THERMOSTAHL PELLET COMPACT PLC 25, PELLET COMPACT PLC 80, PELLET COMPACT PLC 35, PELLET COMPACT PLC 50 Installation And User Manual
PELLET BOILER
PELLET COMPACT PLC
INSTALLATION AND USER MANUAL
VERSION:
2.2
UPDATE:
20.08.2017
Contents
1. GENERAL INFORMATION ................................................................................... 3
1.1. Proper use of the appliance ................................................................................ 3
1.2. Safety warnings ................................................................................................ 3
1.3. Data label ........................................................................................................ 3
1.4. Document information ....................................................................................... 3
2. TECHNICAL FEATURES AND DIMENSIONS ......................................................... 4
2.1. Technical features ............................................................................................. 4
2.2. Function principle .............................................................................................. 4
2.3. Dimensions ...................................................................................................... 5
2.4. Fuel ................................................................................................................. 6
3. BOILER MOUNTING ........................................................................................... 7
3.1. Transportation and delivery ................................................................................ 7
3.2. Boiler room ...................................................................................................... 8
3.3. Chimney .......................................................................................................... 9
3.4. Mounting the burner ........................................................................................ 10
4. INSTALLATION ................................................................................................ 11
4.1. Hydraulic connections ...................................................................................... 11
4.2. Return temperature protection .......................................................................... 11
4.3. Filling the system ............................................................................................ 11
4.4. Connection diagrams ....................................................................................... 12
5. ELECTRICAL CONNECTIONS ............................................................................ 15
5.1. General instructions ......................................................................................... 15
5.2. Electrical connection diagram ............................................................................ 15
6. Controller ........................................................................................................ 16
6.1. General description ......................................................................................... 16
6.2. Description of buttons ...................................................................................... 16
6.3. Operation functions ......................................................................................... 17
6.4. Menu parameters ............................................................................................ 18
7. BOILER START-UP ........................................................................................... 20
7.1. Initial lighting checks ....................................................................................... 20
7.2. Start-up the boiler ........................................................................................... 20
7.3. Fuel loading .................................................................................................... 21
7.4. Feeder filling procedure .................................................................................... 21
7.5. Operation mode .............................................................................................. 21
7.6. Checks to carry after initial start-up .................................................................. 22
8. SERVICE AND MAINTENANCE .......................................................................... 23
8.1. Cleaning the boiler .......................................................................................... 23
8.2. Cleaning the chimney box ................................................................................ 24
8.3. Cleaning burner's chamber ............................................................................... 24
8.4. Maintenance intervals ...................................................................................... 25
8.5. Basic service procedures .................................................................................. 25
8.6. Maintenance after long stop .............................................................................. 26
9. TROUBLESHOOTING ........................................................................................ 27
CE DECLARATION OF CONFORMITY ............................................................................... 28
GENERAL INFORMATION
3
1. GENERAL INFORMATION
1.1. Proper use of the appliance
Before you make use of this appliance make sure you have read and fully understood the
instructions included in this manual.
The installation and use of the appliance must be performed according to the instructions
indicated in this manual in combination with the current national safety regulations.
The appliance is designed for use in pumped hot water central heating systems. Any other use
is considered improper and is prohibited. THERMOSTAHL declines any responsibility for damages
or injuries caused by improper use; in this case the risk is completely at the user’s responsibility.
To ensure an efficient and flawless function of the appliance, it is strongly recommended that
you have performed an annual service by a qualified technician.
1.2. Safety warnings
All installation and maintenance procedures must be carried out by professional and authorized
personnel, in compliance with the indications in the present manual and national regulations.
Any failure to correctly install this appliance could cause damage or injuries!
Do not make modifications to parts of the appliance, unless you have contacted the company
and an authorized service contractor.
Only original accessories and spare parts must be used to ensure correct and safe function.
Make sure you respect the cleaning and maintenance procedures on the corresponding intervals.
Failure to do so can cause malfunction to the appliance and possible damages.
The boiler is design to function on the fuels indicated in the corresponding paragraph. Any other
fuel is prohibited. Do not use explosive or flammable substances! Do not store such substances
inside the boiler room.
The working pressure varies according to the model. Make sure you use the appropriate water
pressure. Working in a pressure higher than the one indicated in this manual is strictly
prohibited and dangerous!
1.3. Data label
The data label of the appliance is placed on the boiler’s side cover, on the external part. Make
sure that it is properly placed and readable.
On the label it is indicated the serial number and the manufacturing year of the appliance.
1.4. Document information
This document is an integral and indispensable part of the product and must be retained in good
condition by the user. Keep it in a safe place for future reference.
If the appliance is sold or transferred to another person, this manual has to always follow the
appliance and handed to the new user or installer.
TECHNICAL FEATURES AND DIMENSIONS
4
2. TECHNICAL FEATURES AND DIMENSIONS
2.1. Technical features
The boiler is made of steel, with horizontal construction, fire-tube type. The heat transfer from
the exhaust gases towards the water is done primarily by thermal radiation in the first two
passes, and in the third is done by thermal conduction. The return of the gases from the second
way toward the third way is done in the door upper side.
PLC boiler is built in such a way so that all surfaces that are exposed to the flame are cooled by
water, including the inferior side where the ash and the burning rest are collected. The unique
construction, the great number of exhaust pipes and the stainless steel turbulators, big firebox
volume and the water from the boiler, as much as the symmetric construction determines a high
efficiency.
The PLC boiler is designed to work efficiently with an automatic pellet burner. The boiler can also
be used with liquid or gas fuels, by mounting an appropriate burner respectively.
DESCIPTION OF COMPONENTS
Steel boiler body with horizontal tube exchanger
Removable rear smoke box with inspection cleaning door and flange for exhaust fan
installation
Door for access to the fire chamber for cleaning the heat exchanger and the burner
Ash box positioned on the lower part of the boiler
Glasswool body insulation of 50 mm thickness
Electrostatically painted external covers
Automatic pellet burner with feeder
Fuel tank
2.2. Function principle
The function of the boiler is is based on the counter-pressure that is created by the returnable
flame in the combustion chamber and by the transmission of heat with radiation. The burned
gases reverse their course at the bottom of the fire chamber, surrounding this way the flame,
which does not get into immediate contact with the surrounding walls.
The burned gases are then guided towards the smoke box through the fire tubes where the heat
transfer is mainly through conductivity, and afterwards evacuated to the chimney. The smoke
box is equipped with an inspection and
cleaning door, which also actions as an
explosion relief. The turbinators in the
tubes create turbulance to the burned
gases, so as to get into a continuous
contact with the walls of the tubes and
increase the heat transfer efficiency.
The door has an insulation cord to ensure
air-tight closing. The door is equipped
with a flange for burner mounting and an
inspection eye for flame inspection.
Fig 1. Boiler function scheme
TECHNICAL FEATURES AND DIMENSIONS
5
2.3. Dimensions
*Nominal output is obtained with premium quality wood pellet, DIN+ certification.
TYPE
W
W1 B C H L
T1-T2
T3
T5
T6
mm
mm
mm
mm
mm
mm
inch
mm
inch
inch
PLC 25
670
1270
820
550
1500
1100
1 ½”
139
½”
½”
PLC 35
670
1270
820
650
1500
1200
1 ½”
139
½”
½”
PLC 50
750
1350
970
850
1500
1260
2”
159
½”
¾”
PLC 80
855
1455
1055
1050
1500
1550
2”
193
½”
1”
TECHNICAL DATA
Boiler
type
Nominal
Output*
T
max
P
max
Effici
ency
Water
contents
Electrical
connections
Weight
kW
o
C
bar % lit
V/Hz
kg
PLC 25
25
90
3
91,5
80
230/50
200
PLC 35
35
90
3
91,5
100
230/50
220
PLC 50
50
90
3
91,5
120
230/50
280
PLC 80
80
90
3
91,5
140
230/50
310
TECHNICAL FEATURES AND DIMENSIONS
6
2.4. Fuel
The PLC series is designed for pellet as fuel, with use of an automatic pellet burner. As fuel, it is
recommended to use only premium quality wood pellet 6-8 mm diameter. Pellet of lower quality
or agropellets can only be used if approved by the pellet burner manufacturer. Note that if lower
quality pellet is used, the ash produced can be signifantly bigger and the cleaning interval more
often.
Table 1. Pellet fuel characteristics
The quality of the pellets, calorific power, humidity and ash content is very
important for the boiler function and efficiency!
Normally, if using pellets with low ash content (DIN+ quality certification) the burner needs
cleaning once every week. If low quality pellets are used this might be needed up to once a day.
The PLC boiler can work with liquid or gas fuel as an alternative solution. For this purpose, a
corresponding burner must be mounted on the boiler’s door with a special flange.
It is prohibited the use of processed wood pellets, or other chemical treatment.
It is prohibited the use of explosive, inflammable materials, plastic, domestic
residues, etc.
NEVER BURN ANY TYPE OF CORN, CHERRY PITS, STICKS OR OTHER TYPES OF FUEL
IN THE BURNER.
It is prohibited to manually feed solid fuel in the boiler!
Pellet fuel characteristics
Diameter
6-8 mm
Length
12-30,5 mm
Density
650-700 kg/m3
Ash content
<1%
Calorific power
>4,8 kWh/kg
Humidity content
<8%
BOILER MOUNTING
INSTALLATION
7
3. BOILER MOUNTING
3.1. Transportation and delivery
The boiler is delivered on wood pallet, well positioned with metal plates. Remove them carefully
by unscrewing the screws holding them in place.
The loading and unloading of the boiler must be performed with a forklift or a crane. A special
hook is provided on the upper part of the boiler for lifting.
The boiler is heavy. Do not try to lift by hands or other unsuitable equipment.
Danger of injury! Perform all moves with extreme attention and care.
Remove the boiler packaging with attention. Keep the packaging material away from
chidren since it can be dangerous. After having unpacked everything, make sure that the
appliacne is intact and undamaged. In case of doubt do not use the appliance and inform the
supplier.
The PLC boiler is delivered with the following equipment already fitted and mounted:
Boiler steel body
Glasswool insulation mounted on the boiler body and tightened with plastic tapes
Metal covers mounted on the boiler body
Turbinators positioned inside the fire tubes
Pellet burner
Fuel feeder
Fuel tank
The following accessories are positioned inside the boiler body. Remove them carefully by
opening the middle door.
Cleaning tools
In the documentation folder you will find:
Technical manual
Warranty leaflet
BOILER MOUNTING
INSTALLATION
8
3.2. Boiler room
3.2.1. General requirements
The boiler must be installed in a special and separate room. This room must be chosen so that
it offers easy access for fuel transport, air supply and exhaust gas evacuation. The doors of the
boiler room must be metallic, open outwards, and have at least 0,9 m width.
The boiler installation is prohibited in rooms with extensive dust, dangerous
gases, and moist spaces.
For the correct boiler function it is necessary that the boiler room has openings for natural
ventilation and combustion air supply. It is recommended that two different openings are used
for this purpose, positioned on opposite walls and diagonally to ensure good air circulation. The
total surface of the openings must be at least 1/12 of the boiler room surface. Forced ventilation
is prohibited in the boiler room.
The boiler room must be provided with a drainage channel. All safety devices must be connected
to this channel.
The boiler room must have an appropriate fire extinguishing system, according to the
regulations in force. In case that the building is designed with a fire alarm system, a smoke
detector must be positioned on top of every boiler.
The fuel storage is prohibited in the boiler room. If so, the storage must be separated from the
boiler with a non-flammable wall, and proper distanced from the boiler.
3.2.2. Boiler room dimensions
The boiler must be placed on a horizontal plane, with adequate mechanical resistance to support
the boiler’s weight. The boiler must be positioned in the room in such a way so that it is easily
accessible from all the sides. The following dimensions are recommended (see Fig 2)
Distance from the front wall (L1): at least 1,5m
Distance from the rear wall (L2): an adequate distance allowing easy access for verification and
maintenance.
Distance from side wall (A3): at least 0,6m
Boiler room height (H1): at least 2,5m
Fig 2. Recommended boiler room dimensions
BOILER MOUNTING
INSTALLATION
9
3.3. Chimney
The chimney installation must supply sufficient draught, air tightness and protection against
condensation.
The appropriate chimney installation is very important for the boiler’s efficient
and safe function!
The chimney must be positioned if possible in the interior of the building. It must be vertical,
with no changes in the direction. The cross-section of the chimney can be round or rectangular.
If the chimney is installed in the exterior, it must be insulated.
The horizontal part connecting the boiler’s chimney pipe with the vertical chimney must have
maximum length 2 m. If this distance is bigger, it is recommended to have a 15-30o inclination
upwards. The connection with the boiler’s chimney pipe must be air-tight.
The chimney must be equipped with a cleaning door at its base. Also cleaning doors are
recommended where there are changes in direction and ash can be accumulated. Tactical
cleaning is recommended (every 3 months) for efficient boiler function.
A chimney terminal must be installed at the end of the chimney for protection against weather
effects and foreign objects entrance. In areas with strong winds a special anti-downdraught
terminal is recommended.
The chimney height must exceed the roofline by at least 1 m. If there are other obstacles
positioned on the roof, the chimney height must exceed them by at least 1 m. If there are
multiple chimneys, minimum distance between them is 0,3m.
Each boiler should be connected to an independent chimney. Connection of multiple boilers to
the same chimney is not recommended.
Fig 3. Chimney distances
Fig 4. Chimney connection
BOILER MOUNTING
INSTALLATION
10
3.4. Mounting the burner
The burner is mounted on the flange provided on the door of the boiler. First install the insulation
cord and then fix the burner on the flange with the four screws provided, as shown on Fig 5. Pay
attention so that the burner furnace is correctly positioned in the fire chamber and the door
opens normally.
Fig 5. Mounting the burner
The pellet silo must be positioned normally from the right side of the boiler, so that the door
opens easily. It must be positioned as close to the boiler as possible so that the feeder length
will be sufficient.
The pellet feeder must be inserted in the silo before you fill it with pellets. The feeder must be
positioned with inclination, optimum at 30-45o to the floor. The pellet feeder cannot be
positioned at angle more than 45o, nor vertically or horizontally! After positioning secure
it so that it doesn’t move. The connection between the pellet feeder and the burner is done by
a flexible hose. This hose must also have an inclination and be tightened so that it allows free
fall of the pellets towards the burner. The connection of the hose with the burner and the feeder
must be air-tight. Use the tighteners provided.
The positioning of the pellet feeder and the silo are very important to the
burner’s operation! If not positioned correctly it can cause malfunction and stop of the
burner.
Legend
1
Fixing screws
2
Sealing cord
3
Pellet burner
INSTALLATION
11
4. INSTALLATION
4.1. Hydraulic connections
The boiler is intended for connection with a closed expansion vessel network. The boiler is
intended for maximum working temperature 90oC and maximum pressure 3 bar.
The expansion vessel must be connected on the return line. The discharge valve be connected
through a pipe to the drainage.
If a connection pipe is not used, it must be sealed before water fill!
4.2. Return temperature protection
For the correct function of the boiler and for protection against corrosion it is very important to
ensure steady temperature at the return of the boiler of at least 55oC.
This can be ensured by installing a recirculation pump between the boiler outlet and return (see
connection diagrams).
An alternative variation is by installing at the return of the boiler a three-way thermostatic valve.
Having a return temperature less than 55oC is very dangerous for the boiler
long-life and can cause warranty loss!
4.3. Filling the system
After completing all the hydraulic connections, the circuit may be filled with water. After filling
the system, open the radiators air valves to get rid of the air in the installation.
Verify that the installation pressure is according to the technical feature of the boiler. The
pressure must be verified through the boiler’s manometer. An additional manometer should be
installed on the cold water inlet to verify the cold pressure, at the lowest point of the installation,
at a point close to the boiler.
The whole installation must remain under nominal pressure for at least 10 minutes. During this
period, check that all the connections are tight and there are no water leakages. Make sure that
during this period no pressure drop appears.
After firing the boiler, make sure the network functions properly at working temperature and
pressure.
The hardness of the mains water supply affects the boiler’s life span. It is
recommended to use a water softener if water hardness exceeds 5oGH.
Legend
T1
Outlet
T2
Return
T3
Chimney connection
T5
Drainage valve
T7
Safety connection
INSTALLATION
12
Do not fill the system at the working pressure! When the boiler will be heated,
the water pressure will raise. Filling pressure must be at least 1 bar lower than
working pressure!
4.4. Connection diagrams
4.4.1. Installation as single heating source
Legend
1.
PLC boiler
2.
Closed expansion vessel
3.
Safety kit
4+5.
Recirculation pump and 3-way thermostatic valve
6.
Filter “Y”
7.
Chemical phosphate filter
8.
Automatic water filling valve
9.
Mechanical filter with nylon “Ny”
10.
Sanitary hot water boiler
11.
Safety pressure valve for sanitary water circuit
12.
Automation for sanitary water
13.
Heating installation (outside the project)
RS
Ball valve
CS
One-way valve
RG
Drainage valve
TC
Room thermostat
MC
Controller module
INSTALLATION
13
4.4.2. Installation with buffer tank
Legend
1.
PLC boiler
2.
Closed expansion vessel
3.
Safety kit
4+5.
Recirculation pump and 3-way thermostatic valve
6.
Filter “Y”
7.
Chemical phosphate filter
8.
Automatic water filling valve
9.
Mechanical filter with nylon “Ny”
10.
Buffer tank-heat storage
11.
Dual safety valve pressure/temperature
12.
Circulation pump for heating & sanitary water
13.
Automation for heating & sanitary water
14.
Sanitary hot water boiler
15.
Safety pressure valve for sanitary water circuit
16.
Heating installation (outside the project)
RS
Ball valve
CS
One-way valve
RG
Drainage valve
TC
Room thermostat
MC
Controller module
INSTALLATION
14
4.4.3. Installation with an alternative heat source
Legend
1.
PLC boiler
2+3.
Alternative oil/gas boiler and burner
4.
Closed expansion vessel
5.
Safety kit
6+7.
Recirculation pump and 3-way thermostatic valve
8.
Filter “Y”
9.
3-way valve with servomotor
10.
Buffer tank-heat storage
11.
Dual safety valve pressure/temperature
12.
Sanitary hot water boiler
13.
Mechanical filter with nylon “Ny”
14.
Chemical phosphate filter
15.
Automatic water filling valve
16.
Circulation pump for heating & sanitary water
17.
Automation for heating & sanitary water
18.
Safety pressure valve for sanitary water circuit
19.
Heating installation (outside the project)
RS
Ball valve
CS
One-way valve
RG
Drainage valve
TC
Room thermostat
MC
Controller module
ELECTRICAL CONNECTIONS
15
5. ELECTRICAL CONNECTIONS
5.1. General instructions
All electrical connection must be performed by an authorized professional, in conformity with the
local regulations and the indications of this manual. Connections must be done according to
norms EN 60529 and EN 60335-1, and protection norms IP 40 and IP 44.
All wiring must be waterproof insulated. Exposed cables should be protected within plastic
channel. The main electrical supply of the boiler must be connected to an independent safety of
max 16A. The boiler room lighting must be on a separate circuit.
THERMOSTAHL is not responsible for accidents or malfunctions caused by wrong
or bad electrical connections.
5.2. Electrical connection diagram
CONTROLLER
16
6. Controller
6.1. General description
Description:
Diodes signalizing the status of outputs and the working mode of the driver,
LCD screen used for communication between the device and the user,
Buttons steering the driver's work.
6.2. Description of buttons
Button
Function
1 Changes the burner's working mode – “STOP”, “IGNITION”, “AUTOMATIC
WORK”.
2
Return to the previous menu
1
Entry on the Menu's parameters
2
Saves the change of a parameter
1
In the Ignition MODE activates the feeder for the time specified on the
parameter “Filling Feeder Time”
2
Go to the previous menu or parameter
Decreases the value of a parameter
1
In the Ignition MODE activates the ignition procedure
2
Go to the menu or parameter
Increases the value of a parameter του καυστήρα.
CONTROLLER
17
6.3. Operation functions
After switching the burner on, it is appeared on the LCD screen the program's logo defining the
type of the driver and the version of the current software
While activating, the burner carries out a test of the connected sensors. In case of one lacking,
on the screen appears an appropriate message (---). The work of the burner without a heating
water temperature sensor (CH) is blocked and an emergency mode is activated (CH pump is still
on).
Correct connection of sensors causes displaying of actual CH furnace's temperature and the
temperature of useful warm water of the WUW buffer (if the function is active). On the screen
appears which function is currently used by the driver.
The burner may work in three working modes (“STOP”, “IGNITION”, “AUTOMATIC WORK”). The
mode changes when the “MODE/ ” button is pressed. Activating the “STOP” mode is possible
in all modes after pressing the “MODE/ ” button for 3 seconds. When Stop is activated, the
burner goes at “Burning off” process (if there is fire) and the at “Cleaning” process.
When the burner is activated for first time, it is on “Stop” mode. Every next time, its status is
saved in the regulator's non-volatile memory. Activating the driver again, automatically causes
switching on of the lately used working mode.
In the table beneath a short description of particular functions of the burner, activated depending
on the working mode of the driver, is shown.
CONTROLLER
18
FUNCTION'S NAME
DESCRIPTION OF FUNCTIONS
STOP
Burner stopped.
FEEDER FILLING
Filling the feeder.
Filling stops automatically after about 10 minutes.
IGNITION
The burner is on Ignition process, which mean that has fed with ignition dose
of pellet, the heating element (igniter) and the air fan are working. The mode
would be automatically changed after detecting a flame by the sensor.
CLEANING
The air fan works at full speed for one minute, to remove the remaining
ashes from the burner's fire chamber. This function takes place also at the
first minute of ignition
WORK
Heating the boiler up to the set temperature. Showing the actual power of
the burner.
MAINTAIN
Sustaining the set temperature (if the burner's working mode is in the mode
of continuous work)
BURNING OFF
Putting off the burner. Active in the “STOP” mode or in the temporal working
mode of the burner.
STANDBY
Standby of the burner for the decline of the temperature of a hysteresis (if
the burner's working mode is in the temporal mode).
6.4. Menu parameters
To move round the menu and to set particular parameters there are four buttons placed on the
driver's panel: “MODE/ ”, “MENU/OK”, “+”, “-”. The parameters chosen by the user are
divided into four groups: (A) “CH FURNACE SETTINGS”, (B) “WUW BUFFER SETTINGS”,
(C) “BURNER SETTINGS”, (D) “DRIVER SETTINGS”. The division of particular parameters
in groups is shown in the “Settings table”.
CH FURNACE SETTINGS (A)
FUNCTION
NO.
FUNCTION
NAME
SETTING
UNIT
SETTING
RANGE
MANUFACTURER
SETTING
1
HEATING WATER
TEMPERATURE
ºC
35 - 85
65*
2
CH PUMP ACTIVATION
TEMPERATURE
ºC
20 - 60
35*
3
CH FURNACE
HYSTERESIS
ºC
1 - 20
5*
4
FURNACE
MODE
---
Winter/Summer
Winter*
CONTROLLER
19
WUW BUFFER SETTINGS (B)
FUNCTION
NO.
FUNCTION
NAME
SETTING
UNIT
SETTING
RANGE
MANUFACTURER
SETTING
1
WUW BUFFER
TEMPERATUR
ºC
20 - 80
40*
2
WUW SURPLUS
TEMPERATURE
ºC
5 - 20
10*
3
WUW
PRIORITY
---
Yes/No
No*
BURNER SETTINGS (C)
FUNCTION
NO.
FUNCTION
NAME
SETTING
UNIT
SETTING
RANGE
MANUFACTURER
SETTING
1
BURNER POWER
(WORK)
kW
10 - 80
30*
2
BURNER POWER
(MAINTAIN)
kW
2- 9
3*
3
BURNER
MODE**
---
Continuous/
Single/Analogue
Continuous*
4
SELF CLEANING FREQUENCY
TIME
Min
10-480
240
5
SELF CLEANING TIME
sec
0-60
0
6
BURNER FLAME MEASUREMENT
%
0-100
-------
** Burner has 3 modes: continuous mode, single mode and analogue mode.
Single mode: The burner reaches the desired “HEATING WATER TEMPERATURE” and burns off.
Then, it starts its operation again when the temperature of the boiler goes down to the
temperature “HEATING WATER TEMPERATURE - CH FURNACE HYSTERESIS”. The CH FURNACE
HYSTERESIS must be more than 10oC.
Continuous mode: The burner reaches the desired “HEATING WATER TEMPERATURE” and goes
down at 3kW (maintain). When the boiler's temperature goes down to the temperature
“HEATING WATER TEMPERATURE - CH FURNACE HYSTERESIS”, the burner increases its power
from 3kW (maintain) to the maximum burner power (i.e30kW). The CH FURNACE HYSTERESIS
must be no more than 5oC.
Analogue mode: The burner reduces its power 1/3 (for example: from 30kW to 21kW) 10oC
before the furnace reaches the “HEATING WATER TEMPERATURE”. When the temperature of the
furnace is 5oC before “HEATING WATER TEMPERATURE”, the burner reduces its power again 1/3
(for example: from 21kW to 12kW).
DEVICE SETTINGS (D)
FUNCTION
NO.
FUNCTION
NAME
SETTING
UNIT
SETTING
RANGE
MANUFACTURER
SETTING
1
LANGUAGE
SETTINGS
---
Polish/
English/
German/Greek/
Serbian/Romanian
English*
2
FACTORY
SETTINGS
---
Yes/No
---
3
ENABLE SERVICE
MODE
---
000 - 999
---
BOILER START-UP
20
7. BOILER START-UP
7.1. Initial lighting checks
Before you start the boiler, make the following checks:
Check that all the hydraulic connections and make sure they are tight. Make sure there is no
leakage or moisture on the pipes or other equipment.
Make sure that the connection with the chimney is air-tight and the chimney installation is
properly made.
Check that the controller bulbs are well inserted and secured in the boiler’s case.
Make sure that the pressure in the network is correct.
Check that the boiler pump and the central heating pumps function properly.
Make sure that the connection with the expansion vessel is correct and the expansion volume
is sufficient for the boiler. No valves should be installed between the boiler and the expansion
vessel.
Make sure the boiler’s separation valves are open.
Make sure that there is sufficient air supply and natural ventilation in the boiler room.
Do not store inflammable materials or fuel close to the boiler! Before you light the
boiler make sure the boiler room is clear and safe.
7.2. Start-up the boiler
1. Ensure that the installation has been done according to this manual
2. Ensure that the plastic pipe is not connected to burner's feeding pipe
3. Fill the feeder up with wood-pellet, by following the direction of paragraph 16 (Feeder's
Filling Procedure). The filling of the feeder lasts 8-15min depended on feeders incline.
4. Ensure that the feeder is full of pellet. Let the feeder working after the first pellets come out
of the feeder for 10-15 minutes (locate a plastic bag at the exit of the feeder)
5. Empty the plastic bag and place it back at the exit of the feeder.
6. Make the feeder work again for 2 minutes, by pressing the button
7. Weight the wood pellet which is in the bag (for example 0.4kg)
8. Multiply it by 30 minutes (0.4x30 = 12kg/h). This is the feeder's performance
9. Repeat the steps 4-8, 2-3 times until you make sure that you weight the right quantity.
10. Place this value (i.e 12kg/h) on manufacturer's settings menu, in the parameter
“5. Feeder Performance”
11. “CHOICE FUNCTION-/+” is written on the screen.
12. By pressing the button “MODE/ “ once, starts the automatic operation of the burner
13. When the maximum power of the burner is reached (from 10 to 35kW), then adjust the
burners flame by calibrating the air.
The burning air is calibrated just by changing the value of “Overflow pellet's air” at
Manufacturer's menu. The value must be between 0.20-0.7, depending on the
maximum burner's power, pellet quality, boilers construction and chimney's draught.
BOILER START-UP
21
7.3. Fuel loading
The fuel must be loaded in the fuel tank and is then supplied to the pellet burner through the
pellet feeder. This is controlled directly by the pellet burner.
The first time the burner is started, the pellet feeder must be filled completely. This can take up
to 15 minutes, depending the length of the feeder and the rotation speed of the motor.
When adding fuel to the silo, be careful for any big woods, plastics or metal items not to enter
the silo. Such objects can block the pellet feeder or even damage it, and stop the burner
operation. Fuel can be added at any time while the boiler is in function.
Do not leave the silo to reach completely empty, because the feeder will empty and will need to
be filled again.
Do not load manually fuel to the burner directly! The burner loading must be done
only through the pellet feeder!
7.4. Feeder filling procedure
1. Remove the plastic tube connection the burner with the feeder
2. Burner must be at stop mode. So, “Stop” appears on the LCD scree
3. By pressing the button “MODE/ “ once changes the operation from “Stop” to “ignition”.
4. “CHOICE FUNCTION-/+” appears on the LCD screen
5. Press the button to start the feeder
6. Feeders operation lasts 11min (Manufacturer's setting / Feeder's filling time"
7. When the wood-pellet starts to come out of the feeder, press to stop the feeder
8. Connect the feeder with the burner, by using the plastic pipe.
9. If the "Feeder's filling time" is not enough, press to start the feeder again
7.5. Operation mode
7.5.1. Starting the burner
1. Activate the burner by connecting it with a power supply (230Volt, 50Hz)
2. It is written on the LCD screen the following
3. By pressing the button “MODE/ “ once changes the operation from “Stop” to “ignition”.
By pressing the button “MODE/ “ changes the operation from “Ignition” to “Automatic”.
BOILER START-UP
22
4. In “Automatic mode”, starts the operation of the burner.
5. When the photo sensors detects fire, then the burner starts its “Work” by increasing its power
gradually to the power it has been set (i.e 30kW)
6. When the boiler's water temperature reaches the desired temperature “HEATING WATER
TEMPERATURE “, the the power of the burner goes down ta 3kW (Maintain mode)
7. The burner works at “Maintain mode” till the boiler's water temperature goes down to the
temperature:
“HEATING WATER TEMPERATURE - CH FURNACE HYSTERESIS”
7.5.2. Stopping the burner
1. The burner can be either at “Work” or “Maintain” or “standby”
2. Press the button “MODE/ “continuously till “STOP MODE” appears on the screen.
3. It is written “Burning off” till the photo sensor stops to detect fire (3-5 min)
4. When the photo sensor stops to detect fire, “cleaning procedure takes place for few seconds.
7.6. Checks to carry after initial start-up
During the first start-up you need to carefully check the air-tightness of all the connections,
especially the doors and the connection with the chimney.
Check that the thermostats function properly and devices operate accordingly. Wait for the boiler
to reach the preset temperature and make sure the fan stops properly and the flame falls down.
Check the temperature and pressure rise in the network. Make sure it is according to the
indications. Check if there is any water leakage in the network.
After burning of the fuel is completed, check the situation inside the boiler. If the walls are too
black, it means that there is insufficient air supply. If there is condensation forming on the boiler
walls, it means that the pump operation starts at a low temperature or the fuel has too big
humidity content. Make sure you set the pump according to the indications and you install a
return temperature protection system as indicated.
SERVICE AND MAINTENANCE
23
8. SERVICE AND MAINTENANCE
8.1. Cleaning the boiler
Pellet boilers require regular cleaning in order to function properly and efficient. The boiler is
equipped with three cleaning tools appropriate for the cleaning procedure of the boiler, as shown
in Fig 6.
Fig 6. Boiler cleaning tools
The boiler function must be stopped before cleaning! Make sure all the devices
are stopped, and the boiler has cooled down. It is strictly prohibited to clean the boiler
while in function!
Open the ash box situated at the bottom of the boiler. First clean the burner head and any other
parts that need to be cleaned.
Open the door to have access to the heat exchanger. Remove the turbinators from the tubes,
and clean the tubes with the brush. Afterwards clean the surfaces of the fire chamber with the
the scraper, as shown in Fig 7. With the same tool, scrape the ash and any other remains from
the walls of the boiler.
The hook can be used to remove the turbinators or other surfaces that might be hot or blocked.
Fig 7. Cleaning of the boiler
When the ash box is filled with ash, dispose it. This interval can vary between 1-3 weeks,
according to the quality of the pellets and the intensity of boiler function.
The ash must be disposed in an appropriate container! Do not throw the ash
together with the domestic garbage. Be careful since ash might contain hot particles,
even long time after stop.
Legend:
1.
Ash scraper
2.
Tubes brush
3.
Hook
SERVICE AND MAINTENANCE
24
8.2. Cleaning the chimney box
To ensure efficient and safe function of the boiler, you must clean the chimney box from ash
residues at least every 3 months.
The ash box is equipped with a cleaning door for this purpose, as shown in Fig 8. In order to
open the door, unscrew the wing nuts, remove the washers and springs that keep it in place.
Clean the interior of the chimney box and remove all the ash and residues.
Put back the door the same way as removed.
The springs must not be omitted! They act as safety in order of explosion of
exhaust gases in the chimney box.
Fig 8. Cleaning the chimney box
8.3. Cleaning burner's chamber
1. The burner can be either at “Work” or “Maintain” or “standby”
2. Press the button “MODE/ “ continuously till “STOP MODE” appears on the screen.
3. It is written “Burning off” till the photo sensor stops to detect fire (3-5 min)
4. When the photo sensor stops to detect fire, “cleaning procedure takes place for few seconds.
5. When “Stop” appears on the LCD screen, waiting few minutes till the burner cools down.
6. Open the boilers door, clean the burners tube and close back the door.
7. By pressing the button “MODE/ “ once changes the operation from “Stop” to “ignition”.
8. By pressing the button “MODE/ “ changes the operation from “Ignition” to “Automatic”.
** The frequency of cleaning burner's chamber is depended on wood pellet quality. If
premium pellet is used, It is suggested the burner's chamber to be cleaned once a
week.
SERVICE AND MAINTENANCE
25
8.4. Maintenance intervals
8.4.1. Daily maintenance
The pressure of the network must be daily verified to be within the allowed limits. Make sure
that all the safety devices and pumps function properly.
8.4.2. Weekly maintenance
The pellet burner must be cleaned according to the manufacturer’s instructions, usually
recommended once a week. The boiler must also be cleaned every 7-15 days, depending on the
ash quantity accumulated on the boiler walls and in the heat exchanger. Cleaning procedure
must be performed according to the instruction given in the corresponding paragraph.
Check the quantity of ash accumulated in the ash box. The ash disposal can be performed every
2-3 weeks, depending on the ash quantity formed.
8.4.3. Monthly maintenance
Check the doors and the sealing cord. Make sure the contact with the boiler is air-tight. If ash
has accumulated on the sealing cord, clean it.
Remove the turbinators from the heat exchanger and check their condition.
It is recommended that you clean the chimney box of the boiler and the chimney pipes at least
every 3-4 months, in order to assure efficient and safe function of the boiler.
8.5. Basic service procedures
8.5.1. Service after overheating
If overheating occurs, the safety valves of the boiler must open.
Make sure the boiler pump is working. In case of blackout open all the valves of the system to
let hot water out of the boiler. In any case a blackout protection UPS is recommended to be
installed on the boiler pump.
If the chimney damper is not fully opened, put it in fully open position.
All safety devices must lead to drainage! After overheating, make sure that all the water from
the safety devices has drained, and the system has filled with cold water. Check the pressure
and the temperature of the boiler.
At overheating, the safety thermostat will activate, and cut electrical supply to the fan. In that
case, you need to manually reset the safety thermostat and put the system back in function.
Unscrew the plastic cover of the safety thermostat and press the switch. Put the plastic cover
back.
Verify the causes of the overheating! If it happens again, check the installation
and function of the pumps and safety devices!
8.5.2. Restart the burner after an error
1. Turn off the burner by using the electric switch the burner is connected.
2. Open the boiler's door and check the burner tube.
3. Remove any ashes and impurities from burner fire chamber.
4. Close the door and switch on the controller by using the electric switch the burner is connected
5. By pressing the button “MODE/ “ once changes the operation from “Stop” to “ignition”.
By pressing the button “MODE/ “ changes the operation from “Ignition” to “Automatic"
SERVICE AND MAINTENANCE
26
8.6. Maintenance after long stop
It is necessary to perform a general maintenance and cleaning of the boiler after the heating
season. Clean thoroughly all the surfaces of the boiler as described in the corresponding
paragraph. Also clean the chimney box, and all the chimney parts where ash might be deposited.
After cleaning all the ash, empty the ash box and leave the boiler clean for the next winter
season.
After long stop of the boiler, before you put in function you need to perform the following checks:
Check the condition of the electric cables and the sensors. Make sure they are not damaged.
Check that the thermometer indicates the correct temperature and all the thermostats
function properly. Make sure the bulbs are properly positioned in the case.
Make a general check of the chimney and make sure it is clean and free of obstacles.
Verify the pressure in the heating network and the boiler.
Do not empty the water of the boiler and the heating installation after the heating
season! It will corrupt all the installation and especially the boiler.
Check that all the valves are working properly. Replace them if necessary. Pay special
attention so that all the safety equipment of the boiler functions properly!
Make sure all the ball valves of the boiler and other relative equipment are open.
Check the function of the pumps. They might be blocked after long stop.
Check that there have been no modifications to the installation and the boiler room
(ventilation openings, chimney, doors).
Check the fan and clean from dust. Turn it manually to ensure it is not blocked.
TROUBLESHOOTING
27
9. TROUBLESHOOTING
Indication
Description
Solution
CH:!!!!
WUW:!!!!!!
STOP
Malfunction of the water
temperature sensors
1. The driver starts up relevant emergency
procedures for every sensor in order to prevent the
boiler from working beyond the safe range for the
installation of the central heating
2. When the boiler cools down, then restart the
controller and set the burner on automatic mode.
"Furnace
protect"
The temperature in the boiler
is higher than 92oC. If the
temperature is above 95oC,
the STB sensor is activated
and the feeder is turned off
automatically (the light next
to the STB sensor is ON).
At any case the pumps are
activated to avoid higher
temperatures
1. Wait till the boilers water temperature goes
down to 60oC
2. Reset the STB sensor, so the light next to it to
be OFF.
3. Restart the controller and set the burner at
automatic mode.
"Burner alarm"
The temperatures on burner's
feeder pipe is higher than
70oC. (Back fire protection)
This is happened either the
chimney's draught is no the
appropriate or the burner
hasn't been cleaned.
If the temperature goes down to 60 oC and the
photo sensor scans light, then the burner's
operation continuous normally.
If the temperature goes down to 60 oC and the
photo sensor doesn't scan any light, then the signal
“Burner alarm” is still on the LCD and you must
restart the controller.
"NO pellet"
No pellet on the silo
1. Fill up the silo with pellet
2. Fill the feeder with pellet (Filling feeder
procedure)
3. Set the burner at automatic mode
The feeder doesn't work
If the light next to STB sensor is ON, it means that
overheat of the boiler has occurred and STB has
turned the feeder OFF.
1. Reset the STB sensor, so the light next to it to
be OFF.
2. Restart the controller and set the burner at
automatic mode.
Check the cable from feeder to the controller
3. Problem during ignition
procedure
Burner's tube hasn't been cleaned properly
1. Clean the burner
2. Restart the controller and set the burner at
automatic mode.
Igniter doesn't work
1. Change the igniter inside the burner.
DECLARAȚIE DE CONFORMITATE EC
CE DECLARATION OF CONFORMITY
(conform cu ANEXA VII din Directiva Europeană 97/23/EC)
(in compliance with the Annex VII of the European Directive 97/23/EC)
Producător / The Manufacturer’s name: THERMOSTAHL ROMANIA SRL
Adresa producătorului / Manufacturer’s address: Str. Drumul Osiei 57-59, sector 6, București, România
PRIN PREZENTA, DECLARĂ
Declares that the equipment
Tip:
Type:
Cazan de apă caldă cu funcționare pe combustibil solid -încărcare manuală
Heating boiler for solid fuel, manually stocked
Obiectul declarației:
Object of the Declaration:
PLC
Seria / Anul:
Serial Number / Year:
ESTE CORESPUNZĂTOR CU CERINȚELE DIRECTIVEI 97/23/EC-ECHIPAMENT SUB PRESIUNE
MEETS THE REQUIREMENTS PROVIDED BY THE 97/23/EC DIRECTIVE-PRESSURE EQUIPMENT
ȘI A URMĂTOARELOR DOCUMENTE:
AND THE REQUIREMENTS OF THE FOLLOWING DOCUMENTS:
Produsul este conform cu următoarele standarde:
The product is in compliance with the following standards:
EN 303-5:2012
Cazane de încălzit.
Partea 5: Cazane speciale care utilizează combustibili solizi, cu încărcare manuală şi automată, cu puterea utilă mai mică sau egală cu 500
kW. Terminologie, cerinţe, încercare şi marcare
Heating boilers.
Part 5: Heating boilers for solid fuels, hand and automatically stocked, nominal heat output of up to 500 kW
Terminology, requirements,testing and marking
Directive Europene aplicabile echipamentului
European Directives applied to the equipment
97/23/EC
Directiva Echipament sub Presiune (HG 584/2004) / Pressure Equipment Directive (PED)
2014/35/EC
Directiva Echipamente de joasă tensiune / Low Voltage Directive (LVD)
2014/30/EC
Directiva Compatibilitate Electromagnetică / Electromagnetic Compatibility Directive (ECD)
Informații suplimentare / Additional information:
Toate echipamentele care fac obiectul prezentei declarații au fost testate hidraulic la presiunde de proba egală cu 1,5 ori presiune maxima de lucru, conform
cu Anexa I – p. 7.4 a Directivei 97/23/EC.
As provided by the Annex I - p. 7.4. of the 97/23/CE Directive, all the equipment object of the present Declaration have been hydraulic tested to a test pressure equal
to 1,5 times the maximum allowed working pressure.
Director General
General Director
România, București, 15 Octombrie 2015
Matsios Dionysios
THERMOSTAHL ROMANIA
SISTEME TERMICE S.R.L.
DRUMUL OSIEI 57-59, sector 6
Bucureşti 062395, România
www.thermostahl.ro
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