Randall EBM 2.1 Boiler Efficiency Control

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The EBM 2.1 Boiler Efficiency Control is designed, with one simple user adjustment, to maximize the efficiency of gas fired wet domestic central heating systems. This is for systems which incorporate time and temperature controls (TRV or room thermostat and cylinder thermostat) and motorized valves. Suitable for both new and existing installations incorporating conventional or condensing boilers in either gravity or fully pumped systems.

The following pages show various systems and their wiring diagrams, however, before turning to these it is important to note the following:

1. The EBM 2.1 should be mounted where it is clearly accessible.
2. The OTS outside sensor should be mounted on an outside wall on the coldest side of the house (usually north facing) about 18 inches below eaves height and away from chimneys, flues or windows, etc. Connection must be made with cable suitable for 240V as follows:
– Terminal 1 on the OTS to terminal 11 on the EBM wallplate.
– Terminal 2 on the OTS to terminal 10 on the EBM wallplate.
3. The BRS boiler return sensor should be mounted on the common return to the boiler between the boiler and by-pass. In gravity hot water systems it should be mounted on the heating return. Connect to EBM as follows:
– Brown lead to terminal 12 on the EBM wallplate.
– Blue lead to terminal 10 on the EBM wallplate.
4. The cylinder thermostat and any motorized valves shown are not included in the kit.
5. The pump should be connected to terminal 5 of the EBM in all cases, even if the boiler has its own pump connection or pump overrun facility.
6. In gravity hot water systems, it is necessary to cut an internal link in the EBM by prizing offthe back cover and cutting the grey link wire located inside the housing on the left.
7. The boiler thermostat should be set to maximum.

Honeywell Y605B Panel Link-Fuel Timed Sundial Plan

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When solid fuel only has been selected. The link-fuel valve will be closed and the solid-fuel valve will be open and the system will operate as follows:

1. No demand within the system slumber valve open to allow full bore gravity circulation to the slumber circuit. Safe operation of solid-fuel appliance without overheating of space or domestic hot water. Heating valve and domestic hot water valve closed, pump off.
2. Heating only: pump on, slumber and hot water valves closed, heating valve open to allow heating to be provided.Water pumped around the slumber circuit through adjustable gate valve.
3. Hot water only: pump on, slumber and heating valves closed, hot water valve open to allow circulation to the domestic hot water. Water pumped around the slumber circuit through adjustable gate valve.
4. Both heating and hot water: pump on, slumber valve closed, heating and hot water valves open to allow circulation throughout the whole of the system. Water pumped around the slumber circuit through the adjustable gate valve.
5. If the temperature of the water exceeds the high-limit setting at any time the safety controls will take effect. Then pump on, slumber valve closed whilst either heating or hot water valve will open to allow for excess heat to be dissipated into either the hot water or heating and slumber circuits, as selected. The high-limit thermostat will automatically reset when the temperature of the water has reduced and the system will return to normal operation.

When the link-fuel has been selected the system operates in conjunction with the limit thermostats:

1. When flow temperature from solid-fuel appliance is below the mid-limit, the linkfuel boiler is brought into use.The slumber valve is closed, link-fuel and solid-fuel valves open and either heating, or hot water, or both, valves open to satisfy demand of the system.Water is supplied to the slumber circuit through the adjustable gate valve and both the pump and link-fuel boiler are on. Operation of the system is switched between the solid-fuel and link-fuel by the mid-limit thermostat.
2. When flow temperature from solid-fuel appliance is between the mid- and high-limit temperatures then the link-fuel boiler is switched off. Full use is made of the output from the solid-fuel appliance only, hence achieving maximum use of the solid-fuel appliance and economizing on other fuels. Link-fuel valve closed.
3. If the flow temperature from the solid-fuel appliance exceeds the high-limit setting then the link-fuel boiler is switched off. Slumber and link-fuel valves close, solidfuel valve opens as well as either heating or hot water valve, depending upon selection of either heating or hot water for dissipation for excess heat. Pump is on to remove excess heat through the chosen circuit and also through the slumber circuit via the adjustable gate valve.
4. The low-limit thermostat provides control of the solid-fuel appliance at low temperature.
(a) Temperatures below the low-limit setting, solid-fuel valve will be closed.
(b) Temperatures above the low-limit setting, solid-fuel valve will be open.
(c) Any requirement for heating or hot water will be met by the link-fuel boiler exactly as Item 1 above.

Honeywell Y605B Panel Link Fuel Timed Sundial Plan Honeywell Y605B Panel Link Fuel Timed Sundial Plan

Honeywell Y604A Panel and Timed Sundial Plans

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The Y604A Panel and Panel Timed Sundial Plans are fully assembled, pre-plumbed and pre-wired control sets and comprise of either a Honeywell S or Y Plan, or Timed S or Y Plan, plus pump and isolating valves in a multipoise carrier bracket.

Honeywell Y604A Panel and Timed Sundial Plans Honeywell Y604A Panel and Timed Sundial Plans

External wiring connections – panel plans

Honeywell Y604A Panel and Timed Sundial Plans1 Honeywell Y604A Panel and Timed Sundial Plans

External wiring connections – panel timed plans

Honeywell AQ 6000 Boiler Control without Domestic Hot Water

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Boiler control without domestic hot water control

The following adjustments must be made before power is applied to the system:
1. System selection switches.
2. Burner cycles per hour (3 to 9), typical setting: 6.
Note: Only recommended for systems up to 70000BTU. Domestic hot water sensor, T4, is not used.

Honeywell AQ 6000 Boiler Control without Domestic Hot Water Honeywell AQ 6000 Boiler Control without Domestic Hot Water

Honeywell AQ 6000 Boiler Control 3 Port Motorized Valve

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Boiler control with domestic hot water control using a 3-port motorized valve

The following adjustments must be made before power is applied to the system:
1. System selection switches.
2. Burner cycles per hour (3 to 9), typical setting: 6.3.
3. Domestic hot water (35 to 100°C), typical setting: 55°C.

Note: The switch A–B should be in position A for the domestic hot water to be off when the system is controlling at the Economy level. The switch should be in position B for the domestic hot water to be continuously serviced. Wiring shows a priority valve. Where a mid-position valve is used the White (or Brown) and Grey go to terminal C.

Honeywell AQ 6000 Boiler Control 3 Port Motorized Valve Honeywell AQ 6000 Boiler Control 3 Port Motorized Valve

Honeywell AQ 6000 Boiler Control Two Motorized Zone Valves

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Boiler control with domestic hot water control using two motorized zone valves

The following adjustments must be made before power is applied to the system:
1. System selection switches.
2. Burner cycles per hour (3 to 9), typical setting: 6.
3. Domestic hot water (35 up to 100°C), typical setting: 55°C.

Note: The switch A–B should be in position A for the domestic hot water to be off when the system is controlling at the Economy level. The switch should be in position B for the domestic hot water to be continuously serviced.

Honeywell AQ 6000 Boiler Control Two Motorized Zone Valves Honeywell AQ 6000 Boiler Control Two Motorized Zone Valves

Honeywell AQ 6000 Installation

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The AQ 6000 is an outside temperature compensator system for use in domestic properties and can be used on new installations or to upgrade existing systems, making use of existing valves that may be installed.The AQ 6000 is available in three packs – an Upgrade pack, a Standard pack or a Modulating pack. The Modulating pack is for use on boilers of 90000–150000BTU and provides control of the heating circuit by modulating a mixing valve. There are five systems – A, B, C, D and E. Systems D and E use the modulating mixing valve and are not shown.

The AQ 6000 consists of a control unit, a room unit and outside, water supply and domestic hot water sensors. All wiring is terminated in the control unit along with boiler, pump and any valve wiring.

A built-in start-up operating sequence allows the system wiring to be tested. Before turning on power to the system, remove the room unit from its mounting bracket.Turn on the power and the control unit will power the valve, pump and boiler.

When the system is operational actual temperatures can be displayed on the room unit.When the green enquiry button is pressed, ‘T1’ will be displayed at the left side of the display and the temperature in °C on the right. Repeated use of this button will display other system temperatures.The codes are listed in Table 11.1.To restore the display to its normal operation press the enquiry button repeatedly until the ‘T’ is no longer displayed and in its place is the current weekday number.

table 1 Honeywell AQ 6000 Installation

When the room unit is connected and the supply switched on, an indication of any faults within the system can be displayed by pressing any four buttons on the unit. A fault code is displayed as an ‘F’ followed by a number. The different numbers correspond to the faults listed in Table 11.2. No ‘F’ on the display means that no fault has been observed by the controller.To clear the fault code, press any button.

table 2 Honeywell AQ 6000 Installation

Dataterm Optimiser

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Dataterm is a microprocessor-based energy management system and can be used as part of a new system or to replace traditional room thermostats and programmer. The fully automatic optimum start function takes into consideration the current weather and calculates the boiler start time eliminating fuel waste through fixed boiler start times. Dataterm is suitable for any conventional oil or gas wet central heating system complete with hot water control, as well as other applications.

The control pack consists of two units, a lowvoltage programmable room thermostat and a controlling power pack located in a convenient position, e.g. adjacent to the boiler or motorized valves.

Dataterm Optimiser Dataterm Optimiser

Danfoss Randall BEM 5000 Boiler Energy Manager

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The BEM 5000 is an electronic control, which, when added to almost any central heating system, reduces unnecessary boiler cycling and improves boiler seasonal efficiency. It is compatible with most popular control systems including radiator thermostats, programmers, motorized valves and even room thermostats, although in systems having radiator thermostats it is recommended that the room thermostat be turned up to maximum or rewired as frost thermostats. Radiator thermostats are recommended, but are not mandatory. If they are fitted, then a by-pass valve should be fitted. If it is impractical to fit a by-pass valve, then one radiator should be left uncontrolled.

Danfoss Randall BEM 5000 Boiler Energy Manager 1 300x176 Danfoss Randall BEM 5000 Boiler Energy Manager

The BEM 5000 measures outdoor temperature and varies the temperature of water flowing to the radiators accordingly. This significantly improves boiler performance. A water temperature sensor is used to monitor temperature of water returning to the boiler. Any change in load on the system is measured and the boiler is controlled accordingly. To minimize energy loss from the boiler case and flue, the pump runs on after the boiler has stopped, circulating all useful heat to the system. When no more heat can be extracted, the pump is stopped. The BEM 5000 integrates the operation of heating and hot water. During periods of hot water demand, water temperature flowing to both water and heating circuits is boosted to boiler thermostat settings to ensure rapid recovery. Figures 11.4 and 11.5 show the BEM 5000 wired into a fully pumped system, one with two 2-port motorized valves and one with a 3-port, mid-position valve. It can also be utilized on a combination boiler.

Danfoss Randall BEM 5000 Boiler Energy Manager 2 Danfoss Randall BEM 5000 Boiler Energy Manager

Danfoss BEM 4000 Commissioning

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Hot water service

Set the programmer to hot water constant, central heating off, and cylinder thermostat to maximum. Set boiler to the design flow temperature of 82°C.

Lamps 1 and 2 will illuminate and boiler and pump will start, except in gravity hot water systems, in which the pump will not start. The hot water valve will open.

Central heating service

Set programmer to hot water off, central heating constant and boiler as above. Where a heating motorized valve is fitted, it will open. Illumination of lamp 3 signifies that the boiler has stopped and after a time lamp 1 will go off, indicating pump stopped.

After testing, set the programmer and cylinder thermostat to the required settings.

Fault finding

When the ‘on’ lamp on the front of the BEM 4000 does not illuminate, check the power supply.There should be 240V across terminals 12 and 13. If this is OK, check the built-in fuse on the rear of the BEM 4000, and if blown, there is a spare attached to the rear of the unit. If this fuse is OK the fault is probably within the electronics, and the BEM 4000 plug-in front plate should be replaced.

Where a zone valve will not open, check that 240V exists at the valve leads. If OK change valve, if not check programmer and other wiring.

In the event of difficulties, the BEM 4000 can be overridden by inserting a link between terminals 14 and 15, ensuring that the power is turned off first.