SAS BIO SOLID 19, BIO SOLID Series, BIO SOLID 36, BIO SOLID 14, BIO SOLID 48 Operation And Maintenance Manual

TABLE OF CONTENTS

Declaration of Conformity CE 3
Fact Sheet 4
Test certificate for the SAS BIO SOLID water boiler 5-6
EcoDesign certificate for the SAS BIO SOLID 14kW boiler 7
EURO TOPTEN award 8

1. Preface 9

2. Purpose, boiler operational conditions 9

3. Boiler design and operation 10

4. SAS BIO SOLID boiler equipment 17

5. Technical and operational parameters 18

6. Fuel 23

7. Boiler installation guidelines 24

7.1 Boiler room requirements 25

7.2 Noise and noise reduction methods 26

7.3 Boiler placement 26

7.4. Boiler stack connection 27

7.5. Boiler connection to a heating system 28

7.5.1. Open vented system 29

7.5.2. Sealed system 31

7.6. Boiler connection to a power supply system 37

8. Guidelines for use and operation 38

8.1. Filling with water 38

8.2. Boiler firing and operation 39

8.3. Boiler cleaning 41

8.4. End of burning 43

9. Conditions for safe operation 44

10. Operation and maintenance of the feeder and burner 45

11. Statuses of incorrect boiler work 46

12. Protective devices 48

13. Delivery terms and conditions 51

14. Boiler disposal 52

15. Warranty terms and conditions 55
Warranty card 55

LIST OF FIGURES AND TABLES

page

. 1 SAS BIO SOLID boiler equipment

Table

. 2 Technical and operational parameters for the SAS BIO SOLID 14-f 48 kW boiler

Table

. 3 Basic parameters of pellets intended for SAS BIO SOLID boilers

Table

. 1 Moving grate positioning sensor (hall effect sensor)

Figure

. 2 Connection terminal strip supplying control equipment

Figure

. 3 Module controlling burner operation

Figure

. 4 The flue gas temperature sensor mounted in flue pipe

Figure

. 5 Location of the temperature sensor with a capillary tube

Figure

– thermal protection sensor

. 6 Diagram of SAS BIO SOLID boiler design with heat output of 14 -f 48 kW

Figure

. 7 Diagram of SAS MULTI FLAME burner design - side view, sectional view

Figure

. 8 Diagram of SAS MULTI FLAME burner design - upper view

Figure

. 9 Installation of adjustment feet in SAS BIO SOLID boiler

Figure

. 10 General connection diagram - an open vented system with a four-way valve

Figure

. 11 General connection diagram - an open vented system with a plate exchanger

Figure

. 12 General connection diagram - sealed system

Figure

. 13 Flue gas turbulator

Figure

. 14 The location of the STB safety temperature limiter and temperature sensor

Figure

2

18
19
23
12
13
14
15

17

20
21
22
27
32
33
34
42

49

Zakład Metalowo-Kotlarski „SAS”

Directive 2006/42/EC

(MD) Machinery Directive

Directive 2004/108/EC

Owczary, ul. Przemysłowa 3
28-100 Busko-Zdrój
tel. [phone] fax [phone]

www.sas.busko.pl

-

--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- --------------

e-mail: [e-mail]

SAS BIO SOLID / DZ/01/2015 Busko-Zdrój, 9 February 2015

EC DECLARATION OF

CONFORMITY

Zakład Metalowo-Kotlarski SAS

28-100 Busko-Zdrój, Owczary, ul. Przemysłowa 3

declares with full responsibility that the product:

Automatic central heating boiler type

The Ordinance Of The Minister Of

(Official Journal No 199/2008, item 1228)

The Economy

with the heat output 14 to 48 kW

equipped with SAS MULTI FLAME burner

complies with the provisions of:

and harmonized standards:

PN-EN ISO 12100: 2012
PN-EN 61000-6-2:2008P

PN-EN 61000-6-3:2008P

This is confirmed by the sign placed on the device

Mieczysław Sas

PN-EN 303-5:2012

SAS BIO SOLID

(Official Journal No. 82/2007, item 556)

(EMC) Electromagnetic
Compatibility Directive

This Declaration of Conformity is invalidated if any design changes are made to the product without

If the product is resold to another owner, this Declaration of Conformity must be enclosed with the

the consent of the manufacturer.

product.

Fact Sheet in accordance with the European Commission (EU) Regulation No. 2015/1187 of April 27, 2015

Model ID

Energy efficiency class

BIO

SOLID 14

A

BIO

SOLID 19

+

A

BIO

SOLID 25

+

A

+

BIO

SOLID 36

+

A

Rated boiler output

15 kW 19 kW 26 kW 36 kW 49 kW

Energy Efficiency Index (EEI)

116 116 118 118 119

Room seasonal heating
energy efficiency (

Special precautions:

The boiler should be installed and operated solely by adults only in conditions meeting those

1.

specified in the operation and maintenance manual delivered with the equipment!

Any changes in the design aiming at adapting the boiler to perform functions not intended by

2.

its manufacturer are strictly forbidden and shall void the warranty!

3. Only recommended fuel must be used!
The boiler is not designed to heat water above the maximum working temperature declared,

4.

i.e. > 85°C.
Flue gases emitted from an obstructed stack are hazardous. The stack and the connector

should be kept clean; they should be cleaned according to the instruction provided by the

5.

manufacturer. The boiler flue gas ducts should be kept clean.
All activities related to the boiler installation and operation should be performed with

caution. Personal protective equipment should be used, and health and safety regulations

6.

should be observed. Some boiler surfaces are hot and protective gloves must be worn before
touching them! Safety goggles should also be used!
Before maintenance, the boiler must be disconnected from the mains supply, and the
manufacturer's instructions must be observed.
All connections to the power supply system can only be made by a person holding relevant

7.

qualifications — SEP (Polish Electricians Association) licence up to 1 kV. Any attempt to
perform unauthorised repairs/changes in the control system may lead to electrocution and
shall void the warranty.

h

)

s

79% 79% 80% 80% 81%

BIO

SOLID 48

+

A

4

56789

1. PREFACE

Dear Buyer and User of the low-temperature SAS BIO SOLID boiler. This ope­rating and maintenance manual contains all necessary information for energy-effi­cient, safe and long operation of your boiler. The device is delivered together with
a set of operating and maintenance manuals for operation of the boiler, burner and
controller.

Before installation and operation of this device you must read and understand
contents of this operating and maintenance manual. After acquainting with this ma­nual you will be able to use this device in an optimum way. By becoming thoroughly
acquainted with this manual you will be able to operate the boiler in an effective and
safe way.

Boilers manufactured by the Zakład Metalowo-Kotlarski “SAS” meet the requ­irements of relevant EU directives and are CE-marked, and this is confirmed in the
enclosed EC DECLARATION OF CONFORMITY.

THIS DOCUMENTATION SHOULD BE KEPT FOR FUTURE USE, IT IS ALSO
A WARRANTY CARD FOR THE BOILER.

2. PURPOSE, BOILER OPERATIONAL CONDITIONS

SAS BIO SOLID boilers with a fuel tank and SAS MULTI FLAME burner are
designed for installation in water central heating systems, open/close system*
with gravitational or forced water flow, secured according to current local or EU
regulations (PN-EN 12828+A1:2014-05 Heating installations in buildings. De­sign of water-based heating systems). They are recommended, in particular, for
heating of residential flats in one- and multi-family houses, and for commercial,
services, catering and workshop facilities, etc., in which maximum acceptable
working temperature of supplied water does not exceed 85°C, and a maximum
working pressure in the system does not exceed 1.5 bar. Required minimum
flue gas pass downstream the boiler od 0,20-0,30 mbar, depending on the no­minal thermal power (according to PN-EN 13384-1:20152008 Chimneys. Me­thods for thermal and flow-through calculations. Part 1: Chimneys serving one
heating appliance).

* The installed system must meet specific requirements of standards in force in a country of destination con-

cerning safety devices for water-based heating equipment in open vented systems,and expansion vessels in
an open vented or sealed systems together with accessories: diaphragm expansion vessel, pressure relief
valve, equipment for control and measurements, or devices for removing excess heat.

These boilers may also work with domestic hot water systems through a heat
exchanger (domestic hot water) of any producer that meets current standards.
The boiler cannot be used as a continuous flow water heater. The SAS BIO SOLID
boiler is also not intended to be used as an air heater.

A boiler for heating a building should be selected on a basis of an energy heat
balance of that building, developed in accordance with specific current national
or EU regulations (PN-EN 12831:2006 Heating systems and water based cooling
systems in buildings - Method for calculation of the design heat load).

NOTE 1: The boiler should be installed and operated only in conditions me-

eting those specified in the operation and maintenance manual (ma­nufacturer documentation delivered together with the device)!

NOTE 2: Any changes in the design aiming at adapting the boiler to perform func-

tions not intended by its manufacturer are strictly forbidden and result in
a loss of warranty rights and documents associated with the product!

3. BOILER DESIGN AND OPERATION

SAS BIO SOLID bolier is a low-temperature CH boiler with automatic fuel sup­ply to the furnace. SAS BIO SOLID with power of 14÷48 kW is designed and
programmed for combustion of the solid fuel in automatic mode. The fuel is bio­mass in the form of wood granules wood (pellets) with parameters defined by EN
14961-2 or PN-EN ISO 17225-2:2014-07p

Basic boiler components are specified in a figure 6.

The SAS MULTI FLAME burner elements are shown in fig. 7 and 8.

NOTICE: The SAS MULTI FLAME burner is affected by Protective Law no
67681 – provided by the Polish Patent Office for the utility model, entitled

“Water boiler burner suitable for combustion of biomass”.

The boiler consists of a water body made of welded steel plates. The boiler
water shell forms a double-walled cuboid divided with water chambers. Internal
partitions of the heat exchanger is made of boiler-grade steel P265GH with a
thickness of 6 mm, external water shell is made of design steel with grade S235JR
with a thickness of 4 mm. The boiler exchanger contains a permanently fixed
system of stud bolts bracing its covers (strengthening components in form of

“seams”). Covers are tested for their strength and tightness under a test pressure

of 3 bar during the production of each boiler. Water compartments of the boiler
and its parts are designed in such way that during its normal operation according
to this operating manual and following correct installation all air will be removed
and no local boiling of water will occur.

10

OPERATION PRINCIPLE FOR AUTOMATIC FUEL DELIVERY SYSTEM:

The boiler operates using a set consisting of:

• a fuel feeder with dual auger and transfer duct,

• blow furnace equipped with the moving grate,

• fan supplying air to the furnace;

• and an electronic temperature regulator – controller.

The fuel is transported from the fuel reservoir into the furnace chamber using
the feed fuel mechanism fuel with two distribution pipes (two transport augers dri­ven by an electric motor) separated with a transfer duct providing distance betwe­en. This solution provides secure transport of biomass, eliminating the need for
additional protection against uncontrolled retraction of fire into the fuel reservoir.
For safety reasons the gate closing the fuel reservoir during the combustion of
biomass in the burner must be sealed. The feeding mechanism consists of gear
motor that drivers the fuel feeding system by means of sprockets and a chain. The
feeder drive is under the safety cover. The fuel feeding mechanism – transport au­gers are located in the closed isolating-and-guiding pipe. The biomass furnace is
installed in the combustion chamber. It is possible to remove the feed mechanism
to periodic cleaning (Fig. 8) – mounting screws, sealing cord.

Biomass is supplied to the furnace chamber, where the automatic combustion
process is performed using the heater (electrical burner). The device is cooled by
a stream of air coming from the air duct. After reaching the preset temperature,
the automatic fuel ignition and fire support system enables the boiler the possibi­lity of efficient operation even with low power thermal demand (possibility of con­tinuous operation with domestic hot water reservoir during the summer period).
A characteristic feature of the SAS MULTI FLAME burner is an automatic, highly-

-effective and self-cleaning furnace burning exactly the portion of fuel necessary
to obtain the value set by the user on the temperature controller.

The burner is provided with a self cleaning furnace fitted with moving grates,
whose cyclic movement enables dropping the biomass ash and slag, ensuring
furnace purity over a long period of time.

The furnace elements (housing, moving grate, furnace grate, mounting plate)
exposed to high temperatures are made of stainless steel heat-proof sheet. Over
the furnace chamber there is a ceramic shape, which further protects the furnace
housing and causes reburning of unburned parts of flammable fuel. The burner
mounting plate is lined with a thermal insulation protecting fuel feeding mecha­nism from heat.

Air for combustion is supplied by the fan driven by the electric motor and
connected to the furnace using an air-blowing duct. Part of the air is led under the
furnace grate, and the rest is blown directly into the combustion zone through the
distribution holes located on the sides of the furnace. The proper – depending on
the type of fuel burned – air flow is delivered by the blowing fan controlled by the
boiler controller.

11

The furnace grate was divided into a fixed part and the moving section. Cyc­lically actuated moving grates driven by a eccentric mechanism enables evacu­ation of fuel combustion residues from the furnace into the boiler chamber, i.e. the
ash in the form of slag. This solution is used to maintain the continuation furnace

in “clean” condition without interrupting the continuity of the combustion process.

After the furnace cleaning cycle, the moving grates take position in the slots of the
lower part of the furnace. The grate is positioned with a position control sensor
(hall effect sensor, see Fig.1 and Fig. 6). A small part of non-combustible fuel –
ash – remaining after combustion of biomass in the final stage of combustion is
transferred to the ash-box in which a drawer is situated. It must be cleaned perio­dically (the ash resulting from the combustion process can be used as a fertilizer).
The frequency of drawer emptying depends on the quality of the pellet.

Figure 1 Moving grate positioning sensor (hall effect sensor).

NOTICE:

Correct operation of the moving grate mechanism requires a correct setting
of the Hall effect sensor. A distance between the position sensor and the moving
grate drive string should be 3 to 5 mm, these components should be aligned
axially.

The controller (temperature regulator) located in the upper boiler cover uses
the readings from the temperature sensors to control all regulating devices, en­suring the efficient and economic use of available power in order to maintain the
operating conditions of the installation. An efficiently working boiler furnace burns
the amount of fuel necessary to maintain the temperature set on the regulator by
the user. Thus, the controller continuously measures a temperature of water in
the boiler, and on this basis appropriately controls operation of the boiler and the
fan. At the same time the controller controls operation of pumps: central heating,
domestic hot water, floor and circulating (if the heating system is equipped with
pumps). The boiler can also be used outside the heating season in a system with
an exchanger, for domestic hot water. In a system equipped with a mixing valve

12

with a cylinder, the mixer can be controlled directly from the boiler controlled.
Connection points for circulatory pumps, temperature sensors and the mixer are
located on the boiler side wall (see Fig. 2 and Fig. 6).

Figure 2 Connection terminal strip supplying control equipment

(An example of the power strip depending on the model of the controller mounted on the boiler)

The control unit (see Fig. 3, Fig. 6) of the burner automatically controls the
heater and the mechanism of furnace cleaning with the positioning sensor (hall
effect sensor). The temperature regulator mounted on the boiler controls the blo­wing fan, fuel feeding mechanism and the feeder temperature sensor. The co­operation between the controller (Fig. 6 item 39) of the feeder SAS MULTI FLAME
type, the master boiler controller (Fig. 6 item 28) is possible thanks to the wired
RS communication system. The control unit has the power cord, main switch and

a fuse. If there is no power supply to the control unit, the regulator displays “No
communication with M1” message and emits the audible alarm. An efficiently

working boiler furnace burns the amount of fuel necessary to maintain the tempe­rature set on the controller by the user.

13

Figure 3 Module controlling burner operation.

(An example of the power strip depending on the model of the controller mounted on the boiler)

An advantage of a boiler is its simple operation in form of periodic replenish­ment of fuel in the tank and removing ash from the ash drawer without a need to
put the furnace off. After firing, the boiler does not require a continuous operation,
and it can be used, generally, in a continuous mode during the heating season
(excluding breaks for periodical cleaning and repairs). Systematically performed
maintenance and cleaning ensures long and trouble-free operation of the boiler.

A boiler room with a solid fuel boiler is not maintenance-free and requ­ires periodic monitoring. During boiler operation certain daily control activi­ties must be performed, to prevent emergency situations.

BOILER DESIGN:

With the boiler structure based on three-pass layout of a flue gas duct in the
exchanger with ceramic panels, flue gas heat is fully recovered and used in a
water-based central heating system. Also the upper part of the furnace chamber
is closed with a water jacket.

Flue gases are directed to a stack through a flue located in the back part of
the boiler. A flue gas damper is installed in the flue, which can reduce the flue gas
flow when it becomes too strong (regulation). A clean out openings are located
on the side of the flue pipe. The flue pipe is fitted with the exhaust gas temperatu-

14

re sensor (solid state, PT1000), which regulates the combustion process and re­duces the stack loss (blowing air adjustment). The adapter cube allows for quick
and simple exchange, when necessary (see Fig. 4).

Figure 4 The flue gas temperature sensor mounted in the flue pipe

NOTICE:

For correct operation of the regulator controlling the combustion process –
operation of the automatic fuel feeder – we encourage you to periodically clean
the sensor surface from dust/soot.

Clean out door, furnace door and ash-box door are located on the front wall of
the boiler. The furnace door enables the access to periodic cleaning of the boiler
and burner.

Front clean out door and top clean out (located under the cover) enables easy
access to cleaning of heat exchanger cartridges and gas turbulator. Side clean
out and ash-box door are used to remove dust settling in the flue gas duct.

Due to an overpressure in the whole inner space of the boiler, it is provided
with fire doors and inspection hatches with circumferential sealing (ceramic rope,
gaskets) and screwed connection, ensuring for its tight closing. Furthermore, it
is also provided with adjustment systems for hinges, and for closing systems for
doors and a fuel tank cover.

Non-flammable insulating materials were installed to reduce heat losses and
secure against excessive increase in a temperature of external boiler surfaces.
The heat exchanger surface is insulated from the environment with external
cladding of powder-coated steel sheets, under which a thermal insulation layer
of asbestos-free non-flammable mineral wool is installed. The insulating mate­rial tightly fills space between the exchanger and the boiler casing (external,
powder painted insulating sheet). The boiler door and the top clean out have
a multi-layer construction made of stainless steel and insulating material which
restricts heat loss (temperature of the external surface of the boiler on a safe
level). And additional insulating partition made of stainless steel and insulating
material in the furnace door was implemented, as well as a stainless steel par­tition in the clean out door. The boiler has an additional layer on front door in
the form of an opening external cover, protecting from an accidental contact
with surfaces susceptible to excessive heat. Door, clean out hatch, and flue gas
damper handles are made of non-flammable components significantly reducing

15

heat transfer, In addition, for safety reasons a pictogram and a message on the
nameplate was used that informs the user about uninsulated hot elements –
(flue pipe).

The moving parts (gear motor, sprocket mechanism and chain driving the
fuel feeder, moving grate drive, blowing fan) located underneath the hopper was
secured against direct access with detachable shields. Furthermore, for safety
reasons, a pictogram informing a user about presence of the mobile components
was used.

HOT

SURFACE

The fuel tank is provided with a loading opening with sealing and a closing
system. The design of the tank equipped with the hopper ensures free transport
of fuel (gravitational discharge). In addition it is fitted with a limit switch that stops
the blowing fan operation and fuel feeder after opening the cover! (See fig. 6) A
message appears on the display: „Cover Open” and an audible alarm is heard
(reminder and signal appear cyclically for a few seconds). When the fuel reservoir
cover is closed, the operation is resumed. Inside the cover there is an information
for the user about the presence and operation of the limit switch (reservoir cover
opening sensor).

NOTE:

Due to the installation of the limit switch, the fuel reservoir cover must al­ways be sealed (during normal operation of the boiler)!

Directly above the furnace and on the side wall of the boiler opposite the SAS
MULTI FLAME burner the heat exchanger chamber has horizontal/vertical parti­tions made of refractory ceramic material increasing the combustion temperature
and reducing the emission of harmful gases into the atmosphere. The number
and layout of horizontal ceramic partitions over the furnace is dependent on the
power of the boiler.

Additionally, the exchanger is equipped with a gas turbulator which forces hot
flue gas whirl and enhanced transmission of heat to the heat exchanger. The flue
gas impacts the turbulator walls, causing the dust fall to the bottom of the boiler.
The dust can be removed by side clean outs of the heat exchanger chamber.

NOTE!

MOVING PARTS

16

A supply water connector is welded to the upper part of the heat exchan-

ger, while a return water connector is welded at the bottom, on the back wall. A

discharge connector (G ¾”) is located on a side wall in the bottom part of the

boiler. It is also used for connection of cooling water (from a water system) when
overheat thermal protection – a thermostat valve (a device removing excess heat,
according to Fig. 11 and Fig. 12) is installed. On the side wall of the top of the

boiler there is a connector (G ½”) for connecting the temperature sensor with a

capillary L=150 mm from thermal protection valve (see fig. 5).

Figure 5 Location of a temperature sensor with a capillary tube– thermal protection

sensor

Adjustment feet (does not apply to boilers with power over 25 kW) with the
adjustment range of 30 mm ensure the boiler final alignment versus the floor.
The user is responsible for possible installation of adjustment feet, according to
guidelines provided in this instruction (Fig. 9).

4. SAS BIO SOLID BOILER EQUIPMENT

SAS BIO SOLID automatic boiler with control is delivered with a controller,
blowing fan, pellet burner (SAS MULTI FLAME), fuel reservoir, ash-box doors,
furnace doors, clean out doors, partitions with refractory ceramic panels. Addi­tional isolation partitions made of stainless steel protect the furnace door and
clean out door. The boiler body has a thermal insulation made of mineral wool
that has the form of the shell made of powder painted steel sheets with high
resistance to corrosion. The SAS BIO SOLID boiler is equipped with the pellet
burner and fuel reservoir installed on the left (L) or the right (R) side. The burner
and fuel reservoir location should be clearly stated (in the order), as it is not
possible to move them to the other side afterwards.

The digital equipment (control systems) for the SAS BIO SOLID boiler is spe­cified in the attached operating manual for the temperature controller.

17

Table 1. SAS BIO SOLID boiler equipment

BOILER STANDARD EQUIPMENT

1 Boiler operating and maintenance documentation (manual + warranty card)
2 Operating manual + warranty card for a temperature regulator (controller)
3 Warranty card for a blower fan

Temperature regulator (controller operating two mixing valves, Ethernet module) with a set of cables and

4

sensors for the system operation (details in the controller operation and maintenance documentation)
5 STB safety temperature limiter
6 Flue gas temperature sensor
7 Analogue thermometer

SAS MULTI FLAME pellet burner

- control unit for the burner, power strip

- blower fan

- fuel feeder with a gearmotor

8

- moving grate with drive motor, biomass furnace

- heater (electric burner)

- shape made of refractory ceramic material

- grate positioning sensor (hallotron), feeder sensor temperature

9 Moving parts guard (fuel tank casing)

10

Partition made of stainless steel, thermally insulated, protecting the furnace door

11 Partition made of stainless steel protecting the cleanout door
12 The set of refractory ceramic panels: rear front, sides, horizontal partitions***
13

The set of refractory ceramic panels - boiler side wall opposite the biomass furnace

14 Flue gas turbulator
15 Fuel tank
16 Feeder flap opening sensor
17 Ash drawer
18 Pressure relief valve (2.5 bar)
19 A set of tools for boiler operation (poker, cleaning rod, scraper, and ash shovel)
20 Adjustment feet for boiler levelling (excluding boilers above 25 kW)
21 Connector (G

***

the number of horizontal ceramic partitions over the furnace is dependent on the power of the boiler

½

) of the overheating protection

pieces

pieces

pieces

pieces

pieces

pieces

pieces

set

set

pieces

pieces

pieces

set

pieces

pieces

pieces

pieces

pieces

set

pieces

pieces

1
1
1

1

1
1
1

1

1
1
1
1
1
1
1
1
1
1
1
4
1

OPTIONAL BOILER EQUIPMENT

1 Room regulator
2 Module controlling an additional mixing valve
3 GSM module

*)

Thermostat valve with a capillary tube (G

4

- open vented system with a plate exchanger (e.g. Regulus, type BVTS)

- sealed system (e.g. SYR 5067)

*)

applies to boilers with a TECH controller

5.

TECHNICAL AND OPERATIONAL PARAMETERS

Basic power parameters together with technical and operational parameters

for SAS BIO SOLID boilers are listed in Tab. 2, and Fig. 6.

18

*)

½

”) protecting against overheating:

pieces

pieces

pieces

pieces

1
1
1

1

Table 2. TECHNICAL AND OPERATIONAL PARAMETERS

SAS BIO SOLID 14-48 kW BOILER

No. Parameter Unit. SAS BIO SOLID

1. Nominal boiler power/type kW 14 19 25 36 48

2. Exchanger heating surface m

3. Power range kW 4,2 ÷ 14 5,7 ÷ 19 7,5 ÷ 25 10,8 ÷ 36 14,4 ÷ 48

4. Energy efficiency class A+ A+ A+ A+ A+ A+

4. Thermal efficiency % 92,1 ÷ 92,4

Boiler class (according to PN-EN 303-5:2012)

5.
efficiency/flue gas emissions

6. Fuel - pellets

7. Fuel grade (EN 14961-2) - biogenic fuel – class „C1”

8. Zużycie paliwa * kg/h 1,6 2,1 2,8 4,1 5,5

9. Fuel reservoir capacity

10. Boiler water holding capacity l 68 82 102 120 168

11. Boiler weight (without water) kg 550 600 660 730 860

12. Required min. hot gas pass mbar ~ 0,20 ~ 0,25 ~ 0,30

13a.

The flow of the exhaust
gases at the

13b. minimum g/s 2,6÷4,3 3,1÷5,3 3,8÷6,8 5,8÷9,3 7,7÷12,1

14a.

Flue gas temperature at the

14b. minimum °C 50 ÷ 80

Water flow resistances

15a.

through the boiler for rated

15b. at T=20K mbar 0,6 ÷ 1,9

power

16. Recommended

17. Max. acceptable operating temperature °C 85

18. Max. acceptable operating pressure bar 1,5

19. Required return water temperature ** °C 50

20. Power supply V/Hz ~230V/50Hz

21. Power consumption *** W up to 220 (600 on ignition)

22. Noise level (by PN-EN 15036-1:2006) dB < 65 dB(A)

Basic boiler

23.
dimensions

24. Flue diameter mm Ø 160 Ø 180 Ø 180 Ø 200 Ø 220

25. Spigot thread (feed/return)

26. Drain spigot diameter

27. Pressure relief valve (2.5 bar)

28. Min. stack height m 6 7 8 9

29. Min. flue pipe diameter

when working with medium load (50% of rated power) for the fuel dedicated referred to in chapter 6. In the actual conditions the fuel consumption

*

may differ from the one given in the table. The fuel consumption is impacted the quality of the fuel, type of heating installation, operating
parameters of the boiler, chimney, degree exchanger contamination, inside and outside temperature of the heated building, building insulation.
when recommendations concerning maintaining of a specified range of heating water temperatures are not followed, the boiler must be obligatorily

**

connected to the heating system equipped with a four-way valve protecting against so-called „low-temperature corrosion”
temporary power consumption depends on the equipment operating mode

***

**)

when adjustment feet are used (excluding boilers of the power exceeding 25 kW), the dimension increases from min. 29 mm to max. 56 mm

operational temperature of heating

nominal g/s 8,8÷9,0 10,2÷11,7 12,7÷15,0 19,2÷20,1 23,8÷25,6

nominal °C 130 ÷ 160

at T=10K mbar 2,3 ÷ 4,1

Amps mm 1230 1270 1270 1290 1410

A1 mm 290 290 290 305 330

B mm 950 1050 1175 1250 1250

B1 mm 450 450 535 605 605

H **) mm 1560 1520 1520 1560 1730

H1 **) mm 1270 1360 1360 1420 1520

H2 **) mm 930 1000 1000 1050 1120

H3 **) mm 180 180 180 180 180

2

1.2 1.7 2.2 3.0 4.0

- class 5 (the highest)

3

150

dm

kg

~95÷105

°C 60 ÷ 80

„

G 1¼ G 1¼ G 1½ G 1½ G 2

„

G ¾ G ¾ G ¾ G ¾ G ¾

„

G ½ G ½ G ½ G ½ G ½

cmxcmmm17x17

Ø 200

200

~130÷140

18x18
Ø 210

210

~140÷150

20x20
Ø 220

270

~175÷185

22x22
Ø 250

305

~200÷210

25x25
Ø 280

19

Figure 6. BOILER DESIGN DIAGRAM

SAS BIO SOLID 14-48 KW BOILER

31. Housing of the front door

32. Ceramic partition - furnaces

33. Furnace housing

34. Side clean out

35. Connector for a thermal protection

36. Guard for moving parts

with a capillary tube *

16. STB safety temperature limiter

17. Power strip

18. Flue gas turbulator

19. Flue gas chamber ap

20. Upper clean out cover

21. Flue gas temperature sensor

22. Flue pipe clean out

37. Housing of the drive mechanism

38. SAS MULTI FLAME pellet burner

39. Module controlling burner operation

40. Burner power strip

41. Feeder temperature sensor

42. Discharge connector

43. Adjusting feet (does not apply to
boilers over 25 kW)

23. Flue gas damper

24. Flue

25. Fuel tank

26. Limit switch in the feeder cover

27. Pressure relief valve

28. Driver

29. Water connector - power

30. Analogue thermometer

1. Boiler housing

2. Thermal insulation

3. Water jacket

4. Ash drawer

5. Water connector - return

6. Air chamber clean out hatch

7. Furnace space

8. Ash box door with “explosion proof” ap

9. Insulated partition (heat)

10. Ceramic panels - side

11. Ceramic panels - rear/front

12. Ceramic shelves **

13. Furnace doors

14. Protective partition

* thermal protection against overheating (e.g., Regulus BVTS for an open vented system with a plate exchanger
or SYR 5067 for a sealed system) is not included in the boiler standard equipment.
** the number and layout of ceramic partitions over the furnace is dependent on the power of the boiler
**) when adjustment feet are used (excluding 25 kW), the dimension increases from min. 29 mm to max. 56 mm

20

15. Clean out hatch door

Figure 7. DIAGRAM OF SAS MULTI FLAME BUR-

NER DESIGN

- side view, sectional view

11. The air supply to the furnace

12. Furnace space

13. Blow duct

14. Air chamber clean out hatch

6. Feeder supporting foot

7. Hall effect sensor (moving grate positioning

sensor)

8. Thermally insulated air duct

9. Furnace housing bracket

10. Shape made of ceramic material

1. Furnace housing

2. Heater (electric burner)

3. Fuel feeder (two transport augers

separated by the transfer duct)

4. Fuel feeder temperature sensor

5. Moving grate drive motor

21

Figure 8. DIAGRAM OF SAS MULTI FLAME

BURNER DESIGN

- upper view

20. Feeder drive unit

21. Housing of the drive

22. Fuel reservoir mounting frame

22

17. Burner mounting plate

18. Blower fan

19. Gear motor for the feeder

15. Moving grates (number depends on the

burner power)

16. Sealing cord

6. FUEL

Seamless operation of the SAS BIO SOLID boiler with SAS MULTI FLAME

pellet burner depends on the application of the respective fuel. The fuel for SAS

BIO SOLID boilers is the biomass is in the form of pressed granules of pellet-

-type wood, acc. to EN 14961-2 Class C1 or by PN-EN ISO 17225-2:2014-07p
class A1. Do not use fuel with granulation thicker than specified*, since such fuel

may hinder the operation of the feeder and lead to its damage. SAS BIO SOLID
boiler equipped with automatic pellet burner is not a device for the combustion
of fossil fuels.

NOTE! The use of other fuels than recommended by the manufacturer

may cause damage to the burner, leading to loss of warranty on the burner.

It is forbidden to burn plastic materials; this may result in damage to the fur­nace. Contamination of the heat exchanger surface leads to reduced boiler effi­ciency and deterioration in the burning process. It is forbidden to use flammable
materials (such as petrol, kerosene, or solvents) for boiler firing, as this may result
in a fire or explosion.

Boilers fired with biogenic class „C1” fuel according to Chapter 1 of PN-EN

303-5:2012 standard.

Table 3 Basic parameters of pellets intended for SAS BIO SOLID boilers:

No. Parameter Unit Scope

1 Diameter mm 6 - 8
2 Length mm 5 - 35
3 Bulk density kg/m
4 Calorific value MJ/kg 16,5 - 19
5 Abrasiveness % ≤ 2,5
6 Ash content % ≤ 0,5
7 Sulphur content % ≤ 0,03
8 Nitrogen content % ≤ 0,3
9 Chlorine content % ≤ 0,02

10 Water content % ≤ 12

3

≥ 600

The density determines the durability of fuel, abrasiveness, pulp formation and
in result too low density may cause jamming of locking mechanism of the feeder.

It is forbidden to use fuel with a humidity higher than specified in the table
above. Fuel with high humidity can impede the combustion process and cause
damage to the auger feeder, feeder tubes, fuel reservoir (premature corrosion).

* In particular, during fuel loading or replenishment attention should be paid to presence of wood pieces, stones or unde­sirable objects that may block the feeder mechanism.

23

In addition, equipping the furnace with the ash-removal mechanism with mo-

ving grates allows the use of fuels with a tendency to slag formation.

The appropriate selection of biomass ensures not only saving the consump­tion of fuel (effective combustion), but also reduces the time required for the use
of the boiler.

Use of the recommended type of fuel ensures correct and trouble-free ope­ration of the feeder and the boiler, economical fuel consumption compared with
poor quality pellets and also reduces the emission of harmful compounds during
the combustion process.

Fuel of poor quality parameters (high water content, low calorific value, pre­sence of stones, etc.) may cause problems with selection of settings for optimum
boiler operation, leading to formation of sinter on the furnace and high fuel losses
with ash.

NOTICE: In the actual conditions the fuel consumption may differ from

the one given in table 2. The fuel consumption is impacted the
quality of the fuel, type of heating installation, operating para­meters of the boiler, chimney, degree exchanger contamination,
inside and outside temperature of the heated building, building
insulation.

NOTICE: The fuel tank should be loaded with fuel free of water and exces-

sive quantities of fine fractions or foreign bodies! High humidity
and pollution delivered to the reservoir with fuel adversely affect
the viability of the hopper! Use fuels recommended by the manu­facturer (possibly certified)!

The fuel landfill should be protected against the effects of weather conditions.

For that purpose prepare the dry, covered and ventilated place. The fuel stora­ge area should allow for the storage during the whole heating season.

7. BOILER INSTALLATION GUIDELINES

The boiler must be installed by qualified personnel holding relevant licences
(a professional, appropriately trained and holding required licences to perform
maintenance and repair works). An installer is obliged to become thoroughly
acquainted with the product and its function, and an operating mode of its pro­tective systems.

They should provide necessary minimum information on the boiler start-up
and daily operation to its final user.

Before starting to connect the boiler to a heating system, you must read
and understand the operation and maintenance manual.

24

7.1. BOILER ROOM REQUIREMENTS

The boiler room in which the central heating boiler is installed must meet
current specific regulations in force in a country of destination (e.g. PN-87/B-02411
Heating. Built in boiler house for solid fuel. Requirements).

NOTICE: Use of mechanical ventilation is unacceptable.

• boilers should be located possibly centrally to heated rooms, and the
boiler should be placed as closely as possible to a chimney;

• an entrance door should open to the outside of the room and must be
constructed of non-flammable materials;

• the boiler room of heat capacity up to 25 kW should be equipped with
supply ventilation in form of a nonclosing aperture of at least 200 cm

• the boiler room of heat capacity above 25 kW should be equipped with
a supply duct of cross-section no less than 50% of a chimney cross-sec­tion area, however, no less than 20x20 cm with an outlet at a height up to
1 m above the floor level in the back part of the room; a device controlling
air flow should be installed in a supply aperture or duct, however, it sho­uld not reduce the cross-section to less than 1/5 (no supply ventilation or
its obstruction may result in such events as smoke formation or inability
to reach higher temperature);

• the boiler room of heat capacity up to 25 kW should be equipped with
exhaust ventilation (a duct of non-flammable material) under a room
ceiling of a cross-section no less than 14x14 cm

• the boiler room of heat capacity above 25 kW should be equipped with
an exhaust duct of cross-section no less than 50% of a chimney cross-

-section area, however, no less than 14x14 cm (the exhaust ventilation
removes harmful gases from the room);

• the exhaust ventilation duct should be routed above a roof level and
located close to the chimney. No closing devices should be installed on
the exhaust duct. The ventilation duct must be made of non-flammable
material.

• The boiler room should be provided with natural and artificial lighting.

2

FOR SAFETY REASONS IT IS RECOMMENDED TO EQUIP THE BO­ILER ROOM WITH A CARBON OXIDE (CO) AND A SMOKE SEN­SORS.

25

7.2. NOISE AND NOISE REDUCTION METHODS

The manufacturer made all efforts possible to maintain a noise emitted by
the heating device at a safe acceptable level of <65dB(A). Sub-assemblies
(fan, fuel feeder, moving grate mechanism) installed in the boiler are cha­racterised by their low noise index. Air-supply ducts were designed in a way
preventing excessive noise during air flow. As there are no technical options to
monitor the condition of wearable boiler components and detect undesirable
objects in the boiler and its sub-assemblies, the boiler operation manual con­tains information on troubleshooting (as well as on technical and maintenance
assistance). Wearable (deformed in operation) components of the boiler, fuel
feeder, moving grate and and blower fan may emit excessive noise; therefo­re, regular technical and maintenance inspections are recommended. Due to
the solid fuel boiler design and its moving components, it should be installed

in a separate room (see chapter 7.1 “Requirements for a boiler room”). To

minimise noise transmission from the heating device onto other parts of the
system, damping connectors (vibration compensator, e.g., EFAR, DANFOSS,
etc.) can be installed. The boiler should be set according to guidelines provi-

ded in chapter 7.3 “Setting a boiler”.

7.3. SETTING A BOILER

The boiler should be set in a way ensuring safe and easy operation of the
furnace and the ash box, as well as fuel loading and boiler cleaning. In par­ticular, an access to side and top clean out hatches and the flue pipe clean
out must be ensured, for periodic removal of the burning process residues.

The distance between the boiler side and the boiler room walls or combu­stible materials should be no less than 1 m.

No special foundations are required for the boiler. It is recommended to set
the boiler on a 5 cm high concrete platform or it can be directly set on a fire
resistant flooring. The floor on which the boiler is installed should be levelled
precisely, and the floor (ceiling) load bearing capacity should be sufficient for the
boiler weight. When the floor is not levelled precisely, adjustment feet can be in­stalled for final alignment of the boiler versus the floor. The SAS BIO SOLID boiler
is provided with 4 adjustment feet with a set of nuts and washers. The adjustment
feet are not provided for boilers above 25 kW. The adjustment feet installation is
shown in Figure 9 A).

26

A) the fitting of adjustment feet

B) boiler with feet

1 – adjustment foot with thread
(adjustment range 30 mm)
2 – nut M12

Figure 9 Installation of adjustment feet in a SAS BIO SOLID boilers

3 – washer Ø13
4 – installation opening Ø13 mm
5 – side skid of the boiler

The boiler alignment versus the floor is adjusted with a wrench No. 19 and
a bottom setting nut (item 2). When the boiler position versus the floor is finally
set, install the upper nut (item 3) and block the whole set by screwing on the
upper blocking nut (item 2). The wrench No. 19 is not provided with the boiler.

7.4. BOILER STACK CONNECTION

The design of a flue pipe and its connection to the boiler should conform to
the requirements of current national regulations in a country of destination (e.g.,
Minister of Infrastructure Regulation of 12 April 2002, Journal of Laws No. 75).

The boiler should be directly connected to the stack with a smoke connection
in form of a steel pipe, >3 mm thick (of a thermal resistance of >400°C) and of a
diameter allowing its tight connection to the flue outlet and inserting into the chim­ney. The connection between the flue pipe and the stack must be tightly sealed
(e.g., with high temperature silicone, ceramic sealant, etc.). The pipe should rise
in the direction of the stack (min.5°).

Dimensioning and selection of the flue pipe and the connector should be
performed by a designer holding necessary licences, and the stack system
should be constructed by a qualified person in accordance with current spe­cific regulations in a country of destination.

The flue pipe to which the central heating boiler will be connected must meet
requirements of current specific regulations of a country of destination (e.g., PN-

-89/B-10425 Smoke, fumes and ventilation ducts, made of bricks. Technical requ­irements and acceptance tests; Minister of Infrastructure Regulation concerning
technical conditions that should be met by buildings and their setting, of 12 April
2002, Journal of Laws No. 75, item 690, as amended).

27

Technical requirements and acceptance tests; Minister of Infrastructure Regu­lation concerning technical conditions that should be met by buildings and their
setting, of 12 April 2002, Journal of Laws No. 75, item 690, as amended 2.

A too small pipe may also cause or facilitate formation of soot deposited in the
boiler convection ducts.

When the flow in the stack is too strong, it will suck excessive amounts of air
from outside to the burner, increasing heat losses and increasing amounts of
dusts blown out of ashes. The flue gas damper installation in flue pipe allows to
dampen too high flow.

It is important for the stack to start at the boiler room floor level, to provide for
flue gas return. It is also important to provide a clean out hatch with a tight closing
system in the bottom part of the stack. To prevent a reverse flow in the flue pipe it
should reach at least 0.6 m above a roof ridge. Stack usefulness (patency) should
be checked and confirmed by a licensed chimney sweep at least once a year.

BEFORE THE BOILER IS STARTED, THE STACK MUST BE WARMED UP!

(See chapter 8.2, Boiler firing and operation)

Due to the low temperature of exhaust gas at the nominal thermal power bo­iler can cause pollution, wet deposition of soot, insufficient chimney flow. This
may result in moisture accumulation and corrosion of masonry chimney stacks.
A chimney liner is recommended.

In accordance with 4.4.3 of the standard PN-EN 303-5:2012, the manufacturer
gives information concerning the implementation of a stack:

• In the case of retrofitting existing stacks and adapting them to all year work

the flue gas outlet system is recommended (e.g. JEREMIAS, KOMINUS,

etc.) made of stainless steel (acid- and heat resistant), single- or double-

-walled (depending on the location of installation).

• In newly built premises for the all year work the boiler should be supported
by the ceramic flue gas removal system resistant to condensate, thermally
insulated, with ventilation (e.g., SCHIEDEL, LEIER, etc.).

7.5. BOILER CONNECTION TO A HEATING SYSTEM

The boiler should be connected to the heating system with screw connections;
it is forbidden to install the boiler by welding it to the system. The main supply/re­turn water system connections cannot be reduced below a diameter of a connector
installed on the boiler.

Before starting works to connect the boiler to the heating system check if all
boiler subassemblies are in a good operational condition and the boiler equipment
is complete.

28

The main supply/return water system connections cannot be reduced below

a diameter of a connector installed on the boiler.

A boiler can only be operated in a sealed system when the system is equip­ped with reliable devices to remove excess heat according to the requirements of
current specific regulations of a country of destination.

NOTICE:

It is recommended to connect the boiler to a heating system equipped with
a four-way valve. Such connection protects the boiler against low-temperature
corrosion, preventing its premature wear.

Mixing of a heating medium with a four-way valve allows to adapt the tempera­ture in the system to changes in the temperature outside. It is necessary to install
a mixing valve when the boiler set temperature would be below 60°C. To protect

the boiler against “low-temperature corrosion”, the temperature of water returning

from the heating system is increased in the four-way valve installed on the return
connection, by mixing it with water heated in the boiler.

To prepare domestic hot water, connect the heat exchanger (domestic hot
water). A heating system for domestic hot water should be equipped with the
following components: a circulatory pump and a domestic hot water temperature
sensor, connected to a supply terminal strip on the boiler side. The system should
be constructed by a qualified person, according to current regulations.

7.5.1. OPEN VENTED SYSTEM

Water-based open vented heating systems should be equipped with protecti­ve devices in accordance with current specific regulations in force in a country of
destination (PN-EN 12828+A1:2014-05 Heating systems in buildings. Design for
water-based heating systems). The expansion vessel volume should correspond to
at least 4% of water volume in the whole heating system.

NOTICE: No valves can be installed on ascending and descending safety
pipes and on a circulatory pipe, and these pipes and the expansion vessel
should be protected against freezing of water in them.

SAS BIO SOLID boilers can work with gravitational or forced water flow. When
a circulatory pump is installed in an open vented system, a differential pressure
control valve should also be installed on a supply/return pipe, so in the even of
power outage or pump failure the valve opens and the system automatically starts
to operate in a gravitational mode. An example of the boiler installation in an open
vented central heating and domestic hot water system with a forced water flow is
shown in Fig. 10.

29

SAS BIO SOLID boilers can also work with a water based central heating sys­tem through a heat exchanger. Due to a small water capacity of the open vented
system, installation of a thermal protection valve is recommended as protection
against overheating. A sealed heating system is located downstream from the
exchanger. An example of the SAS BIO SOLID boiler installation in a central he­ating and domestic hot water system with a heat exchanger is shown in Fig. 11.
The standard boiler equipment includes a connector for a temperature sensor
with a capillary tube (item 2); the temperature sensor is installed in the hottest
part, at the top of the boiler. A thermostat valve, e.g., Regulus type BVTS (optio­nal) (item 8) is thermal protection device protecting against overheating for the
boiler installed in an open vented system working with the system through a heat
exchanger. During normal operation the valve protecting against overheating is
closed and blocks supply of cold water from the water system to the heating
system. When boiler is overheated (jacket temperature above 95°C), the ther­mostat valve installed on the boiler opens, and supplied water from the water
system cools the boiler, leaves the system through an overflow pipe (RP) of an
open expansion vessel (item 10) flowing to a cooling well (item 11), and then to
a sewage system.

Direct discharge of hot water from boiler cooling is forbidden and unac­ceptable, as this may damage the sewage system.

When the temperature in the sensor environment drops below 95°C, the re­lief valve is closed automatically and water flow from the overflow vessel is stop­ped. The pressure reducer (item 7) on the thermostat valve inlet automatically
controls and maintains constant, stable flow conditions for cold cooling water,
regardless of pressure fluctuations upstream from the valve. A pressure of water
from the water supply system should be reduced to ca. 1.5 bar. A thermal pro­tection device (item 8) installed on the cold water inlet prolongs its life, because
the valve is protected against contamination with calcifications caused by hot
water leaks. A sump strainer (item 6) must be installed on the cooling water inlet
to stop mechanical contaminations, thus protecting the opening against sedi­ments and other foreign material (e.g., small grains of corrosion and metals)
which could be deposited in the valve seat resulting in its failure. A check valve
(item 5) protecting against possible water outflow from the system into the water
supply system is installed on the water supply duct.

In the event of power outage, circulatory pump failure or no heat consumption
by the system, the valve protecting against overheating (item 8) can effectively
cool the boiler to a safe temperature, preventing damage to the boiler and the
system in just few minutes. Reliable function of the temperature sensor is ensured
by two independent thermostat components. Each of them is equipped with its
own sensor and casing. When one of this unit is damaged, the other is still able
to open the valve.

30

The thermal protection against overheating can only be installed by a qu­alified person. A precondition for an efficient function of the boiler protection
against overheating is a correctly constructed system conforming to current
regulations, and in particular, meeting the requirements concerning capacity,
equipment, location of an expansion vessel in an open vented system, mini­mum diameters, routing and connection systems for protection pipes, secu­ring protective devices against freezing, and venting of water based heating
system.

It is recommended for the valve protecting against overheating (item 8)
to be checked for its correct function by a qualified person once a year. The
test is performing manually by pressing a red button that opens flow through
a valve. Press the red button at least once a year to remove contaminations
and clean the sump strainer on the cooling water inlet. A condition of the
temperature sensor (item 2) surface should be monitored because precipita­ting deposits may affect temperature indications and prolong the time needed
to open a valve protecting against overheating. For correct operation of the
thermostat valve markings showing a correct flow direction on the valve body
should be observed.

The presented diagrams showing the SAS boiler connection to the open
vented central heating and the domestic hot water systems are an example of
a possible solution. The system layout and technical parameters should be
selected by a designer holding relevant licences, and the system should be
constructed by a qualified person.

7.5.2. SEALED SYSTEM

It is possible to connect the SAS BIO SOLID boiler equipped with a factory in­stalled air supply system and a controller, to a sealed system, provided a pressure
relief valve, a diaphragm expansion vessel, equipment for control and measure­ments (manometer, thermometer, etc.), and devices for removing excess heat – a
thermal protection valve, e.g.SYR type 5067, are installed and requirements for the
boiler operation, particularly, recommended operation temperature of 60°C – 80°C,
maximum acceptable temperature of 85°C, and maximum acceptable working
pressure of 1.5 bar, are met.

31

Figure.10. General diagram for connection of the SAS BIO SOLID boiler to an open vented
central heating and domestic hot water system with a forced water circulation and a four-

-way valve.

1 – SAS BIO SOLID boiler, 2 – open expansion vessel, 3 – check valve, 4 – differential
pressure control valve, 5 – circulatory pump of a domestic hot water system, 6 – domestic
hot water tank, 7 – four-way valve, 8 – circulatory pump of a central heating system, 9 –
central heating system, RW – expansion pipe, RB – pressure relief pipe, RO – venting pipe,
RP – overflow pipe, RS –signalling pipe

32

Figure.11. General diagram for connection of the SAS BIO SOLID boiler to a central heating
and domestic hot water system. The boiler in an open vented system working with the sys­tem through a plate exchanger, protected against overheating with a Regulus thermostatic
valve type BVTS.

CH instalation,
open system

CH instalation,
closed system

water dump into the

sewage system

Supply from the installation

water system

1 – SAS BIO SOLID boiler, 2 – temperature sensor with a capillary tube, 3 – discharge
connection, 4 – cut-off ball valve, 5 – check valve, 6 – sump strainer, 7 – pressure reducer,
8 – Regulus thermostatic valve type BVTS protecting against overheating, 9 – discharge
valve, 10 – open expansion vessel, 11 – overflow cooling well (vessel), 12 – differential
pressure control valve, 13 – circulatory pump of a domestic hot water system, 14 – domestic
hot water tank, 15 – circulatory pump of an open vented system 16 – plate heat exchanger,
17 – circulatory pump of a sealed system, RW – expansion pipe, RB – pressure relief pipe,
RO – venting pipe, RP – overflow pipe, RS –signalling pipe

33

Figure.12. General diagram for connection of the SAS BIO SOLID boiler to a central heating
and domestic hot water system. The boiler in the sealed system, secured against overhe­ating with a SYR thermostatic valve, type 5067

water system
Supply from the installation

sewage system
water dump into the

1- SAS BIO SOLID boiler, 2 – pressure relief valve, 3 – temperature sensor with a capillary
tube, 4 – cut-off ball valve, 5 – sump strainer, 6 – thermal protection device (e.g SYR type

5067) protecting the system against overheating, 7 – differential pressure control valve, 8 –
circulatory pump of a domestic hot water system, 9 – check valve, 10 – domestic hot water
tank, 11 – four-way valve, 12 – circulatory pump of a central heating system, 13 – central
heating system, 14 – diaphragm expansion vessel, 15 – discharge valve, 16 – overflow
cooling well (vessel)

34

THERMAL PROTECTION

5067.

unlabeled dimensions in mm

Applications:

Thermal protection for 5067 installation is used to secure the solid-fuel boilers in heating installations with thermostatic valves according to Polish standard
PN-EN303-5. Highly recommended for boilers not equipped with the cooling exchanger. Figure 1 shows the installation principle, in close proximity to the
boiler, particularly paying attenti on to such guidance and dimensioning of pipes that ensures no pressure losses.

Assembly and operating principle: The t hermal protecti on valve 5067 consists of the foll owing parts: chec k valve ( 1), pressure reducer (2), thermall y
controlled filling valve (3) and discharge valve (4), temperature sensor with a capillary (5).
The reducer (2) is li nked t o the water network , the output of thermally controll ed filling valve (3) is connected t o the return pipe of the boil er. The supply
pipe to the thermally controlled discharge valve (4) with output side leading to the drain. The temperature sensor is mounted in the warmest place, preferably
at the top of the boiler. The relief valve is set permanently at 1.2 bar, hence the operating pressure to the heater unit shoul d be higher by 0.2 – 0.3 bar.
This prevents the opening of the safety valve in the installation. It is recommended to use the safety valve set to at least 2 bar.
When the set opening temperature of approximately 90oC is exceeded, the fill v alve begins to open (3). To maintain the stable pressure in the heat ing
installation, the discharge valve opens at 97oC. After opening the discharge valve, hot water leaves the heating installation and the col d water may flow
from the supply pipe, cooling down the boiler. When lowering the temperatur e of the boiler to 94oC the discharge valve is closed. With thermally controlled
filling valve and temperature sensor the correct pressure flow is restored in the heating installation.
When the water temperature in the boiler reaches 88oC, the filling valve also closes.

Execution:

Thermal safety device is controlled by the independently by other two valves: filli ng and discharge. The device body is moulded from brass, other parts to
come in contact with water are made of stainless steel and the plastic resistant to the temperature. All the sealing elements are made of material which is
elastic and resistant to high temperatures and wear – elastom er. The springs are made of stainless spring steel. The sensor and the capillar y tube are
made of copper, additionally the bushing is nick el-plated.
The opening of the valve is controlled by the d ual temperature sensor. The fittings vent by themselves. Valve components, seat and seal c an be r em oved
and cleaned without changing settings of the opening temperature. Compact tem per ature sensor head may be removed for the time of assembling of the
valve body for the convenience of the user. The capillary tube from the sensor to the actuator is protected by a special metal flex ible hose.

The operating pressure of the pressure reducer:
Maximum inlet water pressure:
The minimum required input water pressure:
Temperature

filling valve

discharge valve
Maximum operating temperature
Capillary tube
Weight

1.2 bar (factory locked)
16 bar

2.3 bar
Opening: Closing:
90°C +0/-2°C 88°C +0/-2°C
97°C +0/-2 °C 94°C +0/-2°C
135°C
1300 mm - standard length

1.5kg

HANS SASSERATH & CO. KG – HUSTY

ul.Rzepakowa 5e, 31-989 Kraków, tel. [phone], fax [phone], e-mail: [e-mail] www.syr.pl

35

When the boiler is installed in a sealed system it is necessary to install in
the heating system a reliable device for removing excess heat. The thermal
protection from overheating in the event of disruption should be able to safely
discharge the maximum possible heat output or with partially switched off
heating, the residual heat output (according to EN 303-5:2012).

The operational principle of the proposed protection for the sealed system, in
form of a cooling valve, is similar to a valve described in Chapter 7.4.1, e.g., the Re­gulus valve, type BVTS, intended for an open vented system with a plate exchanger.
A significant difference is optional work in sealed systems, equipping the valve with
a component letting water in when the temperature is exceeded, a factory check
valve, a pressure reducer and a component gradually removing excess heat when
a specific temperature is exceeded. A gradual operation of the thermal valve SYR
type 5067 stabilises pressure in the sealed system. The proposed thermal protec­tion is effective when the system is connected to a water supply system. It cannot
be used when water is supplied through a pressure tank or in places where frequ­ent breaks in water supply occur In such cases the boiler should not be installed in
the sealed system (see chapter 7.5.1).

Protective devices of the sealed heating system should be constructed in
accordance with current specific regulations in a country of destination (PN-EN
12828+A1:2014-05 Heating systems in buildings. Design for water-based heating
systems, PN-EN 303-5, Minister of Infrastructure Regulation concerning technical
conditions that should be met by buildings and their setting, of 12 April 2002, Jour­nal of Laws No. 75, item 690).

An example of the SAS BIO SOLID boiler installation in a sealed central heating
and domestic hot water system is shown in Fig. 12.

The standard boiler equipment includes a connector for a temperature sensor
with a capillary tube (item 3); the temperature sensor L=150mm is installed in the
hottest part, at the top of the boiler. The thermostatic valve, e.g., SYR type 5067
(optional) (item 6) provides thermal protection for a boiler installed in the sealed
system. When the thermal protection valve is not installed, the connector must be
secured with a plug. During normal operation the valve protecting against overhe­ating is closed and blocks supply of cold water

from the water system to the heating system. When boiler is overheated (jacket
temperature above 90°), the thermostat valve installed on the boiler opens gradu­ally, and supplied water from the water system cools the boiler, leaves the system
through a discharge part of the SYR valve type 5067 to a cooling well (item 16),
and then to a sewage system. A detailed functional characteristic is provided in the
attached catalogue card of the SYR valve type 5067 (see manufacturer catalogue
card, page 32).

The presented diagrams showing the SAS boiler connection to the sealed­central heating and the domestic hot water systems are an example of a possi­ble solution. The system layout and technical parameters should be selected
by a designer holding relevant licences, and the system should be construc-

ted by a qualified person.

36

7.6. BOILER CONNECTION TO A POWER SUPPLY SYSTEM

The boiler room should be equipped with the 230V/50Hz power supply sys­tem in accordance with current specific regulations in force in a country of desti­nation. The power supply system must end with a socket equipped with a pro­tective contact. The plug socket should be located at a safe distance from heat
emission sources. A defective power supply system may damage the controller
and pose a threat to boiler room users. It is forbidden to use extension cords. It
is recommended to connect the heating device on a separate power circuit with
a protective device in the main switchboard.

A descriptive identification of cables and sensors was used, and plugs of

various shapes and colours. An additional label on the boiler “connect cables
according to description”.

Temperature controller, burner controller and devices working with it ope­rate under voltage of 230 V, therefore, all connections can only be made by a
person having required qualifications (Polish Electricians Association licence
up to 1kV). All works should be performed with power supply switched off and
all required safety rules for servicing of electrical devices observed (ensure the
plug is unplugged from the mains!). Any attempt to perform unauthorised re­pairs/changes in the control system may result in electric shock and loss of the
guarantee. Additionally electrical equipment is labelled with pictograms warning
about the hazard.

NOTE!

SHOCK HAZARD

An attention should be paid to route cables supplying energized equip­ment away from the boiler components that become hot during operation
(upper clean out hatch, flue, doors).

An emergency power supply for the heating system (temperature controller,
control module, fan, gearmotor, circulatory pumps, mixing valves with an actu­ator) should be provided in the event of power outage, from additional equip­ment: UPS with a sine wave output or a power generator.

37

8. GUIDELINES FOR USE AND OPERATION

NOTE!
Before starting operation an experienced installer should train the user in
rules for operation and maintenance of the boiler and the whole heating
system. A person operating the boiler should be acquainted with statu­ses of the incorrect device operation and with procedures for dangerous
situations.

8.1. FILLING WITH WATER

Before the first start-up of the boiler, the water tightness test of the whole heating
system should be performed. Before the tightness test is started, the whole system
should be effectively rinsed with water to remove any possible contaminations which
could affect the boiler operation.

Water used to fill the boiler and the heating system should be clean, free of ag­gressive chemical compounds or oil, and meet requirements of current regulations
(PN-C-04607:1993 Water in heating systems – Requirements and tests concerning
water quality).

Water for filling of the system should meet the following requirements:

• pH: 8.0÷9.0 – in a copper system or systems of combined materials steel/
copper; 8.0÷9.5 – in a system of steel and cast iron; 8.0÷8.5 – in a system
with aluminium radiators.

• total water hardness ≤ 4 mval/l (11.2°dH /German degrees/).

• free oxygen content ≤ 0.1 mg O2/l

Temporary hardness caused by hydrogen carbonates that are thermally unstable
and when heated are transformed into water-insoluble carbonates deposited as lime­scale. Some of limescale is deposited on the system components and some on the
boiler components, mainly the exchanger. Limescale has very good thermal insula­tion properties, reducing heat absorption by boiler water and resulting in overheating
of the exchanger and, in consequence, in its destruction.

The boiler and the whole system should be filled with water through the boiler
discharge connector. This operation should be conducted slowly, to ensure the air is
removed from the system. The system is completely filled when water flows out from
the overflow pipe (in an open vented system).

When the central heating system is filled with water, it is recommended to loosen
screws at the connection between the boiler and the system (at the hot water connec­tor). When water flows out, tighten the screws.

The open vented heating system is in a direct contact with air, resulting in water
evaporation and a need to replenish it.

NOTICE: It is forbidden and unacceptable to replenish water in the event of
the system failure – when there is no water in the boiler and the boiler is very
hot, because this may result in damage or cracks!

38

When the heating season is over do not discharge water from the system and
the boiler. Whenever repairs are necessary, after cooling water is discharged thro­ugh the boiler discharge connector to a sink or a drain.

8.2. BOILER FIRING AND OPERATION

Firing of fuel in the boiler equipped with SAS MULTI FLAME pellet burner sho­uld be started after ensuring that a heating system is filled with water and this
water is not frozen. The boiler and threaded connections should also be checked
for any water leakage.

NOTE! It should also be remembered that the stake must be warmed up befo­re the first start-up.

This activity aims at ensuring correct conditions for correct burning of fuel. For this
purpose, burn a small amount of finely chopped wood and crushed paper on the fur­nace with a water-cooled grate (the controller should be set to blowing fan in manual
mode). Then the residues from the furnace should be removed after burning the fuel.
When a correct flue gas flow is created in the stack, the stack is warmed up and the
actual firing process can start (in automatic operation mode).

NOTICE:

When a supply ventilation is not installed or is obstructed, this may lead to
consequences including generation of smoke or inability to reach the required
temperature.

When a supply ventilation is not installed, this may result in generation of large
quantities of flammable, highly-explosive gases (a risk of damage to the flue pipe).

NOTICE:

Both the fuel reservoir and the transport fuel pipes are factory fuel-free. For
this reason is is necessary to fill them before the combustion process. For this
purpose the reservoir should be filled with fuel, and the feeder should be started
in manual mode to ensure filling the transport augers with fuel. The reservoir filling
checks can be performed by removing the furmace housing (see. Figure 7, item

1). The excess fuel should be removed from the furnace (e.g. by dislodging to the
ash box). Is not allowed to leave the excess fuel, because the fixed initial dose
will be provided automatically after the starting the firing process. The excess fuel
in the firing phase can lead to produce the large quantities of highly explosive
flammable gases (risk of damage to the stack). The above-described procedure
is required in the case of both new boiler (Initial start) as well as in situations of
completely draining the reservoir of fuel. In the normal operation of the boiler be
sure to refill the fuel reservoir regularly.

Heating of the stack and filling transport augers with fuel allows proper and
safe firing process. Once the above instructions are followed, the automatic firing
process should start – ceramic burner (see. the operating and maintenance ma­nual of the controller).

39

A person operating the boiler should be aware that some boiler surfaces are
hot, and safety gloves must be worn before touching them!
You should also use protective goggles (hot surfaces are marked with a pic­togram).

HOT

SURFACE

Flue gases emitted from an obstructed stack are hazardous. The stack and the
connector should be kept clean; they should be cleaned according to the manu­facturer instruction. Boiler flue gas ducts should be kept clean.

Use only recommended types of fuel.

Before firing the boiler, load the fuel tank (fuel storage) so it is possible to
close the lid. When fuel is loaded to the hopper check the loaded fuel for sto­nes, metal components and similar objects that may block the screw conveyor
mechanism. Then switch the controller to MANUAL MODE* for a period of time
after which the transport augers fill the feeder tubes with fuel. Then set the au­tomatic firing process on the controller (ceramic burner). In the boiler automatic
mode, a set temperature (boiler water temperature) value must be set on a con­troller along with the operating time and intervals in the moving grate operation.
This action should be performed in accordance with procedures specified in
the operating manual of the controlled (Configuration of User Parameters). The
amount of air supplied by the blower fan should be adapted to intensity of fuel
combustion in the furnace.

Monitor the boiler during firing until the water supply temperature reaches
45°C. This is important because the boiler can go off due to varying quality of
fuel. When the fire in the boiler is extinguished, clean the furnace and air the
boiler ducts during firing, and restart firing.

After a single firing the boiler operation is, in general, maintenance free, and
the burning process is continuous. Further boiler operation is limited to reple­nishing of the fuel tank and removing deposited ash from the ash-box drawer.

* the details are enclosed in the controller manual

40

A boiler room with solid fuel automatic boiler requires periodic supervision.
During boiler operation certain daily activities must be performed, to prevent
emergency situations.

When fuel is loaded into the hopper, it should be ensured that the fuel does
not contain any large pieces of coal, and in particular stones, which may block
the feeder!

The controller settings must be adjusted according to current temperatures
outside and quality of burned fuel. Setting parameters should be selected (moni­toring fire condition and appearance in the furnace).

In the automated mode the controller measures the temperature of water in
the boiler, and uses the results to control work of the fuel feeder and the blower
fan according to previously selected settings optimum for a given fuel type. De­pending on the weather conditions, burning intensity and the boiler heat output
should be adjusted according to changing conditions, regulating a temperature
of water leaving the boiler (or, when the three- or four-way valve is installed, by
changing settings of the control shutter).

At the same time the controller controls operation of pumps: central heating,
domestic hot water, floor and circulation (if the heating system is equipped with
pumps).

Regularly - at least once a day - open the furnace door and check the flame
condition (furnace appearance). When any deviations are noticed, adjust the bo-

iler operation (see Chapter 11 “Statuses of incorrect boiler work”).

In the central heating system, the heat demand changes with changes in the
external conditions, i.e., time of the day and changes in the temperature outside.
The temperature of water leaving the boiler also depends on the building energy
performance, i.e., on construction materials, particularly insulation, used for its
construction.

When the fire in the boiler is extinguished, clean the furnace and air the boiler
ducts during firing, and restart firing.

During firing smoke can penetrate into the boiler room or retting (sweating)
of the boiler. When the boiler and the flue pipe are warmed these adverse effects
should be reversed.

The boiler can stop when there is no fuel in the hopper or the feeder is blocked
with undesirable hard objects, stones, etc.

8.3. BOILER CLEANING

For economic fuel consumption and to obtain declared boiler output and heat
effectiveness, it is necessary to maintain required cleanness of the burner furnace
space and the exchanger convection ducts.

The convection ducts, in which air-born ash is deposited, should be regularly
cleaned, every 3÷7 days. Relevant tools delivered with the boiler should be used

41

for this purpose. Were the boiler is extinguished and cooled down, clean the com­bustion chamber and exhaust ducts through the clean out holes and inspection
doors on the front wall of the boiler. To do this, remove the cover of the top clean
out. The access for cleaning of vertical partitions of the exchanger is possible after
removing the gas chamber cover. Before cleaning the exchanger remove the gas
turbulator through top clean out hole (Fig. 13). Using the available tools, clean the
surface from dust/soot.

Figure 13 Flue gas turbulator

Carefully clean the ceramic panels inside the combustion chamber. After thoro­ugh cleaning of the ducts, clean the flue pipe trough side clean outs. After cleaning
these openings must be tightly closed. Remove periodically precipitated dust/ash
through the door of side clean out and burner air box clean out. The boiler is equip­ped with the ash-box drawer located in the bottom part of the device, and it must be
regularly emptied of the burning process residues (ash, dust, slag).

At the factory, the boiler was equipped with a set of ceramic sealant (see inspec­tion/clean our doors/holes). Regular inspection of the sealant condition is recommen­ded, and its replacement when any wear is discovered.

Inside the furnace special attention should be paid to the periodic cleaning of ho­les in the automatic firebox and on its sides. These operations should be carried out
after the boiler turns off and when furnace cools down to allow safe cleaning. Access
to the furnace is possible after removing the cover (upper section) using available
tools (e.g. poker), using the mounting bracket on the housing. The housing removal
must be carried out carefully so as not to damage the refractory ceramic material
shape. After removing the housing also clean the surface of ceramic shape from the
residues of biomass combustion (ash, slag). Additionally, an air chamber located
below the furnace should also be cleaned periodically, because ash falling from the
automated furnace plate collects there. Cleaning is done through the air chamber
clean out located under the automatic furnace. After cleaning the furnace, close the
air chamber clean out and refit the housing with the ceramic shape (see figure 7).

42

The combustion of inferior quality fuels may cause an increased amount of ash
as the product of the combustion process. Furnace cleaning mechanism performs
recurring blows and movement of grates. The combustion of inferior quality fuels
can cause ash build-up on the furnace plate (fixed part). In such a case you must re­move the furnace housing and remove the ash to the ash drawer. Ash accumulation
is not a defect in the operation of the burner, but a consequence of combustion of
inferior quality fuels. Control of the fuel feeder and blower fan is done automatically
depending on the demand for the heat output. The frequency of the grate moving
should be adjusted depending on the quality of the fuel used.

Any activities related to revision of the auger feeder can only be perfor­med when the boiler is disconnected from the mains.

When the above recommendations related to boiler cleaning are not obse­rved, this may result not only in significant heat losses but also hinder flue gas
circulation in the boiler, resulting in turn in smoke emission from the boiler.

Proper maintenance and systematic maintenance prolongs life of the boiler
and its accessories.

NOTICE: At least once a month check the accumulation if dust in the air
chamber (see fig.7, item14), possibly shutoff the boiler and clean the furnace
– the pellet burner.

When the boiler is equipped with a flue gas temperature sensor, its surfa­ce must be cleaned regularly to ensure correct temperature readouts in the
flue gas pipe, and control over the burning process.

Periodical cleaning of a flue pipe is also of importance for correct operation
of the boiler.

8.4. END OF BURNING

At the end of heating season or in cases of the planned boiler shutdown, switch
off the burner by selecting the extinguish mode on the controller and remove the
residues after combustion to the ash box.

NOTICE: It is forbidden to use water in the boiler room to extinguish fuel!

In the event of the emergency extinguishing, the fired fuel must be removed
into metal containers and removed from the boiler room, or sand should be po­ured over fuel burning in the furnace.

When the boiler is put off and cooled, remove all residues of burned fuel from
the furnace, and perform cleaning and maintenance operations for the whole bo­iler. Required maintenance (lubrication with oil) of inner partitions of the furnace
chamber and moving components should be performed.

Do not discharge water from the boiler and the system for the break in the
heating season. If the boiler has been excluded from the work, the feeder mecha­nism, moving grate, blower fan and circulation pump should be run once a week.
This prevents jamming the moving parts.

43

It is recommended to leave doors (clean out, furnace, ash-box) and clean out
holes open during this operation, to prevent corrosion resulting from water con­densation on cold walls of the heat exchanger.

9. CONDITIONS FOR SAFE OPERATION

To maintain safe operational conditions for the boiler, the following rules must
be observed:

• the boiler can only be operated by adults, according to guidelines provi­ded in the documentation supplied together with the device;

• all connections to the power supply system can only be made by a per­son holding relevant qualifications – Polish Electricians Association li­cence up to 1kV;

• children cannot remain unattended in the boiler vicinity, or have access
to the controller and to moving components of the boiler;

• the boiler and the associated system must be kept in the correct ope­rational condition, and in particular, system tightness and tightness of
doors and clean out hatches must be ensured;

• maintain order in the boiler room and do not stack any objects not used
for boiler operation or flammable materials;

• during winter avoid breaks in heating to prevent freezing of water in the
system or its part. Freezing, particularly of safety (overflow) pipes is very
dangerous, as it may result in the boiler damage;

• it is forbidden to fire the boiler using flammable materials such as petrol,
kerosene, or solvents, as this may result in explosion or burning of the user;

• before each firing and regularly during operation check the amount of
water in the heating system and ensure the valves between the boiler
and the system are opened;

• during the boiler operation the heating water temperature cannot exceed
85°C;

• in the event of the system failure, when there is no water in the boiler do
not replenish it when the boiler is very hot, because this may result in the
boiler failure;

• all activities related to the boiler operation should be performed in pro­tective gloves and with particular care observed; all boiler defects must
be remedied immediately.

NOTICE: The boiler must be regularly cleaned of soot and tar – any de-

posits on convection duct walls affect correct heat transfer
from the exchanger, reducing the device performance and in­creasing fuel consumption.

The pellet feeder is designed in a way not requiring complicated operation
and expensive maintenance. However, its correct operation (influencing boiler
performance and burning economy) requires certain rules to be observed during
the feeder operation and regular performance of certain activities.

44

10. OPERATION AND MAINTENANCE OF THE FEEDER
AND THE BURNER

1. Periodic checks of the furnace during operation of the boiler can only be
carried out through the furnace doors.

2. Remove the slag periodically, if it accumulates in the furnace of the boiler
(it may impede the flow of air).

3. Check the fuel level in the tank.

4. The fuel put into the reservoir must be dry.

5. Check whether no dust or other waste accumulated in the tank and the
feeder cover pipe, and remove it when necessary.

6. Check condition of air nozzles and patency of air outlets.

7. Periodically clean dust and residues of fuel or ash from the feeder.

8. Regularly clean the motor casing using a dry cloth.

9. Do not use any solvents for cleaning as they may damage sealing rings
and gaskets.

10. When the boiler, together with the feeder, is removed from operation, qu­arterly start the augers, moving grate mechanism and blower fan for 15
minutes – thus preventing any blocking of the moving parts.

11. Check the accumulation of dust or other waste in the air chamber – thro­ugh the clean out (access to the ash box, see. Figure 7 item 14)

45

11. STATUSES OF INCORRECT BOILER WORK

PROBLEM CAUSE/APPEARANCE REMEDIES

Low heat
performance
of the device

Smoke

flue gas ducts or air supply
ducts contaminated

no air supply to the boiler
room

explosions in the
combustion chamber,
ignition of flue gas

burning of incorrect fuel

boiler output incorrectly
selected for heated surface

incorrectly designed and
constructed central heating
system

incorrect work of a controller, a
ventilator or a feeder

insufficient chimney draught

contamination of flue gas
ducts,

blocked openings supplying
air to the furnace

sealant sealing doors and
clean out hatch openings is
worn

incorrect connection between
the boiler and the chimney

very low atmospheric pressure

clean the exhaust ducts through clean
outs, holes supplying air to the furnace

check the condition of the supply
ventilation in the boiler room,
improve its patency.

use fuel of adequate quality (see chapter

6 “Fuel”)

check chimney stack patency and
parameters (see a table specifying
appropriate chimney hight and cross­section for a given boiler output), check
whether the chimney does not end
below the highest roof ridge

clean the boiler through the doors and
clean outs

clean the furnace, restore patency of air
supplying openings

replace sealant sealing doors and
clean out hatch openings (this is a
wearable material subject to regular
replacement).

check correctness of the connection
between the boiler with a chimney stack

46

incorrect flue gas damper
position for chimney draught
present

incorrect flue gas damper position for
chimney draught present

PROBLEM CAUSE/APPEARANCE REMEDIES

Sudden
increase in
the boiler
temperature
and pressure

Water leaking
from the boiler

“Rattling, firing”

in the boiler

The fan does
not work
correctly, The
feeder does
not work
correctly

valves in the system closed open the valves

expansion vessel is frozen

so-called boiler “sweating,
retting”, this is a natural

phenomenon resulting from
temperature differences in the
boiler

air in the central heating
system and the boiler, e.g.,
due to incorrect filling of the
system and the boiler with
water

does not start, whines,
problems with start-up, does
not reach set operating values

provide thermal insulation on the
expansion vessel

when starting the boiler and after
each its shutdown the boiler1 must be
heated, i.e. fire it to 70°C and maintain
this temperature of the boiler for several
hours

boiler warming up, i.e., maintaining
the temperature above 70°C for longer
time until air bubbles are completely
removed from the boiler

bleed the central heating system with
vents on radiators

replace the fan capacitor (see the fan
casing), replace the feeder capacitor
(see the feeder casing)

The moving
grate
mechanism
does not work

does not start, a message

“Hall effect sensor” appears

clean the air chamber of the burner,
check the settings of the grate
positioning sensor (Hall effect sensor),
replace the sensor (see the pellet
feeder)

47

12. PROTECTIVE DEVICES

To ensure possibly failure-free and safe operation, the boiler controller is equip­ped with numerous protective devices. The software installed controls operation of
semi-assemblies and performs monitoring and safety operations to prevent hazardo­us conditions (e.g., power outage and its restoration). When any incorrect status is
found an audio alarm is activated, and a relevant message is shown on the display
(see the controller operating manual). To eliminate the effect of voltage fluctuations
or incorrect voltage in the mains, a system controlling the fan rotational speed was
installed (the Hall effect sensor).

When the equipment is installed, each boiler undergoes a test of correct ope­ration of the control system. The temperature regulator, burner control module,
wiring and the supply terminal strip are installed in the insulation lid on purpose,
to eliminate access to locations posing a hazard of an electric shock. Appropriate
tools must be used to remove them.

TEMPERATURE ALARM

This security device is activated only in the operational mode (when the boiler
temperature is below the set temperature). When the boiler temperature does not rise
in the time specified by the user, the alarm is activated, the feeder and the blower are
switched off, and the audio signal is alarmed. The screen displays the following mes­sage: “Temperature does not increase”. When the encoder is pressed, the alarm
is switched off. The controller returns to the last set operational mode.

AUTOMATED SENSOR MONITORING

When the central heating system, the domestic hot water sensor or the fuel
feeder sensor is damaged, the audio alarm is activated signalling additionally a

relevant defect on the display, e.g.: “Central heating sensor damaged”. The feeder

and the blower are switched off. The pump works regardless of the current tempe­rature. When the central heating or the feeder sensor is damaged, the alarm will
remain active until the sensor is replaced with a new one. When the domestic hot
water sensor is damaged, press the encoder knob, switching off the alarm, and
the sensor will return to the central heating pump operation). The the domestic hot
water sensor must be replaced with the new one to enable the boiler operation in
all modes.

TEMPERATURE PROTECTION

The controller is provided with additional software (digital) temperature pro­tection against dangerous increase in the temperature. When the alarm tempe­rature (set within the 80°C÷85°C range) is exceeded, the blower fan and the fuel
feeder are disconnected. At the same time, active pumps start to work to distribu­te heat in the system. When the boiler alarm temperature is exceeded, the audio
alarm is activated and the message is displayed “Temperature too high”. When
the temperature returns to the safe value, the alarm is switched off by pressing the
encoder, and the regulator returns to the last set operating mode.

48

THERMAL PROTECTION
The boiler controller is equipped with the safe temperature limiter STB protec-

ting against boiler overheating (water boiling in the system) when the controller is

damaged. The safe temperature limiter is a mechanical protective device consisting
of a sensor (located near the supply terminal strip on the upper insulation cover),
operating according to a disconnecting contacts principle and cutting off the power
supply to the blower fan and the fuel feeder when the limit temperature is exceeded
(set within a range of 90 to 100°C). The equipment cannot be restarted automatically,
even when the temperature is lowered. The user must switch them on, resetting the
sensor (with the button) after the temperature of the boiler is reduced.

NOTE! An attempt to engage the “dislocated” sensor on the hot boiler can

cause damage to the STB safety temperature limiter.

When this sensor is damaged or overheated, the fan and the feeder are discon­nected (do not work either in the manual or the automated mode), and the message
“Temperature too high” is shown on the controller.

Dismantle the controller to replace the temperature sensor. Then push away
insulation of mineral wool; the temperature sensor is installed in the measuring
well The STB safety temperature limiter is installed in the upper cover on the sup­ply terminal strip (Fig. 14)

temperature Sensor

Figure 14 The location of the STB safety temperature limiter and temperature sensor

STB

49

FUEL TANK SECURITY DEVICES

For the safety of the operation of the boiler the SAS MULTI FLAME burner

is equipped with a multi-level protection system. It has a protection from wi-

thdrawing the flame into the reservoir of fuel by the feeder (mechanism of
two transport augers separated by the transfer duct, temperature sensor of
the fuel ducts) and additionally an overheat protection – a thermal circuit
breaker mounted on the boiler. Fuel transport from the reservoir of fuel into

the chamber of the furnace chamber is carried out in order to eliminate the risk
of withdrawal of flame into the reservoir of fuel during normal operation, feeder
downtime and also in the case of interruption in the supply of electricity. The
task of the mechanism is to protect against uncontrolled retraction of fire into

the reservoir of fuel without the need for extinguishing installation, i.e. “water
fireman”. Safe transport fuel is ensured by the location of openings in fuel di-

stribution pipes and the gap between these pipes. The movement of augers is
carried out with chain-driven gears through the gear motor. For safety reasons
the gate closing the fuel reservoir during the combustion of biomass in the bur­ner must be sealed.

The controller is additionally secured against flashback to the fuel tank (hop­per). The boiler is equipped with a feeder pipe sensor measuring temperature
near the fuel tank. When the temperature increases significantly (when the set
temperature is exceeded), the internal controller software automatically activates
procedures protecting the boiler against overheating or fire in the fuel feeder. The
alarm is activated and the feeder is started cyclically, moving fuel to the furnace
chamber to reduce the temperature of the feeder components.

For safety reasons, the fuel tank is separated from the boiler body – a naturally
ventilated space is provided (separate casings, thermal insulation of the exchan­ger, ceramic sealant, and additional insulation of the feeder components).

The boiler is equipped with a tight fuel reservoir. In the reservoir cover there
is a limit switch that interrupts the feeder fuel and air fan operation at the time of
opening the cover. A message appears on the display: “Cover open” and an
audible alarm (reminder and signal appear cyclically). When the fuel reservoir
cover is closed, the operation is resumed. Inside the cover there is an information
for the user about the presence and operation of the limit switch (reservoir cover
opening sensor).

FUSE

A controller is equipped with WT 6.3 A tube fuse links protecting the mains.

NOTICE:

Do not use a fuse of a higher value. Installation of a larger fuse may damage the
controller.

50

PROTECTION OF THE SCREW CONVEYOR AND THE GEARBOX

The feeder motor is additionally protected against overload in form of a ther-

mal fuse, which automatically switches the feeder off in the event of overheating.

PRESSURE RELIEF VALVE

The boiler is equipped with a factory-installed with the 2.5 bar pressure relief va­lve, being an additional protecting device against the pressure increase when water
freezes in part of the system, and in the expansion vessel in particular. The installer

is obliged to connect a pipe discharging water from the pressure relief valve to
the drain or at the lowest possible level near the floor.

Additionally, an analogue thermometer is installed for a control temperature re­adout or in the event of the control system failure. The heating system should be
equipped with a measuring and monitoring device for pressure readout, in form of a
manometer.

THERMAL PROTECTION VALVE PROTECTING AGAINST OVERHEATING

(additional accessory)

In its standard version, the SAS BIO SOLID boiler is equipped with a connec­tor for installation of the temperature sensor with a capillary tube; the thermostat
valve (optional), e.g., Regulus type BVTS is a thermal protection device for a bo­iler installed through the heat exchanger in an open vented system with the plate
exchanger or for the boiler installed in the sealed system, e.g., SYR, type 5067.
When the boiler is overheated (jacket temperature above 95°C) the thermal pro­tection valve installed on the boiler is opened, the water supplied from the water
supply system cools the boiler, flows from the system to the cooling well, and then
to the sewage system. A detailed description of the valve operation and connec­tion is described in Chapter 7.4 Boiler connection to a heating system.

When the thermostat valve is not installed, the connector must be secured with a plug.

13. DELIVERY TERMS AND CONDITIONS

The boilers for sale are delivered in an assembled condition, with a set of tools for
they operation and with the operation and maintenance documentation (see Chapter

4 “Setting a boiler”).

The boilers are installed at the factory on a transport pallet, protected with a pla­stic film against weather conditions. Brackets are installed for boiler transport with a
pallet/fork lift truck. Individual boiler components can be dismounted: the fuel feeding
system, the fuel reservoir, front door insulation and the temperature sensors, for boiler
transport and installation in the boiler room.

When the fuel feeder must be dismantled, it can only be reinstalled by a qualified
installer! Incorrect connection of cables may damage the regulator.

NOTICE:

Boilers must be transported in a vertical position! Store in roofed and well-

-ventilated rooms! Secure the load against damage! When the boiler is damaged
(in transport), do not use it but contact the manufacturer maintenance service.

51

14. BOILER DISPOSAL

Components used in the boiler are made of materials which physical state and
chemical activity changes at temperatures significantly exceeding temperatures that
can be reached during normal operation of the boiler. Materials used for construction
of the device do not emit substances hazardous to the environment, even in condi­tions exceeding normal operational conditions of the boiler.

To dispose of the boiler, transfer the used device to a specialist disposal company,
in accordance with current specific regulations in force in a country of destination.
Components protecting the boiler for the transport: plastic film, bags, plastic mate­rials, should be transferred to a relevant waste collection entity. The SAS BIO SOLID
boiler is equipped with digital equipment subject to selective collection of electrical
and electronic equipment (a sign of a crossed-out basket on a nominal plate). The
steel structure of the boiler should be disposed of as steel scrap. Before scrapping,
disconnect the controller, the fan, the gearmotor, and power supply cables. Insulation
materials (e.g., mineral wool, sealant, thermal insulation, etc.) should be transferred
to a relevant waste collection entity. The waste collection place should be specified by
relevant municipal or commune services.

15. WARRANTY TERMS AND CONDITIONS

1. The manufacturer grants to the Buyer a warranty for the SAS BIO SOLID
boiler under terms and conditions specified in this warranty. It is confirmed
with the company seal.

2. The manufacturer guarantees efficient work of the boiler when it is installed
and operated according to all conditions and guidelines specified in the
operation and maintenance documentation.

3. The Buyer is issued with the operation and maintenance documentation,
specifying principles for correct operation of the boiler, together with the
warranty terms and conditions. It is mandatory to become acquainted with
the operation and maintenance documentation.

4. Deadline for the guarantee shall be calculated from the date of issue of the
subject matter of the contract to the purchaser (entered in the warranty card
and confirmed by the document purchase) and is:

a. 5 years for efficient operation of the boiler
b. 2 years on additional heat partition of the clean out doors/furnace
c. 2 years for efficient operation of the burner
d. 2 years for electronic and automatic sub-assemblies installed in the
boiler and manufactured by other producers:

• Driver

• Module controlling burner operation

• Blower fan

• Pressure relief valve

• Gear-motor

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• Moving grate drive motors

• The electrical heater (fuel burner)

• Automatic fuel feeding system and its parts

• Analogue thermometer

5. The warranty does not cover components subject to wear and tear:

• Screws, nuts, handles

• Sealant (sealing elements), rubber seals in the fuel reservoir

• Capacitor (see the blower fan, the gearmotor)

• Flue gas turbulator

• Ceramic panels

6. In consequence of any repairs of the boiler or changes in its design or insu­lation made by the Buyer or other third persons during the warranty period
the warranty terms and conditions become invalid.

7. All damages resulting from incorrect operation, incorrect storage, improper
maintenance not conforming to the operation and maintenance documen­tation, or other reasons not attributable to the manufacturer result in loss of
the warranty.

8. Only original spare parts offered by the Zakład Metalowo–Kotlarski “SAS”

should be used. The manufacturer shall not be held responsible for defecti­ve work of the SAS BIO SOLID boiler when incorrect spare parts are used.

9. Sealing cord located in the doors, furnace doors, ash box doors and under
the exhaust chamber cover is not covered by warranty. It is a wearable ma­terial for periodic replacement.

10. During the warranty term the manufacturer ensures free of charge repairs of
the subject matter of the agreement within 14 days of a date of notification.

11. A defect covered by a warranty repair should be notified immediately when
that defect is discovered.

12. The complaint should be sent to the manufacturer address.

13. When the party submitting the complaint prevents twice performance of the
warranty repair despite the guarantor notifying its readiness for such per­formance, it shall be understood as a waiver of the claim included in the
warranty notification.

14. Replacement of the boiler is acceptable when the guarantor decides it can­not be repaired. The guarantor may refuse to carry out the repair when the
access is not given to the boiler.

15. When it is found that the service request was unfounded, the customer shall
bear costs of the technician travel and work Before you call the maintenance

service, please become acquainted with chapter “Statuses of incorrect bo­iler work”. We are always ready to provide advice and assistance by phone.

16. The correctly filled in warranty card, with a signature and a seal of the seller
and a date of the sell is the only basis for free of charge repairs.

17. Keeping the technical and start-up documentation, warranty card for the

entire life of the boiler is required. This operation and maintenance docu­mentation and the warranty card must be delivered together with the boiler
should the title to it be transferred on another person.

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18. In matters not covered by the above conditions shall apply the provisions of
the Civil Code.

19. The complaint notification should include:

• boiler details from the nominal plate: type, size (nominal output), serial num-

ber/production year

• purchase date and place

• controller/feeder/fan model operation and maintenance documentation of

sub-assemblies installed in the device)

• boiler defect description

• boiler owner address and telephone number

20. The above warranty terms are in force on the territory of Poland. Beyond its
boundaries the warrantee’s responsibilities are assumed by a distributor in
a given country.

NOTICE: The manufacturer is entitled to introduce possible design chan­ges in the boiler resulting from a technological progress and product moder­nisation. These changes may not be included in this operation and mainte­nance documentation, while the basic described features of the product will
be maintained.

All issues and queries concerning operation of SAS boilers should be

sent to:

ZAKŁAD METALOWO-KOTLARSKI „SAS”

Owczary, ul. Przemysłowa 3, 28-100 Busko-Zdrój

tel. [phone], fax [phone]

e-mail: [e-mail]

maintenance service: tel. [phone], [e-mail]

technical assistance for SAS boilers: tel. [phone]

TECH controllers: tel. [phone]

RECALART controllers: tel. [phone]

Foreign sales: tel. [phone], + 48 505 950 616

[e-mail]

You can also find operation and maintenance documentation for SAS boilers
and installed sub-assemblies and controllers, as well as all necessary infor­mation at our website: www.sas.busko.pl

Operation and maintenance documentation in a version valid from 10.01.2017.

54

WARRANTY CARD

In accordance with the conditions guarantee for the period of 60

months on low-temperature boiler SAS BIO SOLID boiler is given

in accordance with the technical documentation.

Boiler no.

Thermal power

Heating surface

Year of manufacture

Signature and stamp of the manufacturer Signature and stamp of the dealer

-

-

-

-

Date of sale

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