Kostrzewa PFL 15, PFL 25, pellets fuzzy logic 2, PFL 50, PFL 40 Service Manual

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Pellets Fuzzy Logic - Service Manual- ENGV 10.11

Experts in biomass heating

Dear Users of Pellets Fuzzy Logic Boiler.

Before you connect and start up the Pellets Fuzzy Logic boiler check the parameters of the chimney according to the data contained in the enclosed table (chimney draft, chimney cross-section), and the device matching with the heated surface (heat demand of the building).

Basic principles for the safe operation of the boiler!!!

1. Read the service manual before starting up the boiler.

2. Before starting up the boiler check that the connection to the central heating system and the flue is in accordance with manufacturer’s recommendations.

3. Do not open the doors during the boiler operation.

4. The tank cover must always be tightly closed during the boiler operation.

5. Do not allow the fuel tank to be emptied completely.

For your safety and comfortable use of the boiler, please return the PROPERLY COMPLETED (CONTAINING ALL ENTRIES AND SEALS) last copy of the warranty card and the boiler quality and completeness certificate (the last page of this service and installation manual ) to the following address:

SERWIS KOSTRZEWA ul. Przemysłowa 1, 11-500 Giżycko, POLAND woj. warmińsko – mazurskie tel. +48 87 428 53 51 lub +48 87 428 11 34 e-mail: serwis@kostrzewa.com.pl

Sending back the warranty card will allow us to register you in our database of Pellet Fuzzy Logic users and provide fast and reliable service.

IMPORTANT !!!

PLEASE NOTE THAT FAILING TO RETURN THE WARRANTY CARD OR RETURNING THE WARRANTY CARD AND BOILER QUALITY AND COMPLETENESS CERTIFICATE INCORRECTLY FILLED WITHIN TWO WEEKS FROM THE DATE OF THE BOILER INSTALLATION, HOWEVER NOT LONGER THAN TWO MONTHS FROM THE PURCHASE DATE, RESULTS IN THE LOSS OF WARRANTY FOR THE HEAT EXCHANGER AND ALL COMPONENTS OF THE BOILER. THE LOSS OF WARRANTY WILL CAUSE THE DELAY IN PERFORMING REPAIRS AND NECESSITY TO COVER THE COSTS OF ALL BOILER REPAIRS WITH TRAVEL COSTS OF THE SERVICE PERSONNEL INCLUSIVE.

Thank you for your understanding. Yours sincerely,

Dear user of KOSTRZEWA equipment!

We want to take this opportunity to thank you for choosing our equipment. You have selected the highest quality product of the company known and appreciated throughout the country.

The Kostrzewa company was established in

1978.Since the beginning of activity they are dealing with the production of fossil fuel and biomass-ﬁred boilers for central heating applications. Within theirs 30 years’ activity the company improves and upgrades their equipment so as to be a leader among the Polish manufacturers of solid fuel-ﬁred boilers.

The implementation and designing department for new technologies was created in the company to continually improve the equipment and implement the new technologies. We want to contact with each customer by an intermediary of the companies, which will professionally represent our company.

Your opinion on the activities of our company and our partners is very important to us. Striving to continuously improve the level of our products, we ask you to make any comments about our products and service rendered by our Partners.

Have the warm and comfortable days through the whole year!

KOSTRZEWA sp.j.

ENGV 10.11

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

Experts in biomass heating

Index

I. Pellets Fuzzy Logic Boiler manual

1. General 4

2. Technical data of Pellets Fuzzy Logic boiler 5

3. Fuel parameters 6

4. Description of Pellets Fuzzy Logic boiler design 7

5. Pellets Fuzzy Logic boiler accessories 8

6. Pellets Fuzzy Logic protecting and control ﬁttings 9

7. Pellets Fuzzy Logic Boiler location and installation 10

8. Boiler commissioning - Instructions for AS (Authorized Service) 12

9. Boiler control system user manual 13

10. While using the boiler, keep in mind ... 13

11. Starting up the boiler - User Instructions 14

12. Cleaning and maintenance 21

13. Troubleshooting 25

14. Instructions for boiler disposal after expiration of its service life 26

II. PELLETS CONTROL M Fuzzy Logic Boiler controller service manual

15. General 30

16. Electrical wiring system 32

17. Operation 35

18. Technical data of Pellets Control M Fuzzy Logic 44

19. Terms and Conditions of Warranty and Defects Liability. 46

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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1.1 Application and advantages of the boiler

Automatic PELLETS FUZZY LOGIC boiler is intended for combustion of solid fuels such like pellets, pea coal, cereals, wood. It can be used to heat single or multi-family houses, smaller resorts, workshops, schools, oﬃces, etc.

1.2 Advantages of Pellets Fuzzy Logic boiler

Modern design of steel heat exchanger, allowing the achievement of eﬃciency above 90%; Possible combustion of four types of fuels; Automatic fuel ignition - pellets; Automatic fuel ignition – pea coal; Automatic fuel ignition – cereals; Automatic operation of the boiler controlled by weather controller and room thermostat; To improve the quality of combustion Pellets Fuzzy Logic is ﬁtted with three fans (two pressure and one exhaust);

- exhaust fan - to eliminate odors and dust in the boiler room; during the combustion of fuels the fan draws ﬂue gas from the boiler to the chimney. Fan rotor, through which ﬂue gas pass, is made of stainless steel; Door viewer - to not open the door during operation, a sight glass was mounted to view the ﬂame; Flue gas temperature measurement - this feature allows you to control the eﬃciency of the boiler and its settings. It informs you also about the point at which the boiler heat exchanger must be cleaned; Two operation modes;

- Summer - during the summer season domestic hot water is heated;

- weather - along with the external temperature sensor and the room temperature controller (standard boiler equipment); Modulation of the burner operation by Fuzzy Logic method

- no feeding and standstill times - automatic power adjustment to the heat demand of the building - from 10% to 100% of the boiler output; Lambda probe - inﬁnitely adjustable fan speed (air is tuned by the lambda probe and not by the user. Just press the start button and the boiler will tune the amount of air itself; Temperature limiter - the boiler is ﬁtted with the temperature limiter, independent from the boiler control system, which operates at a temperature higher than 95°C; continuous feeder temperature measurement; feeder alarm condition temperature is programmable; Automatic control of the mixing valve actuator; measurement and regulation of the temperature of the water returning to the boiler; Possible domestic hot water heating; Alphanumeric display with backlight - nice and easy to use; Menu in English, Polish, German;

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Mechanical or electronic (optional) fuel level indicator Economic operation Low levels of harmful substances in ﬂue gas; High eﬃciency of the device Versatile installation options (left / right side).

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1. General

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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2. Technical data of Pellets Fuzzy Logic

PARAMETR SI PFL 15 PFL 25 PFL 40 PFL 50 PFL 75 PFL 100

Rated output kW 15 25 40 50 75 100

Minimum range kW 5 8 12 15 23 30

Control range kW 5 - 15 8 - 25 12-40 15-50 23-75 30-100

Output control method Fuzzy Logic,

PID

Fuzzy Logic,

PID

Fuzzy Logic,

PID

Fuzzy Logic,

PID

Fuzzy Logic,

PID

Fuzzy Logic,

PID

Boiler class acc.to PN EN 303-5 3 3 3 3 3 3

CO concentration acc. to PN-EN 12809 (o2=10%) for rated output

mg/m

283 427 315 184 190 148

Water volume dm

65 80 100 120 150 200

Max. working pressure bar 2 2 2 2 2 2

Testing pressure bar 4 4 4 4 4 4

Recommended heating water temperature

C 70 70 70 70 70 70

Min. temp. of water returning to boiler

C 50 50 50 50 50 50

Chimney draft mbar 0.15 – 0.25 0.15 – 0.25 0.15 – 0.25 0.2 – 0.3 0.2 – 0.3 0.4

Flue gas temperature for rated output

C 140 150 160 160 180 180

Flue gas temperature for min output

C 90 95 100 100 110 110

Heat exchange area m

– 2.35 – – – -

Fuel charge weight - pellets kg 80 220 220 320 400 400

Charging hole dimensions mm 300x300 300x300 350x350 350x350 350x350 350x350

Approximate fuel consumption at rated output (pellets)

kg 3,48 5.8 9,28 11,6 17,4 23.25

Approximate fuel consumption at minimum output (pellets)

kg 1,16 1.9 2,78 3,48 5,33 6,97

Approximate fuel consumption at rated output (pea coal)

kg 2,34 3.9 6,24 7,8 11,70 16,4

Approximate fuel consumption at minimum output (pea coal)

kg 0,78 1.2 1,87 2,34 3,58 3,58

Boiler length (set) mm 960 1080 1080 1080 1495 1495

Boiler width (set) mm 990 1150 1280 1270 1410 1580

Boiler height (set) mm 1050 1230 1230 1230 1565 1565

Supply/return stub pipe cal 1.5 1.5 1.5 1.5 2.0 2,5

Connecting voltage V 230 230 230 230 230 230

Max. power consumption min./max W 140/900 140/900 140/900 200/900 200/900 200/900

Flue diameter mm 160 160 160 160 200 250

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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3. Fuel parameters

Wood

To achieve the boiler rated output, one shall use the dry wood with a moisture content to 20% (equivalent to 18 months of wood drying under a cover) as a fuel. Using the wood pieces of larger sizes (cut into thicker pieces) extend the time of one charge burning even up to 8 hours.

Pellets prepared according

to DIN 51731

granulation 5 – 8 mm recommended caloriﬁc value 17500 – 19500 kJ/kg ash content max. 0.5 % - 600 to 700 kg per m3 moisture content max. 12 % speciﬁc gravity (density) 1.0 – 1.4 kg / dm3

Pea coal

granulation 5 – 25 mm recommended caloriﬁc value >23000 kJ/kg ash contents maks. 12 % moisture contents maks. 12 % volume of volatilizing compounds 28 – 40 % ash deformation temperature > 1150°C low sintering small bulking

Cereals - oats, triticale, fruit pips

Moisture content to 12%.

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Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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Ash pan door Door for cleaning burner and grate installation Boiler control system Top charging door Fuel tank Fuel charging hole to tank Motor with gear unit (gear-motor)

Locking pin (screw connecting worm with gear unit) Fuel feeder (worm) Ignition fan Pressure fan Fuel ignition heater

10.

11.

12.

4. Description of Pellets Fuzzy Logic Boiler design

Fig. 01 Flue gas circulation in boiler exchanger Fig. 02 Flue gas circulation in boiler exchanger

Fig. 03 Boiler design Fig. 04 Boiler design

Lambda probe Boiler thermal protection Boiler sensor, thermal protection 95°C Flue gas sensor Heating medium outlet from boiler

Wiring system ducts Exhaust fan Heating medium return to boiler Water drain

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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4. Description of Pellets Fuzzy Logic Boiler design cont.

Standard accessories:

Boiler service and installation manual (1pcs.)

Cast iron grates (set.)

Flue gas turbulator (1 pc.)

Room controller (1 pc.)

External sensor (1 pc.)

Domestic hot water sensor (1 pc.)

Central heating sensor (1 pc.)

Auxiliary accessories:

Lambda probe module (1 pc.)

Floor heating control module (additional heating circuits) (1 pc.)

Solar system control module (1 pc.)

Boiler clean out Flue gas swirl vanes Flue gas outlet (chimney) Access to clean the third baﬄe Cleanout upper door Charging door for wood

Charging (combustion) chamber Access door to burner and grate Air chamber of the burner with the clean-out at the bottom part Ash pan door

10.

Fig. 05 Boiler design Fig. 06 Pellets Fuzzy Logic Boiler

5. Pellets Fuzzy Logic accessories.

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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6. Protecting and control equipment

Boiler equipment allows the user to set:

boiler temperature temperature in the heating circuit according to the room temperature domestic hot water temperature (full weather control) room temperature temperature of water returning from the central heating system. (the function protecting the boiler exchanger); igniter heating time (depending on the fuel type) operation of the fuel feeder and three fans; manual control of the feeder and fan; automatic burner output modulation (fuzzy logic) automatic air dosage (lambda sensor module)

It is possible to connect the executive modules MU1 to the control system. Each of those modules controls the ﬁve heating circuits or controlled room thermostats. The module of additional heating circuits (control of mixing valves). The solar module to control the solar collector.

Thermal sensor

The mechanical protecting device is mounted in the boiler and protects the heating system from overheating. If it is set to 95°C, it means that above this temperature the feeder and fans will be turned oﬀ and the central heating and domestic hot water pumps start operation.

Room controller with optional programming

(in 7-days cycle)

The digital room thermostat with programming option is used to automatic control of heated rooms.

Fuzzy Logic control method

Advantages of Fuzzy Logic control:

Fuzzy logic algorithm is more advanced than „pid” algorithm used in other appliances ; Reduction of combusted fuel quantities; Eliminates formation of impurities and tar in the boiler to a great extent; High temperature stability of the boiler operation – eliminates water vapor dripping in the boiler; Combustion chamber temperature is high and stabile, thereby the emissivity of carbon oxides is reduced.

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Lambda probe

Voltage generated by the cell is transmitted to the Pellets Control controller governing the fuel-air mixture composition in the boiler. This module continuously adjusts the fuel mixture composition, to ensure the most perfect operation of the device under the determined conditions of the boiler load, fuel type and weather conditions and to minimize the emission of carbon monoxide. A properly adjusted air-fuel mixture can save up to 20% of fuel. Control takes place continuously during the entire cycle of the boiler operation.

Locking pin at the feeder inlet

Located at the beginning of the worm conveyor shaft. Possible blockage of the worm conveyor causes the compression of the above component, thereby protecting the engine from damage (after breaking the locking pin clean the burner knee, insert a new locking pin and start up the boiler).

Automatic motor thermal sensor

It is located in the control system housing at the back of the boiler and protects the motor from damage. When the load is not large enough to break the protective device on the feeder clutch and the motor is under greater and greater load and begins to heat up, the automatic thermal sensor trips oﬀ the motor. To restart the motor, press the button No. 1.

Temperature sensor on the worm conveyor cover

In the event of the ﬂame (heat) reversal to the feeder it transmits a signal to the boiler controller, which in turn switches oﬀ the combustion air fan and forces the feeder operation to remove the heat out of the feeder. This protection works only when the boiler is supplied with electricity.

Flue gas sensor

It is mounted in the chimney ﬂue and measures the ﬂue gas temperature. When the exhaust temperature is above 230 ° C, clean the boiler heat exchanger.

Central heating and domestic hot water pump.

It works according to a proper algorithm, so as to make optimum use of heat.

Mixing valve actuator

This component is used to preset the heating circuit temperature in the central heating system while maintaining a constant temperature in the boiler. The temperature is calculated from the heating curve, external temperature and room temperature.

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

Experts in biomass heating

7. Pellets Fuzzy Logic Boiler location and installation

7.1 Regulations, standards and recommendations

The boiler room should meet the conditions of the building law in force at the site of the boiler installation. In Poland, these provisions are treated by the standard PN-B-02411, and the regulation of the Minister of Infrastructure of 12 April 2002 on the technical requirements to be met by buildings and their location. (Journal of Laws No. 75, item. 690)”. The solid-fuel ﬁred boilers should be installed in separated plant rooms and the fuel storage should be located in a separate plant room near the boiler or in the room in which the boiler is installed, however not closer than 40 cm from the boiler. The boiler room should meet the requirements of ﬁre protection and OH&S regulations.

7.2 Recommended boiler room dimensions

The height of the room shall not be less than two heights of the boiler, however, not less than 2,5 m; The distance between the wall and the boiler unit min. 100 mm; The distance between the tank and wall min. 600 mm; The distance from the rear wall of the boiler to the wall should be min. 300 mm; The distance from the front wall should be min. 400 mm;

7.3 Positioning on a non ammable oor

Boiler should be set on a non-ﬂammable heat insulating pad, which should be greater than the base of the boiler by 2 cm from each side of the boiler; If the boiler is located in the basement, we recommend to set the boiler on the foundation of at least 5 cm in height. The boiler must be positioned vertically.

7.4 Safe distance from ammable materials

During installation and operation of the boiler keep a safe distance of 20 cm from ﬂammable materials; In case of ﬂammable materials of C3 ﬂammability degree, which are quick and easy to burn even after removal of ignition sources (such as paper, paperboard, cardboard, wood, plastics), the said distance is doubled, ie. to 40 cm; If ﬂammability is not known, the safe distance should also be doubled.

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7.5 Ventilation of the boiler room

Air delivery shall take place through the non-closed hole with the minimal cross-section of 200 cm² and the exit to 100 cm above the ﬂoor level.

7.6 Chimneys

Chimneys are designed to remove ﬂue gas to the outside in a reliable manner and draw the air for combustion. The chimney draft necessary for this purpose is conditional on:

temperature diﬀerence between hot ﬂue gas and cold air; eﬀective height of the chimney; chimney cross-section (≥ 100 cm²); chimney execution (possibly smooth internal surfaces) and the tightness of joints;

The eﬀective chimney height is the height diﬀerence between the highest furnace and the chimney outlet. The eﬀective height of individual chimneys must be at least of 4 m, and in the case of the common chimneys for solid and liquid fuels it must be at least of 5 m. The height diﬀerence between the two furnaces cannot be greater than 6.5 m.

In the case of sloping roofs the chimneys should terminate within the ridge (the highest edge of the roof), in the area of free movement of wind, thereby avoiding draft interferences and disturbing eﬀect on and by the environment. You should always pay attention to the location of the building in relation to other buildings.

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Flammability degree of building compounds and products

Building materials and products

A – noncombustible sandstone, concrete, bricks,

ﬁre-protection plaster, mortar, ceramic tiles, Granite

B - slow-burning wood-cement boards,

glass ﬁber, mineral Insulation

C1 – slow-burning beechwood, oak wood,

Plywood

C2 - moderately-burning pine, larch and spruce wood,

cork, Sawn wood planks, Rubber ﬂoor lining

C3 - easily-burning Asphaltic board, celluloid

compounds, polyurethane, Polystyrene, polyethylene, plastic, etc.

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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7. Pellets Fuzzy Logic Boiler location and installation cont.

7.7 Selection of a chimney

In most cases, the selection of a chimney based on an approximate method or chimney manufacturer’s diagrams is suﬃcient. In special cases (adverse pressure and temperature dependence; large volume of ﬂue gas) the chimneys are calculated according to BS EN 13384-1 (PN-EN 13384-1).

The diagrams of chimneys contain such input values as the chimney conduction thermal resistance, roughness of the chimney inner walls, ﬂue conduction thermal resistance and coeﬃcients of hydraulic resistance when changing directions of the tubes.

The diagrams of the manufacturers include the relationship between the rated capacity of the heating unit and the eﬀective height of the chimney for the various cross-sections of the chimney.

The diagrams will vary depending on the used fuel (eg. oil, gas, wood), design of furnaces (eg. pressure boiler with a fan burner), ﬂue gas temperature and type of load.

7.8 Chimneys for solid fuel-red boilers

It should be noted that the solid fuel-ﬁred furnaces with a rated thermal output > 20 kW and w/o fan need their own chimney. For the solid fuel-ﬁred boiler the cross-section of the chimney should be 16cm x 16cm (in Poland - at least 14cm x 14 cm). When the cross-section is diﬀerent, then the ﬂue gas ﬂows too slow and cools down too much. This in turn leads to problems with the draft and formation of deposits in the chimney. These deposits damage the wall, if sulfuric acid and water vapor contained in ﬂue gas cool below the dew point temperature.

For the solid fuel-ﬁred furnaces the single-layer chimneys made from brick, often occurring in old buildings, can be used. Currently the three-layer chimneys with a smooth surface and good thermal insulation are applied.

7.9 Flue

The ﬂues according to DIN 18160, connect a boiler with a chimney. They can be made as the exhaust pipes or as ﬂue gas ducts. Exhaust pipes are the pipes and ﬁttings, which are distributed in the premises. Flue gas ducts comply with the ﬁre-protection requirements for chimneys and are often made from the same material as the main chimney. The connecting units should be as short as possible and placed with an upslope to the chimney to avoid heat losses and additional resistance. They can not be lead onto other ﬂoors. Exhaust pipes should not be laid in the rooms, in which the furnaces cannot be mounted, besides they also should not be mounted in the walls and ceilings.

7.10 Installation and commissioning

The solid fuel-ﬁred boiler must be installed in accordance with applicable regulations by an authorized service company. The boiler commissioning must be carried out by trained service staﬀ of the manufacturer possessing an appropriate license.

7.11 Connecting to the heating system

The hydraulic system should comply with the applicable regulations and standards and must be performed according to building-art principles.

7.12 Requirements for heating system water:

Water must be transparent and colorless w/o additives and other chemically aggressive substances; Water hardness below 20 of PH above 8.5

7.13 Connecting to the wiring system

The boiler is designed for supplying voltage 230V/50Hz. Installation should be performed by a qualiﬁed person with an easy access to the connecting socket of 230V/10A, grounded. Boiler and boiler room lighting system should have a diﬀerent power supply circuit.

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7. Pellets Fuzzy Logic Boiler location and installation cont.

NOTE!!! To ensure optimum performance and proper combustion it is required that chimney draft represent the appropriate values from Table No. 1

Due to low ﬂue gas temperature, in order to protect the chimney from moisture and reducing the draft, it is advised to use the chimney inserts from acid-resistant steel or ceramics with condensate discharge to a ﬂoor drain.

NOTE!!!

In order to avoid the „dew formation” in the ash pan chamber it is recommended to set the boiler on the thermally insulated ﬂoor or put the insulating material under the boiler (for boilers without a double-insulated bottom).

NOTE!!! Central heating system connected to the boiler must be ﬁtted with a drain cock, which must be at the lowest point and as close to the boiler as possible.

8. Boiler commissioning – Instructions for AS

8. Boiler commissioning – instructions for A.S.

Commissioning of the boiler must be carried out only by the service personnel trained by the manufacturer, with a current certiﬁcate of an authorized service performer of Kostrzewa company.

Completion of installation and heating test performance must be recorded in the Warranty Card.

The completed warranty card should be mailed by the user to the address of the manufacturer to register the user in the company system.

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SERWIS KOSTRZEWA ul. Przemysłowa 1, 11-500 Giżycko, POLAND woj. warmińsko – mazurskie tel. 087 428 53 51 e-mail: serwis@kostrzewa.com.pl

Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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9. Boiler control system user manual

As per controller service manual enclosed on page 29 - Pellets Control M Fuzzy Logic

10. While using the Platinum Bio Burner, keep in mind ....

The boiler can be operated only by adult persons familiarized with the above service manual. Children cannot stay close to the boiler without presence of adult persons. When it comes to penetration of ﬂammable gases or vapors to the boiler room or during the work, at which an increased risk of ﬁre or explosion occurs (gluing, painting, etc.) the boiler should be switched oﬀ before starting the work. When cleaning the deposit in the knee, the device must be switched oﬀ (OFF position). It is prohibited to use ﬂammable liquids to ﬁre up the boiler, the boiler must be ﬁred up automatically. When adding fuel to the boiler tank the device should be turned oﬀ (OFF position). When cleaning the boiler, it must be switched oﬀ (OFF position). Flame can be visually controlled by means of a sight glass incorporated in the door. During operation, the boiler cannot be overheated.

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Do not place any ﬂammable objects on the boiler or in its immediate vicinity. When removing ash from the boiler any ﬂammable materials cannot be present in a distance of 1500mm to the minimum from the boiler. Ash should be deposited into the ﬁreproof tanks with a cover. During operation of the boiler at a temperature lower than 60°C the dew formation on the steel heat exchanger may occur and thereby the corrosion due to low temperature, which shortens the life of the heat exchanger. Therefore, the temperature during operation of the boiler must be at least 60°C. After the heating season, clean the boiler and smoke duct thoroughly. Keep the boiler room in clean and dry condition. Any tampering with electrical part or changing the boiler design are prohibited.

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Pellets Fuzzy Logic - Service Manual- ENGV 10.11

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11. Boiler start up – instructions for user

11.1 First start up of the boiler

Pour the fuel into the tank (pellets, pea coal, cereal); Select fuel type; Set the OFF mode on the controller panel; Feed the fuel to the burner with a manual fuel feeding function; Feed the fuel until it appears on the burner bottom (knee); Set the ON mode on the control panel; After more then ten minutes the ﬂame will appear, which can be seen via the sight glass on the boiler door.

11.2 Boiler damping

In the case of the planned longer standstill of the boiler set the controller panel into OFF mode.

11.3 Starting up the boiler after fuel depletion

Remove carbon deposits from the burner knee - applies only to pellets; Pour the fuel into the tank (pellets, pea coal, cereals); Set the OFF mode on the control panel; Feed the fuel to the burner with a manual fuel feeding function; During feeding at the feeder turned oﬀ remove unburnt fuel from the knee manually (if the unburned fuel is not removed, your feeder may be blocked and the locking screw (feeder locking pin) may be broken); Feed the fuel until pure granulate appears at the bottom of the burner; Set the ON mode on the control panel; After more then ten minutes the ﬂame will appear, which can be seen via the sight glass on the boiler door.

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11.4 Starting up the boiler after the feeder locking pin rupture.

Remove carbon deposits from the burner knee - applies only to pellets; In case of pea coal – remove a large coal lump between the tank and fuel feeder, removing the worm from the feeding tube; Pour the fuel into the tank (pellets, pea coal, cereal); Set the OFF mode on the control panel; Feed the fuel to the burner with a manual fuel feeding function; During feeding with the feeder turned oﬀ remove unburnt fuel from the knee manually (if the unburned fuel is not removed, your feeder may be blocked and the locking screw (feeder locking pin) may be broken); Feed the fuel until pure granulate appears at the bottom of the burner; Set the ON mode on the control panel; After more then ten minutes the ﬂame will appear, which can be seen via the sight glass on the boiler door.

11.5 Starting up the boiler with wood as a fuel

NOTE!!!

During wood combustion make sure that the ﬂu gas temperature does not exceed 200°C.

Set the OFF mode on the control panel; Select the fuel type – charging chamber; Place additional grates in the boiler; Put the pieces of paper on the grate; Put the dry wood piece on the grate; Fire up the paper pieces using matches; Close the boiler door; Set the boiler panel into the ON mode; Set the boiler preset temperature to 70°C; Add some dry wood after several hours;

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11. Boiler start up – instructions for user cont.

11.6 Setting up the burner for pellets, pea coal and cereals.

The burner parameters should be set according to Table 3 (a number of the below tables belonging to the table no 3)

Instruction for setting the burner for pellets, cereal*, pea coal.

NOTE!!!

If the boiler is equipped with a lambda probe it is recommended to use the ﬂue gas analyzer to set its characteristic. When setting up the blower output for the subsequent boiler outputs (as described below) the number of oxygen units should be recorded.

In the chimney-sweep mode for the output at 100%, the blower was set to 50, you should check the number of oxygen units. Note this value to be able to enter the proper value to the probe characteristic later; Set the boiler output to 100%; Go to the advanced settings and select the chimney sweep mode (yes). For proper output volumes ranging from 20%, 40%, 60%, 80%, 100%, pre-set the output of the blower; Start up the boiler in the chimney-sweep mode at 100% output, match the output of the blower. If the blower output is properly matched, the pellets should be between the upper and lower row of the burner holes, the ﬂame should be high and clear, and no smoke should be present in the combustion chamber. When the ﬂame is low, with bright yellow color and the pellet is getting black, increase the fan output by 4 units and wait for 0 min. until the furnace operation stabilization; If the air is adjusted properly for 100%, then remaining in the chimney-sweep mode, change the output to 80% and match the air in accordance with the earlier procedure; proceed the same way for 60%, 40% and 20%. If all operations were carried out according to the instructions above, set the required temperature of the boiler operation and turn on the boiler (ON).

In the case of pea coal fuel ﬁring the proper method of combustion will be as follows: the ﬂame is high, transparently yellow, and pea coal will be present approximately 3 cm above the upper edge of the burner (a small pile).

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Experts in biomass heating

11. Boiler start up – instructions for user cont.

11.6 Setting up the burner for pellets, pea coal and cereals cont.

Table 03 part 01

NOTE!!!

When the fuel falls out unburned increase the amount of air and / or reduce the burner output !

Technical parameters of Pellets® Fuzzy Logic - Pellets

RPM

Boiler output [kW] Feeding [s] Standstill [s]

0,9 15 2,5 10

0,9 20 3,3 10

0,9 25 4,1 10

0,9 30 5,0 10

0,9 35 5,8 10

0,9 40 6,6 10

0,9 45 7,4 10

1,8 / 3,6 50 4,1 10

1,8 / 3,6 55 4,5 / 2,3 10

1,8 / 3,6 60 5,0 / 2.5 10

1,8 / 3,6 65 5,4 / 2,7 10

1,8 / 3,6 70 5,8 / 2,9 10

1,8 / 3,6 75 6,2 / 3,1 10

1,8 / 3,6 80 6,6 / 3,3 10

1,8 / 3,6 85 7,0 / 3,5 10

1,8 / 3,6 90 7,4 / 3,7 10

1,8 / 3,6 95 7,8 / 3,9 10

1,8 / 3,6 100 8,2 / 4,1 10

It is necessary to correctly set the air according to feeding and standstill times (air surplus coeﬃcient 2.0-2.4) developed in the company Kostrzewa® Sp.j.

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11. Boiler start up – instructions for user cont.

Table 03 part 02

NOTE!!!

When the fuel falls out unburned increase the amount of air and / or reduce the burner output !

Technical parameters of Pellets® Fuzzy Logic - Pea coal

RPM Boiler output [kW] Feeding [s] Standstill [s]

0,9 15 1,7 10

0,9 20 2,2 10

0,9 25 2,8 10

0,9 30 3,4 10

0,9 35 3,9 10

0,9 40 4,5 10

0,9 45 5,0 10

1,8 / 3,6 50 2,8 / 1,4 10

1,8 / 3,6 55 3,1 / 1,5 10

1,8 / 3,6 60 3,4 / 1,7 10

1,8 / 3,6 65 3,6 / 1,8 10

1,8 / 3,6 70 3,9 / 1,9 10

1,8 / 3,6 75 4,2 / 2,1 10

1,8 / 3,6 80 4,5 / 2,2 10

1,8 / 3,6 85 4,8 / 2,4 10

1,8 / 3,6 90 5,1 / 2,5 10

1,8 / 3,6 95 5,4 / 2,7 10

1,8 / 3,6 100 9,7 / 2,8 10

It is necessary to correctly set the air according to feeding and standstill times (air surplus coeﬃcient 2.0-2.4) developed in the company Kostrzewa® Sp.j.

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11. Boiler start up – instructions for user cont.

Table 03 part 03

Power output Pellets Pea coal

P15 or P14

(Pellets Lambda Control)

Burner output Blower output Oxygen Burner output Blower output Oxygen

100% 35 130-160 100% 40 130-160

80% 30 140-170 80% 35 140-170

60% 25 150-180 60% 30 150-180

40% 20 160-190 40% 25 160-190

20% 18 160-190 20% 22 160-190

P25

100% 45 130-160 100% 50 130-160

80% 40 140-170 80% 45 140-170

60% 35 150-180 60% 40 150-180

40% 30 160-190 40% 25 160-190

20% 28 160-190 20% 32 160-190

P40 or P30

(Pellets Lambda Control)

100% 45 130-160 100% 55 130-160

80% 40 140-170 80% 50 140-170

60% 35 150-180 60% 45 150-180

40% 30 160-190 40% 40 160-190

20% 28 160-190 20% 38 160-190

P50

100% 45 130-160 100% 55 130-160

80% 40 140-170 80% 50 140-170

60% 35 150-180 60% 45 150-180

40% 30 160-190 40% 40 160-190

20% 28 160-190 20% 37 160-190

P75

100% - 130-160 100% - 130-160

80% - 140-170 80% - 140-170

60% - 150-180 60% - 150-180

40% - 160-190 40% - 160-190

20% - 160-190 20% - 160-190

P100

100% - 130-160 100% - 130-160

80% - 140-170 80% - 140-170

60% - 150-180 60% - 150-180

40% - 160-190 40% - 160-190

20% - 160-190 20% - 160-190

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11. Boiler start up – instructions for user cont.

Sustaining

pea coal

Sustaining

standstill ( min )

Sustaining feeder ( s )

Sustaining

Blower rundown ( s )

Sustaining

Blower output ( % )

for p15, p25, P40 20 17 90 40

for p50, p75, P100 20 12 90 40

* suggested minimum burner output 40%; * with P15, P25, P40 models the pressure fan output at pos. 1 (the lowest rpm);

• with P50, P75 models the pressure fan output at pos. 2, 3

• for each device select the maximum burner output for a given fuel ( PFL burner setting)

Table 03 part 04

11.7 Mounting the burner tip

uszczelnić silikonem

Fig. 07 Mounting the burner tip

seal with silicone

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11. Boiler start up – instructions for user cont.

11.8 Switchgear diagram

Fig. 09 View of facade

Fig. 08 Switchgear diagram

silnik mieszacza

pompa c.w.u.

sonda lambda szerokopasmowa

T c.w.u T podajnika

T co T powrotu*

silnik czyszczenia

zasilanie 230V~

seal with silicone

DHW pump

CH pump

igniter

main blower

thermal switch

feeder motor

igniter / blower

exhaust fan

cleaning motor

supply voltage 230 V

Lambda probe

Lambda module ML-2

outside the switchgear

boiler temp

DHW temp. Feeder temp.

ﬂue gas temp. ambient temp

CH temp. return temp

Pellets Control M

NOTE!!!

If the module ML - 2 is connected,

disconnect the probe return temp.

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11. Boiler start up – instructions for user cont.

11.10 Symptoms of abnormal combustion

unburnt pellets overﬂow out of the burner; ﬂame is very short; boiler chamber is full of smoke – check the times

of feeding and standstill, increase the air volume by 2 units, wait 10 minutes; adjust (add)the air for so long, until the ﬂame is high and bright, and no smoke will be present in the combustion chamber;

unburnt pellets „jump” out of the burner, the ﬂame is very sharp and high, the chamber of the boiler is not smoky, pellets are below the level of the upper air holes – check

the times of feeding and standstill, decrease the air volume by 2 units, wait 10 minutes; adjust (reduce) the air for so long, until the ﬂame is high and bright, and no smoke will be present in the combustion chamber;

•

unburnt pea coal overﬂows out of the burner, despite of correct combustion process – reduce the burner output

(feeding and standstill times);

unburnt pea coal overﬂows out of the burner, ﬂame is very short, the chamber of the boiler is smoky –

check the times of feeding and standstill, increase the air volume by 2 units, wait 10 minutes, adjust (add)the air for so long, until the ﬂame is high and bright, and no smoke will be present in the combustion chamber.

•

12. Cleaning and maintenance

12.1 Cleaning and maintenance

Regularly clean the ash pan chamber; Regularly clean the clean-out chamber; Regularly clean the burner chamber; Regularly clean the exhaust fan; Regularly clean the boiler exchanger;

•

Regularly clean the burner knee Regularly clean the carbon deposits oﬀ the lambda probe with a soft brush after every 100 hours of operation - only the pellets; At least once a year, call for AS to perform an annual boiler inspection - obligatory inspection;

•

NOTE!!! Boiler cleaning can be performed only

when the device is disconnected from the mains.

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12. Cleaning and maintenance cont.

Fig. 10 Cleaning the burner knee oﬀ carbon deposits (only for pellets)

Fig. 11 Cleaning the burner knee oﬀ carbon deposits (only for pellets)

Fig. 12 Cleaning the Lambda probe

Fig. 13 Very dirty combustion chamber. Fig. 14 Very clean combustion chamber.

Igniter orﬁce Carbon deposit

Lambda probe

Flue gas temp. sensor

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12. Cleaning and maintenance cont.

Fig. 19 Igniter replacement Fig. 20 Boiler chamber cleaning

Fig. 15 Very dirty boiler exchanger Fig. 16 Very clean boiler exchanger

Fig. 17 Exhaust fan disassembly - cleaning. Fig. 18 Exhaust fan disassembly - cleaning.

Flue gas temp. sensor

Lambda probe

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12. Cleaning and maintenance cont.

Fig. 21 Exchanger cleaning Fig. 22 Locking pin replacement in motoreducer gear unit

Fig. 23 Grate layout

Fig. 24 Pressure fan optional settings Fig. 25 Boiler cleanout opening method

Lid for exchanger cleaning

Lid for sooth removal from exchanger

Allen key No. 6

Loking pin / 8.8 hardness class

Three fan outputs

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13. Troubleshooting

Failure type Probable reason for failure Probable reasons/ suggested remedy

The device does not turn on the igniter

- ZAP message does not appear on the controller display

Sensor improperly inserted into connection block; Flue gas sensor damaged. Flue gas temperature on the

display 630 o C.

•

Check correctness of sensor connection in the connection block; Replace ﬂue gas sensor. Ignite fuel manually.

•

The message „feeder overheating” ﬂashes on the display. The feeder is cold

Sensor improperly inserted into connecting block; Feeder sensor damaged. Feeder is working all the time.

•

Check correctness of sensor connection in the connecting block; Replace the feeder sensor.

•

No readings on the controller display No power supply;

Incorrect connection of plugs and cables of the controller; too much moisture in the controller.

•

Check the boiler connection to power supply source; Check correctness of plugs installation and connections of the controller.

•

One of the control panel push-buttons is out of service.

Control panel failure.• Control panel repair.•

Worm conveyor does not rotate despite of signalized activation.

Gera-motor is not powered; Improper connection of supplying cables; Feeder blockade; Gear-motor failure; Control module failure.

•

Check correctness of plugs installation and connections of the controller Module; Check correctness of connections between gear-motor and worm shaft; Check the eﬃciency of feeder channel and the freedom of rotation of the worm shaft in the feeder channel; Check or replace the condenser (once per year replace the condenser with the new one).

•

Locking pin breaking (multiple). Hard material is clogged between

the tank and feeder; Carbon deposit on the burner knee (only for pellets); Worn worm tip (pellets com out heavily mixed).

•

Remove the worm from the feeder and remove hard element; Hammer out the carbon deposits from the edge of the burner knee and restart the feeder (without removing the worm); Insert a new worm.

•

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13. Troubleshooting cont.

Failure type Probable reason for failure Probable reasons/ suggested remedy

Automatic fuel ignition does not operate. Improper settings of the heater

heating time and ﬁre test; Improper heater connection; Clogged outlet hole of hot air from the heater.

•

Change setting parameters; Check correctness of connections of the heater plugs and conduits (including the connecting blocks); Open the igniter oriﬁce; Very moist fuel; Damaged heater (it does not heat up itself ).

•

During combustion a lot of dark smoke appears in the boiler chamber. A lot of unburned fuel drops to the ash pan.

Air volume set improperly; Feeding and standstill times set improperly for individual output values.

•

Increase the amount of air, check the feeding and standstill times (burner output can be set too high ).

•

During combustion a great quantity of ﬂying fuel pieces is present in the boiler chamber. Great quantity of unburnt fuel drops to the ash pan.

Air volume set improperly; Feeding and standstill times set improperly for individual output values.

•

Diminish the amount of air, check the feeding and standstill times (burner output can be set too high )

•

Boiler does not come up to the preset temperature.

Boiler incorrectly matched with the building; Failure of sensors; the temperature sensor of the water returning to the boiler is situated improperly; Boiler output set too low.

•

Check correctness of boiler matching; Check the sensors; Check the location of the return sensor (water circulation shall be present in this place); Check the feeding and standstill times of the burner;

•

Smoke liberates from the boiler. Clogged ﬂue;

Clogged boiler extension duct; Clogged exchanger channels.

•

Open the channels.•

14. Instructions for boiler disposal after expiration of its service life

Due to the fact that components of the boiler are made up of diﬀerent materials, you can transfer them to the collection point of secondary raw materials, ensuring proper utilization of steel, plastics, etc.

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Pellets Fuzzy Logic boiler connection diagram

Zasilanie

instalacja c.o.

(zimna woda)

Spust wody

z instalacji c.o.

Pellets Fuzzy Logic

Zasilanie 230V

Unicontrol Mix

Czujnik temp.

pokojowej 1

CTP-01/CTP-02

Czujnik

bufor

góra

Czujnik

c.w.u.

Pompy

Zimna woda

Czujnik temp.

pokojowej 2

CTP-01/CTP-02

Obwód grzewczy 1

Obwód grzewczy 2 Obwód grzewczy 16

Czujnik temp.

pokojowej n

CTP-01/CTP-02

Hot water

Cold water

DHW

sensor

Pumps

Buﬀer sensor

on top

Buﬀer sensor

at the bottom

room temperature

sensor n

CTP- 01/CTP - 02

room temperature

sensor 2

CTP- 01/CTP - 02

Unicontrol Mix

heating circuit 16heating circuit 2

heating circuit 1

Pellets Fuzzy Logic

spust wody

z instalacji c.o.

outﬂow

zasilanie instalacja c.o.

(cold water)

external

temperature

sensor CTZ - 01

supply

voltage 230 V

boiler

temperature

sensor

Moduły rozszerzeń

UWAGA!!!

Aby zrealizować wszystkie funkcje ukladu należy dokupić dodatkowe moduły.

room temperature

sensor 1

CTP- 01/CTP - 02

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Czujnik

pokojowy

Czujnik c.o.

Ogrzewanie

Pompy

Czujnik c.w.u.

Zimna woda

Zasilanie

instalacja c.o.

(zimna woda)

Zasilanie 230V

Spust wody

z instalacji c.o.

Pellets Fuzzy Logic

Pellets Fuzzy Logic boiler connection diagram

DHW sensor

Hot water

Cold water

Pumps

Pellets Fuzzy Logic

external temperature

sensor CTZ - 01

supply voltage 230 V

spust wody

z instalacji c.o.

outﬂow

zasilanie instalacja c.o.

(cold water)

Heating

Mixing valve

CH sensor

room controller

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Boiler controller service manual.

Pellets Fuzzy Logic

The Second Generation

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Introduction

Pellets Fuzzy Logic The Second Generation boiler controller is a modern microprocessor system, which controls not only the boiler, but also the central heating system in weather and domestic hot water mode.

The device controls the volume of fuel fed through the cyclic operation of the feeder motor and the quantity of air supplied to the combustion process. Thanks to application of solid state relays the blower output is regulated smoothly and the reliability of the control system of the feeder motor is increased many times.

Automatic fuel ignition. Pellets Fuzzy Logic The Second Generation controller allows to automatically ignite the fuel in the retort.

Measurement of ﬂue gas temperature. The controller will allow reading the ﬂue gas temperature, which is essential at the boiler operation with automatic lighting up. Knowing the ﬂue gas temperature is also very helpful in monitoring and control of the boiler.

Weather control provides the maximum thermal comfort, because the heating medium temperature is adjusted as a function of outdoor temperature. Adjustment is done by mixing valve actuator.

Application of the temperature sensor of the heating medium returning from the installation to the boiler reduces water vapor condensation in the boiler and increases its life. Thanks to the advanced algorithm and the possibility of adjusting many parameters, the system can be very ﬂexibly adapted to the needs of the heating system.

The controller is ﬁtted with the output testing function. This function is available in SERVICE MODE and allows you to check the correctness of electrical connections and eﬃciency of executive modules (pumps, blower, feeder, mixing valve actuator) before starting the boiler.

A large alphanumeric display facilitates communication between the device and the user and the operation is very simple. The new intuitive menus in several languages: Polish, English, German, French.

The lambda sensor ensures proper dosage of air into the combustion process, which signiﬁcantly simpliﬁes operation, reduces fuel consumption and improves combustion and thereby reduces the emissions of harmful substances to environment (optional boiler equipment).

15. General

+ 72 hidden pages

Kostrzewa PFL 15, PFL 25, pellets fuzzy logic 2, PFL 50, PFL 40 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual