder in auto mode
The option allows enabling and disabling the automatic operation of the feeder. The feeder can
be disabled to feed fuel manually or to shut the boiler down.
III.i) Blowing in auto mode
Automatic operation of the fan can be enabled or disabled using this function. Blowing can be
disabled to manually control the natural chimney draught.

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III.j) Floor pump
The function is used to control the floor heating. The user sets the floor heating temperature in
the range between 30ºC to 55ºC. After activation of the floor pump the minimum (threshold)
temperature (measured on the boiler) and the maximum (preset) temperature of the floor
heating (measured on the pump sensor) should be set. The floor pump is not operating below
the minimum temperature. It turns on after the minimum temperature is exceeded until the
preset maximum temperature is reached.
Once the preset temperature is reached the pump turns off and it is restarted if the temperature
drops 2ºC below the pre-set value.
III.k) Circulation pump
The function allows to control the pump which is used to mix hot water between the boiler and
the domestic hot water taps. After the function is activated the user sets the 24h activation
cycle or pause cycle accurate to 30 minutes.
To facilitate the 24h operation and pause cycle setting it is possible to copy the selected
time interval to another interval.
After the operation schedule has been set it is necessary to set the working and pause
times for the pump while the previously selected time period is active. If necessary the previous
settings can be easily deleted to facilitate setting of new intervals.
III.l) Clock
You can use the clock settings to enter the current time and day of the week.