03 NES Tech Manual WBS Active-Pell

03 NES Tech Manual WBS Active-Pell

EN

Set solid fuel boiler with pellet burner

WBS Active - Pell

TECHNICAL PASSPORT

INSTALLATION and OPERATION MANUAL model: serial number:

Version i0.1.1

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

TABLE OF CONTENTS

1. EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS ........................................................ 4

1.1. Explanation of symbols .......................................................................................................... 4

1.2. Requirements to boiler installation room .............................................................................. 4

1.2.1. Instructions to boiler installer ............................................................................................. 4

1.2.2. Instructions to installation user .......................................................................................... 4

1.2.3. Minimum clearances for installation and combustibility of building materials ..................... 5

2. PRODUCT DESCRIPTION ............................................................................................................ 6

3. FUELS ........................................................................................................................................ 8

4. TRANSPORTATION OF THE BOILER AND BURNRER ................................................................... 9

5. DELIVERY OF THE BOILER AND BURNER .................................................................................. 10

6. INSTALLATION OF THE HEATING BOILER ................................................................................. 10

6.1. Requirements ...................................................................................................................... 10

6.2. Check door tightness ........................................................................................................... 11

7. SETUP OF THE HEATING BOILER AND BURNER ...................................................................... 11

7.1. Connecting the boiler to a chimney .................................................................................... 11

7.2. Connecting the safety heat exchanger ................................................................................ 12

7.3. Connecting the boiler to the heating installation ............................................................... 13

7.4. Connection diagrams .......................................................................................................... 16

7.5. Connecting the boiler to the mains power supply ................................................................ 16

7.5. Pellet burner connection to the fuel hopper and pellet auger ............................................ 20

7.6. Connecting the pellet burner to the mains power supply ................................................... 20

8. BURNER OPERATING ............................................................................................................... 23

8.1. Ignition ................................................................................................................................. 23

8.2. Combustion ......................................................................................................................... 23

8.3. Automatic cleaning system .................................................................................................. 22

8.4. Installer prescriptions regarding burner servicing and maintenance ................................... 23

8.5. Important recommendation for long-lasting and correct operation of the burner ............... 23

9. OPERATION OF BOILER WHEN BURNING SOLID FUEL ............................................................ 24

10. OPERATION OF MICROPROCESSOR CONTROLER WHEN BURNING WOOD-PELLETS ........................ 27

11. SETTING OUTPUT MODES OF OPERATION OF THE PELL PELLET BURNER ............................ 35

12. OPERATION OF MICROPROCESSOR CONTROLER WHEN BURNING SOLID FUEL ........................ 38

13. WARRANTY TERMS ............................................................................................................... 44

14. TECHNICAL PARAMETERS OF SOLID FUEL BOILER WBS ACTIVE ........................................... 44

14.1. General features ................................................................................................................ 44

14.2. Technical parameters ......................................................................................................... 46

14.3. Elements of burner PELL .................................................................................................... 48

14.4. Technical parameters of fuel hopper FH 500 ..................................................................... 49

15. RECYCLING AND WASTE DISPOSAL ....................................................................................... 50

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1. EXPLANATION OF SYMBOLS AND

SAFETY INSTRUCTIONS

1.1. Explanation of symbols

CAUTION!

Important

recommendation or warning concerning safety conditions during installation and operation of the heating boiler

DANGER! fault or improper use

may cause injury or be hazardous to life of humans or animals.

FIRE HAZARD! fault or improper

installation and operation may cause fire.

INFORMATION

Important

information on the proper operation of the product.

1.2. Requirements to boiler installation room

This manual contains important information for the safe and correct installation, start-up and trouble-free operation and maintenance of the heating boiler.

The heating boiler can be used for heating rooms only in the manner described in this manual.

Note of the boiler type data on the factory rating label and the technical data provided in chapter 11 in order to ensure proper operation of the product.

1.2.1. Instructions to boiler installer

During installation and operation, the country-specific regulations must be observed:

• local construction regulations on the installation, air supply and exhaust gas extraction as well as chimney connection.

requirements and

• regulations and norms concerning the fitting of the heating installation with safety devices.

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Use only original BURNiT parts

DANGER of intoxication, suffocation.

Inadequate inflow of fresh air to the boiler room may result in dangerous leak of exhaust gases during boiler operation.

- Make sure the air inlets and exhaust gas outlets are not clogged or closed.

- If faults are not remedied immediately, the boiler must not be operated, and the user must be provided with written instructions on the fault and the hazard it entails.

DANGER of fire when burning flammable materials or liquids.

- Flammable materials/liquids must not be left in close proximity of the heating boiler.

- Instruct system user of the allowed minimum clearances from surrounding objects.

It is mandatory to assure a backup power generator of corresponding rated power! (see 14.1)

1.2.2. Instructions to installation user

DANGER of intoxication or explosion

Toxic gases may be discharged when burning waste, plastics, liquids.

- Use only the fuels indicated in this manual.

- In case of danger of explosion, ignition or discharge of exhaust gases in the room, stop the heating boiler from operation.

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

CAUTION! Danger of injury

/ damage of system due to incompetent operation.

- The heating boiler must be serviced only by persons familiar with the operation manual.

- As a user, you are only allowed to start the boiler up, adjust the temperature of the boiler, shut the boiler down and clean it.

- Unattended children must not be allowed access to premises with running pellet burner inside.

It is mandatory to assure a backup power generator of corresponding rated power! (see 14.2)

recommend that the boiler be placed on a foundation with height of 100 mm made of class A material, see table 1.

Diagram 1

Recommended clearances between the boiler and walls.

Safety rules for user operation:

- Operate the heating boiler at a maximum temperature of 80°C, and to that end you must regularly inspect the boiler room.

- Do not use flammable liquids for ignition or increase of burner output.

- Collect ash in lid-covered fireproof containers.

- Clean the heating boiler surface using non-flammable agents only.

- Do not place flammable objects onto the heating boiler or in its proximity. (see diagram 1 for the minimum clearances)

- Do not store flammable materials in the boiler room.

Table 1. Combustibility of construction materials

Class

А – noncombustible

Class

B – hard combustible

Minimum clearances for installation and combustibility of construction materials

The applicable minimum clearances in your country may differ from the ones specified bellow. Please, consult your installer.

The minimum distance from the heating boiler or exhaust gas pipe to objects or walls must be at least 200 mm.

For general safety considerations, we

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Class С1/С2

Medium combustible

Class

C3 – easy combustible

Stone, bricks, ceramic tiles, baked clay, solutions, plaster free of organic additives.

Gypsum board panels, basalt fiber needled felt, fiberglass board, AKUMIN,

Izomin, Rajolit, Lignos,

Velox, Heraklit.

Wood beech, oak, Wood softwood, layered wood

Asphalt, cardboard, cellulose, tar, fiberboard, cork, polyethylene.

polyurethane,

2. PRODUCT DESCRIPTION

WBS Active boiler is with built-up controller and electric fan for forced air feed, for firing solid fuel - firewood , Class

B wood briquettes or coal. Designed to satisfy the heating demands of medium to large sized spaces. They are engineered for burning solid fuel only and provide the option for fitting pellet, oil or gas-fired burners.

Set BURNiT WBS Active – Pell: tested according to European standards

EN 303-5, class 5.

2.1. Description of WBS Active

Design. Boiler body is made of highquality boiler steel sheets with thickness of 5 mm for the combustion chamber and 3 mm for the water mantle.

Built-up controller. The electronic control unit controls the operation of the flue fan, the circulation pump of the central heating and the pump of the domestic hot water system (DHW).

The power of the fan is regulated in relation to the fuel consumed and the momentary chimney draft.

Efficient. The flue gas makes a three-pass movement around three water-filled barriers in the combustion chamber on its way to the chimney. This way the gas is cool when it leaves the boiler and its energy has been transferred to the water in the mantle. The water mantle embraces the combustion chamber in full to utilize the emitted heat most efficiently. To keep from losing heat into the ambience, the boiler is insulated on the outside by 50 mm high-temperature wool.

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Reliable and safe. The heat exchanging tubular grill is protected by a replaceable metal grate. A complex of safety devices provide for the safety of the appliance.

Versatile. Designed for firing wood with option for adapting to other fuel types by mounting a gas, oil- or pelletfired burner on the specially designated flange located on the lower door.

• Fuel loading door

• Cleaning door (combustion chamber)

• Air flaps for feed-in air adjustment

• Draft regulating flap, mounted on flue end

• Safety heat exchanger

• Safety devices of the boiler

2.2. Description of pellet burner

The BURNiT Pell pellet burner for hot water boilers is designed to burn only and exclusively wood pellets and it is intended to heat up heating boilers. The built-in control unit, automatic cleaning system and internal pellet auger ensure the automated operation of the burner and optimal burning of the fuel.

Design.

The burner is made of high-quality stainless steel able to withstand temperatures of up to 1150°С. The burner must be installed on a heating boiler.

The burner consists of two parts: combustion chamber tube and external tube with sheet metal mantle.

Longitudinally, under the housing, there are blow chamber, fuel ignition heater, fan and power supply. On the upper part of the burner there is a feeder chute to which the pellet auger is attached. The housing of the burner has been designed

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

to meet all regulatory safety requirements

(no sharp or protruding elements) with operating temperature not exceeding

50°C.

The combustion chamber consists of two tubes:

Ember resistant steel tube inside the burner with holes for air intake along its entire length, opening for the hot air from the fuel ignition heater, opening for photosensor.

Outer stainless steel tube. Between the two tubes there is a gap which provides for free circulation of the air necessary both for cooling and oxygen supply into the combustion chamber.

The feeder chute allows 360° rotation for its best convenient positioning when connecting the pellet auger to the hopper.

Diagram 2. Pellet burner Pell design

• Built-in controller.

The main control unit, located in the burner, manages the entire heating process. Controler functions:

Controler functions:

1) fully automated ignition and pellet

7 feed;

2) self-cleaning function (adjustable 1-6 times over 24 hours at equal intervals), programmable start time;

3) controls the operation of the circulation pump of the central heating;

4) controls the operation of the pump of the domestic hot water;

5) option for control by room thermostat;

6) timer;

Photo-sensor - monitors the power of the burner flame

Internal auger

• Dry contactless resistance heater assuring ignition of fuel

Innovative cleaning system of the combustion chamber

Air feed fan, step-regulated (0% to 100

%).

2.3. Burner safety devices

Elbow-shape feeder chute. The geometrical shape of burner feeder chute prevents backfire entry from burner into pellet hopper.

Thermostatic protection (80°С). The thermostatic protection is fitted on the feeder chute. When the surface of the feeder chute reaches 80°С, the control stops the feeding of pellets into the burner and signals for fault.

Fuse. In case of electrical fault in the system of the burner (short circuit, high current, etc.), the overload is borne by the electrical fuse fitted on the main control panel of the burner (10 А).

Power interruption. In case of power interruption, all parameter settings are stored in the memory of the controller.

Upon the subsequent restart of the burner, the controller resumes the

execution of the program from the point when the power interruption occurred.

3. FUEL

All pellets are biomass manufactured from common low-growing plants and trees. The most common household type pellets are made of sawdust and milled wood chippings which are waste material from wood used in the production of logs, furniture and other products. Wood is the richest raw material which does not have any impact on the production costs of food products or ethyl alcohol (ethanol).

The raw material is processed under highpressure and temperature and is pressed to produce small-size cylindrical pellets.

The production process may utilize soft wood material (such as softwood, pine), hardwood (oak) as well as recycled waste wood. Wood pellets are produced in hammer mills or wood pellet plants.

Advantages of wood pellets:

Convenient storage. Pellet bags can be stored on a small area in a dry garage, basement, service room or shed.

Easy loading. In most cases the boiler hopper needs loading only once a week – this depends on the hopper capacity.

Better control of fuel quantity. The small size of the pellets allows for precise fuel feeding. On the other hand, the supply of air for reaching optimal combustion efficiency is easier to adjust since the fuel quantity in the combustion chamber remains constant and predictable.

Fuel efficiency. High combustion efficiency is also determined by consistently low moister content of pellets (consistently under 10% as opposed to 20% to 60% moisture content of the logs). Low moisture content, controlled fuel

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portions and precise air setting means high combustion efficiency and very low carbon oxides in the flue gases.

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When purchasing pellets, ask for conformity declaration and certificate issued by an accredited laboratory and make sure the fuel meets the requirements indicated in the manual. If you purchase large amount of pellets

(bulk supply for the entire heating season for example), ask your supplier to provde accurate and true information about the storage conditions.

We recommend to use pellet with size of

6 - 8mm. Density 600 - 750kg/m

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heating value 4.7 - 5.5 kWh/kg. Ash content – less than 1% and moisture content up to 8%,

EN 14961-2:2011.

The optimal density of the pellets which guarantees their quality is 605-700 kg per cubic meter.

Pellet moisture content must not exceed

10%. Make sure you store your fuel in a dry and well-ventilated place.

The optimal pellet ash content is ≤ 1%.

This also provides for less frequent cleaning intervals for the burner.

The table below contains the parameters which we recommend that you take into consideration when choosing fuel for your

„Pell” burner.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Table2. European Certification of Wood Pellets for Heating Purposes

Parameters

Diameter

Lenght

Bulk dentsity

Calorific/heating value

Humidity /moisture

Dust

Mechanical durability

Ash

Melting point of ash

Chlorine content

Sulfur content

Nitrogen content

Copper content

Chromium content

Arsenic content

Cadmium content

Units

mm mm kg / m

2

MJ / kg

Ма .-%

Ма .-%

Ма .-%

Ма .-%

2)

°C

Ма .-%

Ма .-%

Ма .-% mg / kg mg / kg mg / kg mg / kg

2)

2)

2)

2)

2)

2)

2)

ENplus-A1 ENplus-A2

6 (± 1)

8 (± 1)

6 (± 1)

8 (± 1)

EN-B

6 (± 1)

8 (± 1)

15 ≤ L ≤ 40

1)

15 ≤ L ≤ 40

1)

15 ≤ L ≤ 40

1)

≥ 600 ≥ 600

≥ 16,5-19 ≥ 16,3-19

≤ 10

≤ 1

3)

≥ 97,5

4)

≤ 0,7

≥ 1200

≤ 0,02

≤ 0,03

≤ 0,3

≤ 10

≤ 10

≤ 1,0

≤ 0,5

≤ 10

≤ 1

3)

≥ 97,5

≤ 1,5

≥ 1100

≤ 0,02

≤ 0,03

≤ 0,3

≤ 10

≤ 10

≤ 1,0

≤ 0,5

4)

≥ 600

≥ 16,0-19

≤ 10

≤ 1

≥ 96,5

≤ 3,5

-

3)

≤ 0,03

≤ 0,04

≤ 1,0

≤ 10

≤ 10

≤ 1,0

≤ 0,5

Mercury content

Plumbum content mg / kg

2) mg / kg

2)

≤ 0,1

≤ 10

≤ 0,1

≤ 10

≤ 0,1

≤ 10

Nickel content

Zinc content mg / kg mg / kg

2)

2)

≤ 10

≤ 100

≤ 10

≤ 100

1) Not more than 1% of the pellets may be longer than 40 mm, max. Length 45 mm;

2) Dry weight;

3) Particles <3.15 Mm, particulate matter, before handing over the goods;

4) Measurements with lignotester limit value ≥ 97,7% by weight.

≤ 10

≤ 100

4)

4. TRANSPORTATION OF THE BOILER

AND BURNRER

4.1. Transportation of the boiler

We recommend to transport the heating boiler to the installation site in its packaging placed on the pallet. During transport and installation, depending on the weight, suitable safety devices should be used in accordance with Directive

2006/42/EC.

When transporting items weighing more

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than 30 kg, the use of pallet jack, fork truck or other hoisting devices is a must.

The boiler is securely fastened with fasteners to a wooden pallet.

Important: When installing the boiler, the wooden pallet onto which the boiler is placed must be removed by unscrewing the bolted connections using flat ring wrench S13.

Model WBS

Active

20 kW

25 kW

30 kW

40 kW

50 kW

70 kW

90 kW

110 kW

A, mm

Table 3. Overall dimensions of model WBS boiler Active

B, mm

C, mm

D, mm

Weight, kg

650 1050 125 1475 270

650 1050 125 1475 285

650 1050 125 1475 315

750 1100 125 1475 360

750 1100 125 1475 390

810 1300 125 1620 470

810 1300 125 1620 500

880 1300 125 1620 530

Diagram 3. Overall dimensions of boiler and pallet, model WBS ctive

4.2. Transportation of the pellet and auger.

It is mandatory for transportation to place and secure the burner and auger on a pallet.

- Dimensions of the packaging of the burner: 450х350х750 mm;

- Dimensions of the packaging of the auger: 260х120х1700 mm;

5. DELIVERY OF THE BOILER AND

BURNER

• Inspect the integrity of the packaging upon delivery.

• Check whether all components have been delivered to you.

1. Boiler scope of delivery includes:

1) Boiler body with boiler doors

2) Control unit

3) Safety valve 3 bar

4) Fire irons

5) Cleaning brush for flue pipes

6) Technical passport. Installation and operation manual

7) Service booklet and Warranty card If any of the above items are missing, contact your supplier.

2. Burner consignment package includes:

1) Pellet Burner Pell with built-up Control unit

2) Feeding chute

3) Fire irons

4) Auger

5) Technical passport. Installation and operation manual

6) Service booklet and Warranty card

3. Fuel Hopper.

4. Mounting kit for particular model burner.

If you find a missing component, contact your provider.

6. INSTALLATION OF THE HEATING

BOILER

The assembly, installation and set-up of the boiler must be performed by a technician authorized for such operations.

Installer must indicate to the user of the installation the minimum clearances from flammable materials and liquids.

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6.1. Requirements:

- Boiler room must be frost-proof;

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

- Boiler room must allow for continuous access of air necessary to maintain combustion;

- Boilers must not be placed in inhabitable rooms;

- All boiler rooms must have correctly calculated vent depending on the boiler output. The vent must be protected by means of a net or grate.

The size of the vent is calculated according to the formula:

Q – boiler output in kW

- Remove the packaging without polluting the environment

- Observe building supervision instructions, in particular the existing

Ordinance on combustion devices and storage of combustion materials, on building requirements applicable to installation sites and on ventilation;

- The boiler must be placed on a foundation whose surface area is larger than the base of the heating boiler according to diagram 1;

- The boiler must be placed in a position which allows for the easiest possible cleaning and servicing;

- Installation must be carried out according to installation diagram 1 which shows the boiler housing;

- No objects made of flammable materials or liquids may be placed on/near the boiler;

6.2. Check door tightness

Open boiler doors.

Place paper strips on the four sides of the doors and close leaving part of the strips protruding outside.

Pull the paper strips. If the strips tear

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upon pulling, doors seal tightly.

Caution! Inadequate adjustment of the hinges may result in air being sucked in through the doors and the boiler burning uncontrollably.

7. SETUP OF THE HEATING BOILER AND

BURNER

7.1. Connecting the boiler to a chimney

Boiler-to-chimney connection must always comply with the existing standards and rules. The chimney must provide sufficient draught for evacuation of the smoke under any conditions.

Diagram 4. Boiler size and chimney parameters

setting up is outside.

The inner diameter of the chimney depends on its real height and the power capacity of the boiler (see diagram 4).

Please entrust choosing a chimney and its installation by a qualified professional.

The required distance between the boiler and the chimney is 300-600 mm.

The proper functioning of the chimney requires adequate sizing of the chimney itself since the draught it produces affects combustion, boiler’s output and life span.

The draught created by the chimney is in functional relation to its crosssection, height and the roughness of its interior walls. No other appliance may be connected to the chimney serving the boiler. Chimney diameter must not be smaller than the flue outlet of the boiler.

Flue outlet must be connected to the chimney opening. In terms of mechanical properties, the flue outlet must be sturdy and properly sealed (to avoid gas leak) and allow for easy access for cleaning on the inside. The inner section of the flue outlet must not be greater than the effective section of the chimney and must not narrow. Avoid using elbow joints.

The chimney cleaning opening has to be in its lowest part. The chimney’s wall has to be threeplied where the medium layer is from mineral wool. The thickness of the insulation is not less than 30 mm when the chimney is setting up inside the house and the thickness is 50 mm, when the

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Data in the tables are for indicative purposes.

Draught depends on the diameter, height, uneven sections along the chimney surface and differences in temperature of combustion products and outside air. We recommend that you use chimney fitted with flue terminal.

Heating specialist must calculate the precise sizing of the chimney.

7.2 Connecting the safety heat exchanger

Such connection must be performed by a technician / service shop authorized for such operations.

The heating boiler is equipped with safety heat exchanger (cooling circuit). It connects to the water system through a thermostatic valve. In case of overheating, the thermostatic valve feeds in cold water from the water mains which passes through the heat exchanger and absorbs the heat in the boiler. The water is then discharged into the sewage system. This arrangement ensures safe evacuation of the excess heat without the need for additional energy. This guarantees that the water in the boiler will not exceed the maximum safe level of 95°C.

The minimum operating pressure of the cooling water in the safety heat exchanger must be within the range 2 ÷ 10 bar.

A flow rate of at least 12 l/min is required.

Connect the safety heat exchanger

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

according to the hydraulic diagram using thermostatic valve. Install a filter on the inlet before the thermostatic valve.

Diagram 5. Connecting the safety heat exchanger

1. Water supply network

(pressure 6-10 bar)

2. Drainage (sewerage)

3. Boiler WBS Active

4. Safety heat exchanger inlet

5. BVTS valve sensor

6. Safety heat exchanger outlet

7.3. Connecting the boiler to the heating installation.

Such connection must be performed by a technician / service shop authorized for such operations.

When the boiler is connected to a heating system, it is mandatory to install a 3 bar relief valve and expansion vessel. No shutoff fittings may be installed between the relief valve, expansion vessel and boiler.

It is mandatory to install a threeway valve (Laddomat or similar) or a four-way mixing valve which to ensure that the temperature of the heating medium fed into the boiler from the heating installation is at least 65°С.

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Table 4.1 TROUBLE-SHOOTING TABLE - when burning solid fuel

Cause Solution

1.

Due to unsealed connections

2.

Due to accumulation of deposits.

Condensate and tar formation may reduce the performance and life of the heating boiler. The temperature at the boiler inlet must not be less than 65°C, boiler water temperature at the outlet must be between 80°C and 85°C.

3. Due to freezing

Installation damage

1.

Install the connecting piping strain-free to the boiler connections. Connect the heating installation outlet to connection B. Connect the heating installation inlet to connection A. Mount the cock Y included in the set.

-

2.

It is mandatory to install a three-way thermostatic valve which will prevent the temperature dropping under 65°C at the inlet.

In order to increase the operational life of the boiler it is recommended to install a buffer vessel with capacity of 55 l per 1 kW of installed power.

3.

If the heating installation, including the piping network, has not been built frost-proof, we recommend that you fill the heating installation with a liquid which has low freezing point and corrosion protection and antifreeze agent.

1.

2.

Insufficient draught

Heating value of the fuel is too low.

3.

tar on the flue damper in the upper chamber which prevent its tight closure.

4.

Presence of soot deposits and/or

Presence of soot deposits and/or tar in the flue pipes in water jacket in the back of the boiler

Output too low

1.

Check chimney condition and measure draught.

(must be performed by an authorized service)

2.

Make sure you use sufficiently dry fuel. When using fuel with high moisture content, after the reloading the boiler may burn for some time at significantly lower output level until the fuel in the combustion chamber has dried.

3.

Clean the flue damper and make sure that when moving its closing/opening lever it provides adequate sealing of the flue gas outlet in the upper chamber.

(must be performed by an authorized service)

4.

Clean the heat exchange surface of the flue pipes using the brush from the cleaning tools set. After the cleaning is completed, remove any soot through the inspection opening in the back of the boiler. Must be performed by an authorized service.

Boiler water too hot, heating bodies too cold

1. Hydraulic resistance is too high.

2. Air in the system

3. Inoperable circulation pump

Make sure the circulation pump has been properly selected and the heating installation is of the proper dimensions. (You must contact your installer.)

Boiler temperature too high. Controller failure

1. Grid power fluctuations

2. Power failure

It is mandatory to assure a backup power generator of corresponding rated power! (see 14.2)

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Table 4.2 TROUBLE-SHOOTING TABLE - when burning wood-pellets

Cause Solution

1.

Due to unsealed connections

2.

Due to accumulation of deposits.

Condensate and tar formation may reduce the performance and life of the heating boiler. The temperature at the boiler inlet must not be less than 65°C, boiler water temperature at the outlet must be between 80°C and 85°C.

3. Due to freezing

Installation damage

1.

Install the connecting piping strain-free to the boiler connections. Connect the heating installation outlet to connection B. Connect the heating installation inlet to connection A. Mount the cock Y included in the set.

-

2.

It is mandatory to install a three-way thermostatic valve which will prevent the temperature dropping under 65°C at the inlet.

In order to increase the operational life of the boiler it is recommended to install a buffer vessel with capacity of 55 l per 1 kW of installed power.

3.

If the heating installation, including the piping network, has not been built frost-proof, we recommend that you fill the heating installation with a liquid which has low freezing point and corrosion protection and antifreeze agent.

1.

2.

Insufficient draught

Heating value of the fuel is too low.

3.

tar on the flue damper in the upper chamber which prevent its tight closure.

4.

Presence of soot deposits and/or

Presence of soot deposits and/or tar in the flue pipes in water jacket in the back of the boiler

Output too low

1.

Check chimney condition and measure draught.

(must be performed by an authorized service)

2.

Make sure you use sufficiently dry fuel. When using fuel with high moisture content, after the reloading the boiler may burn for some time at significantly lower output level until the fuel in the combustion chamber has dried.

3.

Clean the flue damper and make sure that when moving its closing/opening lever it provides adequate sealing of the flue gas outlet in the upper chamber.

(must be performed by an authorized service)

4.

Clean the heat exchange surface of the flue pipes using the brush from the cleaning tools set. After the cleaning is completed, remove any soot through the inspection opening in the back of the boiler. Must be performed by an authorized service.

Boiler water too hot, heating bodies too cold

1. Hydraulic resistance is too high.

2. Air in the system

3. Inoperable circulation pump

Make sure the circulation pump has been properly selected and the heating installation is of the proper dimensions. (You must contact your installer.)

Boiler temperature too high. Controller failure

1. Grid power fluctuations

2. Power failure

It is mandatory to assure a backup power generator of corresponding rated power! (see 14.2)

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7.4. Connection diagrams

Such connections must be performed by a technician / service shop authorized for such operations.

Diagram 6. Connection of BURNiT WBS Active boiler to three-way valve

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Diagram 7. Connection of BURNiT WBS Active boiler to P type buffer tank and three-way valve

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Diagram 8. Connection of BURNiT WBS Active boiler to combi tank KSC2, flat plate solar collector PK and three-way valve

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Diagram 9. Connection of BURNiT WBS Active boiler to solar tank SON, buffer thank P, flat plate solar collector PK and three-way valve

19

7.5. Pellet burner connection to the fuel hopper and pellet auger

Take the feeder chute flexible hose (from the auger set). Using a bracket, clamp one end of the hose onto the motor-end outlet of the pellet auger.

- Remember – pellet auger must be installed at 45° angle to the ground horizontal surface.

- Fill the hopper with fuel (see table 2 for parameters of the fuel types used)

- Plug the power cord of the pellet auger into the indicated Schuko-type burner socket on the left side of the burner housing.

It is mandatory to assure a backup power generator of corresponding rated power! (see

12.4)

Improper cable connections may damage the regulator!

The device may be damaged if struck by a lightning. Make sure it is unplugged during the storms.

It is imperative that the installation of the sensor to control the temperature in the boiler. View a scheme 5 point 6.

ATTENTION! STB - thermostat

(located on the front panel of the boiler) to be bound to the burner according to wiring diagram 12

The boiler must be connected to a

220V/50Hz mains using power plug (3 meters long, bound to the burner).

Create tight connection with the electrical mains which complies with the local regulations.

1.

WBS boiler; 4.

Auger;

2.

Pellet burner Pell; 5.

Fuel hopper.

3.

Auger flexible pipe;

Diagram 10. Mounting the pellet burner Pell to WBS boiler

7.6. Connecting the pellet burner to the mains power supply

Such connection must be performed by a technician / service shop authorized for such operations.

Caution! ELECTRIC SHOCK

HAZARD!

- Before opening the unit: switch off the voltage and secure the unit against accidental restart.

- Observe installation instructions.

20

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Diagram 11 Wiring diagram of connection of internal devices / sensors to the burner

Inputs

Group 1

RT Room thermostat

PS Photo sensor

RB Reverse burning

B Boiler

Group 2

WH Water heater

Outputs

FM Fan main

SF Screw fuel

SB Screw burner

PH Pump heating

PWH Pump water heater

IGN Igniter

FC Fan cleaning

21

EMC

FILTER

STB

/mounted on the front panel/

Diagram 12.

Wiring diagram of connection of external devices / sensors to the burner

22

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

8. BURNER OPERATING

8.1. Ignition.

After the start up of the burner from the control panel, the main pellet auger conveys certain amount of fuel from the pellet hopper to the burner. This specific amount of pellets is set by the installer and depends on the fuel characteristics.

The fed-in quantity of pellets is conveyed from the auger conveyor built in the burner to the combustion chamber where it is being ignited using hot air.

8.2. Burning.

The burning process takes place in the combustion chamber and, after it has been fed into the combustion chamber, the fuel is then transported from the internal auger conveyor to the combustion chamber in portions. This allows for constant and optimal burning rate of the fuel . Flame intensity is monitored by a photosensor which monitors the burning and feeds data into the control unit which enables the starting or stopping of the combustion process, if necessary. The output of the burner is determined by the intervals preset on the control panel taking into account the heating value, size and density of the pellets.

8.3. Automatic cleaning system.

The “Pell” pellet burner is equipped with innovative automatic cleaning system for the combustion chamber. Thanks to a powerful cleaning motor built in the burner body, air is being blown in at high speed and rate thus removing all residues

– ash, noncombustible inclusions, etc. built up into the combustion chamber of the boiler. These automatic cleaning cycles last several seconds and can be additionally adjusted as well as their repeat rate depending on the load of the burner.

23

8.4. Installer prescriptions regarding burner servicing and maintenance

Before the heating season it is mandatory to check up and clean the burner and its components.

It is mandatory to clean up the combustion chamber of burner using the scraper brush from the maintenance kit. In case of combustion chamber orifices clogged by non-combustive material, those should be released using a bodkin. Clean thoroughly the inner combustion chamber using the scraper brush to remove all deposits on the metal surface. Use a vacuum cleaner to remove all sand and ashes from inside the combustion chamber. Check integrity of gasket between outer combustion chamber and closing hatch, replace if compromised.

It is mandatory to clean dust off main fan and controller board

8.5. Important recommendations for long-lasting and correct operation of the boiler

- For assembly and installation of the burner follow the requirements in this manual.

- Use only recommended in this manual fuel.

- Disassemble the burner from the boiler body before clean it. Depending on fuel and burner settings, clean the pellet burner once a month.

- User`s training for operation and maintenance of burner is performed by an authorized installer or service shop.

Failure to observe the installation and operating requirements described in the manual and the service booklet voids the warranty.

Type of maintenance

Weekly

Monthly

Yearly

Procedure

Cleaning of combustion chamber by poker and scraper brush

Dismantling of combustion chamber housing (A).

Cleaning of combustion chamber by scraper brush and vacuum cleaner. Replacement of gasket if faulty (see

Diagram 13)

Full dismantling and cleaning of burner. Replacement of all gaskets (see Diagram 14.3.)

Duty of:

User

User /

Installer

Installer

Diagram 13. Dismantling of the combustion chamber housing.

9. OPERATION OF BOILER WHEN

BURNING SOLID FUEL

9.1. Loading and ignition the boiler

When ignition the boiler for the first time, a condensate is formed which is later drained (this is not a fault in the boiler).

Fuel is loaded in the combustion chamber and it is recommended to load logs of length equal to the combustion chamber length and stack them tight inside with least possible air gaps. The chamber door as well as all inspection openings must be closed and sealed. Open the thermostatic draft regulator and chimney flap to ignite the boiler. When boiler temperature reach 85°С, adjust intake air by the chimney flap and boiler air-intake

24

door flap. The position of boiler air-intake door flap adjust by thermostatic draft regulator.

When burning wood with moisture content more than 20%, results in:

- significantly increases fuel consumption;

- not reach the desired power;

- lifetime of the boiler and chimney fall.

Maintain operating temperature between 65°C and 80°C.

9.2. Cleaning of the boiler

Caution! Hot surfaces.

Before cleaning the boiler, make sure the fire in it has died out and the boiler has cooled down.

Boiler cleaning must be carried out

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

periodically and adequately every 3 to 5 days. Ash accumulated in the combustion chamber, condensed moisture and tar deposits significantly reduce the life span and performance of the boiler and result in deterioration of the properties of the heat exchange surface In case of larger ash accumulation there is not enough space for fuel combustion which may result in damage of the boiler as a whole. Regular cleaning is important to ensure the optimal performance and long operational life of the boiler.

It is recommended that the ash-and sootcontainer be emptied and cleaned every 3 to 5 days depending on fuel used. Scrape the inside of flue pipes if necessary. Use the scraper tool.

Additional barrier ribs into combustion chamber

ATTENTION! Disassemble barrier ribs (1), (2) and pellet burner before change boiler burning mode to solid fuel.

Disassembling of barrier ribs:

protective door (1) in this order:

- lift the door gently up and forward

- detach the door from retaining hinges

- remove gently upper protective door.

2. Gently pull out lower barrier rib (2) which is on top of middle water rib (3)

3. Gently pull out upper barrier rib (4) which is on top of upper water rib

4. For assembling the barrier ribs back into boiler follow the steps in reverse order.

4

1. Open upper boiler door. Just behind the boiler door are fitted upper and lower protective doors. Disassemble upper

25

Scrape the inside of flue pipes if necessary.

Use the scraper tool.

It is mandatory to clean once a week additional barrier ribs into combustion chamber

Disassemble the barrier ribs.

Follow described above instructions for assembly and disassembly.

Clean barrier ribs.

Clean the accumulated ash from heat exchanging ribs

Caution! Ashes may contain smoldering charcoal. Dispose of ashes only in specially designated facilities. Disposing of ashes into public garbage containers may cause fire.

9.2.1. Preparing for the new heating season. Recommended boiler maintenance procedures:

1. Remove internal safety gates inside the boiler firebox (combustion chamber).

Scrape thoroughly the firebox using the scraper brush from the boiler cleaning kit. Remove tar and soot deposits as they obstruct normal heat radiation.

2. Clean thoroughly water jacket ribs.

Remove cinder and soot deposits using the scraper tool and brush from cleaning kit.

3. Remove inspection opening lid below the boiler flue opening and remove ash deposits in there.

Caution! Replace inspection opening lid gasket wth a new item if its integrity is broken.

4. Clean well metal grill in the bottom part of the boiler. Check whether gaps between flue pipes are well cleaned. Tar deposits or residues of non-combustive materials inside the boiler firebox deteriorate normal combustion process.

5. Check for good sealing of doors:

- Open the doors of the boiler.

- Place four strips of paper sides of the doors and close so that some of the tapes to be submitted outside.

- Pull the paper strip. If to break during pull, the doors are sealed.

If necessary, adjustment of of boiler doors or replacing insulation rope, please contact in your installer.

6. Clean air distribution pipes located below boiler flue pipes. Ash deposits inside them obstruct the inflow of air into the firebox (combustion chamber).

In case dismantling of air distribution pipes is needed use wrench S13. Once

26

the ash is swept out mount them back in place.

7. Clean fan turbine. Use a vacuum cleaner unit to remove dust from inside the fan turbine.

9.3. Important recommendations for long-lasting and correct operation of the boiler.

- Carry out periodic maintenance of boiler following the prescriptions in Section

9.2.

- The allowed moisture content of the fuel used must not exceed 15% ÷ 20%.

- Gas emission in the combustion chamber may result in the formation of tar and condensate (acids). Therefore, a mixing valve must be installed and it must be adjusted so that the minimum temperature of the water returning in the boiler is 65°С. This extends the life span of the boiler and its warranty. The operating temperature of the water in the boiler must be within the 65°С ÷

80°С range.

- It is not recommended to operate the boiler for a long period of time at an output lower than 50%.

- When using circulation pump, boiler operation must be controlled via a separate thermostat in order to ensure the prescribed rated temperature of the return water.

- The eco-friendly operation of the boiler is realized at rated output.

- It is recommended to install a storage/ buffer tank and pump type group with thermostatic mixing valve to the boiler.

The capacity of the storage tank is 55 L of water per 1 kW installed boiler power.

- Maintenance and operation training for the boiler is conducted by an authorized installer

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Failure to observe the installation and operating requirements described in the manual and the service booklet voids the warranty.

10. OPERATION OF MICROPROCESSOR

CONTROLER WHEN BURNING WOOD-

PELLETS

ATTENTION: The boiler should have non-return valves mounted on the central heating pump circuit and the hot consumption water pump circuit. A valve mounted on the hot consumption water pump will prevent hot consumption water from being drawn from the water heater.

10.1. Controller view. Explanation of buttons and indicators.

LCD screen:

The controller screen displays the information for the operation of the facility.

Explanation buttons: of

Button F

function key

(button). Used to move from one page to the next menu, and passing the burner from one stage to another (Manual -Auto

– Programe).

Button „Enter”

– Used to move from one line to another menu of the controller. Confirm the entered value.

Buttons „Navigation arrow Up”

and

„Navigation arrow Down”

– Used to change the value of a parameter in the menu. After entering the correct value

27

press button “Enter”, to move to next parameter.

Display symbols explanation:

Auto Clean symbol appears in right upper part of display. Active auto cleaning symbol means boiler automatic cleaning mode.

Crossed-out flame symbol appears in upper right part of display. Means that the boiler enters into Extinguish mode.

CH priority /Radiator/ symbol appears in upper part of display.

Means than Central Heating priority is set to heat up the central heating.

Domestic Hot Water /shower/ priority symbol appears in upper part of display. Means than DHW priority is set to heat up the domestic hot water.

When set DHW temperature is reached,

DHW pump stops and CH pump is activated.

Parallel pumps /shower and radiator/ symbol appears in upper part of display. Means that is set equal priority to both pumps. They work in parallel and are controlled by temperature sensors.

Summer mode /shower and sun/ symbol means than is set Summer heating mode. Only DHW pump is active.

that burner is activated. Burner goes into

Ignition mode and upcoming boiler fire up.

Burner flame symbol appears in upper right part of display. Means

Flame 3 symbol means Maximum

output mode of boiler. In this mode the boiler operates at maximum output.

Flame 2 symbol means Medium

output mode of boiler. In this mode

the boiler operates at partial output.

Flame 1 symbol means Low output

mode of boiler. In this mode the boiler operates at minimum output.

This symbol means Suspend mode of boiler.

The notice “Hi” appearance on the screen where the boiler temperature is displayed means that the measured Boiler body temperature is above 120°C. Flashing and beeping alarm is activated. When the issue is corrected, notification can be deleted. When disconnect the boiler from electrical supply for few seconds and then switch on it again, boiler goes back to normal operation.

Notify the authorized installer/ service to be performed immediately inspection of the boiler and heating installation.

deleted).

Notify the authorized installer/ service to be performed immediately inspection of the boiler and heating installation.

BB

ALARM

SENSOR

E1

SENSOR

E2

IGNITION

FAIL

Factory setting - Alarms

Reverse fire Alarm (when the thermostat contact RB input is open)

Boiler Temperature Sensor is missing (input B)

Boiler Temperature Sensor

Short circuit ( input B)

Failure ingnition temperature is displayed means that boiler temperature has increased up to

99°C.

Boiler increased temperature.

Those two symbols appearance on the screen where the boiler

Notify the authorized installer/ service to be performed immediately inspection of the boiler and heating installation.

Error symbol appears in right upper part of display. Flashing and beeping error symbol mean error or fault in boiler operation. Use “Enter“ button to move to next screen with error notification in lower left part of display. When the issue is corrected, error notification can be deleted. When disconnect the boiler from electrical supply for few seconds and then switch on it again, boiler goes back to normal operation (error notification is

28

DHW E2

Sensor is missing (input WH)

Water Heater Temperature

Sensor Short circuit (input

WH)

When restarting the controller alarm is deactivated.

”С” symbol means that the motor of automatic

cleaning system is activated.

T“ symbol indicates connection of room thermostat to burner

(boiler) controller.

In „CH Priority“ mode burner on and off is controlled by the room thermostat.

In „DHW Priority“ mode the room thermostat activates and operates the CH pump when the temperature of domestic hot water /DHW/ reach maximum set temperature.

In „Parallel Pumps“ mode the room thermostat controls CH pump in parallel with DHW pump /until domestic hot water reaches set temperature/.

In „Summer Mode“ room thermostat is

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

not active.

Lights for operating:

- Pump heating system.

- Pump Domestic hot water.

Use UP and DOWN arrow keys in Set

Date menu to set the date.

Use UP and DOWN arrow keys in Contrast

menu to adjust the LCD display backlight level.

Confirm settings by shifting to next submenu through a single pressing of the functional key F.

Use UP and DOWN arrow keys in Set

Time menu to set the unit’s built-in timer/clock.

10.2. User`s menu

10.2.1. Initial (start-up screen) “Standby”

For access to user settings menu press and hold functional key F for 3-4 seconds.

Use UP and DOWN arrow keys in CH

Setup menu to select desired temperature of engagement of circulation pump.

In DHW Setup menu – set domestic hot water

(DHW) pump switch on/off temperature.

Use UP and DOWN arrow keys to select desired temperature in “Set Temp _ _°” and hysteresis in “Hysteresis _ _°”. Upon reaching the preset temperature of water in boiler the DHW pump will engage. It will stop when water inside the DHW storage tank reaches the preset temperature.

Example: On Set Temp 70°C and

Hysteresis 05°C when water inside the boiler heats up to 70°C the pump will start. When water temperature inside the DHW storage tank reaches 70°C the pump will stop. It will restart once the water temperature inside the DHW tank drops by 5°C. In this way the water temperature inside the DHW tank will be kept at a hysteresis of 5°C, i.e. the water temperature will be between 65°C and

70°C.

The burner is in standby mode.

The display shows:

29

- Temperature in the boiler (23°C), time, and by pressing the Enter button you can browse the quick menu (bottom left) where the following read-only data is displayed:

- Maximum set temperature t = 85°C, temperature of domestic hot water

(where such heating circuit is connected)

- Light intensity in the burner

- Burner status (detected errors, if any)

- Date.

10.2.2. Burner star up “Switch mode”

Burner start-up.

After pressing the

“F” button and using the „navi-gation arrows”, the “Auto” menu is selected. Pressing the F button will open the next page of the menu.

Set the priority mode of the burner through “navigation arrows.”

- CH Priority

Priority heating system pump

- DHW Priority

Priority pump for domestic hot water

- Parallel Pumps – parallel operation of both pumps.

- Summer Mode – Summer mode. Burner works for heating of domestic hot water only.

Select the desired option using the navigation arrows. Use the „F” button to open the next page of the menu.

i

Important – The use of “External room thermostat for the burner” option (Thermostat) is active only if option is selected

(CH Priority – priority of central heating installation pump).

10.2.3. Automatic mode of operation

“Auto”

The burner goes into automatic mode of operation

Auto”. In this operation mode the ignition and the combustion process are automatic as well as the pump control.

The burner operates in this mode until the maximum preset temperature has been reached. It then enters into

Suspend” mode.

10.2.4. Burner shut-down “Standby”

Pressing the “F” button will take you to the main menu and by using the navigation arrows you can select the “Standby” menu and confirm the selection by pressing “F”. The burner goes into extinguishing mode.

30

10.2.5. Setting up delayed start

From the start-up screen, press „F” to enter into the burner status

Switch Mode”. Use the navigation arrows to select the

Programme” menu and confirm your selection by pressing the “F” button.

This will open a menu where within a 24hour period you can set up to 3 /three/ delayed start-ups and shut-downs of the burner.

Example: The picture shows the first checkmark being set and next to it is the start-up time at 06:00 and burner shut-down time at 22:00.

Programming desired time:

- Activate the checkmark in the box

Select the desired option using the navigation arrows. Use the „Enter” button to open the next page of the menu.

Heating priority selection - Menu.

From this menu you can select the priority of one of the two pumps:

(CH Priority) or (DHW Priority).

Parallel Pumps – parallel operation of both pumps.

Summer Mode.

Important – The use of “External thermostat for the burner” option is active only if option is selected

(CH Priority – priority of central heating installation pump).

Use the navigation arrows to select the desired priority and press the “F” button

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

to open the next page.

After all settings have been confirmed, the burner will initiate ignition sequence according to the input parameters.

10.3. Installer’s menu (setting the combustion parameters in the burner controller)

CAUTION! We recommend that this menu be used only by an authorized installer/service shop in order to ensure efficient and safe operation of the equipment

2.3 / 2.2

To access the settings adjustment mode, simultaneously press the “Enter” and „F” buttons and hold them pressed for 4 /four/ seconds.

This will display the controller hardware and software version on the screen. Press again button “F” and this will open the initial page for the burner settings.

For access to service settings menu you need a service menu code.

The service menu comprises only and u n i q u e l y parameters with direct impact on boiler combustion process, as well as on heating installation management (depending on the peripherals management capacity of the boiler digital controller unit).

10.3.1. Cleaning setup

The burner performs automatic cleaning before each ignition and shut-down.

31

You can use this menu to adjust the running time of the main fan (FAN) and of the cleaning motor (Cleaner).

Important: Once you have browsed to the next page you cannot return to the previous one.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

In this submenu you can activate or deactivate the automatic cleaning of the burner in

Ignition (Start) mode or extinguished

(Stop) mode.

The checkmark in the box indicates that the automatic cleaning system is active.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

10.3.2. General setup

In this submenu you can set the number of attempts (Retries) to ignite the burner and the time of the initial feed portion of pellets (Feed).

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

10.3.3. Cycle setup

Use this submenu to adjust the running time of the heater

(Heater) and the

running time and output of the main fan during the ignition of the initial portion of pellets.

Principle of operation:

After feeding the initial portion of pellets, the heater operates for 3 minutes , and the main fan is turned on at 5% of its capacity and operates for 2 minutes (the heater continues to work). After the two minutes have expired, the fan starts to work at 15% of its capacity and continues at that level for 3 minutes. If upon the expiration of that period the photosensor detects the presence of stable flame, the burner enters into operating mode. If no stable flame is present, the burner feeds in pellets again and repeats the process.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

10.3.4. Burn Level

The burner has three main levels of burning (three main output modes of operation). Use this menu to set the temperature differences at which the burner will shift from higher output mode to lower (step modulation).

Example: We have set maximum temperature of 85°С. Upon reaching

77°С, the burner will shift down to lower mode of operation (two flames). Upon reaching 82°С, the burner enters into still lower mode of operation (one flame).

Upon reaching 85°С, the burner enters into suspend mode (Suspend).

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

10.3.5. Setup of burning Level

This submenu allows you to adjust the parameters of the main mode of o p e r a t i o n

Maximum output of the burner. It is indicated by three flames .

You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).

Example: with the period set at 20 seconds, the pellet auger runs for 13.1 seconds feeding pellets in the burner, and is off for 6.9 seconds.

Select the desired option using the navigation arrows. Use the “Enter” button to open the next parameter. Use the “F” button to open the next page of the menu.

of the burner.

In this submenu you can adjust the parameters of the medium output mode of operation

32

It is indicated by two flames .

We recommend to set at 50% of the main mode.

You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).

Example: with the period set at 20 seconds, the pellet auger runs for 8,3 seconds feeding pellets in the burner, and is off for 11,7 seconds.

Select the desired option using the

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

In this submenu you can adjust the parameters of the

lowest output mode of operation of the burner. It is indicated by one flame .

We recommend to set at 10÷35% of the main mode.

You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).

Example: with the period set at 20 seconds, the pellet auger runs for 5,4 seconds feeding pellets in the burner, and is off for 14,6 seconds.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

Complete description of the output modes is provided in section 10 of this manual.

navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

10.3.7. Suspend Time

In this menu you can adjust the time period for which the burner will remain in suspended mode and the time can be set in minutes with a maximum duration of 180 minutes.

If within a set time (20 minutes) the temperature in the boiler does not decrease, the burner enters into

Extinguish mode – crossed-out flame .

10.3.8. Auto Clean Setup

You can set time and number of engagements of the burner self-cleaning system.

It is mandatory to have at least one selfcleaning session in 24 hours.

Maximum number of self-cleaning sessions in 24 hours – six.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

10.3.6. Suspend

This submenu allows you to adjust the parameters of the suspended mode of operation of the burner. You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).

Example: with the period set at 20 seconds, the pellet auger runs for 5 seconds feeding pellets in the burner, and is off for 115 seconds.

Select the desired option using the

33

10.3.9. Hardware Setup

Use this submenu to activate or deactivate some internal burner devices.

The checkmark in the box indicates that the device is active.

Burner Feeder - internal burner auger /feeder/

Cleaner Motor

Tstat NO -

Thermostat, normally open.

There must be a checkmark on the internal pellet auger of the burner (Burner Feeder)

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

Set the sensor switch and control an external device

(vacuum or screw auger for loading the main hopper with pellets).

NO - normally open; NC- normally closed.

Burner feeder – Use this submenu to adjust the internal auger of the burner as a percentage value of the operation of the external pellet auger.

Example: If the external pellet auger runs for 10 seconds and feeds fuel in the burner, the internal auger will run for 20 seconds, if the setting is (Duty 200% - see picture). Duty parameter can be changed from 0% up to 300%.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

Use this submenu to activate or deactivate the additional peripheral components.

CH PUMP - central heating pump

DHW PUMP - domestic hot water pump

Thermostat

The checkmark in the box indicates that the device is active.

Select the desired option using the

34

navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

This submenu allows you to adjust the conditions under which the

photosensor detects the presence of stable or unstable flame and signals the burner to shift to operating mode or be extinguished.

Example: (see picture) If the light intensity in the burner is above 100 units over a period of more than 20 sec, the burner will detect that there is a stable burning process going on and will shift from ignition to burning. If the light intensity in the burner is under 40 units over a period of more than 60 sec, the burner will detect that there is no stable burning process going on and will extinguish the burner and attempt to reignite.

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the „F” button to open the next page of the menu.

Use this menu to conduct fan operation

test.

You can control the fan in real time, without confirming anything, using only the navigation arrows.

Important. This menu is for installers only and it is active and visible only if the controller is in „Standby” mode.

Use the „F” button to open the next page of the menu.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Test Outputs

A1

CS

VF

CA

This menu allows you to check the operation of the various

 pellet burner components.

Using the navigation arrows, you can turn on and off the various components and each time the respective components is being activated a checkmark will appear in front of its name. Use the „Enter” button to select the individual components.

Description of components:

1) FF – Fuel

Feeder – main auger

2) BF – Burner

Feeder – internal burner auger / feeder

3) CH – Central Heating pump

4) DHW – Domestic Hot Water pump

5) Ign – Ignition

6) CM – Cleaning Motor

Important. This menu is for

installers only. It is active and visible only if the controller is in "Standby".

This menu allows you to select maximum boiler temperature. In other words, the maximum temperature to heat the boiler on which the burner has been installed.

The maximum value for this setting is

85°С.

Select the desired option using the button to open the next parameter. Use the „F” button to open the next page of the menu.

navigation arrows.

Use the „Enter

11. SETTING OUTPUT MODES OF

OPERATION OF THE PELL PELLET

BURNER

CAUTION! You must use gas analyzer when setting the burner.

The Pell pellet burner is equipped with three-step output adjustment and their setting depends on the boiler and heat requirements of the heating installation.

11.1. Calibration of auger fuel feed rate.

The auger fuel feed rate changes depending on the density and size of the fuel used. Therefore it is necessary to calibrate the main auger every time you change the type of the fuel used.

CAUTION! It is recommended to use the same fuel throughout the heating season.

Once you have installed the pellet auger according to the instructions in the manual, fill the hopper with fuel (pellets).

Connect the power supply of the pellet auger directly to the power mains. The auger is now in operation. Wait about

15-20 minutes for the pellet auger to fill with pellets. The auger is filled with pellets when pellets begin to fall from the

T-branch of the auger at the point where the flexible pipe is attached.

Filling of the pellet auger is necessary when the fuel in the hopper has been depleted or when fuel has been changed.

Once you have ensured that the pellet auger has been filled, take an empty plastic bag and fixed it securely on the pellet auger, at the place of the flexible pipe. Reconnect the auger to the power socket and measure the amount of pellets collected in the bag over a period of 15 minutes using scales/weighing scale.

(In our example, the amount of pellets collected in the bag over a 15-minute

35

period is 3240 grams (900 sec). We then divide 3240 by 900 and get 3.6 grams of pellets per 1 second. Repeat the measurement in order to obtain conclusive results.

t

11.2. Burner output adjustment.

In the burner output settings menu you can adjust the running time of the main auger (Feed); main running interval

(Cycle) and fan output (Fan).

Example for Pell 25 model: we select mode Cycle = 20 sec. The heating value of your fuel is 4.8kWh/kg. (manufacturers indicate the heating value of the fuel on the packing – take it from there). We then employ the following formula to calculate the number of seconds for setting the operation of the main auger for these 20

sec:

FEED

= 25 000 / (4,8 x 180 x 3,6)

hence t

FEED

= 8 сек.,

where 25,000 is the desired output of the burner in Watts (W), 4.8 is the heating value of the fuel in kWh/kg, 180 is the number of burning cycles per 1 hour,

3.6 is the amount of pellets in grams fed by the auger per 1 second. This way the output mode can be changed and instead the number 25,000 – 25kW, we input the desired kilowatts (40 kW=40000 W, 70

kW=70000 W etc.).

Take also note of the fuel heating value which would change the value for the feed and the burner output.

Using the above procedure, you can set any of the three output modes of the burner.

Mode : Maximum output

mode – It is indicated by three flames.

Pellet auger running time (Feed)8 sec.

(25kW)

Main combustion cycle (Cycle)20 sec.

(recommended)

Fan output (Fan) - adjust using gas analyzer.

36

Mode

: Medium output mode – It is indicated by two flames.

We recommend to set value at 50% (0,5) of the main mode.

Pellet auger running time (Feed)4 sec.

(12,5kW; 8 х 0,5 = 4)

Main combustion cycle (Cycle)20 sec.

(recommended)

Fan output (Fan) - adjust using gas analyzer.

Mode

: Low output mode – It is indicated by one flame.

We recommend to set value at 30% (0,3) of the main mode.

Pellet auger running time (Feed)2,4

sec. (7,5 kW; 8 х 0,3 = 2,4)

Main combustion cycle (Cycle)20 sec.

(recommended)

Fan output (Fan) – adjust using gas analyzer.

i

whose carbon footprint values are approximately (СО = 100 ppm), which is 2.5 times lower than the maximum allowed limits for harmful emissions in the EU Member States. Thus you can reduce the amount of to environment protection.

output modes the optimal fan setting is tweaked by using gas analyzer to control the oxygen amount registered by the device

(within the range 8% ÷ 10%, and for the lower modes up to 16%).

The specific setting depends also on the internal resistance of the boiler combustion chamber on which the burner has been installed as well as on the chimney draught. Therefore it is not possible to provide here the exact value for the fan output and it must be entered by a technician using gas analyzer

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Service code

Cleaning Setup

Use Cleaner

Clean Soot

General Setup

Cycle Setup

Burn Level

Actuator

Fan

Cleaner

Cleaner

Retries

Feed

Heater

Pell 25 Pell 30 Pell 40 Pell 70 Pell 90 Pell 150

Parameter value:

00000012

180 sec

20 sec v On start v On Stop

30 sec

3

45 sec

3 min

1 min

1 min dt>8 dt>8 dt>8 dt>8 dt>8 dt>8 dt>4 dt>4 dt>4 dt>4 dt>4 dt>4

Setup

Setup

Setup

Suspend

Suspend Time

Auto Clean Setup

Hardware Setup

Vacuum Feeder

Burner Feeder

Addons Activacion

Ir Level Setup

Set Temperature

Test Fan Speed

Test EFan Speed

Test Outputs v v v dt>0 dt>0 dt>0 dt>0 dt>0 dt>0

Feed

Cycle

Fan

Feed

Cycle

Fan

Feed

Cycle

Fan

Feed

Cycle

Fan

-

Duty

Ign >

Ext <

Max

8 sec

20 sec

37

4 sec

20 sec

30

8,5 10 sec 12 sec

20 20 sec 20 sec

32

4,3

20

28

2,4 sec 2,6

20 sec

29 26

5 sec 6 sec

20 sec 20 sec

20 20

9

20

35

4,5

20

22

8 sec

20 sec

50

4 sec

20 sec

32

3 sec 3,6 sec 2,7 2,4 sec

25

5 sec

60 sec 60 sec 60 sec 60 sec 60 sec 60 sec

20

20

25

5

20

25 sec 20 sec

17 17

20

15

20 sec

17

5 sec 5 sec 2 sec 5 sec

17 17 5 17 v 8:00

□ 00:00

5 min v 14:00

□ 00:00

v 22:00

Cleaning Motor

Tstat NO

NO

NC v v

CH Pump

DHW Pump

200%

Termostat

100/020 s

040/060 s

85 o

C

00

00

FF; BF; CH; DHW; Ign; CM

37

12. OPERATION OF MICROPROCESSOR

The controller is designed for controlling

CH boilers. It is regulating the pump responsible for CH water circulation,

HCW pump and the fan. Model ST-81 is

PID controller using current signals and power the fan is adjusted depending on the temperature of the boiler. The fan runs continuously and its power depends directly on the measured temperature of the boiler.

12.1. Controllers view. Explanation of buttons and light indicators.

This controller can save up to 13% fuel and provide a constant water temperature and longer life of your boiler.

The heat of the flue gas is used for heating rather than lost through the flue.

p q

CONTROLER WHEN BURNING SOLID

FUEL

Explanation of buttons:

- Navigation arrow UP / PLUS

- Navigation arrow DOWN / MINUS

MENU button - Enter menu / approve settings

EXIT button - canceling settings

- Power switch ON/OFF

- Fan

- CH -central heating - pump

- HCW - hot water- pump

- Manual operation

38

12.1.1. Fire up – The cycle begins when you activate the fire up function in the controller’s menu and is active until the central heating boiler temperature reaches 40°C (the default fire-up threshold), on condition that the temperature does not drop below this value for 2 min. (the default fire-up time).

If these conditions are met, the controller will switch to the operation mode and the manual operation symbol on the housing will be deactivated. If the controller fails to reach parameters required for entering into the operation mode within 30 min. from activation of the fire-up function, the „Unable to fire up“ message will appear on the display. In such a case, the fire-up cycle needs to be restarted.

12.1.2. Operation – The operation cycle is the basic functionality of the controller.

The power of fan is regulated by the user.

If the temperature rises above the set temperature a so called suspension mode will be activated.

12.1.3. Suspension mode – this mode will be activated automatically if the temperature is equal or higher than the set temperature. In that case, in order to ensure smooth decrease of temperature of circulating water it is necessary to properly set operation times of the fan.

12.1.4. Damping - if boiler temperature drops by 2°C below the fire-up threshold and fails to rise above this value for 60 min. (default damping time), the controler will switch to the damping mode. While in this mode, the fan is deactivated and the display shows “Damping”. In case of voltage loss, the controller ceases to operate. When power is restored, the controller returns to operation with

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

previously set parameters using its builtin memory.

12.2. Main page

threshold) during 30 min. the display will present the following alarm:

During normal operation (in only CH mode) the LCD display shows the main page which presents the following information:

Boiler temperature (on the left side of the display)

Set temperature (on the right side of the boiler)

Operating mode - in the lower right corner appear in capital letters initials of the respective operating mode:

D - home heating; R - parallel pumps;

B - DHW priority; L - summer mode.

This screen allows for quick change of the set temperature, by the means of

PLUS and MINUS buttons. Pressing down

MENU moves the user to the 1st level menu, the display then shows the first two rows of the menu. In each menu the user can move up and down by the means of

PLUS and MINUS buttons. Pressing down

MENU moves the user to the consecutive menu or enables a specific function. EXIT moves the user back to the root menu.

12.3. Fire-up

This function starts up the fan during fire up sequence. If the fan is not operating, a star symbol will appear in the upper right corner of the display. This function allows the user to safely operate the boiler. If the fan is turned on DO NOT open the boiler.

This setting allows to temporarily switch off the fan at any time e.g. during feeding fuel. If, during fire up sequence the boiler will not reach 40°C (default damping

39

In this case the user should restart the fire up sequence – the thermoregulator will once again start the fire up sequence.

12.4. Manual operation

In this mode each executive element can be switched off and on independently from all the other elements.

Pressing down MENU starts the fan, which remains turned on until the next pressing of the MENU button

Pressing down MENU Turns on/ off CH water pump.

Pressing down MENU Turns on/ off HCWhot water- pump.

Pressing down MENU Turns on/ off alarm signal

12.5. Pumps (CH and HCW) switch on temperature

This option is used in order to set the switch on temperature of the CH and HCW pump (it is measured in the boiler). If the temperature increase above the set level the pumps will switch on. The pumps will switch off after the temperature drops below the set temperature (minus 2°С of hysteresis), in this case the pump will

switch when the temperature in boiler drops below 33°С.

B switch on. The HCW pump will restart if the temperature decreases to 50°C.

12.6. Hysteresis of the boiler

This option can be used to set the hysteresis of the set temperature. It is the difference between the temperature of start of the suspension mode and the temperature of restarting the operation mode (e.g. when value of the set temperature is 60°C and hysteresis is

2°C, the start of the suspension mode will take place at 60°C, whereas the restart of the operation mode will take place at

58°C. Hysteresis can be set in the range between 2°C and 6°C.

12.8. Fan force

This function allows to choose the operations speed of the fan. Range of regulations is between 1 and 10 (one can assume those are the gears of the fan). The higher the gear the faster the operation of the fan, whereas gear 1 is the minimal speed and gear 10 is the maximal speed. Change of gears is being done by the means of PLUS and MINUS buttons.

The fan always starts up with the maximal speed which allows it to start operation even with some amount of dust present in the engine.

12.7. HCW - hot water - Hysteresis

This option can be used to set the value of the hysteresis of the boiler set temperature. It is the difference between the set temperature (that is the boiler required temperature) and the actual boiler temperature (e.g. if the set temperature has the value of 55°C, and the hysteresis is 5°C. After the set temperature (55°C) is reached the HCW pump will switch off and the CH pump will

40

12.9. Modes of operation

A proper symbol for each operation mode is shown in the lower, right corner of the display. Depending on the mode of operation a specific letter is displayed:

42 0 C | 55 0 C *

CH SET D

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Fan speed

WORK MODE

D – house heating, B – boiler priority,

R – paralel pumps, L – summer mode.

12.9.1. House heating priority

If you select this option, the controller will switch to the house heating mode. The central heating pump starts to run above the pump activation temperature (set to

35°C by default). Below this temperature

(minus central heating hysteresis of 2°C), the pump is shut off. While in the house heating mode, the letter D is displayed in the bottom right corner of the main screen.

12.9.2. HCW priority

Activating the hot consumption water priority will cause the regulator to switch into the water heater priority mode. In this mode, the (hot consumption water) heater pump is activated until the set

H.C.W. temperature is reached. Then, the

H.C.W. pump is shut off and the C.H. pump is activated. The central heating pump will run until the water heater temperature drops below the set point value (and the

H.C.W. hysteresis); then, the C.H. pump is shut off and the H.C.W. pump is activated.

41

In this mode, the fan is operated as long as the temperature is below 62°C to prevent the boiler from overheating. The hot consumption water priority function consists in that the consumption water is heated up before heating up water in radiators. Change of the set HCW temperature can be done by pressing

Exit button (holding down for a few seconds). The display will show the HCW temperatures screen for a few moments.

Set temperature can changed with buttons UP and DOWN. After few seconds the display will return to its previous state. When HCW priority mode is on the main the letter B is show in the lower right corner of the display.

ATTENTION: The boiler should have non-return valves mounted on the central heating pump

circuit and the hot consumption water pump circuit. A valve mounted on the hot consumption water pump will prevent hot consumption water from being drawn from the water heater.

12.9.3. Parallel pumps

In this mode, the pumps start to run in parallel above the pump activation temperature (set by default to 35°C). The central heating pump runs continuously, while the hot consumption water pump stops after the set point temperature is reached in the boiler; it then restarts when the temperature drops by 2°C.

Change of the set HCW temperature can be done by pressing button EXIT (holding down for a few seconds). The display will show the HCW temperatures screen for a few moments. Set temperature can changed with buttons UP and DOWN.

After few seconds the display will return to its previous state.

ATTENTION: In this mode, a non-return valve should be fitted to maintain different heater and in the house.

After activation of the parallel pumps function, three items appear on the display. Starting from the left, these are:

Boiler Temperature (C.H.); Water Heater

Temperature (H.C.W.) and Set point

Temperature (C.H.). When parallel pumps mode is on the letter R is show in the lower right corner of the display.

12.9.4. Summer mode

When the function is enabled, only the hot consumption water pump is running in order to heat water in the water heater. The pump is switched on above a predefined activation threshold (see the pump activation temperature function) and will run until the set point temperature has been reached. The pump will start again when the temperature drops below the set hysteresis. In the Summer Mode, only the set point temperature is set on the boiler that heats up water for the water heater (the temperature set for the boiler is also the temperature set for the water heater).While in the Summer

Mode, the letter L is displayed in the bottom right corner of the main screen.

12.10. Room regulator

In this mode the controller is being managed by the room regulator and does not take into account the temperature set on controller main unit. The fan is operating until the temperature set on the room regulator is reached. However the operation of the boiler is limited by the temperature set on the thermo regulator mounted on the boiler.

CONNECTION OF THE ROOM REGULATOR: there is a 2-lead cable coming out of the room regulator which should be connected to the montage slit of the controller in the position described as

“room regulator”.

ATTENTION: no external voltage can be connected to the room regulator

12.11. Suspension operation

This option allows the user to set the time of operations of the fan in the suspension mode (above the set temperature).

12.12. Suspension pause

This option allows the user to set the time of the pause in the fan operation during the suspension in order to prevent

42

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

the boiler burn out, in case when the temperature will hold over the set point value.

ATTENTION: Improper setting of this option may cause a constant rise of the temperature!

Suspension pause shouldn’t be too short.

12.13. Language

This function allows the user to change the language version.

12.14. Factory Settings

There is always the possibility of returning it to factory (default) settings. Switching on this function will cause the user to lose all personal device settings which will be replaced by the settings saved by the manufacturer (this does not apply to settings of the service menu). At this point it is possible to re-set personal settings of the controller.

case of the C.H. Temperature Too High alarm, wait until the temperature drops below the alarm value.

Thermal protection

The boiler is protected with an additional bimetal sensor (located at the boiler temperature sensor) that disables the fan when the temperature exceeds the critical value: 85°C. This is to prevent water from boiling in the system when the boiler has been overheated or the controller is damaged. When the protective function is enabled and the temperature drops to a safe value, the sensor will automatically restart the device and the alarm will be deactivated. If the sensor is damaged or overheated, the fan is disabled.

Automatic sensor check

In case when the CH temperature sensor is missing or damaged an alarm is activated, which additional reports the fault on the display e.g.:

12.15. Controller safeguards

In order to ensure a safe and faultless operation, the controller has been provided with numerous protections. In the case of an alarm, an acoustic warning is sounded and the display shows a corresponding message. Press MENU to restore the controller to operation. In the

43

The fan is being turned off, whereas CH and

HCW pumps are operating independently from the current temperature, each in accordance with its specific settings. In case of CH sensor damage, the alarm will remain active until the sensor is replaced.

If the HCW sensor is damaged, the user should press MENU which will turn off the alarm and the controller will return to one pump operation (house heating). In order for the boiler to operate in all modes the sensor needs to be replaced.

Temperature protection

After the temperature exceeds 85°C, the alarm is sounded with the display showing the following message:

The current temperature is read from an electronic sensor and processed by the thermo controller. When the alarm temperature is exceeded, the fan is shut off and both pumps begin to run in order to distribute hot consumption water throughout the system.

Anti-boil protection. This protective function is used only with the water heater priority mode. For example, when the water heater setpoint temperature is 55°C and the boiler temperature rises to 65°C (so-called priority temperature), the controller shuts off the fan. If the boiler temperature reaches 80°C, the

C.H. pump will be activated. If the temperature continues to rise, the alarm will be activated at 85°C. Such condition may appear when the water heater or the pump is damaged or when the sensor has been improperly installed. However, if the temperature drops, the controller will activate the fan at 63°C and it will remain in the duty mode maintaining the priority temperature of 65°C.

Fuse. The controller has a network protection WT 3.15 A tube fuse.

ATTENTION: Higher current ratings may cause damage to the controller.

12.16. Technical specifications of controller ST 81

1 Supply voltage

2 Power consumption W outlet load

5 Fan outlet load

°C

A

A

+/-10%

5

10÷50

0.5

0.6

0÷90 resistance

10 Fuse insert

°C -25÷100

А 3.15

13. WARRANTY TERMS

The warranty terms are described in the

Service booklet included in the supply.

14. TECHNICAL PARAMETERS OF SOLID

FUEL BOILER WBS ACTIVE

14.1. General features

- Electronic control unit controls the combustion by modulating the fan speed. Optional control of circulation pumps for central heating and domestic hot water (DHW).

- Air feed fan optimizes the combustion and the fuel consumption rate.

- Combustion chamber with large heat exchanging surface and low chamber resistance.

- Large firebox door ensures easy loading even with bigger logs (length of logs up to 50 cm).

- Ribbed chamber surface and threepass flue gas flow for improved heat exchange.

- Exchangeable metallic ash grate protects the pipe grid from the flame.

- Burner flange on lower door for fitting pellet burners (optional)

- Safety devices:

1) Pressure relief valve 3 bar

2) Safety heat evacuator a tap-water-filled line passes throug the upmost part of the boiler body. In case of overheating is triggered open by a thermostatic valve (not included) t evacuate the heat off the boiler;

3) STB - thermostat;

4) Air intake flap;

°C 1

°C 45÷80

44

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

1. Control unit

2. Housing

Diagram 14. Elemets of WBS Active boiler

8. Metal ash grate

3. High efficiency thermal insulation

4. Safety heat evacuator (exchanger)

5. Three-pas flue gas flow

6. Water mantle

7. Combustion chamber

9. Ash-andsoot-container

10. Burner flange (option)

11. Flue

12. Air feed fan

13. Air intake flap

D

Diagram 15. Technical parameters of WBS Active - Pell

45

14.2. Technical parameters

Heat output kW

Heating surface m²

Height H mm

Width L / Depth D mm

Mantle volume

Combustion chamber volume l l

Combustion chamber resistance Pa/mbar

Required chimney draught Pa/mbar

Insulation

Boiler

Doors

Maximum power consumption of the boiler W

Electric power supply V/Hz

Recommended fuel

Operating temperature range °C

Operating pressure bar

Weight kg

Cold water inlet A, mm

WBS Active 20 –

Pell25

WBS Active 25 –

Pell25

17

90 ÷ 120

1215

540/860

92

58

20/0.20

12/0.12

22

100÷150

1215

540/925

100

62

25/0.25

12/0.12

high-efficiency thermal wool high-efficiency thermal wool

60

230/50

60

230/50

Safety line sleeve К, mm

Safety heat evacuator inlet/outlet Е, mm

Flue F

Ash-and-soot container

ø mm

J, mm

Flue cleaning opening O, mm

Drain Y, mm

X

65 - 80

3

252

R1¼/212

R1¼/1245

270

G½/1055

R½/1052

150

925

270

150/70

G½/212

P

65 - 80

3

260

R1¼/212

R1¼/1245

270

G½/1055

R½/1052

150

925

270

150/70

G½/212

P

46

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

WBS Active

30 – Pell25

WBS Active

40 – Pell25

WBS Active

50 – Pell 40

WBS Active

70 – Pell 70

WBS Active

90 – Pell 70

kW m² mm mm l l

Pa/mbar

Pa/mbar

W

V/Hz

25

120÷180

1215

600/925

105

73

28/0.28

12/0.12

60

230/50

30

140÷250

1215

700/925

118

84

32/0.32

12/0.12

60

230/50

35

160÷340

1215

700/985

128

97

56/0.56

12/0.12

52

250÷410

1365

700/1105

141

120

89/0.89

14/0.14

65

350÷480

1365

760/1105

156

133

115/1,15

16/0.16

high-efficiency thermal wool high-efficiency thermal wool

60

230/50

110

230/50

110

230/50

Пелети клас ENplus-A1; ENplus-A2; EN-B

°C bar

65 - 80

3 kg 285

A, mm R1¼/212

J, mm

К, mm G½/1055

Е, mm

F ømm

J, mm

O, mm

Y, mm

X

300

R½/1052

150

925

300

150/70

G½/212

P

65 - 80

3

330

R1¼/212

B, mm R1¼/1245 R1¼/1245 R1¼/1245 R1½/1400 R1½/1400

350

G½/1055

R½/1052

180

910

350

150/70

G½/212

P

65 - 80

3

355

R1¼/212

350

G½/1055

R½/1052

180

910

350

150/70

G½/ 212

P

65-80

3

430

R1½/212

350

G½/1205

R½/1202

200

1045

350

150/70

G1/ 212

P

65 - 80

3

464

R1½/212

380

G½/1205

R½/1202

200

1045

380

150/70

G1/ 212

P

WBS Active

110 – Pell 90

80

400÷650

1365

820/1105

171

160

130/1,3

20/0,20

110

230/50

65 - 80

3

493

R1½/212

R1½/1400

410

G½/1205

R½/1202

200

1045

410

150/70

G1/ 212

P

47

14.3. Elements of burner PELL

10

11

11

12

8

9

8

8

7

7

5

6

5

5

4

5

13

13

14

14

14

14

15

3

4

3

3

2

3

2

2

2

2

1

1

1

1

1

Diagram 16. Elements of burner PELL

Part Number

82801300000002

89081300000016

82801300000003

82801300000005

82801300000007

82801300000001

89091300000032

82801300000004

82801300000006

82801300000008

89801300000006

89081300000020

89801300000024

89801300000037

89800000000005

89800000000011

89801381000001

89801381000002

89081300000023

89801381000003

78801100000001

83801200000001

83801200000009

32800032000001

32800032000007

32800032000017

89080000000006

89801200000006

89800000000004

89801300000046

32590000000092

89080000000007

89080000000013

32640000000002

32640000000003

32640032000017

32640032000020

32800000000006 х х х х х х х х х x(C130) х х

PEll 25 PELL 30 PEll 40 PEll 70 PELL 90 х х х x х х х х х х х х х х х х х х х х х х х х х х x(C130) x(C130) х х х х х х х х х

48

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

14.4. Technical parameters of fuel hopper FH 500

Capacity

Max/Min wood pellets load ø, 6÷8 mm

Height H

Width L / Depth D kg l mm mm

Foundation B, mm

Auger mounting opening C, ø mm

Auger holder E

Pellet-load hatch F, mm

Hatch support

Drainage holes

Dust container

Inclination of guide plates

Pellet-colecting bottom R, mm

Leveling feet Z

Guide plate seal

Weight

X

P

G

J kg

FH 500

500

280÷300 / 15

1260

772 / 730

53

76

P

400 / 772

P

P

P

45°

300 / 300

P

P

82

49

15. RECYCLING AND WASTE DISPOSAL

15.1. Recycling of boiler packaging

Parts of the packaging made of wood or paper can be used as combustible for the boiler. Submit the rest of the packaging material for recycling according to the local regulations and requirements.

Replaced heating installation components must be submitted for processing to an authorized factory which complies with the environmental protection regulation.

15.2. Recycling and waste disposal

At the end of life cycle of each product its components are due to be disposed of in conformity with regulatory prescriptions.

Obsolete equipment shall be collected separately from other recyclable waste containing materials with adverse effect on health and environment.

Metal details, as well as non-metal ones shall be sold to licensed recyclable metal or non-metal waste collection organizations.

Those should not be treated as domestic waste.

50

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

BG119996Q

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