MCZ Flux HYDRO User Manual

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INSTALLATION GUIDE EN

PELLET STOVE

FLUX HYDRO

PART 1 - REGULATIONS AND ASSEMBLY

Instructions in English

TABLE OF CONTENTS

TABLE OF CONTENTS ...................................................................................... II

INTRODUCTION ............................................................................................. 1

1  WARNINGS AND WARRANTY CONDITIONS .................................................... 2

2  INSTALLATION INSTRUCTIONS .................................................................... 8

3  DRAWINGS AND TECHNICAL CHARACTERISTICS ............................................18

4  UNPACKING ............................................................................................20

5  POSITIONING ..........................................................................................21

6  PANEL REMOVAL ......................................................................................24

7  HYDRAULIC CONNECTION .......................................................................... 36

8  ELECTRICAL CONNECTION .........................................................................39

INTRODUCTION

Dear Customer, our products are designed and manufactured in compliance with European reference Standards for construction products (EN13240 wood-burning stoves, EN14785 pellet-burning appliances, EN13229 replaces/wood-burning inserts, EN 12815 wood-burning cookers), with high quality materials and extensive experience in the transformation processes. The products also meet the essential requirements of Directive 2006/95/EC (Low Voltage) and Directive 2004/108/EC (Electromagnetic Compatibility). To get the best performance, we suggest you read the instructions in this manual carefully. This installation and use manual forms an integral part of the product ensure that the manual is always supplied with the appliance, even if it changes owner. If the manual is lost, you can request another copy from the local technical service or download it directly from the company website. All local regulations, including those regarding national and European regulations, must be observed when the appliance is installed. In Italy, for the installation of systems with biomass below 35KW, refer to ministerial decree D.M. 37/08, and the qualied installation technician with the appropriate requisites must issue a certicate of compliance for the system installed. (By system one means Stove+Chimney+Air inlet).

REVISIONS TO THE PUBLICATION

The content of this manual is strictly technical and the property of MCZ Group Spa. No part of this manual may be translated into other languages and/or adapted and/or reproduced, even in part, in other mechanical or electronic forms, photocopies, recordings or other, without the prior written authorisation from MCZ Group Spa. The company reserves the right to make changes to the product at any time without prior notice. The proprietary company reserves its rights according to the law.

CARE OF THE MANUAL AND HOW TO CONSULT IT

• Take care of this manual and keep it in an easily accessible place.

• Should the manual be misplaced or ruined, request a copy from your retailer or directly from the authorised Technical Assistance Department. It can be downloaded from the company website.

• The “text in bold” must be read with particular care.

• “The “text in italics” draws attention to other sections in this manual or clarications.

• “NOTE” provides the reader with additional information.

SYMBOLS USED IN THE MANUAL

ATTENTION: Read the relative message with care as failure to observe the information provided could result in serious damage to the product and put the persons who use it at risk.

INFORMATION:

failure to comply with these provisions will compromise the use of the product.

OPERATING SEQUENCES:

sequence of buttons to be pressed to access the menus or change settings.

MANUAL

carefully read this manual or the relative instructions.

1 - WARNINGS AND WARRANTY CONDITIONS

SAFETY PRECAUTIONS

• Installation, electrical connection, function test and maintenance must only be carried out by authorised and qualied personnel.

• Install the product in accordance with all local and national legislation and regulations in force in the region or state.

• A bad use or unproper maintainance of the product can bring to a serious risk of explosion in the combustion chamber.

• Only use the fuel recommended by the manufacturer. The product must not be used as an incinerator.

• It is strictly forbidden to use alcohol, petrol, liquid fuel for lanterns, diesel, bioethanol, uids for lighting charcoal or similar liquids to light/rekindle the ame in these devices. Keep these ammable liquids well away from the appliance when in use.

• Do not put any fuel other than wood pellets in the hopper.

• The instructions provided in this manual must always be complied with to ensure the product and any electronic appliances connected to it are used correctly and accidents are prevented.

• This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision.

• The user, or whoever is operating the product, must read and fully understand the contents of this installation guide before performing any operation. Errors or incorrect settings can cause hazardous conditions and/or poor operation.

• Do not climb on or lean on the product.

• Do not put linen on the product to dry. Any drying racks or similar objects must be kept at a safe distance from the product. Fire hazard.

• All liability for improper use of the product is entirely borne by the user and relieves the Manufacturer from any civil and criminal liability.

1 - WARNINGS AND WARRANTY CONDITIONS

• Any type of tampering or unauthorised replacement with non-original spare parts could be hazardous for the operator’s safety and relieves the company from any civil and criminal liability.

• Many of the surfaces of the product get very hot (door, handle, glass, smoke extraction pipes, etc.). Avoid coming into contact with these parts

without adequate protective clothing or suitable means, such as gloves with thermal protection or “cold handle” operating systems.

• It is forbidden to operate the product with the door open or the glass broken.

• The doors/covers on the appliance must remain closed when it is not used.

• The product must be powered by an electrical system that is equipped with an eective earthing device.

• Switch the product o in the event of a fault or malfunction.

• Accumulated unburned pellets in the burner after each “failed start-up” must be removed before lighting again. Check that the burner is clean and positioned properly before lighting again.

• Shut the stove down in the event of a breakdown or bad running and contact the engineer immediately.

• Pellets must not be fed manually into the burner – this wrong behaviour can generate an abnormal amount of unburned gas, with a risk of explosion in the chamber.

• Accumulated unburnt pellets in the burner after a failed ignitions must be removed before lighting.

• Failure too clean and maintain the brazier can result in improper running and explosions within the stove. Make sure you remove and clear the holes in the brazier and any loose encrustations every time you empty the ash from the stove or every time you have a failed ignition.Make sure that the holes in the brazier are never reduced in size as this will aect the safe performance of the stove if not maintained.

• Do not wash the product with water. The water could get inside the unit and damage the electrical insulation and cause electric shocks.

1 - WARNINGS AND WARRANTY CONDITIONS

• A carbon monoxide alarm must be tted in the room where the appliance is sited Refer too ADJ part 2.34 through too 2.36 page 41 (ONLY FOR UK).

• If there is a re in the ue pipe, extinguish the stove, disconnect it from the power supply and never open the door. Then contact the competent authorities.

• Do not light the stove with ammable materials if the ignition system breaks down.

• Do not stand for a long time in front of the product in operation. Do not overheat the room you are in and where the product is installed. This could cause injuries and health problems.

• Install the product in a location that does not present a re hazard and is equipped with power and air supplies and smoke extractors.

• In the event of re in the chimney, turn o the device, disconnect it from the mains electricity and do not open the hatch. Then contact the competent authorities.

• The product and the cladding must be stored in a dry place and must not be exposed to weathering.

• It is recommended not to remove the feet that support the product in order to guarantee adequate insulation, especially if the ooring is made of ammable materials.

• In the event of a malfunction with the ignition system, do not force it to light by using ammable materials.

• Special maintenance must only be performed by authorised and qualied personnel.

• Assess the static conditions of the surface on which the weight of the product will rest and provide suitable insulation if it is made of ammable material (e.g. wood, tted carpet or plastic).

• Live electrical parts: only power the product after completing assembly.

• Disconnect the product from the 230V power supply before performing any maintenance operation.

• IF ANY SMOKE SPILLAGE IS SEEN WITHIN THE ROOM OR THE APPLIANCE SUFFERS FROM AN EXPLOSIVE IGNITION PLEASE TURN OFF THE APPLIANCE, VENTILATE THE ROOM AND CONTACT THE INSTALLER/

SERVICE ENGINEER IMMEDIATELY.

1 - WARNINGS AND WARRANTY CONDITIONS

INFORMATION

• In case of any problems, get in touch with your dealer, or a qualied engineer authorised by MCZ, and if a repair is necessary, insist on the use of original spare parts.

• Use only the fuel recommended by MCZ (for Italy pellets with a diameter of 6 mm and for other European countries with a diameter of 6-8 mm) and provided only with an automatic supply system.

• Periodically check and clean the smoke outlet ducts (connection to the ue pipe).

• Accumulated unburnt pellets in the burner after repeated failed ignitions must be removed before lighting.

• The pellet stove is not a cooking appliance.

• Always keep the cover of the fuel hopper closed.

• Keep this instruction manual carefully because it must stay with the stove throughout its working life. If the stove is sold or transferred to another user, always make sure that the booklet goes with the product.

• If it gets lost, ask MCZ or your authorised dealer for another copy.

INTENDED USE

The product only works with wood pellets and must be installed indoors.

WARRANTY CONDITIONS

The company guarantees the product, with the exception of elements subject to normal wear (listed on the following page), for a period of 2 (two) years from the date of purchase attested by:

• a document to serve as proof of purchase (invoice and/or receipt) that shows the name of the vendor and the date on which the purchase was made;

• forwarding of the completed certicate of guarantee within 8 days of purchase.

Furthermore, the product must be installed and started by specialised personnel who must, where provided, issue a declaration of conformity of the plant and of the proper functioning of the product, for the warranty to be valid and eective. We recommend functionally testing the product before completion with the relevant nishes, where provided (claddings, painting of walls, etc.). Installations not meeting the current standards, improper use and lack of maintenance as expected by the manufacturer, void the product warranty. The guarantee is valid on the condition that the instructions and warnings contained in the use and maintenance manual are observed, and therefore the product is used correctly. The replacement of the entire system or the repair of one of its components does not extend the guarantee period, and the original expiry date remains unchanged. The guarantee covers the replacement or free repair of parts recognised as being faulty at source due to manufacturing defects.

In order to activate the product warranty the commissioning document which is supplied with the appliance and also is available as a download from the Specue website must be lled in correctlty and returned within 14 days (ONLY FOR UK).

1 - WARNINGS AND WARRANTY CONDITIONS

EXCLUSIONS

The guarantee does not cover malfunctions and/or damage to the appliance that arise due to the following causes:

• Damage caused during transportation or relocation

• all parts that develop faults due to negligence or improper use, incorrect maintenance, installation that does not comply with the manufacturer’s instructions (always refer to the installation and use manual provided with the appliance)

• incorrect dimensioning with regards to the use or faults in the installation or failure to adopt the necessary devices to guarantee proper execution

• improper overheating of the equipment, use of fuels not conforming to the types and quantities indicated in the instructions provided

• further damage caused by incorrect user interventions in an attempt to x the initial fault

• worsening of the damage due to the continued use of the equipment by the user, once the defect has been noticed

• in the presence of a boiler, any corrosions, incrustations or breaks caused by water ow, condensation, hardness or acidity of the water, improperly performed descaling treatments, lack of water, mud or limescale deposits

• ineciency of chimneys, ues or parts of the plant aecting the equipment

• damage caused by tampering with the appliance, atmospheric agents, natural disasters, vandalism, electrical discharges, res, faults in the electric and/or hydraulic system.

• Failure to have the stove cleaned on an annual basis by an authorised technician or qualied personnel will result in the loss of the warranty.

Also excluded from this guarantee are:

• parts subject to normal wear such as gaskets, glass, claddings and cast iron grids, painted, chrome-plated or gilded parts, handles and electric cables, bulbs, indicator lights, knobs, all parts which can be removed from the hearth.

• Variations in colour of the painted or ceramic/serpentine parts and craquelure ceramics as they are natural characteristics of the material and product use.

• masonry work

• plant parts (if present) not supplied by the manufacturer

Any technical interventions on the product to eliminate the above-said defects and consequent damages must be agreed upon with the Technical Assistance Centre, who reserves the right to accept the relative appointment or not. However, said interventions will not be carried out under warranty but as technical assistance to be granted at part of any eventual and specic agreed conditions and in accordance with the fee in force for the work to be carried out. The user will also be charged for any costs incurred to remedy the incorrect technical interventions, tampering or damage to the appliance, not attributable to original faults. Save for the legal or regulatory limits, the guarantee does not cover the containment of atmospheric and acoustic pollution.

The company declines all liability for any damage which may be caused, directly or indirectly, to persons, animals or objects as a consequence of non compliance with any prescription specied in the manual, especially warnings regarding installation, use and maintenance of the appliance.

1 - WARNINGS AND WARRANTY CONDITIONS

SPARE PARTS

In the event of a malfunction, consult the retailer who will forward the call to the Technical Assistance Service.

Use only original spare parts. The retailer or service centre can provide all necessary information regarding spare parts. We do not recommend waiting for the parts to be worn before having them replaced. It is important to perform regular maintenance.

The company declines all liability if the product and any other accessory is used improperly or modied without authorisation. All parts must be replaced with original spare parts.

WARNINGS FOR THE CORRECT DISPOSAL OF THE PRODUCT.

The owner is the sole party responsible for demolishing and disposing of the product. This must be performed in compliance with laws related to safety and environmental protection in force in his/her country. At the end of its working life, the product must not be disposed of as urban waste. It must be taken to a special dierentiated waste collection centre set up by the local authorities or to a retailer that provides this service. Separating and recycling prevents potential negative eects on the environment and health (often caused by inappropriately disposing of product parts). It also allows materials to be recovered in order to obtain signicant savings in energy and resources.

2 - INSTALLATION INSTRUCTIONS

RULES FOR INSTALLATION

The product in question is a stove that uses wood pellets. Below is a list of the European regulations regarding the installation of the product:

EN 12828 Heating systems design. IEC 64-8 Electrical systems with rated voltage not exceeding 1000 V AC and 1500 V DC. EN 1443 General chimney regulation EN 1856-1 metal smoke ducts EN 1856-2 metal smoke extraction channels EN 1457 chimneys - Interior terracotta / ceramic ues EN 13384-1 Chimneys - Thermal and dynamic uid calculation methods - Part 1: Chimneys connected to a single appliance

Below are some applicable regulations for Italy: UNI 10683:2012 Heat generators fuelled by wood or other solid bio-fuels - Test, installation, control and maintenance (for thermochemical power at the rebox lower than 35kW)

UNI/TS 11278 general technical regulation for the choice of smoke duct/ue UNI 10847:2000 Smoke extractor systems for liquid and solid fuelled generators - Maintenance and control - Guidelines and procedures UNI 8065 water treatment in civil plants. UNI 9182 Hot and cold (sanitary) water supply and distribution systems.

Installation must be carried out with reference to the diagram of the heating system prepared in accordance with the standards and local recommendations in force:

In any case, respect: For the heating system Local requirements concerning the chimney connection. Local requirements for re-ghting standards. For electrical parts - EN 60335 ''Safety of electrical household appliances and similar'' Part 1 - General requirements Part 2 - Special regulations for appliances with gas, gas oil and solid fuel burners with electrical connections.

2 - INSTALLATION INSTRUCTIONS

The instructions in this chapter refer explicitly to the Italian installation regulation UNI 10683. In any case, always observe the domestic regulations in force.

PELLETS

Wood pellets are manufactured by hot-extruding compressed sawdust which is produced during the working of natural dried wood. The compactness of the material is guaranteed by the lignin contained in the wood itself and allows pellets to be produced without glue or binders. The market oers dierent types of pellets with characteristics that vary according to the wood mixtures used. The most common diameter on the market is 6 mm (although 8 mm diameter is available too) with a length, on average, of between 3 and 40 mm. A good quality pellet has a density of between 600 and 750 or more kg/metres cubed and a water content that accounts for 5 to 8% of its weight. Pellets have technical advantages besides being an ecological fuel, as the wood residue is used completely, thereby achieving cleaner combustion than that of fossil fuels. Good-quality wood has a caloric value of 4.4 kW/kg (15% moisture, after about 18 months of seasoning), whereas that of pellets is 4.9 kW/kg. To ensure good combustion, the pellets must be stored in a dry place and protected from dirt. Pellets are usually supplied in 15 kg bags, therefore, storing them is very convenient.

15 Kg BAG OF FUEL

Good quality pellets guarantee good combustion, thereby decreasing harmful emissions into the atmosphere.

The poorer the quality of the fuel, the more often the internal parts of the brazier and combustion chamber must be cleaned.

The main quality certications for pellets currently available on the European market guarantee that the fuel complies with class A1/A2 according to EN14961-2. These certications include, for example, ENPlus, DINplus, Ö-Norm M7135, and in particular, guarantee the following characteristics:

• caloric value: 4.6 ÷ 5.3 kWh/kg.

• Moisture content: ≤ 10% of the weight.

• Percentage of ash: max 1.5% of the weight.

• Diameter: 6±1/8±1 mm.

• Length: 3÷40 mm.

• Content: 100% untreated wood without the addition of binding substances (max 5% bark).

• Packaging: in sacks made from ecologically compatible or biologically decomposing material.

The company strongly recommends using certied fuel for its products (ENplus, DINplus, Ö-Norm M7135). Poor quality pellets or others that do not comply with the characteristics specied previously may compromise the operation of your product and can therefore render the guarantee and product liability invalid.

2 - INSTALLATION INSTRUCTIONS

FOREWORD

The installation position must be chosen according to the room, to the smoke extraction system, to the chimney ue. Check with local authorities whether there are any restrictive regulations in force regarding the combustion air inlet, the smoke outlet system, the ue or the chimney cap. The manufacturer declines all responsibility in the event of installations that do not comply with the laws in force, incorrect room air exchange, electrical connection non-compliant with the standards and inappropriate use of the appliance. The installation must be carried out by a qualied technician, who must issue a declaration of conformity of the system to the purchaser and will assume full responsibility for nal installation and consequent good operation of the product. In particular one must ensure that:

• there is a suitable combustion air inlet and smoke outlet in compliance with the type of product installed

• other stoves or devices installed do not cause depression in the room where the product is installed (for sealed appliances only, a maximum of 15 Pa of depression in the room is allowed)

• when the product is switched on there is no reux of smoke in the room

• fumes extraction takes place in total safety (sizing, smoke seal, distances from ammable materials..).

We especially recommend to check the data tags of the ue for the safety distances that must be observed in presence of combustible materials and the type of insulating material to be used. These indications must be followed strictly to prevent serious harm to people and the integrity of the home. The installation of the appliance must ensure easy access to clean the appliance itself, the smoke outlet pipes and the ue. It is forbidden to install the stove in rooms with a re hazard. Installation in studio ats, bedrooms and bathrooms is only allowed with sealed or closed appliances equipped with suitable combustion air ducting directly outside. Always maintain adequate distance and protection in order to prevent the product from coming into contact with water.

In the event there are several appliances installed, the external air inlet must be sized accordingly.

MINIMUM DISTANCES

It is recommended to install the stove detached from any walls and/or furniture, with a minimum clearance to allow eective aeration of the appliance and a good distribution of heat in the room.Observe distances from ammable or heat-sensitive objects (sofas, furniture, wood panelling, etc..) as specied below. The front distance from ammable materials must be at least as set out in the product’s technical data table. If particularly delicate objects are present, such as furniture, curtains or sofas, increase the stove clearance accordingly.

If the oor is made of wood, it is recommended to t a oor protection sheet in compliance with the Standards in force in the country of installation.

Distance from ammable material (see p.18)

FLUX HYDRO

side = 2 cm (MIN. 30 cm to open the door)

If the oor is made of combustible material, it is recommended to use protection made of non-combustible material (steel, glass...) that also protects the front from falling combusted material during cleaning operations. The appliance must be installed on a oor with adequate load capacity. If the existing construction does not meet this requirement, one must take appropriate measures (for example a load distribution plate).

back = 1 cm

2 - INSTALLATION INSTRUCTIONS

FOREWORD

This chapter on the Smoke Flue has been produced in reference to the prescriptions of European regulations (EN13384 - EN1443 - EN1856

- EN1457).

The chapter provides indications for installing an ecient and correct smoke ue but is under no circumstances to substitute the regulations in force, which the qualied technician must be in possession of. Check with local authorities whether there are any restrictive regulations in force regarding the intake of air for combustion, the smoke extraction system, the ue or the chimney. The company declines all liability relating to the poor functioning of the boiler if this is due to the use of an insuciently sized ue in violation of regulations in force.

SMOKE FLUE

The ue or chimney is of great importance for the proper operation of a solid fuel-burning heating appliance with natural draught, as modern heating appliances have high eciency with cooler ue gasses and consequently less draught, it is therefore essential that the ue is built up to standard and always kept in perfect working order. A ue that serves a pellet/wood fuelled appliance must be at least category T400 (or greater if the appliance requires, and resistant to soot res. Smoke must be extracted through a single ue made of insulated steel (A) or an existing ue that complies with the intended use (B). A simple air shaft in cement must be suitably lined. In both solutions there must be an inspection cap (AT) and/or inspection hatch (AP)

- FIG.1.

It is prohibited to connect more than one wood/pellet or any other type of appliance (vent cowling...) to the same ue.

The stove must be connected to a ue pipe or an internal or external vertical duct conforming to EN 1856-1-2 to suit the appliance and types of fuels to be burnt – refer to detailed guidance in sections 2, 3 and 4 in ADJ (ONLY FOR UK).

min.3,5 metri

(A)

FIGURE 1  SMOKE FLUE

(B)

2 - INSTALLATION INSTRUCTIONS

TECHNICAL CHARACTERISTICS

Have the eciency of the ue checked by an authorised technician. The ue must be sealed against ue gasses, in a vertical direction without narrowing, be made with materials impermeable to smoke, condensation, thermally insulated and suitable to resist normal mechanical stress over time (we recommend replaces made of A/316 or refractory material with insulated round section double chamber). Be suitably insulated externally to avoid condensation and reduce smoke cooling. It should be separated from combustible or ammable materials with an air gap or insulating materials: check the distance specied by the manufacturer of the replace according to EN1443. The chimney opening must be in the same room as the appliance, or at most in the adjoining room, and have a soot and condensation collection chamber beneath the opening, and be accessible via a watertight metal hatch.

FLAT ROOF

A = 0.50 metres B = DISTANCE > 2 metres

C = DISTANCE < 2 metres

ROOF AT 15°

15°

D = O.50 metres E = TECHNICAL VOLUME

FIGURE 2

A = MIN. 1.00 metres B = DISTANCE > 1.85 metres C = DISTANCE < 1.85 metres D = 0.50 metres above highest point E = 0.50 metres F = REFLUX ZONE

FIGURE 3

ROOF AT 30°

A = MIN. 1.30 metres B = DISTANCE > 1.50 metres C = DISTANCE < 1.50 metres D = 0.50 metres ABOVE

HIGHEST POINT E = 0.80 metres F = REFLUX ZONE

30°

FIGURE 4

2 - INSTALLATION INSTRUCTIONS

ROOF AT 60° ROOF AT 45°

A = MIN. 2.60 metres B = DISTANCE > 1.20 metres C = DISTANCE < 1.20 metres D = 0.50 metres ABOVE HIGHEST POINT E = 2.10 metres F = REFLUX ZONE

60°

FIGURE 5 FIGURE 6

A = MIN. 2.00 metres

45°

B = DISTANCE > 1.30 metres C = DISTANCE < 1.30 metres D = 0.50 metres ABOVE HIGHEST POINT E = 1.50 metres F = REFLUX ZONE

DIMENSIONING

The drop in pressure (draft) of a ue depends on its height. Check the drop in pressure with the values indicated in the technical characteristics. The minimum height of the chimney is 3.5 meters.

The interior cross-section of the ue can be circular (best variation), square or rectangular (the ratio between the interior sides must be ≤1.5) with the sides joined with a minimum radius of 20 mm. The dimension of the cross-section must be minimum Ø100mm.

The cross sections/lengths of chimneys must be correctly sized in accordance with the general method of calculation of UNI EN13384-1 or other proven eciency methods.

Below is a list of some ues available on the market:

Steel chimney AISI 316 with double chamber insulated with ceramic bre or equivalent resistant up to 400°C.

Refractory chimney with double insulated chamber and external lightweight concrete cladding with cellular material such as clay.

Traditional square-section clay chimney with insulating empty inserts.

Avoid products with an internal rectangular section where the larger side is 1.5 times the smaller side (e.g. 20x40 or 15x30).

EXCELLENT GOOD POOR VERY POOR

2 - INSTALLATION INSTRUCTIONS

MAINTENANCE

The ue must be kept clean, since the deposit of soot or unburned oils reduces the cross-section reducing the draft and thus compromising the ecient functioning of the heater and, if large build-ups accumulate, can catch re. The ue and chimney must be cleaned and checked by a qualied chimney sweep at least once a year. Once the maintenance has been performed, request a written declaration that the device is safe. Failure to clean the system jeopardises the safety.

CHIMNEY

The chimney is a crucial element for the heating appliance to work properly: we recommend a wind proof chimney (A), see Figure 7.

The area of the opening for smoke extraction must be at least double the cross-section of the smoke duct/ue system, and arranged so that smoke extraction is ensured even in strong wind. The chimney must prevent rain, snow or animals from entering the chimney. The height of outow into the atmosphere must be beyond the reux zone created by the shape of the roof or any obstacles near the outlet (see Figures 2-3-4-5-6).

CHIMNEY COMPONENTS

FIGURE 7

KE Y: (1) CHIMNEY (2) REFLUX CHANNEL (3) SMOKE DUCT (4) THERMAL INSULATION (5) OUTSIDE WALL (6) CHIMNEY CONNECTION (7) SMOKE CHANNEL (8) HEAT GENERATOR (9) INSPECTION ACCESS PANEL

FIGURE 8

2 - INSTALLATION INSTRUCTIONS

EXTERNAL AIR INLET

It is mandatory to provide an adequate external air intake that supplies the combustion air required for the product to work properly. The ow of air between the outside and the installation room may be direct, through an inlet in an external wall of the room; or indirect, via air intake from adjoining rooms and connecting permanently with the installation room (see Figure 9 b). Adjoining areas may not include sleeping areas, garages or general areas with a re hazard. During installation one must check the minimum clearances required for air intake from outside. Take into account the presence of doors and windows that could interfere with the proper ow of air to the stove (see diagram below). The air intake must have a minimum total net area of 80 cm2: the surface must be increased accordingly if within the room there are other active generators (for example: electric fan for stale air extraction, kitchen hood, other stoves, etc...), which could cause cause depression in the room. One must verify that, with all the equipment on, the pressure drop between the room and the outside does not exceed a value of 4 Pa. If necessary increase the intake section of the air inlet, which must be made at oor level and always protected with a bird-proof outer protection grid and in such a way that it cannot be obstructed by any object.

B B

FIGURE 9 A  DIRECTLY FROM OUTSIDE

MIN.1,5 m MIN.1,5 m

MIN.0,3 m

MIN.1,5 m

FIGURE 9 B  INDIRECTLY FROM THE ADJACENT ROOM

A=AIR INLET B=ROOM TO BE VENTILATED C=INCREASE OF THE GAP UNDER THE DOOR

It is possible to connect the air required for combustion directly to the outside air inlet, with a pipe of at least Ø50mm, with maximum length of 3linear metres; each pipe bend shall be considered equivalent to a linear metre. To attach the pipe see the back of the stove. For stoves installed in studio ats, bedrooms and bathrooms (where allowed), it is mandatory to connect the combustion air outside. In particular for sealed stoves the connection must be sealed in order not to compromise the overall sealed characteristic of the system.

FIGURE 10

2 - INSTALLATION INSTRUCTIONS

DISTANCE (metres) The air inlet must be at a distance of:

1.5 m UNDER Windows, doors, smoke outlets, cavities, ....

1.5 m HORIZONTALLY Windows, doors, smoke outlets, cavities, ....

0.3 m ABOVE Windows, doors, smoke outlets, cavities, ....

1.5 m AWAY from smoke outlet

CONNECTION TO FLUE

The connection between the ue and the appliance must be via a smoke duct that conforms with EN 1856-2. The connecting section must extend no more than 4 m horizontally, with a maximum incline of 3% and containing a maximum of 3 90% bends (accessible for inspection - do not count the T joint at the appliance outlet). The diameter of the smoke duct must be equal to or greater than that of the appliance outlet (Ø 80 mm).

TYPE OF DEVICE SMOKE DUCT

Minimum vertical length 1.5 metres

Maximum length (with 1 accessible 90° bend)

Maximum length (with 3 accessible 90° bends)

Maximum number of accessible 90° bends 3

Horizontal sections (minimum incline 3%)

6.5 metres

4.5 metres

4 metres

Use a smoke duct according to the regulations in force in the country of installation and verify that it is compatible with the product and installation characteristics. The temperature class of the smoke duct must exceed operating temperatures of the appliance. It is prohibited to connect more than one appliance to the same smoke duct, or the discharge from overhead cowling. It is prohibited to extract the products of combustion directly through the wall, whether into indoor spaces or outdoors. Should there be ammable or heat-sensitive structures, the smoke duct must respect the safety distances specied in the data plate.

SUPPLEMENTARY ISTRUCTIONS ONLY FOR UK

FOR CONNECTION TO THE FLUE PIPE, NOT MORE THAN 150mm OF HORIZONTAL PIPE MUST BE USED AND NOT MORE THAN 4 x 45° bends MUST BE USED. I accordance with UK Building Regulations .

All exterior ue or ue used internaly above 1.8m should be twin wall insulated pipe installed in accordance with ADJ reference page 23 section 1.31 and 1.32 and 1.33 & Hetas regulations.

The external uepipe must have internal dimensions of a minimum of 150mm, and maximum 180mm.

Check with suitable instruments that there is a minimum draught of 5 Pa. on low re and 10pa on high re. The ue must always run under negative pressure and a cold ue pull of – 2>3 pascals must be secured.

2 - INSTALLATION INSTRUCTIONS

EXAMPLES OF CORRECT INSTALLATION

1. Installation of Ø150mm ue with hole for the passage of the tube increased by: minimum 100 mm around the tube if next to non ammable parts such as cement, brick, etc.; or minimum 300 mm around the tube (or as prescribed by

data tags) if next to ammable parts such as wood etc. In both cases, install suitable insulation between the ue

and the ceiling. Always check and respect the data tags on the ue, in particular the minimum safety distances from combustible materials. The previous rules also apply for holes made in walls.

2. Old ue, minimum pipe Ø100mm with the inclusion of an external access door for chimney cleaning.

3. External ue made of insulated stainless steel pipes, i.e. with double walls minimum Ø100mm: all securely mounted on the wall. With wind-proof chimney. See g. 7 type A.

4. Ducting system using T joints that allow easy access for cleaning without having to remove the tubes

FIGURE 11

U = INSULATING V = ANY REDUCTION FROM 100 TO 80 MM I = INSPECTION CAP

S = INSPECTION ACCESS PANEL

P = AIR INLET T = T JOINT WITH INSPECTION CAP

A = MINIMUM 40 MM B = MAXIMUM 4 M C = MINIMUM 3° D = MINIMUM 400 MM E = HOLE DIAMETER F = SEE FIG.23456

3 - DRAWINGS AND TECHNICAL CHARACTERISTICS

DRAWINGS AND CHARACTERISTICS

FLUX HYDRO DIMENSIONS (dimensions in mm)

279

973

989

1119

279

8 1111

ø80

357

ø48

709 197

3 - DRAWINGS AND TECHNICAL CHARACTERISTICS

TECHNICAL CHARACTERISTICS FLUX HYDRO

Nominal output power

Nominal output power (H2O)

Minimum output power

Minimum output power (H2O)

Eciency at Max

Eciency at Min

Temperature of exhaust smoke at Max

Temperature of exhaust smoke at Min

Particles/OGC/Nox (13%O2)

CO at 13% O2 at Min and at Max

CO2 at Min and at Max

Maximum water pressure 2,5 bar - 250 kPa Recommended draught at Max power***

Recommended draught at Min power

Smoke mass 9,8 g/sec

Hopper capacity 33 litres

Type of pellet fuel Pellet diameter 6-8 mm and size 3-40 mm

Pellet hourly consumption Min ~ 1 kg/h* - Max ~ 3,3 kg/h*

Autonomy At min ~ 21 h* - At max ~ 7 h* Heatable volume m

Combustion air inlet  50 mm

Smoke outlet  80 mm

Air intlet 80 cm

Rated electrical power (EN 60335-1) 80 W (Max 420 W )

Supply voltage and frequency 230 Volt / 50 Hz

Net weight 180 kg

Weight with packaging 190 kg

Distance from ammable material (back) 10 mm

Distance from ammable material (side) 20 mm

16 kW (13760 kcal/h)

13,5 kW (11610 kcal/h)

4,5 kW (3870 kcal/h)

3,4 kW (2924 kcal/h)

95,6%

97,1%

90°C

50°C

14 mg/Nm3 - 2 mg/Nm

3 -

107 mg/Nm

0,046 - 0,014%

7,0 - 11,1%

0,10 mbar - 10 Pa***

0,02 mbar - 2 Pa

344/40 – 393/35 – 459/30 **

* Data that may vary depending on the type of pellets used ** Volume that can be heated, according to the power requirement per m3 (respectively 40-35-30 Kcal/h per m3) ***Value recommended by the manufacturer (non-binding) for optimal product operation

Tested according to EN 14785 in accordance with European regulation for Construction Products (UE 305/2011)

4 - UNPACKING

PREPARATION AND UNPACKING

The FLUX stove is delivered complete with all its electrical, mechanical, and hydraulic components after it has been tested in the factory: Remove the cardboard, supports, and polystyrene that secure the stove to the pallet. At this point, open the two side panels and remove the two brackets holding the stove. To remove the brackets, undo the two "t" screws between the bracket and the pallet and the two "u" screws between the bracket and the stove (g.1).

Figure 1 - Packaging

Attention! Above the stove's packing structure there is a cardboard package containing the lateral sides (2 pieces) and front parts (3 pieces).

Install the stove in the chosen area, making sure it complies with the requirements. The stove body or unit must always be kept in a vertical position when handled, and handled using carts only. Pay particular attention to the door and its glass, protecting them from mechanical knocks that would compromise their integrity.

The product must always be moved with care. If possible, unwrap the stove near the chosen area of installation. The packaging materials are neither toxic nor harmful, and therefore no particular disposal measures are required. The product, as indicated in gure 1 consists of a single packaged unit. After removing all the packaging, check that the stove is complete and not damaged. If in doubt, contact the retailer. The following documents are provided in the package:

• Plant booklet

• Instruction booklet

• Annex G - Technical test report for thermal plant of less than 35 kW.

• Guarantee

5 - POSITIONING

REQUIREMENTS FOR INSTALLATION OF THE PLANT - POSITIONING

The most important thing to do before installing the stove is to choose a suitable place that meets the minimum requirements for installation.

• the minimum clearance in front of the product to allow suitable access for cleaning, maintenance, etc. must be 400 mm;

• the minimum permissible distance between the back of the product and a wall must be 10 mm;

• the minimum distance between the top of the product and the ceiling must be 600 mm to ensure easy access to the heat exchanger for the purpose of cleaning and maintenance (e.g. for removing ash);

• the minimum clearance between the product and the wall (side) must be 300 mm.

MINIMUM REQUIREMENTS

MIN. 300

MIN.

1500

1800

MIN. 300

MIN.

400

4 - UNPACKING

FOOT ADJUSTMENT

The underside of the stove is tted with adjustable feet.

Use a spanner to unscrew the feet to adjust the length and make the structure stable.

TURN THE FEET CLOCKWISE TO LOWER THE PRODUCT. TURN THE FEET ANTI-CLOCKWISE TO RAISE THE PRODUCT.

4 - UNPACKING

CONNECTION OF THE SMOKE OUTLET PIPE

You can choose whether to extract the smoke from the rear or the top of the product. The product arrives set up with the outlet at the back, if you wish to connect the outlet to the top, proceed as follows:

• Remove cap "H" and place it on the rear smoke outlet

• Insert the tube "P" until it engages with the smoke joint.

REAR SMOKE OUTLET FITTING UPPER SMOKE OUTLET

6 - PANEL REMOVAL

COVERING KIT

The covering of the stove is composed of:

• lateral side - 2 pieces

• right front side - 1 piece

• left front side - 1 piece

• central side - 1 piece

• screws

6 - PANEL REMOVAL

FRONT LATERAL PANELS B-D

The rst thing to do is to x the magnets, which will be then required to close the two lateral panels.

• position magnet “f ” on the lower side and at the top

• screw the self-tapping screw “g” onto the magnet “f ”/panel “B” -“D”

• place the supplied felt pad “e” onto the screw “g” (to avoid vibrations and noise during operation of the stove).

In order to easily distinguish the right panel from the left one, and understand where to x the magnets, the tongue “h” must be placed outwards of the structure.

Attention!! Do not apply pressure to close the self-tapping screws “g” onto the magnet “f ” as this may cause the said magnet to break.

f g

6 - PANEL REMOVAL

Place panels “B” and “D” making sure that wire “x” of the panel is aligned with wire “y” of the top of the structure.Ax panels “B” and “D” with the three screws “i-l-m”. Before applying the panels also on the inside towards the hearth, place the central panel “C” to adjust the alignment of the panels B-C-D.

6 - PANEL REMOVAL

At this point, place the central panel “C” ensuring that slot “n” enters the panel at joint “o” of the structure. Verify the alignment between the three panels “B-C-D” If the alignment is satisfactory proceed with xing the side panels B and D onto the lower part of the internal section of the central panel “C”, otherwise proceed with the adjustment.

6 - PANEL REMOVAL

Adjustment of the central panel “C”.

Loosen the three screws “p” and lower or raise the stopper “q” where the central panel “C” is to be applied. Once the correct alignment has been found, denitively apply the side panels “B” and “D”.

6 - PANEL REMOVAL

Applying side panels

Panel “D” (and the left one “B”) were previously axed to the structure from the outside by way of screws l-m-n; now you must complete the application using screw “s” on the internal part towards the hearth.

6 - PANEL REMOVAL

Applying the central panel

Both side front panels (“B” and “D”) having been xed into place, you may proceed with applying panel “C”.Open the door of the stove, insert the panel in its place (as previously explained) and x it to the structure by means of two screws “s”.

6 - PANEL REMOVAL

Applying side panels “A”

In order to install the side panels “A”, proceed as follows:

• Lift the top “W” or “Z”

• Insert panel “A” in track “t”

The side panels close by means of a magnet (previously applied to panels “B” and “D”; to open them, simply exert slight traction.

6 - PANEL REMOVAL

Complete top "T"

Remove the three screws "u", loosen the two screws "k", the three screws “j”, and the three screws "y" until the top "T" can come out of the slot at the top.

Attention! This operation must be carried out without the covering panels of the stove and with the two side panels open.

OPENING/CLOSING THE DOOR OF THE FIREBOX

ATTENTION! The door must be securely closed for the stove to work correctly!

To open the door, insert a cold hand into the hole in the handle, lift and pull towards you.

6 - PANEL REMOVAL

ACCESS TO THE ELECTRONIC BOARD

To access the electronic board you must open the side panel, remove the two screws "p" and lower the window.

If it is necessary to connect external cables to the appliance, feed the cables through the hole "F" on the back and fasten the cables "C" to the board with the window lowered to avoid the cables being moved the next time the window is opened.

6 - PANEL REMOVAL

LOADING THE PELLETS

The pellets can be loaded either manually or automatically. The tank can contain up to 57 litres or 40 kg of pellets.

Manual Loading:

• Open the top panel of the stove and pour in the pellets.

Automatic Loading (with remote tank of 100/200 or 400 kg - optional - see accessories):

• At the back of the stove, remove the knockout hole "U" and attach the duct "V" for the additional tank (optional - see accessories). Then connect the additional tank.

Never remove the protective grate from inside the tank. When loading pellets, keep the bag from coming into contact with hot surfaces.

6 - PANEL REMOVAL

SAFETY PROCEDURE TO FOLLOW IF ANY SMOKE SPILLAGE IS SEEN WITHIN THE ROOM OR THE APPLIANCE SUFFERS FROM AN EXPLOSIVE IGNITION PLEASE TURN OFF THE APPLIANCE, VENTILATE THE ROOM AND CONTACT THE INSTALLER/ SERVICE ENGINEER IMIDIATLE Y.

User Training

In ALL cases the installation and commissioning engineer MUST carry out a thorough handover of the appliance to the homeowner / end user. The following elements should be covered to the satisfaction of the end user. Failure to do this may result in unsafe use of the appliance:

• Explanation of the appliance and how it works

• Necessity to maintain ventilation to the appliance and the issues that may arise otherwise

• Fuel useage and supply

• How to light the appliance safely

• What to do in the event of failed ignitions

• What to do in the event of alarms (in particular those generated when the appliance runs out of fuel)

• How to maintain the appliance correctly and the importance of carrying out these tasks each month

• It is good practise to agree a date for the srt annual service

• Explain the importance of the CO alarm in accordance with approved document J of the building regs (ONLY FOR UK)

• Explain the need for the ue draft stabiliser and its position within the ue system (ONLY FOR UK)

• Discuss the use of secondary heating systems if applicable

• Explain how the remote control or room stats operate and their optimal positioning

• Explain the need for the appliance data plate in accordance with approved document J of the building regulations (ONLY FOR UK)

The commissioning process and paperwork should also be explained to the homeowner. A copy of the base settings on the commissioning paperwork should also be left with the appliance (ONLY FOR UK).

7 - HYDRAULIC CONNECTION

HYDRAULIC CONNECTION

7982

SAFETY VALVE 3 bar – 1/2” F

Heating water supply 3/4”M

SYSTEM EMPTYING 1/2”F

HEATING WATER RETURN 3/4” M

559

172

IMPORTANT!!! CLEAN THE ENTIRE SYSTEM BEFORE CONNECTING THE STOVE, IN ORDER TO REMOVE ALL RESIDUE AND DEPOSITS. Always install shutters in the system leading to the stove so as to disconnect it from the hydraulic system in order to carry out routine and/or special maintenance. Connect the stove using exible pipes.

7 - HYDRAULIC CONNECTION

CONNECTING THE SYSTEM

Make the connections to the corresponding ttings shown in the diagram on the previous page. Make sure the pipes are not placed under tension or undersized.

IT IS STRONGLY RECOMMENDED TO WASH THE ENTIRE SYSTEM BEFORE CONNECTING THE STOVE IN ORDER TO GET RID OF RESIDUES AND DEPOSITS. Always install shutters in the system leading to the stove so as to disconnect it from the hydraulic system should it be necessary to move it, or when it requires routine and/or special maintenance. Connect the stove using exible pipes so that the stove is not excessively constrained to the system, and to allow slight movements. The pressure discharge valve (C) is always connected to a water drain pipe. The pipe must be adequate to support the water's high temperature and pressure.

It is important that ONLY qualied engineers are used to t and commission the appliance in ALL cases. The installing engineer MUST hold a QCF recognised biomass qualication. Any company using sub-contractors MUST ensure they also hold the relevant qualications (ONLY FOR UK).

CLEANING THE SYSTEM

It is mandatory for the connections to be easy to disconnect by way of unions with rotating connections. Install suitable shutters to cut o the tubes from the heating system. Assembling the safety valve on the system is compulsory. In order to protect the heating system from damage caused by corrosion, incrustation or deposit build-up, it is important to clean the appliance before installation, using suitable products, in compliance with Standard UNI 8065 (water treatment of thermal plants for civil

use).

The use of FERNOX PROTECTOR F1 (available at our authorised centres) product is recommended, this provides long-term protection of heating systems against corrosion and calcium build-up. It prevents the corrosion of the metal parts of the appliance, i.e. the ferrous metals, copper and copper and aluminium alloys. It also reduces the noise produced by the boiler. Refer to the instructions on the product. Cleaning should be performed by a qualied technician. We also recommend the use of FERNOX CLEANER F3 and LEAK SEALER F4, always available from our authorised distribution centres. FERNOX F3 is a neutral product for rapid and ecient cleaning of heating appliances. It has been designed to eliminate residues, oily deposits and incrustations from existing appliances of all ages. It can help restore the heating eciency of the boiler and reduce the noise it generates. FERNOX F4 is intended to be used with all heating appliances to seal micro fractures that cause small and inaccessible leaks.

FILLING THE SYSTEM

To ll the system, the stove can be equipped with an end piece (optional) with a non-return valve for manual lling of the heating system (if the optional is not installed, the lling tap on the main boiler will be used). During this operation, any air in the system is released from the automatic vent valve located under the top. To ensure the valve vents, it is advisable to loosen the grey cap one turn and leave the red cap blocked (see gure). The lling pressure of the system WHEN COLD must be 1 bar. During operation, if the system pressure drops (due to evaporation of dissolved gases in the water) to values lower than the minimum indicated above, the user must use the lling tap to bring the pressure back up to its normal pressure. For proper operation of the stove WHEN HOT, the pressure in the boiler must be 1.5 bar.

To monitor the system's pressure, the terminal (optional) is equipped with a manometer.

Upon completion of this operation, always close the tap.

7 - HYDRAULIC CONNECTION

PURGE VALVE WITH CAP

WATER CHARACTERISTICS

The characteristics of the water used to ll the system are very important to prevent the build-up of mineral salts and the formation of incrustations along the pipes, in the boiler and in the heat exchangers.

Therefore, please GET YOUR PLUMBER'S ADVICE CONCERNING:

• Hardness of water circulating in the system, to prevent problems of incrustation and limescale, especially in the domestic water heat exchanger. (> 25° French).

• Installation of a water softener (if water hardness exceeds 25° French).

• Filling the system with treated water (demineralised).

• Possibly providing an anti-condensation circuit.

• Installation of plumbing bumpers to prevent the phenomenon known as “water hammer” from occurring along the ttings and pipes.

For those who have very extensive systems (with large amounts of water) or which require frequent relling, to install water softening systems.

It should be remembered that incrustations drastically reduce performance due to low thermal conductivity.

8 - ELECTRICAL CONNECTION

ELECTRICAL CONNECTION

Connect the supply cable coming from the circuit board to an electrical wall socket. The main switch must only be activated to switch the stove on; otherwise, it is advisable to keep it switched o.

It is recommended to disconnect the power cable when the stove is not used.

STOVE POWER SUPPLY

Once the supply cable has been connected, turn the switch, which is situated on the left side in the circuit board panel, to position “I” (ON). The switch on the stove is used to power the system.

OFF

8 - ELECTRICAL CONNECTION

OPERATING MODE

The operating mode for hydro stoves is only AUTOMATIC (there is no manual operating mode available). The modulation of the ame is controlled according to the "System conguration" by the room temperature probe located at the back of the appliance (see img.), by the external thermostat, by the temperature of the water in the boiler, or by the NTC probes.

ELECTRICAL CONNECTIONS

TERMINAL BLOCK CONTACTS

POS.1-2 EXTERNAL THERMOSTAT/PUFFER THERMOSTAT POS.8 NEUTRAL THREE-WAY VALVE

POS.3-4 PUFFER/BOILER PROBE POS.9 THREE-WAY VALVE PHASE (heating)

POS.5 EARTHING

POS.6-7 AUXILIARY STOVE

Via La Croce n°8

33074 Vigonovo di Fontanafredda (PN) – ITALY

Telephone: +39 0434/599599 r.a.

Fax: +39 0434/599598

Internet: www.mcz.it

e-mail: info.red@mcz.it

REV. 08901506100 12/01/2015

MCZ Flux HYDRO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual