ATTACK AWP 25 Instructions For Use Manual

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W W W . A T T A C K . S K

Combined boiler

ATTACK Wood&PelleT

for Wood And PelleTs

insTrUCTions for Use

CONTENTS

CONTENTS ...................................................................................................................................................................... 2

1. GENERAL INFORMATION ....................................................................................................................................... 4

1.1 INTRODUCTION ................................................................................................................................................. 4

1.2. SAFETY ................................................................................................................................................................. 4

1.3 BOILER OPERATION .......................................................................................................................................... 4

1.4 SAFETY ITEMS FOR WORK WITH THE BOILER ........................................................................................... 5

1.5 BOILER MODIFICATION ................................................................................................................................... 5

1.6. BASIC DESCRIPTION OF THE BOILER: ......................................................................................................... 5

1.7 FUEL ....................................................................................................................................................................... 6

1.7.1 WOOD ........................................................................................................................................................... 6

1.7.2 PELLETS ......................................................................................................................................................... 7

1.7.3 ALTERNATIVE FUELS ................................................................................................................................. 7

2. BOILER ASSEMBLY AND INSTALLATION ........................................................................................................... 8

2.1 HANDLING THE BOILER ................................................................................................................................... 8

2.2 GENERAL CONDITIONS OF INSTALLATION ............................................................................................... 8

BINDING NORMS FOR PROJECTING AND INSTALLATION OF THE BOILERS ..................................... 9

2.3 PLACING THE BOILER .................................................................................................................................... 10

2.4 BOILER CONNECTION TO THE HEATING SYSTEM ................................................................................ 11

2.4.1 PROTECTION AGAINST CORROSION ................................................................................................ 12

2.4.2 CHIMNEY ................................................................................................................................................... 13

2.4.3 FLUE GAS CONNECTION OF THE BOILER ........................................................................................ 13

2.4.4 CONNECTION TO THE ELECTRICITY MAINS ................................................................................... 13

2.4.5 CONNECTION OF THE EXTERNAL PELLET TANK........................................................................... 14

2.4.6 LEFT DOOR VERSION ............................................................................................................................. 14

2.4.7 CHOICE AND WAY OF CONNECTION OF THE CONTROL AND SAFETY ELEMENTS ........... 14

2.4.8 CONNECTION TO THE ACCUMULATION TANKS .......................................................................... 16

2.4.9 RECOMMENDED HYDRAULIC SCHEMES OF BOILER CONNECTION....................................... 18

3. BOILER START-UP .................................................................................................................................................. 19

4. WARRANTY CONDITIONS ................................................................................................................................... 19

5. TECHNICAL PARAMETERS .................................................................................................................................. 20

5.1 DIMENSIONS OF THE BOILER ATTACK WOOD&PELLET 25 ............................................................... 21

6. REGULATION OF THE BOILER AND THE HEATING SYSTEM ..................................................................... 22

6.1 IN GENERAL ...................................................................................................................................................... 22

6.2 EMERGENCY ACTIONS .................................................................................................................................. 22

6.3 PREPARATION FOR THE OPERATION, FILLING THE INTEGRATED PELLET TANK ....................... 23

6.4 DESCRIPTION OF THE SAFETY DEVICES .................................................................................................. 23

6.5 BOILER CONTROL AND OPERATION ........................................................................................................ 24

6.5.1 DESCRIPTION OF THE MAIN CONTROL MODES ........................................................................... 25

6.5.2 DESCRIPTION OF THE CONTROL MODES, RELATION BETWEEN THE MODE WOOD AND

COMBI ................................................................................................................................................................... 26

6.5.3 OPERATION WITH WOOD .................................................................................................................... 26

6.5.3.1 MANUAL LIGHT UP OF WOOD........................................................................................................ 27

6.5.3.2 AUTOMATIC LIGHT-UP OF WOOD................................................................................................. 31

6.5.4 COMBINED OPERATION MODE .......................................................................................................... 33

7. DISPLAYING INFORMATION .............................................................................................................................. 35

8. SETTING THE PARAMETERS ............................................................................................................................... 37

8.1 LEVEL OF SETTING THE BASIC PARAMETERS ........................................................................................ 37

8.2 LEVEL OF SETTING THE ADVANCED PARAMETERS ............................................................................. 39

9. SPECIAL SETTINGS AND INFORMATION ........................................................................................................ 48

10. INTERNET CONNECTION .................................................................................................................................. 49

11. SOFTWARE UPDATES ........................................................................................................................................ 50

12. FACTORY SETTINGS AND RESET .................................................................................................................... 51

13. BOILER MAINTENANCE ..................................................................................................................................... 51

14. BOILER CLEANING .............................................................................................................................................. 52

15. ASSEMBLY AND DISSASSEMBLY OF THE REFRACTORY ITEMS ............................................................ 53

16. TABLE OF RELATION OF THE RESISTANCE AND THE TEMPERATURE OF THE SENSOR PT 1000 54

17. ELECTRICAL CONNECTION SCHEME ............................................................................................................ 55

18. ACCESSORIES ....................................................................................................................................................... 58

19. INSTRUCTIONS FOR DISPOSAL OF THE APPLIANCE AFTER ITS LIFETIME ENDS ............................ 58

19.1 DISPOSAL OF PACKAGING ........................................................................................................................ 58

1. GENERAL INFORMATION

1.1 INTRODUCTION

Dear customer,

thank you for your trust and purchase of our product – the combined boiler ATTACK WOOD&PELLET. The boiler construction is based on the newest knowledge of the biomass combustion and meets all current test criteria and EU directives.

Please read this manual carefully and keep it near the boiler for reference. This manual contains important information, including information for correct, safe and economical boiler operation.

Constant improvement of our products may mean small differences in the pictures and content and we reserve right to make technical changes of products without previous announcement.

1.2. SAFETY

The following three warning signs are used in this manual for illustration of the threat of danger and for important safety notifications:

DANGERNGER

There is imminent danger and serious threat to health or property. Follow the given instructions!

WARNING

Potentionally dangerous situation that could cause serious threat to health or property if advised actions are not taken. Take care!

CAUTION

Take care and follow the advised actions.

1.3 BOILER OPERATION

CAUTION

No unauthorized personel to enter the boiler room, there may be serious risk to health or property. Operator of the system must ensure that no unauthorized person, particularly children, enter the boiler room.

1.4 SAFETY ITEMS FOR WORK WITH THE BOILER

To work on the boiler please use correct personal protective equipment including heat resistant gloves, suitable cloths and safety shoes.

1.5 BOILER MODIFICATION

CAUTION

It is forbidden to make any changes to the construction of the boiler or disable any safety and protection devices fitted to the boiler.

1.6. BASIC DESCRIPTION OF THE BOILER

The ATTACK WOOD&PELLET is a modern environmentally friendly boiler that saves environment by efficient burning of biomass. The user gets the advantage of low operating costs from wood combustion as well as the convenience of the heating system comparable with gas boilers when burning the pellets. The boiler is intended for heating of dwelling houses, cottages, factories, industrial units, etc.

Pic. 1 Basic description of the boiler

1 –wood feeding chamber door, 2 –middle door for ignition and cleaning, 3 –combustion chamber door with a sight-hole, 4 – main door, 5 – burner for pellet combustion, 6 – secondary and primary air inlet for gasification, 7 – boiler flow connection, 8 – boiler control electronics.

The boiler consists of the wood feeding and combustion chamber, pellet combustion chamber, pellet burner, integrated pellet tank and heat exchanger. The boiler can be operated in either wood mode or pellet mode, but not at the same time. The boiler is designed with reference to the user comfort, i.e. to save time for heat-up, fuel cutting, cleaning and total time spent by the boiler. The basic part of the boiler is a water cooled body, welded from boiler steel plate of 3– 6 mm to ensure long life time. The feeding chamber for gasification is equipped with a dry coat. By elimination and moving the condensation point from the boiler body to the surface of the dry coat is the boiler´s life extended. The dry coat can be easily exchanged, if it comes to its damage. Turbulators in the tubular exchanger improve heat transfer into the heating water and ensure automatic exchanger cleaning to maintain high efficiency during the operation and to extend the boiler life. The boiler body is insulated with mineral wool. The covering is powder coated.

1.7 FUEL

1.7.1 WOOD

In the boiler ATTACK WOOD&PELLET it is possible to burn soft and hard chopped fuel wood with the heat value 15–17 MJ/kg. Particularly suitable is beech, oak, fir, spruce, pine, poplar, alder, willow, birch, ash, wych-hazel, locust, always within the humidity range of 12–20 %. Recommended diameter of the wood logs is in the range of 80–150 mm. The maximum length of wood logs is 580 mm and it must not be exceeded, otherwise they would get stuck in the feeding chamber.

The heat value of the particular wood types:

Units Wood Kcal/kg

MJ/kg

kWh/kg

Spruce 3 900 16,25 4,5 Pine 3 800 15,80 4,4 Birch 3 750 15,50 4,3 Oak 3 600 15,10 4,2 Beech 3 450 14,40 4,0

CAUTION

Wrong humidity or size of the wood may cause increase or decrease of output, low or high flue gas temperature, excessive condensation, flame loss during the gasification process or uncontrollable combustion.

Recommended storing and drying the wood:

Hard wood: 2 years in dry environment Soft wood: 1 year in dry environment

When storing (drying) the wood, it has to be protected against rain. To dry the wood more efficiently, stack to keep as large air gaps as possible. The wood will season faster with airflow over the wood. If possible, store the wood for at least 1 day at a warm place (e.g. boiler room) before loading it into the boiler (as it is warm, the efficiency of burning is increased).

1.7.2 PELLETS

The pressed wood pellets wihout any additional materials can be burned in the boiler. Parameters of the pellets should be following:

Approved pellet specification:

Measured weight: 600–750 kg/m3 Heat value: 4,7–5,0 kWh/kg Size/diameter: 6 mm Size/length: Caution! Max. 35 mm Humidity – max.: 12 % Ash content: 0,5–1 % Content of crumble (dust:) max. 3 % Ash melting temperature: min. 1 100°C Norms : DIN 51 731 – HP 5, DIN Plus, or EN 14961-2 – A1

1.7.3 ALTERNATIVE FUELS

It is possible to use the wood briquettes made from pressed wood sawdust without any additional adhesives or bidning materials.The briquettes must be always mixed in the appropriate ratio to the wood (dependent on the size and shape of the briquettes) and must not stuck in the refractory nozzle for wood gasification.

CAUTION

Use of unsuitable fuel types causes higher cleaning requirements and accumulation of an agressive sediments and condensation that may lead to reduced functionality, damage to the boiler and invalidate the warranty. Burning the wrong fuels may cause incorrect and uncontrollable combustion.

2. BOILER ASSEMBLY AND INSTALLATION

2.1 HANDLING THE BOILER

The boiler is delivered on a pallet. Handle it always on the pallet and put it down from the pallet only at the point of installation. This can be done by a manipulation trolley or a crane and lifting eye that is not included into the delivery (recommended specification: lifting screw with an eye M20 ISO 3266, or M20 DIN 580). The lifting eye can be screwed into the chassis welded on the upper cover of the boiler to hang the boiler. Carrying capacity of the hanging eye M20 is 1 200 kg, weight of the boiler is approximately 860 kg. Remove the upper boiler cover before hanging the boiler on the hanging eye.

Pic. 2 Handling the boiler with the hanging screw with eye

2.2 GENERAL CONDITIONS OF INSTALLATION

The boiler can only be installed by a properly certified installer with valid certification to install and assemble the heating appliances. Before installation, there must be a project made following to the valid prescriptions. Before installation of the boiler, the worker must check accordance of the data on the data plate with the data given in the project and documentation of the boiler. Connection of the boiler must be done in conformity to the valid directives, norms, ordinances and this instruction manual.

CAUTION

The producer takes no responsibility for damage caused by incorrect connection or incorrect operation.

BINDING NORMS FOR PROJECTING AND INSTALLATION OF THE BOILERS

Installation of the boiler must be done in conformity with the following norms:

STN EN 303-5 Heating boilers for solid fuels STN 92 0300 Fire safety of the local appliances and heat sources STN EN 60 335.1 +A11 Safety of the electrical appliances for household STN 06 10 00 Local appliances for solid, liquid and gaseous fuels STN 06 03 10 Central heating, projecting and installation STN 06 08 30 Safety devices for central heating and D.H.W. preparation STN 07 74 01 Water and steam for thermal energetic devices with

operation pressure of steam up to 8 MPa STN 332000 4-46 Electrical installations of buildings – part 4: Ensuring safety STN 332000–3 Electrical installations of buildings – part 3: Definition of the

basic characteristics STN EN ISO 11202 Acoustics. Noise generated by machines and devices.

Definition of the emissions levels of the acoustic pressure at

a workplace and other precisely defined places by using the

approximative corrections in environment. (ISO 11202: 2010) STN EN ISO 12100 Safety of machines. General principles of construction of

machines. Consideration and elimination of the risk (ISO

12100: 2010) STN EN 953+A1 Safety of machines. Protection covers. General requirements

for design and construction of fixed and movable covers. STN ISO 27574-2 Acoustics. Statistical methods for definition and verification

of the determined values of the noise emission of machines

and devices. Part 4: Methods for series of machines. STN ISO 1819 Devices for fluent cargo transport. Safety prescriptions.

General clauses. STN EN ISO 15614-1 Requirements for quality of the fusion welding of metal

materials STN EN 287-1 Welding of reserved technical devices STN 07 0240 Low pressure boilers, technical prescriptions STN 07 0245 Warm water boiler with the output up to 50 kW. Technical

requirements, testing

STN 07 7401 Water and steam for heat energy devices with the steam

operating overpressure up to 8 MPa.

STN 73 4210 Manufacturing the chimneys and flue ways and connection

of devices STN 92 0300:1997 Minimum distance of the external surface of the appliance or

flue way from the building constructions

2.3 PLACING THE BOILER

The boiler is intended for installation and operation in an area conforming to (AA5/AB5) under the STN 33 2000-3.

The boiler room must fulfill the above mentioned and the following requirements:

 There can be no potentionally explosive environment in the boiler room, as the boiler is not

suitable for usage in such environments.

 The temperature in the boiler room must not drop below freezing  Boiler itself does not provide any lighting. The user must ensure sufficient source of light,

according to the local norms and directives.

 If the boiler is going to be installed above an altitude of 1 800 m, the installation has to be

consulted with the manufacturer

 There must be an opening of at least 200 cm

in the boiler room for sufficient ventilation and supply of the required amount of the air for combustion. The external environment should not influence the functionality of the opening (rain, snow, wind).

When installing the boiler, it is necessary to keep a safe distance of its surface from flammable materials, according to the degree of flammability:

 from materials of flammability B, C1 a C2 200 mm  from materials of flammability C3 400 mm  from materials with the grade of flammability not approved under the STN 73 0853

400 mm

Examples of classification of the building materials by their degree of flammability:

 degree of flammability A inflammable (bricks, blocks, ceramic tiles, mortar, parging)  degree of flammability B partly flammable (heraklith, lignos, board from basalt felt, novodur)  degree of flammability C1 difficult to ignite (hardwood (oak, beech), plywood, werzalit,

hardened paper)

 degree of flammability C2 normal combustibility (softwood (pine, spruce), chipboard,

solodur)

 degree of flammability C3 easily ignited (wood fibre boards, polyurethane, PVC, foam rubber,

polystyrene)

The sealing board or protection covering on the protected items must exceed the boiler edge for at least 300 mm. Also other items from flammable materials must be protected in this way, if they are placed near the boiler and it is not possible to keep the safe distance. If the boiler stands on a flammable surface, it must be protected by an inflammable, heat insulating mat, which exceeds the edge on the side of the feeding door and the ash tray door for at least 100 mm. All materials of the A flammability degree can be used as an inflammable, heat insulating mat. The boiler must be placed in a such way ensuring sufficient space of at least 1 m from the front and 0,5 m from the left (right) and rear side. It is necessary to leave the space of at least 1 m above the boiler.

This space is necessary for basic operation, maintenance and eventual service of the boiler. It is not allowed to place the boiler in dwelling premises (including corridors).

CAUTION

The items from flammable materials must not be laid on the boiler and within the minimum distance specified for material type, the permitted (safe) one. The boiler must be turned off, if there is a danger of fire or explosion due to flammable gases from paints or materials in the vicinity (e.g. work with painting materials, glues, etc.).

It is not allowed to place the boiler in dwelling premises (including corridors)!

2.4 BOILER CONNECTION TO THE HEATING SYSTEM

The ATTACK WOOD&PELLET must be installed in the system that fulfils the requirements for quality of the heating water: Slovak republic: STN 07 7401:1991 Austria: ONORM H5195-1 Germany: VDI 2035 Switzerland: SWKI 97-1 Italy: D.P.R. no. 412

To fill or re-fill the water in the system it is possible to use only the water treated to the values under the STN 07 7401: 1992. The water must be pure, colourless, without suspendous substances, oils, nor chemically aggressive ingredients. The water cannot be acidic (pH must be higher than 7,2). Callosity of the water must not exceed 1mmol/l and concentration of the Ca²Ѐ must be lower than 0,3 mmol/l.

CAUTION

If the above mentioned conditions are not adhered to, then the warranty provided by the manufacturer is void!

Use of antifreeze mixtures

It is not recommended to use antifreeze mixtures as their properties that are not suitable for operation of the boiler. This particularly concerns decreased heat transfer, large thermal expansion, ageing, damage of the rubber parts. When it is necessary, it is possible to use the antifreeze mixture Alicol Termo (producer: Slovnaft Bratislava) – following experience of the producer there will not come to the decreased safety of usage, nor to the significant influence on the boiler operation. If this way of protection against freeze is not possible under the particular conditions and the different antifreeze mixture is used, the warranty does not relate to the wrong functionality, nor to the eventual faults of the boiler.

2.4.1 PROTECTION AGAINST CORROSION

The boiler must be connected with a device regulating the temperature of the boiler´s return connection. It is suitable to use the mixing device Attack-Oventrop (Pic.3), which enables creation of the separate boiler and heating circuit. Thereby is the boiler protected against undercooling and the creation of water steam. Acids and tars in the boiler´s feeding chamber are eliminated. The Attack-Oventrop device keeps the constant temperature of the return heating water flowing into the boiler over 65 °C by setting the thermostatic head to the level 5–6.When the individual thermal regulation mixing valve is used, it is possible to control the temperature of the heating water independently on the temperature of water in the boiler by setting the flap. The temperature in the boiler has to be kept in the range of 80–90 °C.

Pic. 3 Device ATTACK Oventrop

CAUTION

If a protection device against corrosion is not intalled in the system or the device does not work properly, it may lead to creation of an aggressive condensate and thereby boiler damage.

Protection against condensation must be used during boiler operation, otherwise the warranty is void!

2.4.2 CHIMNEY

Connection of the appliance to the chimney hole must be always done with in line with local regulations and the appropriate chimney association. The chimney must generate sufficient draught and take the flue gas out into the atmosphere under all operating conditions. Correct dimensions of the chimney are important for correct boiler function, because the burning, output and boiler life-time are influenced by the draught. The chimney draught directly depends on its diameter, height and surface finish of the internal wall. It is not allowed to connect any other appliance to the chimney, where the boiler is connected. Diameter of the chimney must not be smaller than the connection part on the boiler. The chimney draught must achieve the precribed values, but it cannot be too high, not to decrease the boiler output and interrupt the burning (flame). If there is too strong draught, install the throttle flap into the chimney hole between the boiler and the chimney.

Minimum dimensions of the chimneys:

20×20cm min. height 7 m



20 cm min. height 8 m

15×15 cm min. height 11 m



16 cm min. height 12 m

The exact chimney dimension is defined by the STN 73 42 10. The prescribed chimney draught is given in the Technical parameters.

2.4.3 FLUE GAS CONNECTION OF THE BOILER

The flue connection must lead into the chimney hole. If it is not possible to connect the boiler to the chimney hole directly, then the appropriate extension should be as short as possible, of up to 1 m length, without any additional heating area and it should ascend in direction to the chimney. It is suitable to insulate the flue connection to achieve the sufficient flue gas temperature and to prevent the condensation in the chimney. The flue connection must be mechanically tight (it should be mounted to the boiler and tightly fixed by screws) and tight against the flue leakage. There must be possibility of the internal cleaning. The flue connections must to lead through the foreign dwelling or commercial premisses. The internal diameter of the flue connection must not taper in direction to the chimney. It is not suitable to use the elbow connectors. There must be a „T“connection of the flue outlet to the chimney, to ensure that the condensate must leak into the appropriate tray and not into the boiler. The flue connection must comply with local regulations and only be conducted by authorised and trained personel.

2.4.4 CONNECTION TO THE ELECTRICITY MAINS

The boiler is connected to the electricity mains of 230V/ 50Hz/16A by an electrical cord with plug. In the case of need, the power supply cord of the M type must be replaced with an adequate one by the service organization. The appliance must be placed in such a way that enables the user to reach the connection plug. The boiler must be connected to the 16A socket circuit by a circuit breaker (following the STN EN 60 335-1 + A11:1997).

2.4.5 CONNECTION OF THE EXTERNAL PELLET TANK

The boiler is equipped by a motor for vacuum pellet feeding from an external tank. The external tank can be placed nearby the boiler or in another room. The max. length of the suction tube is 10 m. The tank can be in the higher position, but not in the lower position than the boiler. It is recommended to use the ATTACK vacuum tanks for the ATTACK WOOD&PELLET boiler. The

suction tubes ( 50 mm) and the vacuum tank can be ordered as accessories together with the boiler. Connection of the suction and blow out tube marked on the rear side boiler as „PELLET IN“and „PELLET OUT“.

2.4.6 LEFT DOOR VERSION

There is an option of the ATTACK WOOD&PELLET boiler with the left door (door hinges on the left side). It can be done before the boiler start-up or later, when the boiler is not in service. The main, upper, middle and bottom door can be turned without need of the any additional tools. Everything necessary is contained in the boiler. Use the standard tools: cross screwdriver, fork key of 8–13 mm or nut, allan key of 6 mm, etc. The adjustment has to be done by a trained worker.

2.4.7 CHOICE AND WAY OF CONNECTION OF THE CONTROL AND SAFETY ELEMENTS

The boiler is delivered with the basic regulation and control equipment. This equipment must be completed with other items (not delivered with the boiler) in line with local regulations, that have to be installed in the heating circuit – particularly the following ones: safety valve (Pic. 4) against exceeding the permitted pressure in the heating system (prescribed value: 2,5 bar), valve of the boiler aftercooling loop to take the excessive heat from the boiler into the waste and deaeration valve for the correct boiler function. The volume of the expanse vessel in the system has to be defined by a designer of the heating system according to the system design and local regulations. The electrical installation related to the additional boiler equipment has to be done by a specialist and following the valid regulations.

DANGER

The heating system must be equipped with a safety valve against exceeding the pressure in the boiler (2,5 bar). This valve should be placed on the flow connection of the boiler, always installed in front of the boiler closing valve (or in front of the Oventrop – scheme 1). If the safety valve is not functional, the excessive

pressure will not be eliminated and it may cause an explosion of the boiler.

Pic. 4 Safety valve against the overpressure

Boiler protection against overheating

Every wood gasifying boiler must be fitted with a functional aftercooling circuit. The appropriate valve ensuring this function can be ordered as an accessory. On the pic. 5 you can see the correct installation of the valve of the aftercooling circuit.

DANGER

Following the norm EN303-5, the aftercooling circuit against overhetaing must not be used for other purpose than the boiler protection against overheating.

Pic. 5 Connection of the thermostatic valve to the aftercooling loop

The valve must be permanently opened at the cold water inlet into the boiler aftercooling circuit. The aftercooling circuit must be connected to the functional distribution of the cooling water (e.g. to the distribution of the cold water in the water supply network) with the temperature of 10–15 °C and operating overpressure of 2–6 bar, ensuring the safe operation even by a power failure. The thermostatic valve at the outlet of the aftercooling circuit with the sensor placed in the rear side of the boiler protects the boiler in the following way. If temperature of the water in the boiler exceeds 95 °C, the valve fills the aftercooling circuit with the water from the water supply network to absorb the excessive heat. For the case that the boiler gets overheated and the thermostatic valve is open, it is necessary to ensure the permanent outtake of the warm water from the aftercooling circuit into the waste. Functionality of the aftercooling circuit and the thermostatic valve can be checked manually, by the manual button of the thermostatic valve.

DANGER

If the circulation of the cooling water through the aftercooling circuit is not ensured, when the thermostatic valve is open, there is a danger of the boiler damage! The warranty is not valid in such a case.

2.4.8 CONNECTION TO THE ACCUMULATION TANKS

The accumulation tanks are connected to be warmed and the accumulated heat is continually used according to the requirements of the heated space. When the boiler operates at full output, the accumulation tanks are heated to 80–90 °C. Usage of the accumulation tanks together with the boiler ATTACK WOOD&PELLET brings several advantages. The main advantages are: prolonged life of the boiler, cleaner operation, minimal creation of acids and condensate, smaller frequency of the fuel loading, lower probability of the boiler overheating and fuel saving. The recommended volume of the accumulation tank for the boiler ATTACK WOOD&PELLET 25 is

2.000 l (the min. volume is 1.250 l). By full load of the hardwood (i.e. 6 hours of operation at full output of 25 kW), the boiler produces 150 kWh of energy. This is adequate to the loading of the

2.000 l accumulation tank from 20 °C to 80 °C, if there is no other energy consumption. Thereby it is necessary to consider the boiler usage and operation as well, when you are choosing the accumulation tank: by the accumulation tank of 2.000 l it is necessary to load the full chamber, by 1.000 l there is half of the chamber to be loaded (if there is no energy outtake from the tank).

Example 1:

The external temperature of environment is -5 °C and the heat loss of the building is 10 kW. The boiler output by full operation is 25 kW. There is an accumulation tank of 1.250 l, that is discharged (its upper and bottom temperature is 20 °C). As the heating system (to cover the heat loss) takes 10 kW from the accumulation tank and the boiler has the output of 25 kW, the accumulation tank is heated by the remaining 15 kW. The output of 15 kW, by the full load of hard wood and during the 6 hours of operation, creates the energy of 90 kWh. This energy heats the accumulation tank from 20 °C to 62 °C despite of the fact, that the 10 kW are being taken. This is a safe and economical operation, when the heat is not taken into the waste (the boiler was cooled down by the aftercooling circuit). The boiler is able to cover the heat loss for 15 hours just by a single load of the wood.

Example 2:

The external temperature of the environment is +3 °C and the heat loss of the object by this temperature is 5 kW. The boiler output at full operation is 25 kW. There is an accumulation tank of 1.250 l, that is discharged (its upper and bottom temperature is 20 °C). As the heating system (to cover the heat loss) takes 5 kW from the accumulation tank and the boiler has the output of 25 kW, the accumulation tank is heated by the remaining 20 kW. The output of 20 kW, by the full load of hard wood and during the 6 hours of operation, creates the energy of 90 kWh. This energy heats the accumulation tank from 20 °C to 82 °C despite of the fact, that the 10 kW are being taken. This is a safe and economical operation, when the heat is not taken into the waste, but if the heat loss was smaller, the boiler could get overheated, because it would not be cooled down. In such case it would come to activation of the aftercooling circuit and the excessing heat would be taken into the waste. In case of the constant heat loss of the object (5 kW), the charged accumulation tank would cover the heat loss approximately for the next 24 h. It means that by a single load of wood and under the above mentioned conditions it would be possible to cover the heat loss of the building for 30 hours.

Thereby it is very important to load just the amount of wood, adequate for heating the accumulation tank and not to overheat it, because the excessive heat would be taken into the waste unused. Such operation would not be economical and the safety element, the aftercooling circuit would have to be activated.

The bigger volume of the accumulation tank decreases the risk of overheating and the frequency of loading the wood.

Note: The above mentioned fact is relevant by the operation with WOOD.

By the operation with PELLETS it is not relevant, as the boiler does not have to be connected to the accumulation tank, if ONLY PELLETS would be used.

Standardly delivered accumulation tanks ATTACK*

AK AS HR HRS

TUV

TUVS S SS

300 300 — —

300

300 — —

400 400 — —

400

400 — —

500 500 600 600

500

500 500 500

800 800 800 800

600

600 800 800

1000 1000 1000 1000

800

800 1000 1000

1500 1500 1250 1250

1000

1000 1250 1250

2000 2000 1500 1500

1250

1250 1500 1500

2500 2500 2000 2000

1500

1500 2000 2000

3000 3000 — —

2000

2000 — — 4000 4000 — — — — — — 5000 5000 — — — — — —

AK – standard accumulation tank intended for the accumulation of energy of the heating water AS –standard accumulation tank intended for the accumulation of energy of the heating water,

equipped with a coil for connection of the solar panels HR – combined accumulation tank for accumulation of energy of the heating water and the domestic hot water preparation HRS – combined accumulation tank for accumulation of energy of the heating water and the domestic hot water preparation, equipped with a coil for connection of the solar panels

* The volume necessary for the accumulation of energy can be covered by one or by several accumulation tanks. The accumulation tanks can be connected together to create the sufficient volume of water for accumulation. Thereby, if you decide for a volume of 2.000 l, it is possible to use one tank of 2.000 l or two tanks of 1.000 l connected together. The required way of connection is given in the chapter „Recommended hydraulic schemes of boiler connection“.

2.4.9 RECOMMENDED HYDRAULIC SCHEMES OF BOILER CONNECTION

Pic. 6. Hydraulic connection of the boiler into the heating system

1 – boiler, 2 – safety valve, 3 – deaeration valve, 4 – Attack Oventrop, 5 – accumulation tank Attack AK or HR, 6 – distributor, 7 – tank for domestic hot water, 8 – direct heating circuit, 9 – mixing heating circuit

3. BOILER START-UP

Boiler preparation for operation

The boiler must be assembled, installed and started-up only by an installer certified for the installation of the heating appliances. Before starting the boiler, it is necessary to check, if the hydraulic system is filled with water by the correct pressure, deaerated and without decreasing pressure of the heating water. Check tightness and strength of the flue construction and functionality of the aftercooling circuit by pressing the valve manually. The boiler must be operated in conformity with the instructions given in this manual to achieve the quality function.

CAUTION

There may come be condensation and condensate leakage by the first firing of the boiler. This will disappear after the the first burn. It is a natural effect.

WARNING

It is necessary to be more careful, if the boiler was out of order for a longer period (in summer or in case of failure). The pump could get blocked (and the boiler could get overheated and the aftercooling circuit would be started), or the water could leak out of the system. Check the

correct pump function and the pressure of water in the heating system!

See the chapter „BOILER CONTROL“about putting the boiler into operation (heating up, loading, filling the tank with pellets, etc.).

4. WARRANTY CONDITIONS

The warranty for the boiler is valid only if the boiler installation was done by a person certified under the valid norms and following the instruction manual. The company who performed the installation must completely and clearly fill the form. If the boiler is damaged by an inexpert installation, the company who installed it has to carry the costs for repair, only use approved and properly trained installers. The user has to respect the instructions for operation and maintenance given in the manual. If the instructions for operation and maintenance are not kept, the use of the boiler is unauthorised and careless or incorrect fuel is used, the warranty is not valid and the customer has to carry the costs by damage.

The warranty is valid only in the case, that the boiler was installed and operated in the following way:

 together with device for the boiler protection against condensation ATTACK-OVENTROP  with prescribed fuel given in the chapter „FUEL“  with the thermostatic valve installed against the boiler overheating  with the chimney of appropriate parameters (diameter, height) given in the chapter

„CHIMNEY“

 the boiler was regularly and sufficiently cleaned as it is given in the chapter „CLEANING“  the boiler was operated following the instructions given in this manual and not in the

different way.

The warranty is valid for a complete boiler ATTACK WOOD&PELLET, except of wearing boiler parts that are usually worn, and therefore they cannot be included into the warranty:

 glass sealing cords of the door and ash tray.  refractory nozzle

5. TECHNICAL PARAMETERS

Parameter Units AWP 25

Nominal output by wood kW 25 Nominal output by pellets kW 30 Range of the output by wood kW 12,5 ÷ 25 Range of the output by pellets kW 9 ÷ 30 Heat-exchange area m² 2,18 Volume of the feeding chamber l 160 Volume of the integrated pellet tank l 48 Dimension of the feeding door mm 230×445 Prescribed chimney draught Pa 23 Max. operation overpressure of water kPa 250 Pressure loss of water (T 10 K)

kPa 2,1

Pressure loss of water (T 20 K)

kPa 0,6 Boiler weight kg 860 Diameter of the flue outlet mm 150 Boiler height "A" mm 1620 Boiler width "B" mm 940 Boiler depth "C" mm 1220 Length of the feeding chamber "D" mm 580 Diameter of the flow connection " G 6/4" Diameter of the return connection " G 6/4" Grade of protection IP 21 El. input by a nominal output W 90 El. input by a minimal output W 32 El. input in the standby mode W < 15 Efficiency of the wood boiler % 90,5 Efficiency of the pellet boiler % 90,4 Boiler class EN 303-5:2012 — 5 Flue gas temperature by the nominal output by wood °C 156 Flue gas temperature by the min. output by wood °C 92 Flue gas temperature by the nominal output by pellets °C 130 Flue gas temperature by the min. output by pellets °C 86 Flue gas flow by nominal output kg/s 0,019 Flue gas flow by min. output kg/s 0,005 Max. noise level dB 65 Wood consumption by nominal output kg/h 7,2 Pellet consumption by nominal output kg/h 6,8 Max. length of wood logs mm 560 Time of operation by max output by wood h 6 Volume of water in the boiler l 126 Min. volume of accumulation tank l 1250 Connection voltage V/Hz/A 230/50/16

The producer, ATTACK, s.r.o. reserves right of technical changes of the products without any previous announcement!

Pic. 7 Description of particular boiler parts

1 – boiler body, 2 – main door, 3 – cover of the air inlets into the wood gasifying section, 4 – display cooling, 5 – touch display, 6 – cover of electronics, 7 – flow connection, 8 – aftercooling circuit, 9 – cover of turbulators, 10 – lambda probe, 11 – flue connection, 12 – exhaust fan, 13 – return connection

426

312

G 6/4"

G 1/2" G1/2"

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776

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150

568

904

951

1207

5.1 DIMENSIONS OF THE BOILER ATTACK WOOD&PELLET 25

6. REGULATION OF THE BOILER AND THE HEATING SYSTEM

6.1 IN GENERAL

DANGER

If you tun the main switch off during the boiler operation, it has no regulation. Then, any dangerous states may cause the serious health or property damage. Always let the fuel

completely burn out and the boiler cool down before turning the main switch off!

WARNING

Opening the upper and middle door of the feeding chamber or the bottom door of the combustion chamber during the operation may cause accumulation of the flammable gases and their explosion, this may cause serious damage to health or property. It is forbidden to open any door behind the main door during the operation!

CAUTION

6.2 EMERGENCY ACTIONS

Boiler overheating

If the boiler is in WOOD mode and it starts to overheat and the functionality of the aftercooling loop fails from any reason, do the following:

 Do not open any door of the boiler!  Turn the boiler off by the STOP button and confirm the red emergency message „I really

want to stop the boiler“

 Start all the pumps, heating circuits, open all the 3-way valves (attention, the max.

temperature by the floor heating is 40 °C), to ensure the max. heat energy outtake from the boiler

 Leave the boiler room and close the door.  Open the thermostatic heads on all radiators (the heating season does not make

a difference), eventually let the domestic hot water flow - run hot water tap, if the boiler is connected for the D.H.W. preparation as well

 Contact your installer

DANGER

Never turn the main switch off, nor disconnect the boiler from the electricity mains, when the boiler gets overheated!!

6.3 PREPARATION FOR THE OPERATION, FILLING THE INTEGRATED PELLET TANK

CAUTION

Check, that the hoses of the vacuum suction are connected correctly and airtight, before starting the pellet suction into the integrated tank.

Before starting the operation of the boiler ATTACK WOOD&PELLET for pellets, it is necessary to suck the pellets into the integrated tank manually. Use the TEST mode, by clicking on the „vacuum suction“. Watch the level of the pellets sucked through the side control opening or in the information menu of the PELLET SENSOR. The sufficient amount of pellets in the integrated tank is visible through the full pellet indicator and by the green light of the PELLET SENSOR. After this, the pellets will be sucked automatically. In the case of error you can always fill the tank by the TEST mode.

6.4 DESCRIPTION OF THE SAFETY DEVICES

Description of the main regulation of the boiler (Pic. 8):

1. Emergency thermostat with reset – boiler protection against overheating (when the temperature of 110 °C is exceeded, all the electrical devices in the boiler are disconnected, except of the circulation pump; when the temperature of the water in the boiler decreases under 85 °C, it is necessary to demount the cover and to manually press the thermostat button.

2. Main fuse – boiler protection against the electrical short circuit

3. Main switch – start/stop of the boiler. Unplug the whole boiler from the electrical mains.

4. Combined thermo manometer. Actual information about the temperature and pressure, independent of power supply.

Pic. 8 Description of the main regulation of the boiler

6.5 BOILER CONTROL AND OPERATION

The combustion process in the boiler ATTACK WOOD&PELLET is controlled by the modern electronics, equipped with software operating on the basis of the latest knowledge in the field of the biomass burning. There is an advanced touch screen, displaying multiple information to enable the quick identification of the state of the boiler and its parameters. On the pic. 9 there is the basic data display.

Pic. 9 The basic data display

1 – boiler temperature, 2 – flue gas temperature, 3 – actual fan output, 4 – operation mode, 5 – boiler state, 6 – state of regulation, 7 – records of errors and error messages, 8 – time remaining until the cleaning starts (of the burner, of the exchanger), 9 – setting of parameters (basic, service ones), 10 – general settings, 11 – information, 12 – indicator of the actual pellet level, 13 – language, 14 – actual boiler output (relevant for wood and pellets)

The regulation of the WOOD burning is ensured by the Lambda probe together with the controlled rotations of the exhaust fan, controlled inlet of the primary and the secondary air, measuring the temperature of the boiler and flue gas.

The regulation of the PELLETS burning and feeding is ensured by the integrated vacuum feeder (pellet suction from the main tank into the built-in integrated tank), sensor of the pellet presence, turnstile auger, ignition coil, photocell, fan with controlled rotations and by the automatic cleaning.

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6.5.1 DESCRIPTION OF THE MAIN CONTROL MODES

Pic. 10 The main control modes

The way of the boiler operation can be changed in dependence on the operation mode in the following way (Pic.10): HEATING OFF – select this mode, if the boiler is going to be unused for a longer period. It is

usually in summer, if the boiler is not used to prepare the domestic hot water. Then, the boiler will be switched into the STANDBY mode. TESTMODE – under this mode you can test the functionality of particular devices in the boiler (fans, grate cleaning, coil, vacuum suction, turbulator cleaning, pump, etc.). AUTOMATIC – under this mode is boiler working automatically and it is regulated by the boiler temperature. Always, when the temperature decreases under the adjusted temperature decreased by hysteresis, the boiler is started (if the boiler works under the mode WOOD, it will not be started automatically, as it is possible only under the COMBI mode). TIME – this mode determines the particular time intervals, when the boiler is going to work (this is related only to the COMBI mode for the PELLET burning). The time mode does not influence the boiler operation for WOOD, because the purpose of such operation is to keep the output of 100 % and to produce as much energy as possible to be stored in an accumulation tank. PUFFER/BOILER – this mode serves to control the discharging of the accumulation tank. The external module is required. EXTERNAL START– this mode works under the room thermostat. If you connect the room thermostat into the electronics and select this mode, then boiler in the COMBI mode, operating for PELLETS, will work according to the requirement for heat from the room thermostat.

6.5.2 DESCRIPTION OF THE CONTROL MODES, RELATION BETWEEN THE

MODE WOOD AND COMBI

The ATTACK WOOD&PELLET boiler belongs to the combined boilers indeed, without for user interaction with the boiler after the wood is burned out, to start the pellet burning process. The boiler automatically detects, that the wood is burned out and if there is a requirement for heating, the pellet combustion is started. The boiler can work under two control modes: the WOOD and the COMBI. The WOOD mode is especially intended for the wood burning and the combined boiler works as the standard wood gasifying boiler. After starting the WOOD mode, the boiler controls the wood combustion process, which is stopped, when the wood burns out. In this mode is the accumulation tank charged to use the heat during the next day and night, while the pellets are not being burned. This mode is advantageous within the periods like autumn and spring, because the heat loss of the building can be covered by the heat from the accumulation tank for a couple of hours or days. The WOOD mode cannot be interrupted anytime – it is necessary to wait, until the wood burns out. Then it is possible to get into the COMBI mode. Under the COMBI mode you can select the fuel for the start of operation (WOOD or PELLETS). If you select the WOOD operation, the boiler controls the process of wood gasification and the process of pellet burning is started, when the wood burns out and there is a requirement for heating. Under the COMBI mode, the boiler starts the process of pellet burning and it works as a standard pellet boiler. If the boiler currently burns pellets, this operation can be anytime interrupted (it takes approximately 5 min, until the pellets are burned out) and the wood combustion can start. As it is given above, the opposite process is not possible.

DANGER

Under the COMBI mode, when you are starting the operation with pellets, always check that there is no wood or other fuel in the feeding chamber. Otherwise, you may cause the

uncontrolled burning and there is a risk of the serious injury or property damage.

6.5.3 OPERATION WITH WOOD

Use this mode, if:

You wish to operate the boiler as a WOOD gasifying boiler. When the WOOD is burned out in the feeding chamber, the boiler is stopped (the pellet part will not be automatically started to work).

The ways to light the boiler up:

 The manual mode of lighting up the wood is used, if the boiler was heating during the day

before or if there are cinders remained in the feeding chamber.

 The automatic mode of lighting up the wood can be used after the boiler is cleaned and

there are no cinders to make it easier. The automatic mode of lighting up the wood needs more electrical energy than the manual mode and it requires the sufficient amount of pellets in the integrated tank.

6.5.3.1 MANUAL LIGHT UP OF WOOD

1. Turn the main switch on, if it has not been done yet.

2. Open the main door and the door of the feeding chamber. Check the level of ash in the

feeding chamber. If it exceeds 50 mm, clean the feeding chamber – it is not necessary to clean the feeding chamber every day, if the ash still contains the solid cinders. The cinders that remain in the ash contain the usable energy and they enable faster lighting up the wood. The feeding chamber is cleaned through the middle door by the fire hook (See the chapter 14. Boiler cleaning).

3. Open the door of the feeding chamber and clean it. It is the best to use a fire hook and to

remove the ash ash in direction to you. Always clean the combustion chamber before heating the boiler up!

CAUTION

If the combustion chamber is not cleaned properly, its volume is rapidly decreased and it may cause imperfect burning and dangerous states. Never operate the boiler with the uncleaned

combustion chamber!

4. Put the paper or cardboard (the best material), rolled into tubes (Pic. 11). If there are cinders

on the bottom of the feeding chamber, put the paper or the cardboard on them.

Pic. 11 Preparation for lighting up the wood

5. Put the wood of a smaller diameter (chips of 20×20 mm) on the cardboard (pic. 12) to make

the process of lighting up faster and more stable. Put the casual wood on the fine wood in the way enabling the free air flow. Try to use the feeding chamber in the best way to load as much wood as possible. Load the full chamber (Pic. 13).

Pic. 12 The way to prepare the wood for lighting up

Pic. 13 Loading the full chamber

6. Close the upper and the bottom door, manually light up through the middle door only.

7. Enter the WOOD mode via display and confirm it by click (Pic. 14).

Pic. 14 Starting the WOOD mode.

8. After selecting the wood operation mode, activate the lighting up process by the START

button (Pic.15).

Pic. 15 Activation of the wood operation mode

9. There are two options of lighting up under the WOOD operation mode (Pic. 16) – the manual

and the automatic way. Under this mode, select the manual ignition. The exhaust fan will start to work and the boiler will be prepared for lighting up.

Pic. 16 Lighting up the wood in the wood gasification part:

1 – manual ignition (by wood chips, newspaper, cardboard or a liquid fire starter 2 – automatic ignition, 3- period of lighting the wood up by the pellet part, 4 – delayed start, 5 – output of the pellet burner, while the wood is being ignited

10. Light the paper or the cardboard through the middle door by a lighter (Pic. 17). Keep the

middle door partly open, until the cardboard and the wood chips light up (approximately for 5 min) and the chimney gets the draught. Afterwards, close the door. This way of heating is very quick and it enables to heat the boiler up without any smoke. Through the pivot control opening on the bottom door you can watch the flame created by the process of gasification. Close the main door after verifying, that the flame was created and the boiler correctly gasifies.

Pic. 17 Manual light-up of the wood

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6.5.3.2 AUTOMATIC LIGHT-UP OF WOOD

The wood can be automatically ignited by pellets, with no need to prepare the lighting-up with paper, nor cardboard. However, it is necessary to use the wood of small diameter (wood chips of 20×20 mm).

CAUTION

The automatic light-up of the wood is a complicated process and the first trial requires the attention of the customer. It is necessary to select the parameters of the automatic light-up carefully, to avoid the uncontrolled wood burning in the feeding chamber of the boiler. Do not

use the automatic light-up of wood, if the parameters of your chimney do not achieve the values given in this manual. The problems with the automatic wood ignition may occur due to

the cold chimney or in summer, when there is a chimney draught naturally decreased. Thereby it is necessary to consider the automatic wood ignition carefully in summer and by the cold chimney.

Procedure of starting up the automatic wood ignition:

1. Repeat the procedure under the 6.5.2.1, points 1–3.

2. Put the wood of small diameter (wood chips of 20×20 mm) on the bottom of the chamber to

make the process of heating-up faster and more stable. Put the ordinary wood on the fine wood in the way enabling the free air flow. In the ¼ of height should be the wood laid crosswise to make a tunel to light the wood up from the pellet part (Pic. 18). Try to use the loading chamber in the best way to feed as much wood as possible. Load the full chamber.

Pic. 18 Loading the wood into the chamber by the automatic light –up

3. Close all door (upper, middle, bottom, main ones).

7. Use display to enter into the WOOD mode following the chapter 6.5.2.1, point 7 and 8.

8. After the “start options” are displayed, select the parameters to start the automatic WOOD

light up (Pic. 19). The “starting time” defines how long the flame from the pellet part will be igniting the wood. The “start in” defines the time delay of start. Here you can set, that the boiler will not start the automatic light up immediately, but with a time delay given as the “start in” parameter. The value of the output for the wood ignition by the pellet part must be considered carefully. Too high output may cause an inappropriate emission of the gas substances from wood and to leak of the smoke from the loading chamber into the primary air of the boiler. Thereby we recommend to try the automatic wood light up by the lower output as first (approximately 30 %).

Pic. 19 Parameters of the automatic wood light up

2 – start of the automatic wood light up, 3 – starting time, 4 – start in, 5 – output

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6.5.4 COMBINED OPERATION MODE

The combined operation mode is a fully automatic mode that is able to operate the WOOD burning or the PELLET burning, but not both at the same time.

DANGER

The combined mode serves for operation with either of the fuel types – the WOOD or the PELLETS. Never try to burn WOOD and PELLETS at once, because it may cause uncontrolled

burning, a health hazard or property damage.

Use this mode, if:

1. You are going to load the full loading chamber with wood and you wish to cover the

requirement for heat with the pellet burning, after the wood burns out.

2. You wish to operate the boiler with PELLETS only.

Start the COMBI mode through the mode options (Pic. 20) by a double-click on the COMBI.

Pic. 20 Start of the COMBI mode

The combined mode can start with burning the wood or burning the pellets. It is not possible to burn both fuels (i.e. the wood and the pellets) at the same time.

After selecting the COMBI mode it is necessary to choose the fuel that will be burned as first. (Pic. 21).

Pic. 21 Selection of the fuel to start the COMBI mode

If the WOOD is in the loading chamber, the PELLET mode must not be started!

If the boiler was started with wood, pellets can be used after it burns out. The operation with wood cannot be interrupted by the operation with pellets. The boiler struggles to burn all wood before it starts to burn pellets. The operation with pellets can be anytime interrupted (the pellets must automatically burn down in the burner) and the wood can be loaded and burned.

DANGER

It is very dangerous to load the WOOD and to start the PELLET burning at the same time. It may cause an uncontrolled burning, health hazard or damage of health or property.

CAUTION

ATTENTION! It is not allowed to put any flammable materials or objects into the loading chamber of the boiler during the operation with pellets. The pellet operation is stopped in 15 seconds, if the feeding door is opened.

7. DISPLAYING INFORMATION

During and also out of the boiler operation it is possible to read the information from the touch display about the state of the boiler and particular devices (ventilators, heating coils, flaps, etc.). By pressing the “i” button you get into the menu (Pic. 22). There are three pages in the information menu.

The first page – the “Information 1” – gives the basic information about the boiler state: boiler, temperature, flue gas temperature, actual value of the oxygen in the flue gas, presence of the flame in the combustion chamber – the photocell, cycle of the pellet feeding and duration of the feeding in one cycle) (Pic. 22)

Pic. 22 Display with the basic information, page 1

The second page – the “Information 2” – displays the actual output of the exhaust ventilator and the burner ventilator, actual rotations of the burner ventilator, position of the primary and secondary flap serving to control the wood gasification process (Pic. 23).

Pic. 23 Display with the basic information, page 2

The third page – the “Information 3” – displays the state of start or stop of the particular outputs (if they work or not) and of the particular inputs (if they are connected or disconnected). It is well-readable, whether the door of the loading chamber is closed properly, whether the integrated pellet tank is fully loaded, whether the emergency thermostat is connected or disconnected, etc. (Pic.24).

Pic. 24 Display with the basic information, page 3

8. SETTING THE PARAMETERS

The ATTACK WOOD&PELLET boiler enables to set the parameters in two levels. The first level is intended for the end user to set the basic parameters of the boiler (the boiler temperature, flue gas temperature, temperature of the pump start, etc.).

To set the advanced parameters that control the boiler operation it is necessary to enter the second level by using the access code. Thereby it is protected against access of the unauthorized person that could negatively affect the boiler operation.

CAUTION

Only the authorized technician can change the parameters at the advanced level. The incorrectly given parameters may cause the wrong boiler operation or boiler damage. Any parameter changes must be consulted with your installer or with the producer.

8.1 LEVEL OF SETTING THE BASIC PARAMETERS

It is always possible to change the basic parameters without need to enter the code. The access to the basic parameters is under the button 9 (pic. 25). The basic parameters are on the pages 1 and 2.

Pic. 25 Setting the basic parameters for the end user

Decription of the basic parameters: Boiler temperature – enables to set the temperature that should be achieved by boiler. This

parameter is related to the both modes – the WOOD and the COMBI. Difference temperature Start (Pellet)- the boiler temperature must be decreased by this value to start the boiler operation again. This is related to the PELLET mode.

Difference temperature Stop (Pellet) – the pellet mode is stopped, when this temperature is achieved. The burner starts to decrease the output after achieving the boiler temperature, until this limit is achieved and the burner is stopped. Exhaust temperature Stop (Woodbrick) – if the flue gas temperature under the WOOD mode is lower than this value during the period of 15 min., or the oxygen content in the flue gas is higher than 14 % during the period of 15 min., the boiler stops the wood gasifying part and indicates the fuel shortage. If you set this temperature to higher value, you can influence the amount of cinders remaining in the loading chamber of the boiler and they can ensure easier heat-up. The higher is the temperature, the more cinders remain.

Start boiler pump – temperature to start the pump for accumulation tank.

Difference temperature Start (Woodbrick) – the excessive boiler temperature must be

decreased for this value to start the boiler operation again. This is related to the WOOD mode.

Pic. 26. Setting the basic parameters for the end user

Difference temperature Stop (Woodbrick) – the wood gasification part (i.e. is stopped) by this

temperature. The boiler will modulate its output between the adjusted temperature and the temperature increased by this value. Exchanger cleaning interval – this time interval defines the frequency of the automatic exchanger cleaning by turbulators. Only the time of the boiler operation is considered. Max. combustion time – this is the max. time of the boiler operation. When this time expires, the burner is automatically cleaned. This time serves to shorten the burner operation period with the pellets of lower quality.

8.2 LEVEL OF SETTING THE ADVANCED PARAMETERS

Settings of the advanced parameters are available only with the access code. Click on the upper blue batten to get the keyboard for entering the code. There is the “MAIN PAGE” text (Pic. 27). After entering the code, the inaccessible parameters become adjustable. If you need to change the advanced parameters, contact your installer or producer to give you the access code.

Pic. 27 Access to the advanced parameters

The advanced parameters of the boiler become adjustable after enetering the access code of the service technician.

Pic. 28 Advanced parameters, page 2

Description of the advanved parameters (Pic. 28): Ignit during filling – starts to heat the coil by ignition, while the pellets are fed into the burner. It reduces the time of the pellet ignition. Maximum ignition time – defines the max. acceptable time, when the heating coil and the

ventilator work to ignite the pellets. If the pellets are not ignited during this time, the ignition process will repeat or the error will be indicated. Starting feeding time 1 – the amount of pellets that are loaded into the burner for the first time. Starting feeding time 2 – the amount of pellets that are loaded into the burner, if it does not come to ignition within the max. ignition time.

Pic. 29 Description of the advanced parameters, page 3

Photocell Fire – after exceeding this value, the boiler detects the pellet ignition in the burner Photocell Fire off – if the value of the flame intensity in the burner decreases under this value,

the boiler detects the flame loss in the burner and thereby the burn down. This is considered as an error. Burn-On time after ignition – this is the time necessary for creation of the stable layer in the burner that enables an increase in output Burn-Off time – this is the max. time after which will the burner be cleaned, despite of the fact that the pellets did not burn out. Exhaust fan regulation max. power (Pellet) – output of the exhaust fan by the max. output of the burner Exhaust fan regulation min. power (Pellet) – output of the exhaust fan by the min. output of the burner

Pic. 30 Advanced parameters, page 4

Exhaust fan max. power – the max. output of the exhaust fan Exhaust fan min. power – the min. output of the exhaust fan Pellet fan during ignition – the output of the ventilator by the pellet ignition Pellet fan during Starting – the output of the ventilator during the stable burning after ignition Pellet fan max. power – the max. output of the burner fan Pellet fan min. power – the min. output of the burner fan Exchanger cleaning work time – within this period will be the exchanger tubes cleaned by

turbulators

Pic. 31 Advanced parameters, page 5

Burner cleaning work time – time of moving the grate of the burner in and out to be cleaned Time before restarting the boiler – when the wood or pellets burnm out, it is possible to set

the time, after which will the boiler start to work again. Exhaust temperature max. power (Wood brick) – the boiler has to achieve this flue gas temperature during its max. output by wood burning Exhaust temperature max. power (Wood brick) – the boiler has to achieve this flue gas temperature during its min. output by wood burning Exhaust temperature ignition (Wood bricks) – after achieving this flue gas temperature the boiler considers the wood ignition as successful Oxygen setpoint max. power (Wood bricks) – the boiler will control the burning process according to this value for the max. output Oxygen setpoint min. power (Wood bricks) – the boiler will control the burning process according to this value for the min. output

Pic. 32 Advanced parameters, Page 6

Feeding cycle at 100 % power – the cycle of the pellet feeding into the burner Feeding time at 100 % power – cycle time of pellets loaded into the burner Difference temp. power regulation (Wood brick)– when the actual temperature decreases in

comparison with the adjusted temperature for this value, the boiler is started again. Exhaust temperature regulation start – by this flue gas temperature will the boiler start to control the wood burning process by the Lambda probe. Maximum power (Pellet) – the max. output of the burner operation

Pic. 33 Advanced parameters, page 7

Primary – airflap max. open– max. opening of the primary flap Secondary – airflap max. open– max. opening of the secondary flap Secondary airflap ignition (Wood brick) – position of the flap during wood ignition Secondary airflap pre-heating (Wood brick) – position of the secondary flap for the phase of

the wood pre-heating Ignition max. time (Woodbrick) –the flue gas temperature must achieve this value of flue gas during wood ignition. If this temperature is not reached, the boiler is stopped and the fuel shortage is indicated.

Pic. 34 Advanced parameters, page 8

Exhaust Fan Autom. Ignition (Wood) – the fan output during the automatic wood light up by pellets Primary Air Flap Autom. Ignition (Wood) – position of the primary flap during the wood light ignition by pellets Secondary Air Flap Autom. Ignition (Wood) – position of the secondary flap during the wood light up by pellets Power regulator worktime – time of conversion of the PID control model Power regulator P – part – a proportional part of the PID control model Power regulator D – part - difference part of the PID control model Power regulator I – part – integral part of the PID control model

Pic. 35 Advanced parameters, page 9

Pump delay – time of the pump over run, when the temperature gets back under the safety

temperature of the pump start

Pump safety temperature – when this temperature is be exceeded, the pump will run Turbine max runtime – time limit for the max. period of operation of the vacuum motor Turbine rest time – time to cool down the vacuum motor Number of suction retries – max. number of repeating the suction of the vacuum motor into

the integrated tank

Automatic pellets suction – option to turn the automatic pellet feeding off Size of pellet tank – given in seconds (during this period the auger feeder is able to empty the

integrated pellet tank)

Pic. 36 Advanced parameters, page 10

Ignition retry numbers – if the pellet ignition in the burner fails, it is possible to repeat it again.

The number of trials can be set.

9. SPECIAL SETTINGS AND INFORMATION

The following special settings can be made in the boiler ATTACK WOOD&PELLET (Pic. 37)

Pic. 37 The special settings are displayed after pressing the key sign.

Set Time, Set Date – it is possible to set the date and time. If the boiler is disconnected from the

electricity mains or the power supply fails, the date and time are in the memory for approximately 3 days.

Screen saver – defines the time, when the screen saver is activated. Program version – information about the actual program version PLC Serial No. – the serial number of electronics Alarms messages – enables the sound notification of errors and notifications of the boiler. Automatic quit – if it comes to errors like a fail of ignition, flame loss or failure of the pellet feed,

they can be automatically erased and the boiler can be started again. This is possible only by small errors. The problems like the damaged boiler temperature sensor or damaged flue gas temperature sensor cannot be automatically erased. The time, after which will be the error erased can be defined by the “after” parameter.

10. INTERNET CONNECTION

The boiler can be connected to the internet by the LAN and it can be regulated through the remote control. The control is available via the local network and via internet as well. It is necessary to have the IP address from the internet provider to have an access from internet.

The LAN cable has to be connected in the following way:

1. Prepare the LAN cable of appropriate length. The length of the cable in the boiler is

approximately 2,6 m.

2. Disconnect the boiler from the electricity mains.

3. Undo the rear covering.

4. Undo the cover of electronics.

5. Undo the internal zinc plate on the upper door to get an access to the touch display.

6. Lead the cable from the rear side of the right covering, around the electronics and through

the opening in the middle door to the connector placed on the bottom side of the touch display, marked as the ETHERNET.

7. Mount the dismantled parts back.

8. Set the correct parameters of connection to the network (Pic. 38).

Pic. 38 Setting the IP address for communication via the LAN or internet

The boiler can be reached and controlled also by the smartphone applications:

Android: Mocha VNC Lite iOS: Mocha VNC Lite Destination port: 1954 Pasword: attack

Pic. 39 Setting the time programs of the operation under the pellet mode

11. SOFTWARE UPDATES

The software of the electronics can be updated by the trained technician by the USB key.

12. FACTORY SETTINGS AND RESET

If there is a fatal error of the boiler occurred and the boiler is in fatal state, in which the error cannot be removed or the boiler mode cannot be changed, it is necessary to restart the boiler. The option of reset is displayed after entering into the special settings and click on the floppy disc icon (Pic. 40). After click on the floppy disc you will see several windows. To reset the boiler and to reset the original settings, press the “Restore Factory Settings”.

Pic. 40 Reset of the factory settings

13. BOILER MAINTENANCE

To ensure the correct boiler function during its life, it is necessary to do the maintenance. The frequency of the maintenance depends on the frequency of operation and usage of the boiler.

The maintenance of the heating system and the boiler

The level of the water in the system has to be checked and eventually filled at least once in 14 days. If the boiler is out of order during the winter period, the water could freeze in the system. Thereby it is better to empty the system or to fill the antifreeze mixture. Otherwise should be the water removed from the system just in the necessary cases and for the shortest time possible. After the end of the heating season it is necessary to clean the boiler and to replace the damaged parts. Undo the ventilator two times a year and clean the radial impeller and the air chamber of the ventilator.

Tightening the hinges and exchange of the sealing cord of the door

The cords of the door are losing their elasticity by the ordinary operation and thereby they decrease their tightness. To increase the tightness when doing the maintenance, it is possible to change the position of the cord in direction into the boiler and to make it more pressed. When the cord totally loses its elasticity, or when the hinges cannot be shifted further into the boiler, it is necessary to exchange the cord. Remove the old sealing cord by a screw driver and clean the groove, where it was placed. Take the new cord and place its ending into the horizontal parts of the groove. Use your hand or the hammer to press the cord into the groove around the door. Release the hinges and find the appropriate position of the hinges according to the door.

14. BOILER CLEANING

To ensure the correct boiler operation and the appropriate comfort and life, it is necessary to clean it regularly.

CAUTION

Always clean the boiler regularly and properly, otherwise it my cause decreased boiler life or wrong burning. If the boiler is not cleaned regularly and sufficiently, the warranty is not valid.

The boiler must be cleaned regularly and properly, every 3–5 days, because the ash accumulated in the feeding chamber or the combustion chamber together with the condensate and tar significantly decrease the lifetime, output and efficiency of the boiler.When there is more ash, there is not enough space for fuel burn-out and the holder of the ceramic nozzle could get damaged and thereby the whole boiler would be damaged. Remove the ash and soot through the bottom opening. Open the bottom door and clean the bottom space form dirts. The frequency of cleaning depends on the quality (humidity) of wood and the intensity of heating, chimney draught and other conditions. We recommend to clean the boiler 1× a week. Do not take the refractory piece out, when the boiler is being cleaned.

It is necessary to clean the following places in the below mentioned intervals:

 feeding chamber of the gasification part (every 3 days)  combustion chamber of the gasification part (everytime before loading)  space under the combustion chamber of the gasification part (everytime before loading)  removable ash tray of the pellet part (depends on a boiler usage, but at least every 2 weeks).  burner grate (2× a year)  pellet chamber (1× a year)  radial impeller of the ventilator (2× a year)  air chamber of the vetilator (2× a year)  pipes of exchanger (1× a year, it is necessary to undo the turbulators)  integrated pellet tank from the residual pellet powder (depends on the operation, at least 1×

a year)

 filter of the integrated tank (1× a year)

Pic. 41 Cleaning of the feeding chamber and the combustion chamber

15. ASSEMBLY AND DISSASSEMBLY OF THE REFRACTORY

ITEMS

The estimated lifetime of the refractory pieces is the same as the lifetime of the boiler. Thereby it is not necessary to disassembly them for exchange, if they are not damaged.

Pic. 42 Assembly and disassembly of the refractory pieces

On the Pic. 42 you can see, how to assemble the refractory pieces.

Assembly of the refractory items:

Assembly the refractory items in the correct order. As the first, insert the item marked as the nr. 1 through the bottom door on the water rib and shift it totally rearwards.Then, insert the item number 2 (through the bottom door as well), put it on the water rib and shift it snugly to the item number 1. Prepare the sealing cord, put the 300 mm part on the rear side of the item nr. 1. Fit 2 pcs. of 75 mm vertically to ensure, that secondary air will not flow into the item nr. 3. Put the item nr. 3 on the item nr. 1 and shift it rearwards. Insert the item nr. 4 with the arrow in direction to the internal part of the boiler. Insert the refractory nozzle marked as the nr. 5. Then, tighten the upper sides of the refractory pieces nr. 3 and 4. Tighten the nozzle nr. 5 by a special INCONEL cord, which is more resistant against temperature.

16. TABLE OF RELATION OF THE RESISTANCE AND THE

TEMPERATURE OF THE SENSOR PT 1000

The characteristics relates to the boiler temperature sensor and to the flue gas temperature sensor as well:

Temperature [⁰C] Resistance [Ω]

-20 921

-10 960 0 1 000

10 1 039 20 1 077 30 1 116 40 1 155 50 1 193 60 1 232 70 1 270 80 1 308

90 1 347 100 1 385 110 1 422 120 1 460 130 1 498 140 1 535 150 1 573 160 1 610 170 1 647 180 1 684 190 1 721 200 1 758 210 1 795 220 1 831 230 1 868 240 1 904 250 1 940

By measuring the resistance of the sensor and the temperature using the energy meter you can easily check, if the sensor is broken and is achieving the correct characteristics. If the sensor indicates the values that are significantly different from the above given characteristics or if it does not indicate anything, it could be faulty and it should be replaced.

CAUTION

The sensors of the boiler temperature and the flue gas temperature have the same characteristic, but the different temperature resistance. Thereby they are not interchangeable!

17. ELECTRICAL CONNECTION SCHEME

Description of the electrical scheme:

CL – motor of the burner cleaning FL – flap of the air inlet into the burner HS – ignition coil F – female M – male FAN – ventilator of the burner HALL – sensor of rotations of the burner´s ventilator PH – photocell GND – grounding P – servogear of the primary air of the gasification part S – servogear of the secondary air of the gasification part M1 – motor of the vacuum pellet supply M2 – motor of the gear for turbulator cleaning M3 – exhaust fan EL – electrical lock MD – end-switch of the main door FD – end-switch of the door of the feeding chamber CARD – place for a memory card with software LAN – place of the internet connection STB – emergency thermostat Tex – flue gas temperature sensor Tb – boiler temperature sensor LS – lambda probe PS – sensor of the pellet presence BR – burner EMC – filter L – phase N – neutral PE – grounding S – signal

Colours of conductors:

A – black B – blue C – green-yellow D – red E – white F – brown G – yellow H – green J – grey

X10

X11X12

X13

L N PE

NO C NC

+24

N L

+24

X35

X34

X33

X32

X31

1 2

3 4

+22V

1 2

+22V

3 4

1 2

L N

3 4

A E D

A B D C

GND

HALL

FAN

+10V

EAD

H F E

B A

X1X2

L N PE PE

L L

L N PE

L_O L_C N PE

X30

X29

X28

X27 X26

X25

X24X23

X22

X17X16 X15

X14

X21

X20X19

X18

X36

X37

A B D C

LAN

CARD

LAN

Tex

1 2

STB

E D

AEA

EMC

18. ACCESSORIES

The ATTACK WOOD&PELLET boiler is delivered functionally tested, packed and placed on a wooden pallet.

The following accessory items are delivered:

 Instruction manual  Warranty letter  USB key with software  Firehook

The following items can be optionally ordered:

 The REGUMAX regulator to control the other devices in the heating system  Vacuum pellet tank  Supply hoses for the vacuum pellet tank  Ashtray suitable for the boiler cleaning

19. INSTRUCTIONS FOR DISPOSAL OF THE APPLIANCE AFTER ITS LIFETIME ENDS

Ensure the disposal of the appliance (boiler) by the waste disposal service, eventually use the regulated waste dump, controlled by the municipal authority.

19.1 DISPOSAL OF PACKAGING

Dispose the packaging by the waste disposal service, eventually use the regulated waste dump.

Stamp, signature of the service organization: ....................................

Obligatory service inspection after the 1st year of operation

Date: .............................

Obligatory service inspection after the 2nd year of operation

Obligatory service inspection after the 3rd year of operation

Stamp, signature of the service organization: ....................................Date: .............................

Data of the customer: (legibly) Name and surname:

...........................................................................

Street: ................................................................

ZIP code, town: ..................................................

Tel.: ....................................................................

Boiler commissioning certificate

Serial number: ...............................................

Date of commission: ......................................

Service organization:

.......................................................................

Stamp, signature

This page serves for confirming the service inspections and is kept by the customer!

ATTACK, s.r.o. – 11/2014

ATTACK, s.r.o. Dielenská Kružná 5020 038 61 Vrútky Slovakia

Tel: +421 43 4003 103 Fax: +421 43 4003 116 E-mail: export@attack.sk Web: www.attack.sk

Výrobca ATTACK, s.r.o. si vyhradzuje právo technických zmien výrobkov bez predchádzajúceho upozornenia. • ATTACK, s.r.o. producer reserves the right to change technical parameters and dimensions of boilers without previous warning. •Der Hersteller ATTACK, s.r.o. behält sich das Recht der technischen Veräderungen an Produkten ohne eine vorige Warnung. • Изготовитель ATTACK, s.r.o. оставляет за собой право изменения технических параметров и размеров котла без предыдующего предупреждения.

• Le producteur ATTACK, s.r.o. réserve le droit des modiﬁcations techniques sans l‘avertissement précédent. • Productor ATTACK, s.r.o. reserva el derecho de cambios técnicos sin advertencia anterior.

ATTACK AWP 25 Instructions For Use Manual

Specifications and Main Features

Frequently Asked Questions

User Manual