Operating and Assembly Manual Control Panel 412 for the KNZEL Wood Gasication Boiler

Paul Knzel GmbH Ohlrattweg 5 25497 Prisdorf 6th July 2005

1 Operating and installation instructions for the Control Panel 412

1.1 General advice concerning the operating

Before using the control panel, please read the manual carefully and keep it within reach. Dont pass the control panel on to others without the manual. The producer isnt liable in cases of wrong handling or of use for divergent purposes. The device has been designed according to safety regulations. The improper use can cause damage to persons and property. The Control Panel 412 is made for KNZEL wood gasication boilers type HV, HV-S and HV-RL only. Divergent use of the control panel is at your own risk. The producer is not liable for damage caused by wrong handling or improper use. The correct application of the control panel is the responsability of the installation company. In case you have any questions, please ask your heating technician. Unauthorized persons, especially children, should not have access to the control of your heating system. Dont let children touch the control panel or the boiler when heating is in process. Caution! Danger of burning! The boiler produces very high temperatures! Dont leave the control panel and the boiler unattended while running. The control panel must be installed with suitable tools and by experts only. Wrong installation can cause severe problems and even lead to the destruction of the device. Before connecting up the control panel check its electronic data (voltage and frecuency). It has to coincide with your electricity supply. In case of doubts, please ask your electrician. Dont pull the plug of the control panel when it is switched on, it has to be switched off beforehand. To avoid touching electric parts, use the control panel only when mounted to the boiler. Electrical safety and protection of malfunction and faults are given only if the control panel ist connected to a protection ground according to the regulations. In case of doubts consult an expert on electrical installations. The producer is not liable for damage or malfunction caused by missing or interrupted protection ground. The Control Panel 412 must be opened by the producer or by authorized KNZEL customer service personnel only. 3

1.2 Manual

Figure 1: Control Panel 412

Figure 2: Control Panel 412, back

1. ON / OFF switch 2. START button 3. Control button for temperature at top sensor of accu tank 4. Regulator for boiler target temperature 5. Temperature display 6. Regulator for fan reduction 7. LED Secondary heating active 8. LED Accu tank full 4

9. LED Upper door open 10. Main fuse 6,3 amp. 11. Control button for exhaust gas temperature 12. Control button for temperature at bottom sensor of accu tank 13. Regulator for boiler change-over temperature 14. LED for fan activity 15. LED overtemperature 16. LED boiler circulation pump working 17. Changing exhaust gas target temperature for the fan reduction 18. Multi connector for sensors and door contact 19. DIP switch 1 Operation mode of boiler circulation pump 2 Locking of secondary heating when boiler circulation pump starts / when boiler change-over temperature at top sensor of accu tank has been exceeded 3 Switch for qualied / permanent control of accu tank 4 Switch for waste gas fan / non waste gas fan 20. Secondary heating 21. Fan fuse 2A/fast 22. Fan 23. Reversing valve 24. Boiler circulation pump 25. Network The electronic Control Panel 412 for the KNZEL wood gasication boiler HV offers all functions necessary for the control of a wood gasication boiler and boiler circulation pump. Additionally it is possible to steer a secondary heating (e.g. external oil or gas boiler) as well as a reversing valve depending on the upper accu tank temperature.

1.3 Settings
The Control Panel 412 has got three regulators at the front as well as two DIP switches and one potentiometer (to be handled with a screwdriver) at the back. With these actuators it is possible to change the most important parameters of the control panel. 5

1.3.1

Type of Fan

Before using the control panel for the rst time, please set the type of fan with switch [19/4]. The Control Panel 412 usually is pre-set for the use of a normal (not waste gas-) fan (position D ). Thus, if your wood gasication boiler is equipped with a waste gas fan, the switch has to be moved to position S . 1.3.2 Setting the control of the accu tank

The setting of the control of the accu tank depends on the type of accu tank you use. The Control Panel 412 is delivered pre-set on permanent control (switch [19/3] in position S ). This setting is suitable for systems with an accu tank without integrated hot water tank. Using a combined accumulator / hot water tank (combi tank), the DIP switch [19/3] has to be set on qualied control (position B ). If using a combi tank in a wood-only heating system like in KNZEL package A, it is as well possible to run the system with hot water priority. The circulation pump receives pump receives electricity always if the heating installaelectricity via the contact reversing valve The tion is operating in wood heating mode. If now the position of switch [19/2] is changed to position E, the circulation pump only starts running, if at the upper sensor of the accu tank (which includes the hot water tank) the boiler change over temperature is beeing exceeded. In this type of heating installation the boiler change over temperature determines the minimum temperature of the hot water. 1.3.3 Operation mode of the boiler circulation pump

With the DIP switch [19/1] you can change the operation mode of the boiler circulation pump. With the switch in position K, the boiler circulation pump starts running if the boiler temperature exceeds 70 C and switches off again if the temperature sinks below 67 C. If the accu tank reaches at the bottom a temperature, which lies only 5 C below the boiler temperature, the boiler circulation pump stops working until the temperature difference is bigger again. With the switch in position A, the boiler circulation pump starts working if the exhaust gas temperature exceeds 90 C. The pump switches off again if the temperature sinks below 90 C. If the accu tank at the bottom reaches a temperature, which lies only 5 C below the boiler temperature, the boiler circulation pump stops working until the temperature difference is bigger again. 1.3.4 Setting the target temperature of the boiler

C and 90 C. Regulator [4] sets the boiler target temperature. You can choose a temperature between 80 We recommend a boiler target temperature of 85 C.

1.3.5

Setting the boiler changeover temperature

The boiler changeover temperature is the signal for the secondary heating to start running: If the temperature at the upper sensor of the accu tank falls below the boilerchange over temperature, the secondary C higher than the desired hot heating starts running. The boiler changeover temperature has to be set 5 water temperature. 6

1.3.6

Setting the fan reduction

To optimize the efciency of the boiler and to avoid smouldering re, the Control Panel 412 can reduce the rotational speed of the fan. Always if the parameters described as follows below are fullled, the Control Panel 412 reduces automatically the rotational speed of the fan and, at the same time, the output of the boiler. The reduction offers 4 alternative grades. 0 stands for no reduction and 3 means maximum reduction. With regulator [17] you can choose the exhaust gas temperature at which the fan reduction will be activated. This value is pre-set on 150 C.

2 Description of functioning
2.1 General functioning
Switch the Control Panel 412 on with the ON / OFF switch, prepare the wood gasication boiler according to the manual and light the re. As soon as the rebed is thick enough, put on wood according to the manual, close the upper door and press the START button. The fan starts running continuously now. If the waste gas temperature exceeds 90 C the control panel switches from the operation mode Start in into the operation mode Activity . During activity the boiler temperature rises and exceeds the start temperature for the boiler circulation pump (70 C). If the DIP switch [19/2] is in position [A], a secondary heating (oil or gas) will be turned off now and the reversing valve changes to wood heating If the DIP switch [19/2] is in position [E], the secondary heating stays activated until the temperature at the upper sensor of the accu tank exceeds a boiler changeover temperature to be set at regulator [13].
C below) the fan reduction If the boiler temperature nearly reaches the boiler target temperature (about 5 is activated, indicated by the ashing of lamp [14]. How much the rotational speed of the fan is beeing reduced, depends on regulator [6]. There are four different possible grades of reduction: 0 stands for no reduction.

The fan reduction will be activated as well, if the exhaust gas temperature exceeds the value necessary for the nominal output of the boiler. This helps avoiding unnessecarily high exhaust gas temperatures and lowering of boiler efciency are and burner parts wear out less. In case the boiler reaches its target temperature in spite of fan reduction, the fan stops and a you can hear a sound signal. If then the temperature falls below the boiler target temperature, the fan starts again and the sound stops. If the boiler temperature falls below 67 C, the boiler circulation pump stops working. If the boiler reaches 70 C again, the boiler circulation pump restarts. With an exhaust gas temperature falling below 90 C the control panel switches to heating from the accu tank and turns off the fan. If the temperature in the upper part of the accu tank exceeds the set boiler changeover temperature, the reverse valve stays set on wood heating and the secondary heating stays locked. Only if the temperature of the accu tank falls below the boiler changeover temperature, the reverse valve changes to secondary 7

heating. The contact for the secondary heating is closed if the system is running without electricity. That way the control panel neednt be switched on for operating the external heating. With DIP switch [19/2] in position [A] and with the temperature of the accu tank rising above the boiler changeover temperature (e.g. by a solar system), the secondary heating will be locked and the reversing valve will be switched to wood heating . If DIP switch [19/2] is set on qualied control of the accu tank (position [E]) a re-rise of temperature in the accu tank will be ignored by the control panel. We recommend this setting for wood gasication heating installations with a combined accumulator / hot water tank, e.g. like in KNZEL package D.
C, make Advice: If the control panel is in burn-off state and the boiler temperature still lies above 67 sure the control panel restarts when using the upper door of the boiler. The fan should start working anew after closing the upper door. If you dont wish to continue ring, you must switch off the fan by quickly turning the main switch off and then on again.

2.2 Fan control

2.2.1 General

To start the fan, the upper door of the boiler and the bypass ap have to be closed (the yellow light goes out).
C. The fan starts working if you push the START button or if the exhaust gas temperature exceeds 90 C, the fan reduction is If the boiler temperature approaches to the boiler target temperature by about 5 activated, indicated by the ashing of lamp [14]. How much the rotational speed of the fan is beeing reduced, depends on regulator [6]. There are four different possible grades of reduction: 0 stands for no reduction.

The fan reduction will be activated as well, if the exhaust gas temperature exceeds the value necessary for the nominal output of the boiler. This way unnessecarily high exhaust gas temperatures and lowering of boiler efciency are avoided and wear of burner parts diminished. If exceeding the set boiler target C and 90 C) the fan stops and you temperature (regulator boilertarget temperature range between 80 can hear a sound signal. When the temperature has fallen again (2K below the boilertarget temperature), the fan starts working anew. If the exhaust gas temperature falls below 90 C, the control panel switches to accu tank activity and turns off the fan. If the exhaust gas temperature falls below 90 C while putting on wood, the fan will be turned off as well, but starts working again automatically after closing the upper door, as long as the boiler circulation pump is active. If not, you have to push the START button after closing the upper door.
C If after the start or after manipulating the door contact, the exhaust gas temperature doesnt exceed 90 within 30 minutes, this causes a false start and the fan stops.

2.2.2

System with waste gas fan

If your boiler works with a waste gas fan, you have to put the DIP switch at the back of the control panel in position S This type of fan then doesnt stop if the upper boiler door is being opened. In case the fan stands still because it just hasnt been turned on yet or because the boiler target temperature has been 8

exceeded, the fan will be started when you open the door to avoid deagration. With boiler temperatures above 90 C (red LED burning) the fan wont start running even if the door is open. If you open the upper door of the boiler, the waste gas fan - if running at reduced rotational speed - will start running at full speed as long as the door is open. 2.2.3 System with "normal" (non waste gas) fan

This type of fan stops running as soon as you open the upper boiler door. To support the process of heating up you can switch on the fan for a short time, even if the door is open. Just keep switch [2] pressed, then push switch [3] and stay with your ngers on there.

2.3 Boiler circulation pump

With switch [19/1] you can choose between two operation modes for the boiler circulation pump: Position K: The start temperature for the boiler circulation pump is 70 C. The boiler circulation pump will be switched off if the boiler temperature falls below 67 C. If the bottom of the accu tank reaches a temperature of about 5 C less than the boiler temperature, the boiler circulation pump will be switched off until C again. the temperature difference between the bottom of the accu tank and the boiler is bigger than 5 Position A:
C, and stops again if the The boiler circulation pump starts if the exhaust gas temperature exceeds 90 exhaust gas temperature falls below 90 C.

If the bottom of the accu tank reaches a temperature of about 5 C less than the boiler temperature, the boiler circulation pump will be switched off until the temperature difference between the bottom of the accu tank and the boiler is bigger than 5 C again. In case that the boiler temperature exceeds 90 C the boiler circulation pump will work as long as the temperature stays above 90 C(Hysteresis 2 C).

2.4 Reversing valve / external burner

2.4.1 Permanent control of accu tank

This operation mode is chosen by putting the DIP switch [19/3] at the back of the control panel into position S . The reversing valve and the contact secondary heating change to wood heating as soon as the boiler temperature exceeds the set pump start temperature (switch 19/2 in position A), or if the temperature in the upper part of the accu tank exceeds the boiler changeover temperature (switch 19/2 in position E). If, at the time when the control panel detects a burn-off, at the upper part of the accu tank the temperature is lower than the dened boiler changeover temperature, the secondary heating starts. If at the upper part of the accu tank the temperature lies above the boiler changeover temperature, the secondary heating only starts - after a completed burn-off - if the temperature in the upper part of the accu tank has fallen below the boiler changeover temperature (Hysteresis 2K). In case, the temperature rises again by inuence of a solar system, the secondary heating will not be turned on again. 9

2.4.2

Qualied control of accu tank

You choose this operation mode by putting the DIP switch [19/3] at the back of the control panel into position B . The reversing valve and the contact secondary heating change to wood heating , as soon as the boiler circulation pump (switch 19/2, position A) starts for the rst time or as soon as the changeover temperature for the reversing valve (to be set at the control panel) is beeing exceeded at the upper sensor of the accu tank (switch 19/2 in position E). The control panel stays in wood heating mode until it detects a burnoff. If, at the time when the control panel detects a burn-off, the temperature in the upper part of the accu tank is lower than the set boiler changeover temperature, the secondary heating starts operating. If the temperature in the upper part ot the accu tank lies above the boiler changeover temperature, the secondary heating will only be activated, if - because of the burn-off - the temperature in the upper part of the accu tank has fallen below the boiler changeover temperature yet (Hysteresis 2K). In case, the temperature rises again by inuence of a solar system, the secondary heating will not be activated again.

2.5 Boiler target temperature

We recommend a boiler target temperature high enough to keep the fan working as continuously as possible and avoid interruption of fan activity. If the fan stops running, no controlled burning of carbonization gas takes place, which causes acids noxious to the boiler as well as high emission. Important: It is not for regulatory but for safety reasons, if the fan stops at reaching boiler target temperature! To avoid that the fan switches off, the rotational speed of the fan will be reduced depending on the C below the boiler target position of regulator [6], as soon as the boiler reaches a temperature of about 5 temperature (set with regulator [4]). The fan reduction will be activated as well, if the exhaust gas exceeds the temperature necessary for the nominal output of the boiler. This avoids unnessecary high exhaust gas temperatures and lowering of the boiler efciency as well as wear of burner parts. Exceeding the boiler target temperature, the fan stops and you can hear an acoustic signal, which ceases as soon as the boiler temperature falls below the boiler target temperature again. C. The boiler circulation pump runs always if the boiler temperature lies above 90

2.6 Electrical power outage

In case of an electrical power outage the control panel reacts as follows: 1. After the electrical power has been restored, the fan starts running again due to the still high exhaust gas temperature. The control panel starts automatically and the reversing valve / secondary heating change into the position wood heating. 2. If the boiler temperature stays below the start temperature after the restoration of electrical power, the boiler wont start again, the secondary heating keeps on running. During an electrical power outage may occur the development of large amounts of carbonization gas inside the boiler. 10

3 Assembly instruction

Figure 3: Mounting of the control panel

3.1 State at delivery

The Control Panel 412 comes enclosed in an environment-friendly cardboard box. Inside you nd the necessary mating plugs for the network (white plug), for the boiler circulation pump (white socket), for the reversing valve (the black plug with four contacts) and for the external burner (brown plug). A boiler sensor with a cable of 0,7m lenght and two accu tank sensors (red = upper sensor, blue = lower sensor) with a cable of 6m lenght are included as well. The contact for the fan is ready for use. It has only got to be connected to the control panel. All plugs are encoded and not interchangeable. The cables for the upper door switch and for the exhaust gas sensor have to be joint with the according contacts of the sensor terminal. Make sure that all contacts t well and that no bits of insulation get in the way.

3.2 Assembly
The relevant regulations for electrical installations have to be observed. The electronics must be mounted C by professional electricians only. Use cables resistant to permanent high temperature of at least 120 inside the boiler. We recommend the use of silicon cables. The control panel has to be connected to earth and in-phase. An emergency heating switch outside the heating room as well as protection by fuses with 10 A is obligatory. We recommend the use of a fault current protection switch. For mounting the control panel, take the top part of the red casing off the boiler. Above the upper door you nd a shiny aluminium reector. For mounting the control panel you have to break the upper middle part of it out of the perforation or fold it backwards. Take off the white plastic foil completely. When delivered, you nd inside the immersion shell (T) a tension spring (S), which has to be taken out. Careful: The immersion shell is located between the lifting lug and the nozzle for the ow and is welded to the boiler. 11

The sensors should be placed into the immersion shell that way that they keep to the wall of the shell with light pressure. Fit in too loosely theyve got a bad heat transfer which leads to hook-up errors. For optimal switching exactness we recommend lling the immersion shell with thermally conductive paste or thermo-oil. Caution: Conductions for sensors, network and consumer loads have to run separately. Important: The sensors of the accu tank must be connected at any rate, even if there is no accu tank in the installation. The sensors will be hanged simply into the air. Important: As well for working at the sensors the control panel has to be disconnected at all poles. Attention: Before working at the electricity network, take out the fuse! Extreme danger! Power cable, pump cable, reversing valve and the secondary heating are connected according to the applied hydraulic of the installation. After connecting all plugs and sensors with the control panel, push it carefully onto the fastening nuts until it snaps in. Now close the casing of the boiler again. The control panel is ready for use.

4 Technical data
4.1 Electronic data
Supply voltage Power consumption without consumer load Fuse Relais exits 50Hz, 230Volt 10VA 6,3A, medium slow, ICE12724 DIN 41668 4A inductive at 230 Volt 50Hz

4.2 Sensors

For all temperatures KTY81 semiconducting sensors are applied. 0 C to 120 C correspond to 815Ohm up to 1900Ohm. 12

Figure 4: KTY81 Values of resistance

5 Alarm messages
If the temperature at one of the sensors exceeds the allowed limits, both decimal points light up. Please check the corresponding sensor.

13