technical passport installation and operation …€¦ · information for the safe and correct...

Set pellet boiler with pellet burner WBS Active - Pell

Version i0.2.6

EN

TECHNICAL PASSPORTINSTALLATION and OPERATION MANUAL

FOR AUTHORIZED INSTALLER / SERVICE SHOP

2

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUALTECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

TABLE OF CONTENTS

1. EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS ........................................................ 31.1. Explanation of symbols .......................................................................................................... 31.2. Requirements to boiler installation room .............................................................................. 31.2.1. Instructions to boiler installer ............................................................................................. 31.2.2. Instructions to installation user .......................................................................................... 31.2.3. Minimum clearances for installation and combustibility of construction materials .............. 4

2. PRODUCT DESCRIPTION ............................................................................................................ 5

3. FUELS ........................................................................................................................................ 7

4. TRANSPORTATION OF THE BOILER AND BURNER ..................................................................... 8

5. DELIVERY OF THE BOILER AND BURNER .................................................................................... 9

6. INSTALLATION OF THE HEATING BOILER ................................................................................... 96.1. Requirements ........................................................................................................................ 96.2. Check door tightness ........................................................................................................... 10

7. SETUP OF THE HEATING BOILER AND BURNER ...................................................................... 107.1. Connecting the boiler to a chimney .................................................................................... 107.2. Connecting the safety heat exchanger ................................................................................ 117.3. Connecting the boiler to the heating installation ................................................................ 127.4. Connection diagrams .......................................................................................................... 147.5. Pellet burner connection to the fuel hopper and pellet auger ............................................ 187.6. Connecting the pellet burner to the mains power supply ................................................... 18

8. BURNER OPERATING ............................................................................................................. 218.1. Ignition ................................................................................................................................. 218.2. Burning ................................................................................................................................ 218.3. Automatic cleaning system .................................................................................................. 218.4. Installer prescriptions regarding burner servicing and maintenance ................................... 218.5. Important recommendation for long-lasting and correct operation of the burner ............... 219. MAINTENANCE AND CLEANING OF THE BOILER ..................................................................... 22

10. OPERATION OF MICROPROCESSOR CONTROLER WHEN BURNING WOOD-PELLETS ........................ 2410.1. Controller view. Explanation of buttons and indicators ..................................................... 2410.2. User`s menu ...................................................................................................................... 2710.3. Installer’s menu .................................................................................................................. 29

11. SETTING OUTPUT MODES OF OPERATION OF THE PELLET BURNER PELL ............................. 33

12. WARRANTY TERMS ............................................................................................................... 37

13. TECHNICAL PARAMETERS OF WBS ACTIVE - PELL ................................................................. 3713.1. General features ................................................................................................................ 3713.2. Technical parameters ......................................................................................................... 3813.3. Elements of burner PELL .................................................................................................... 4113.4. Technical parameters of fuel hopper FH 500-V2 ............................................................... 42

14. RECYCLING AND WASTE DISPOSAL ....................................................................................... 42

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

1. EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS

1.1. Explanation of symbolsCAUTION! – Important recommendation or warning

concerning safety conditions during installation and operation of the heating boiler.

DANGER! – fault or improper use may cause injury or be hazardous

to life of humans or animals.FIRE HAZARD! – fault or improper installation and operation may

cause fire.INFORMATION – Important information on the proper operation

of the product.

1.2. Requirements to boiler installation roomThis manual contains important information for the safe and correct installation, start-up and trouble-free operation and maintenance of the heating boiler.The heating boiler can be used for heating rooms only in the manner described in this manual.Note of the boiler type data on the factory rating label and the technical data provided in chapter 13 in order to ensure proper operation of the product.

1.2.1. Instructions to boiler installerDuring installation and operation, the country-specific requirements and regulations must be observed:• local construction regulations on the

installation, air supply and exhaust gas extraction as well as chimney connection.

• regulations and norms concerning the

fitting of the heating installation with safety devices.

i Use only original BURNiT parts

DANGER of intoxication, suffocation.

Inadequate inflow of fresh air to the boiler room may result in dangerous leak of exhaust gases during boiler operation.- Make sure the air inlets and

exhaust gas outlets are not clogged or closed.

- If faults are not remedied immediately, the boiler must not be operated, and the user must be provided with written instructions on the fault and the hazard it entails.

DANGER of fire when burning flammable materials or liquids.

- Flammable materials/liquids must not be left in close proximity of the heating boiler.

- Instruct system user of the allowed minimum clearances from surrounding objects.

It is mandatory to assure a backup power generator of corresponding rated power! (see 13.2)

1.2.2. Instructions to installation user

DANGER of intoxication or explosion

Toxic gases may be discharged when burning waste, plastics, liquids.- Use only the fuels indicated in

this manual.- In case of danger of explosion,

ignition or discharge of exhaust gases in the room, stop the heating boiler from operation.

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CAUTION! Danger of injury / damage of system due to

incompetent operation.- The heating boiler must be serviced only by persons familiar with the operation manual.

- As a user, you are only allowed to start the boiler up, adjust the temperature of the boiler, shut the boiler down and clean it.

- Unattended children must not be allowed access to premises with running pellet burner inside.


Safety rules for user operation:- Operate the heating boiler at a maximum

temperature of 80°C, and to that end you must regularly inspect the boiler room.

- Do not use flammable liquids for ignition or increase of burner output.

- Collect ash in lid-covered fireproof containers.

- Clean the heating boiler surface using non-flammable agents only.

- Do not place flammable objects onto the heating boiler or in its proximity. (see diagram 1 for the minimum clearances)

- Do not store flammable materials in the boiler room.

1.2.3. Minimum clearances for installation and combustibility of construction materialsThe applicable minimum clearances in your country may differ from the ones specified bellow. Please, consult your installer.The minimum distance from the heating boiler or exhaust gas pipe to objects or walls must be at least 200 mm.For general safety considerations, we

recommend that the boiler be placed on a foundation with height of 100 mm made of class A material, see table 1.

Diagram 1Recommended clearances between the

boiler and walls.

Table 1. Combustibility of construction materials

Class А - non-

combustible

Stone, bricks, ceramic tiles, baked clay, solutions, plaster free of organic additives.

Class B - hard

combustible

Gypsum board panels, basalt fiber needled felt, fiberglass board, AKUMIN, Izomin, Rajolit, Lignos, Velox, Heraklit.

Class С1/С2- Medium

combustible

Wood beech, oak, Wood softwood, layered wood

Class C3 -easy

combustible

Asphalt, cardboard, cellulose, tar, fiberboard, cork, polyurethane, polyethylene.

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2. PRODUCT DESCRIPTION

Set BURNiT WBS Active - Pell: tested according to European standards EN 303-5, class 5.

2.1. Description of WBS Active• Design. Boiler body is made of high-

quality boiler steel sheets with thickness of 5 mm for the combustion chamber and 3 mm for the water mantle.

• Efficient. The flue gas makes a three-pass movement around three water-filled barriers in the combustion chamber on its way to the chimney. This way the gas is cool when it leaves the boiler and its energy has been transferred to the water in the mantle. The water mantle embraces the combustion chamber in full to utilize the emitted heat most efficiently. To keep from losing heat into the ambience, the boiler is insulated on the outside by 50 mm high-temperature wool.

• Reliable and safe. The heat exchanging tubular grill is protected by a replaceable metal grate. A complex of safety devices provide for the safety of the appliance.

• Cleaning door (combustion chamber)• Draft regulating flap, mounted on flue

end • Safety heat exchanger

2.2. Description of pellet burnerThe BURNiT Pell pellet burner for hot water boilers is designed to burn only and exclusively wood pellets and it is intended to heat up heating boilers. The built-in control unit, automatic cleaning system and internal pellet auger ensure the automated operation of the burner and

optimal burning of the fuel.

Design.The burner is made of high-quality stainless steel able to withstand temperatures of up to 1150°С. The burner must be installed on a heating boiler.The burner consists of two parts: combustion chamber tube and external tube with sheet metal mantle. Longitudinally, under the housing, there are blow chamber, fuel ignition heater, fan and power supply. On the upper part of the burner there is a feeder chute to which the pellet auger is attached. The housing of the burner has been designed to meet all regulatory safety requirements (no sharp or protruding elements) with operating temperature not exceeding 50°C.The combustion chamber consists of two tubes:Ember resistant steel tube inside the burner with holes for air intake along its entire length, opening for the hot air from the fuel ignition heater, opening for photosensor.Outer stainless steel tube. Between the two tubes there is a gap which provides for free circulation of the air necessary both for cooling and oxygen supply into the combustion chamber.The feeder chute allows 360° rotation for its best convenient positioning when connecting the pellet auger to the hopper.

• Built-in controller.The main control unit, located in the burner, manages the entire heating process.

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Diagram 2. Pellet burner Pell design

Controler functions:

1) fully automated ignition and pellet feed;

2) self-cleaning function (adjustable 1-6 times over 24 hours at equal intervals), programmable start time;

3) controls the operation of the circulation pump of the central heating;

4) option for control by room thermostat;5) timer; 6) controls the operation of the pump of

the domestic hot water;

• Photo-sensor - monitors the power of the burner flame

• Internal auger• Dry contactless resistance heater

assuring ignition of fuel• Innovative cleaning system of the

combustion chamber• Air feed fan, step-regulated (0% to 100

%).

2.3. Burner safety devices• Elbow-shape feeder chute. The

geometrical shape of burner feeder chute prevents backfire entry from burner into pellet hopper.

• Thermostatic protection (80°С). The thermostatic protection is fitted on the feeder chute. When the surface of the feeder chute reaches 80°С, the control stops the feeding of pellets into the burner and signals for fault.

• Fuse. In case of electrical fault in the system of the burner (short circuit, high current, etc.), the overload is borne by the electrical fuse fitted on the main control panel of the burner (10 А).

• Power interruption. In case of power interruption, all parameter settings are stored in the memory of the controller. Upon the subsequent restart of the burner, the controller resumes the execution of the program from the point when the power interruption occurred.

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3. FUEL

All pellets are biomass manufactured from common low-growing plants and trees. The most common household type pellets are made of sawdust and milled wood chippings which are waste material from wood used in the production of logs, furniture and other products. Wood is the richest raw material which does not have any impact on the production costs of food products or ethyl alcohol (ethanol). The raw material is processed under high-pressure and temperature and is pressed to produce small-size cylindrical pellets. The production process may utilize soft wood material (such as softwood, pine), hardwood (oak) as well as recycled waste wood. Wood pellets are produced in hammer mills or wood pellet plants.

Advantages of wood pellets:

Convenient storage. Pellet bags can be stored on a small area in a dry garage, basement, service room or shed.Easy loading. In most cases the boiler hopper needs loading only once a week – this depends on the hopper capacity.Better control of fuel quantity. The small size of the pellets allows for precise fuel feeding. On the other hand, the supply of air for reaching optimal combustion efficiency is easier to adjust since the fuel quantity in the combustion chamber remains constant and predictable.Fuel efficiency. High combustion efficiency is also determined by consistently low moister content of pellets (consistently under 10% as opposed to 20% to 60% moisture content of the logs). Low moisture content, controlled fuel

portions and precise air setting means high combustion efficiency and very low carbon oxides in the flue gases.

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When purchasing pellets, ask for conformity declaration and certificate issued by an accredited laboratory and make sure the fuel meets the requirements indicated in the manual. If you purchase large amount of pellets (bulk supply for the entire heating season for example), ask your supplier to provde accurate and true information about the storage conditions.

We recommend to use pellet with size of 6 - 8mm. Density 600 - 750kg/m3 heating value 4.7 - 5.5 kWh/kg. Ash content – less than 1% and moisture content up to 8%, EN ISO 17225-2:2014.The optimal density of the pellets which guarantees their quality is 605-700 kg per cubic meter.Pellet moisture content must not exceed 10%. Make sure you store your fuel in a dry and well-ventilated place.The optimal pellet ash content is ≤ 1%. This also provides for less frequent cleaning intervals for the burner.The table below contains the parameters which we recommend that you take into consideration when choosing fuel for your „Pell” burner.

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Table2. European Certification of Wood Pellets for Heating Purposes

Parameters Units ENplus-A1 ENplus-A2 EN-B

Diameter mm 6 (± 1)8 (± 1)

6 (± 1)8 (± 1)

6 (± 1)8 (± 1)

Lenght mm 15 ≤ L ≤ 40 1) 15 ≤ L ≤ 40 1) 15 ≤ L ≤ 40 1)

Bulk dentsity kg / m2 ≥ 600 ≥ 600 ≥ 600Calorific/heating value MJ / kg ≥ 16,5-19 ≥ 16,3-19 ≥ 16,0-19

Humidity /moisture Ма .-% ≤ 10 ≤ 10 ≤ 10Dust Ма .-% ≤ 1 3) ≤ 1 3) ≤ 1 3)

Mechanical durability Ма .-% ≥ 97,5 4) ≥ 97,5 4) ≥ 96,5 4)

Ash Ма .-% 2) ≤ 0,7 ≤ 1,5 ≤ 3,5Melting point of ash °C ≥ 1200 ≥ 1100 -

Chlorine content Ма .-% 2) ≤ 0,02 ≤ 0,02 ≤ 0,03Sulfur content Ма .-% 2) ≤ 0,03 ≤ 0,03 ≤ 0,04

Nitrogen content Ма .-% 2) ≤ 0,3 ≤ 0,3 ≤ 1,0Copper content mg / kg 2) ≤ 10 ≤ 10 ≤ 10

Chromium content mg / kg 2) ≤ 10 ≤ 10 ≤ 10Arsenic content mg / kg 2) ≤ 1,0 ≤ 1,0 ≤ 1,0

Cadmium content mg / kg 2) ≤ 0,5 ≤ 0,5 ≤ 0,5Mercury content mg / kg 2) ≤ 0,1 ≤ 0,1 ≤ 0,1

Plumbum content mg / kg 2) ≤ 10 ≤ 10 ≤ 10Nickel content mg / kg 2) ≤ 10 ≤ 10 ≤ 10

Zinc content mg / kg 2) ≤ 100 ≤ 100 ≤ 1001) Not more than 1% of the pellets may be longer than 40 mm, max. Length 45 mm;2) Dry weight;3) Particles <3.15 Mm, particulate matter, before handing over the goods;4) Measurements with lignotester limit value ≥ 97,7% by weight.

4. TRANSPORTATION OF THE BOILER AND BURNER

4.1. Transportation of the boilerWe recommend to transport the heating boiler to the installation site in its packaging placed on the pallet. During transport and installation, depending on the weight, suitable safety devices should be used in accordance with Directive 2006/42/EC.

When transporting items weighing more than 30 kg, the use of pallet jack, fork truck or other hoisting devices is a must.The boiler is securely fastened with fasteners to a wooden pallet.

Important: When installing the boiler, the wooden pallet onto which the boiler is placed must be removed by unscrewing the bolted connections using flat ring wrench S13.

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4.2. Transportation of the pellet and auger.It is mandatory for transportation to place and secure the burner and auger on a pallet.- Dimensions of the packaging of the burner: 450х350х750 mm;- Dimensions of the packaging of the auger: 260х120х1700 mm;

5. DELIVERY OF THE BOILER AND BURNER

• Inspect the integrity of the packaging upon delivery.

• Check whether all components have been delivered to you.

1. Boiler scope of delivery includes:1) Boiler body with boiler doors 2) Control unit3) Safety valve 3 bar4) Fire irons5) Cleaning brush for flue pipes6) Technical passport. Installation and

operation manual 7) Service booklet and Warranty card If

any of the above items are missing, contact your supplier.

2. Burner consignment package includes:1) Pellet Burner Pell with built-up Control

unit2) Feeding chute3) Fire irons4) Auger5) Technical passport. Installation and

operation manual6) Service booklet and Warranty card

3. Fuel Hopper.4. Mounting kit for particular model

burner.If you find a missing component, contact your provider.

6. INSTALLATION OF THE HEATING BOILER

The assembly, installation and set-up of the boiler must be performed by a technician authorized for such operations. Installer must indicate to the user of the installation the minimum clearances from flammable materials and liquids.

6.1. Requirements:- Boiler room must be frost-proof;- Boiler room must allow for continuous

Table 3. Overall dimensions of model WBS Active boiler

Model A, mm

B, mm

C, mm

D, mm

Weight, kg

Diagram 3. Overall dimensions of boiler and pallet, model WBS Active

WBS-A 20 650 1050 125 1475 255WBS-A 25 650 1050 125 1475 300WBS-A 30 650 1050 125 1475 322WBS-A 40 750 1100 125 1475 362WBS-A 50 750 1100 125 1475 392WBS-A 70 810 1300 125 1620 466WBS-A 90 810 1300 125 1620 508

WBS-A 110 880 1300 125 1620 531

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access of air necessary to maintain combustion;

- Boilers must not be placed in inhabitable rooms;

- All boiler rooms must have correctly calculated vent depending on the boiler output. The vent must be protected by means of a net or grate.

The size of the vent is calculated according to the formula: А = 6,02*Q - where: А – area of the vent in cm2, Q – boiler output in kW- Remove the packaging without polluting

the environment- Observe building supervision

instructions, in particular the existing Ordinance on combustion devices and storage of combustion materials, on building requirements applicable to installation sites and on ventilation;

- The boiler must be placed on a foundation whose surface area is larger than the base of the heating boiler according to diagram 1;

- The boiler must be placed in a position which allows for the easiest possible cleaning and servicing;

- Installation must be carried out according to installation diagram 1 which shows the boiler housing;

- No objects made of flammable materials or liquids may be placed on/near the boiler;

6.2. Check door tightnessOpen boiler doors.Place paper strips on the four sides of the doors and close leaving part of the strips protruding outside.Pull the paper strips. If the strips tear upon pulling, doors seal tightly.

Caution! Inadequate adjustment of the hinges may result in air being sucked in through the doors and the boiler burning uncontrollably.

7. SETUP OF THE HEATING BOILER AND BURNER

7.1. Connecting the boiler to a chimneyBoiler-to-chimney connection must always comply with the existing standards and rules. The chimney must provide sufficient draught for evacuation of the smoke under any conditions.The proper functioning of the chimney requires adequate sizing of the chimney itself since the draught it produces affects combustion, boiler’s output and life span.The draught created by the chimney is in functional relation to its cross-section, height and the roughness of its interior walls. No other appliance may be connected to the chimney serving the boiler. Chimney diameter must not be smaller than the flue outlet of the boiler. Flue outlet must be connected to the chimney opening. In terms of mechanical properties, the flue outlet must be sturdy and properly sealed (to avoid gas leak) and allow for easy access for cleaning on the inside. The inner section of the flue outlet must not be greater than the effective section of the chimney and must not narrow. Avoid using elbow joints.The chimney cleaning opening has to be in its lowest part. The chimney’s wall has to be threeplied where the medium layer is from mineral wool. The thickness of the insulation is not less than 30 mm when the chimney is setting up inside the house and the thickness is 50 mm, when the setting up is outside.

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The inner diameter of the chimney depends on its real height and the power capacity of the boiler (see diagram 4). Please entrust choosing a chimney and its installation by a qualified professional. The required distance between the boiler and the chimney is 300-600 mm.

Diagram 4. Interdependence between boiler rated power and flue dimensions

Table Recuired chimney height, depending on boiler capacity and chimney diameter

Boiler output

Diameter of boiler chimney

Chimney clear

opening

Chimney minimum

height20 kW Ø 150 mm 160 mm ≥ 5,5 m25 kW Ø 150 mm 160 mm ≥ 6 m30 kW Ø 150 mm 160 mm ≥ 7 m

40 kW Ø 180 mm 180 mm /200 mm

≥ 11,5 m / ≥ 8 m

50 kW Ø 180 mm 180 mm /200 mm

≥ 12 m / ≥ 10 m

70 kW Ø 200 mm 220 mm ≥ 10 m90 kW Ø 200 mm 220 mm ≥ 12 m

110 kW Ø 200 mm 220 mm ≥ 14 m

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Data in the tables are for indicative purposes.Draught depends on the diameter, height, uneven sections along the chimney surface and differences in temperature of combustion products and outside air. We recommend that you use chimney fitted with flue terminal. Heating specialist must calculate the precise sizing of the chimney.

7.2 Connecting the safety heat exchanger

Such connection must be performed by a technician / service shop authorized for such operations.

The heating boiler is equipped with safety heat exchanger (cooling circuit). It connects to the water system through a thermostatic valve. In case of overheating, the thermostatic valve feeds in cold water from the water mains which passes through the heat exchanger and absorbs the heat in the boiler. The water is then discharged into the sewage system. This arrangement ensures safe evacuation of the excess heat without the need for additional energy. This guarantees that the water in the boiler will not exceed the maximum safe level of 95°C.The minimum operating pressure of the cooling water in the safety heat exchanger must be within the range 2 ÷ 10 bar. A flow rate of at least 12 l/min is required. Connect the safety heat exchanger according to the hydraulic diagram using thermostatic valve. Install a filter on the inlet before the thermostatic valve.

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Diagram 5. Connecting the safety heat exchanger

1. Water supply network (pressure 6-10 bar)2. Drainage (sewerage)3. Boiler WBS Active4. Safety heat exchanger inlet5. BVTS valve sensor6. Safety heat exchanger outlet

7.3. Connecting the boiler to the heating installation.


When the boiler is connected to a heating system, it is mandatory to install a 3 bar relief valve and expansion vessel. No shut-

off fittings may be installed between the relief valve, expansion vessel and boiler.

It is mandatory to install a three-way valve (Laddomat or similar) or a four-way mixing valve which to ensure that the temperature of the heating medium fed into the boiler from the heating installation is at least 65°С.

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Table 4. TROUBLE-SHOOTING TABLE Fault Cause Solution

1. Low temperature in the boiler on which the burner is installed. Unable to reach normal temperature mode of 65° - 85° С

1.1. Inadequate sizing and/or combination of heating appliances

1.1. Immediately consult your installer about the problem. Mount the supplied filling and drainage cock on the drainage outlet Y.

2. Ejection of unburned pellets into the combustion chamber of the boiler

2.1. Poor adjustment of the fuel-to-air ratio from the burner controller

2.1. Contact your installer. It is necessary to set the burner properly using gas analyzer

2.2. Utilization of low-quality pellets (shorter than the specified length)

2.2. Use only fuel which meets the requirements specified in the manual.

3. Formation of clinkers and noncombustible inclusions inside burner body.

3.1. Utilization of low-quality pellets (with higher ash content)

3.1. Use only fuel which meets the requirements specified in the manual.

3.2. Low performance of the automatic cleaning system

3.2. Increase turn-on frequency of the automatic cleaning system.

3.3. Improper setting of fuel-air mixture 3.3. Adjust using gas analyzer

4. Smoke in the pellet hopper

4.1. Poor chimney draught or high internal resistance of the boiler combustion chamber

4.1. Immediately consult your installer about the problem.

4.2. Blockage of burner combustion chamber due to build-up of noncombustible materials

4.2. It is necessary to clean the burner combustion chamber using brush


5. Unstable flame (photosensor detects > 180 units at maximum output)

5.1. Blockage of burner combustion chamber due to build-up of noncombustible materials

5.1. It is necessary to clean the burner combustion chamber using brush

5.2. Dust on the photosensor

5.2. It is necessary to clean the photosensor. Refer to the manual for the cleaning procedure.


6. Boiler temperature too high. Controller failure

6.1. Grid power fluctuations6.2. Power failure


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7.4. Connection diagrams

Such connections must be performed by a technician / service shop authorized for such operations.

CH

Pum

p

Sens

or B

oile

r *

Diagram 6. Connection of WBS Active-Pell boiler to three-way valve

* Sensor Boiler - water jacket temperature sensor

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Sens

or B

u�er

top

Sens

or B

u�er

bot

tom

CH

Pum

p

Sens

or B

oile

r *

Diagram 7. Connection of WBS Active-Pell boiler to P type buffer tank and three-way valve


16


Sens

or B

oile

r *

Sens

or B

u�er

top

Sens

or B

u�er

bot

tom

CH

Pum

p

Diagram 8. Connection of WBS Active-Pell boiler to combi tank KSC2, flat plate solar collector PK and three-way valve


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Sens

or B

oile

r *

Sens

or D

HW

Sens

or B

u�er

top

Sens

or B

u�er

bot

tom

CH

Pum

p

DH

W P

ump

Diagram 9. Connection of WBS Active-Pell boiler to solar tank SON, buffer thank P, flat plate solar collector PK and three-way valve


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7.5. Pellet burner connection to the fuel hopper and pellet augerTake the feeder chute flexible hose (from the auger set). Using a bracket, clamp one end of the hose onto the motor-end outlet of the pellet auger.- Remember – pellet auger must be

installed at 45° angle to the ground horizontal surface.

- Fill the hopper with fuel (see table 2 for parameters of the fuel types used)

- Plug the power cord of the pellet auger into the indicated Schuko-type burner socket on the left side of the burner housing.

Diagram 10. Mounting the pellet burner Pell to WBS Active boiler

1. WBS Active boiler;2. Pellet burner Pell;3. Auger flexible pipe;4. Auger;5. Fuel hopper.

7.6. Connecting the pellet burner to the mains power supply


Caution! ELECTRIC SHOCK HAZARD!

- Before opening the unit: switch off the voltage and secure the unit against accidental restart.

- Observe installation instructions.


Improper cable connections may damage the regulator!

The device may be damaged if struck by a lightning. Make sure it is unplugged during the storms.

It is imperative that the installation of the sensor to control the temperature in the boiler. View a scheme 5 point 6.

ATTENTION! STB - thermostat (located on the front panel of the boiler) to be bound to the burner according to wiring diagram 12.

The boiler must be connected to a 220V/50Hz mains using power plug (3 meters long, bound to the burner).Create tight connection with the electrical mains which complies with the local regulations.

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Diagram 11 Wiring diagram of connection of internal devices / sensors to the burner

KSD 30180DEG0

С

NP

BC

V3M

-2

Cleaner

OD

brown

brown

brownHeater

blue

brown

blue

brown

brown

Fan

Photosensor

STB Reverse rin

sensor

Buer bottomSensor

DHWSensor

Buer top Sensor

Temperature sensor in the water jacket of the boiler

Internal Feeder

blue

blue

STB KSD 301 80° C

Photosensor

Cleaner

Internel Feeder

Heater

Fan

С

blue

brown

brownbrown

NP

BC

V3

M-2

bluebrown

bluered

whiteblackblack

Buffer boom Sensor

DHW Sensor

Boiler temperaturesensor ( Pell )

Buffer top Sensor

Capacitor2.5 µF 450V

External Feeder conneconElectric motor model 8IN25GN4C

bluebrawn

black


red8IN25GN4C

Electric motor model 4IK25GN-C

bluered

white


4IK25GN-C

OD

PT

WH

B

RB

PS

RT

FC

IGN

PWH

PH

SB

SF

FM

FSG

External Feeder connecon

InputsGroup 1

RT Room thermostatPS Photo sensorRB Temperature sensor at the top of the bufferB Boiler temperature sensor

Group 2WH DHW SensorPT Temperature sensot at the bottom of the bufferOD Sensor reverse burning

OutputsFM Fan mainFSG Fan smoke gasesSF Screw fuelSB Screw burnerPH Pump heating

PWH Pump water heaterIGN IgniterFC Fan cleaning

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Diagram 12. Wiring diagram of connection of external devices / sensors to the burner

Power Supply

220 V

L N L N

Fuel Feeder

CH Pump 220 V

DHW Pump 220 V

L N

RoomTherm.

L N L N

NPBC V3M-2

Buffer topSensor

DHWSensor

Buffer boomSensor

Boilerwater mantle

temperaturesensor

STB IMIT 105° CMounted on boiler

Front panelBoiler temperaturesensor ( STB )

WBS Acve + Pell FH 500-V2 + EKO L

ODPT

WHB

RBPS

RT

FCIGN

PW

H

PH

SB

SF

FM

FSG

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8. BURNER OPERATING

8.1. IgnitionAfter the start up of the burner from the control panel, the main pellet auger conveys certain amount of fuel from the pellet hopper to the burner. This specific amount of pellets is set by the installer and depends on the fuel characteristics. The fed-in quantity of pellets is conveyed from the auger conveyor built in the burner to the combustion chamber where it is being ignited using hot air.8.2. BurningThe burning process takes place in the combustion chamber and, after it has been fed into the combustion chamber, the fuel is then transported from the internal auger conveyor to the combustion chamber in portions. This allows for constant and optimal burning rate of the fuel . Flame intensity is monitored by a photosensor which monitors the burning and feeds data into the control unit which enables the starting or stopping of the combustion process, if necessary. The output of the burner is determined by the intervals preset on the control panel taking into account the heating value, size and density of the pellets.8.3. Automatic cleaning systemThe “Pell” pellet burner is equipped with innovative automatic cleaning system for the combustion chamber. Thanks to a powerful cleaning motor built in the burner body, air is being blown in at high speed and rate thus removing all residues – ash, noncombustible inclusions, etc. built up into the combustion chamber of the boiler. These automatic cleaning cycles last several seconds and can be additionally adjusted as well as their repeat rate depending on the load of the

burner.8.4. Installer prescriptions regarding burner servicing and maintenanceBefore the heating season it is mandatory to check up and clean the burner and its components.It is mandatory to clean up the combustion chamber of burner using the scraper brush from the maintenance kit. In case of combustion chamber orifices clogged by non-combustive material, those should be released using a bodkin. Clean thoroughly the inner combustion chamber using the scraper brush to remove all deposits on the metal surface. Use a vacuum cleaner to remove all sand and ashes from inside the combustion chamber. Check integrity of gasket between outer combustion chamber and closing hatch, replace if compromised.It is mandatory to clean dust off main fan and controller board8.5. Important recommendations for long-lasting and correct operation of the burner- For assembly and installation of the

burner follow the requirements in this manual.

- Use only recommended in this manual fuel.

- Disassemble the burner from the boiler body before clean it. Depending on fuel and burner settings, clean the pellet burner once a month.

- User`s training for operation and maintenance of burner is performed by an authorized installer or service shop.

Failure to observe the installation and operating requirements described in the manual and the service booklet voids the warranty.

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Type of maintenance Procedure Duty of:

Weekly Cleaning of combustion chamber by poker and scraper brush. User

Monthly

Dismantling of combustion chamber housing (A). Cleaning of combustion chamber by scraper brush and vacuum cleaner. Replacement of gasket if faulty (see Diagram 13)

User / Installer

Yearly Full dismantling and cleaning of burner. Replacement of all gaskets (see Diagram 13.3) Installer

Diagram 13. Dismantling of the combustion chamber housing.

9. MAINTENANCE AND CLEANING OF THE BOILER

9.1. Cleaning of the boiler

Caution! Hot surfaces.

Before cleaning the boiler, make sure the fire in it has died out and the boiler has cooled down.

Boiler cleaning must be carried out periodically and adequately every 3 to 5 days. Ash accumulated in the combustion chamber, condensed moisture and tar deposits significantly reduce the life span and performance of the boiler and result in deterioration of the properties of the heat exchange surface In case of larger ash accumulation there is not

enough space for fuel combustion which may result in damage of the boiler as a whole. Regular cleaning is important to ensure the optimal performance and long operational life of the boiler.It is recommended that the ash-and soot-container be emptied and cleaned every 3 to 5 days depending on fuel used. Scrape the inside of flue pipes if necessary. Use the scraper tool.

Disassembling of barrier ribs:1. Open upper boiler door. Just behind the boiler door are fitted upper and lower protective doors. Disassemble upper protective door (1) in this order:- lift the door gently up and forward- detach the door from retaining hinges

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- remove gently upper protective door.

4

2. Gently pull out lower barrier rib (2) which is on top of middle water rib.3. Gently pull out upper barrier rib (3) which is on top of upper water rib (4)4. For assembling the barrier ribs back into boiler follow the steps in reverse order.

Caution! When mounting the upper resistance rib (3) bend pointing upwards!

Scrape the inside of flue pipes if necessary. Use the scraper tool.It is mandatory to clean once a week additional barrier ribs into combustion

chamber.Disassemble the barrier ribs.Follow described above instructions for assembly and disassembly.Clean barrier ribs.Clean the accumulated ash from heat exchanging ribs.

Caution! Ashes may contain smoldering charcoal. Dispose of ashes only in specially designated facilities. Disposing of ashes into public garbage containers may cause fire.

9.1.1. Preparing for the new heating season. Recommended boiler maintenance procedures:1. Remove internal safety gates inside the

boiler firebox (combustion chamber). Scrape thoroughly the firebox using the scraper brush from the boiler cleaning kit. Remove tar and soot deposits as they obstruct normal heat radiation.

2. Clean thoroughly water jacket ribs. Remove cinder and soot deposits using the scraper tool and brush from cleaning kit.

3. Remove inspection opening lid below the boiler flue opening and remove ash deposits in there.

Caution! Replace inspection opening lid gasket wth a new item if its integrity is broken.

4. Clean well metal grill in the bottom part of the boiler. Check whether gaps between flue pipes are well cleaned. Tar deposits or residues of non-combustive materials inside the boiler firebox deteriorate normal combustion process.

5. Check for good sealing of doors: - Open the doors of the boiler.- Place four strips of paper sides of the

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doors and close so that some of the tapes to be submitted outside.

- Pull the paper strip. If to break during pull, the doors are sealed.

If necessary, adjustment of of boiler doors or replacing insulation rope, please contact in your installer.

9.2. Important recommendations for long-lasting and correct operation of the boiler.- Carry out periodic maintenance of boiler

following the prescriptions in Section 9.1.

- Gas emission in the combustion chamber may result in the formation of tar and condensate (acids). Therefore, a mixing valve must be installed and it must be adjusted so that the minimum temperature of the water returning in the boiler is 65°С. This extends the life span of the boiler and its warranty. The operating temperature of the water in the boiler must be within the 65°С ÷ 80°С range.

- It is not recommended to operate the boiler for a long period of time at an output lower than 50%.

- When using circulation pump, boiler operation must be controlled via a separate thermostat in order to ensure the prescribed rated temperature of the return water.

- The eco-friendly operation of the boiler is realized at rated output.

- It is recommended to install a storage/buffer tank and pump type group with thermostatic mixing valve to the boiler. The capacity of the storage tank is 55 L of water per 1 kW installed boiler power.

- Maintenance and operation training for

the boiler is conducted by an authorized installer

Failure to observe the installation and operating requirements described in the manual and the service booklet voids the warranty.

10. OPERATION OF MICROPROCESSOR CONTROLLER WHEN BURNING WOOD-

PELLETS

ATTENTION: The boiler should have non-return valves mounted on the central heating pump circuit and the hot consumption water pump circuit. A valve mounted on the hot consumption water pump will prevent hot consumption water from being drawn from the water heater.

10.1. Controller view. Explanation of buttons and indicators.LCD screen:

The controller screen displays the information for the operation of the facility.Explanation of buttons:

Button F function button.

Apply for: - exit of the current menu- taking back to main screen- burner transfer from one condition to anotherButton „Enter” – apply for switching from one parameter to another in certain screen or to correct the certain parameter.

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Buttons „Navigation arrow Up” and

„Navigation arrow Down” – Used

to change the value of a parameter in the menu and to move to the next menu page After entering the correct value press button “Enter”, to move to next parameter.

Display symbols explanation:

Auto Clean symbol appears in right upper part of display. Active auto

cleaning symbol means boiler automatic cleaning mode.

Crossed-out flame symbol appears in upper right part of display. Means

that the boiler enters into Extinguish mode.

CH priority /Radiator/ symbol appears in upper part of display.

Means than Central Heating priority is set to heat up the central heating.

Domestic Hot Water /shower/ priority symbol appears in upper part of display. Means than DHW

priority is set to heat up the domestic hot water. When set DHW temperature is reached, DHW pump stops and CH pump is activated.

Parallel pumps /shower and radiator/ symbol appears in upper

part of display. Means that is set equal priority to both pumps. They work in parallel and are controlled by temperature sensors.

Summer mode /shower and sun/ symbol means than is set Summer

heating mode. Only DHW pump is active.Burner flame symbol appears in upper right part of display. Means

that burner is activated. Burner goes into Ignition mode and upcoming boiler fire up.

Flame 3 symbol means Maximum output mode of boiler. In this mode

the boiler operates at maximum output.Flame 2 symbol means Medium output mode of boiler. In this mode

the boiler operates at partial output.Flame 1 symbol means Low output mode of boiler. In this mode the boiler operates at minimum output.This symbol means Suspend mode of boiler.The notice “Hi” appearance on the screen where the boiler temperature is displayed means

that the measured Boiler body temperature is above 120°C. Flashing and beeping alarm is activated. When the issue is corrected, notification can be deleted. When disconnect the boiler from electrical supply for few seconds and then switch on it again, boiler goes back to normal operation.

Notify the authorized installer/ service to be performed immediately inspection of the boiler and heating installation.

Boiler increased temperature. Those two symbols appearance on the screen where the boiler

temperature is displayed means that boiler temperature has increased up to 99°C.


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Error symbol appears in right upper part of display. Flashing and beeping error symbol mean error or fault in

boiler operation. Use “Enter“ button to move to next screen with error notification in lower left part of display. When the issue is corrected, error notification can be deleted. When disconnect the boiler from electrical supply for few seconds and then switch on it again, boiler goes back to normal operation (error notification is deleted).


Factory setting - Alarms

BB ALARM

Reverse fire Alarm (when the thermostat contact OD input is open)

SENSOR E1

Boiler Temperature Sensor is missing (input B)

SENSOR E2

Boiler Temperature Sensor Short circuit ( input B)

IGNITION FAIL Failure ingnition

DHW E1 Water Heater Temperature Sensor is missing (input WH)

DHW E2Water Heater Temperature Sensor Short circuit (input WH)

CH btm E1

Temperature sensor of lower part of buffer tank is missing (when is chosen scheme with buffer tank)

CH btm E2

Short circuit of temperature sensor of lower part of buffer tank (when is chosen scheme with buffer tank)

CH top E1Temperature sensor of upperr part of buffer tank is missing (when is chosen scheme with buffer tank)

CH top E2Short circuit of temperature sensor of upper part of buffer tank (when is chosen scheme with buffer tank)

When restarting the controller alarm is deactivated.

”С” symbol means that the motor of automatic cleaning system is

activated.Symbol “T” indicates, that room termostat has been activated.

In “CH only” mode when there is a signal from room termostat, the burner burns 5 min at max power, followed by transer to power level 2. After 5 min the burner transfers to power level 1, and after 5 min transfers in Suspend mode. When there is no signal from room termostat or there is non-fullfilled requirement for DHW, the burner will fire up.In “CH + DHW” mode when DHW (Domestic hot water) requirement is fullfilled and there is a signal from room termostat, the burner burns 5 min at max power, followed by transfer to power level 2. After 5 min burner transfers to power level 1 and after 5 min transfers to Suspend mode. Hen there is no signal from room termostat or there is non-fullfilled requirement for DHW, the burner will fire up.When room termostat is activated, CH pump stops in both modes (CH Only, CH+DHW). In CH+DHW mode when there is a signal from room termostat, CH pump turns off. The burner countinues

27


to burn until DHW (Domestic hot water) requiremend is fullfilled.In „Summer Mode“ room thermostat is not active.

Lights for operating:

- Pump heating system.

- Pump Domestic hot water.

10.2. User`s menu10.2.1. Initial (start-up screen) “Standby”For access to user settings menu press and hold functional key F for 3-4 seconds.

Use UP and DOWN arrow keys in CH Setup menu to select desired temperature of

engagement of circulation pump.From this menu you can preset buffer tank circulation pump switch-on and

switch-off temperatures provided such heating installation scheme (with buffer tank included) is selected, whereas the two sensors reading these temperatures are mounted in the upper, respectively lower part of the buffer tank (cf. boiler connection schemes). Use button F to navigate to the next menu.

In DHW Setup menu – set domestic hot water (DHW) pump switch on/off temperature.

Use UP and DOWN arrow keys to select desired temperature in “Set Temp _ _°”

and hysteresis in “Hysteresis _ _°”. Upon reaching the preset temperature of water in boiler the DHW pump will engage. It will stop when water inside the DHW storage tank reaches the preset temperature.Example: On Set Temp 75°C and Hysteresis 05°C when water inside the boiler heats up to 70°C the pump will start. When water temperature inside the DHW storage tank reaches 75°C the pump will stop. It will restart once the water temperature inside the DHW tank drops by 5°C. In this way the water temperature inside the DHW tank will be kept at a hysteresis of 5°C, i.e. the water temperature will be between 70°C and 75°C.

Use UP and DOWN arrow keys in Set Time menu to set the unit’s built-in timer/clock.

Use UP and DOWN arrow keys in Set Date menu to set the date.

Use UP and DOWN arrow keys in Contrast menu to adjust the LCD display backlight

level. Confirm settings by shifting to next submenu through a single pressing of the functional key F.

Choose a language by pressing navigation arrows and button “Enter”.

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The burner is in Standby mode.The display shows:

- Temperature in the boiler (23°C), time, and by pressing the Enter button you can browse the quick menu (bottom left) where the following read-only data is displayed:

t = 85° - Maximum set temperature;

tDHW = 42° - Parameter tDHW indicates temperature of domestic hot

water (DHW);tCH = 77°/70° - Parameter tCH indicates

top and bottom buffer temperature (visualized only in Buffer mode);

0 - Light intensity in the burner (in the range of 0 ÷ 190);

- Burner status (detected errors, if any);

- Current date.

10.2.2. Burner star up “Switch mode”Burner start-up. After pressing the “F” button and using the „Navigation arrows”, the “Auto”

menu is selected. Pressing the “F” button will open the next page of the menu.Set the priority mode of the burner through “navigation arrows.”

Set the priority mode of the burner through “navigation arrows.”

- CH + DHW – Both pumps /CH-central

heating pump and DHW – domestic hot water pump / are active.

- CH only – In this mode of operation the only active pump is the CH circulation pump for the heating installation (CH pump). In this mode, the boiler can be managed via a room thermostat or be temperature-controlled by the temperature inside the connected buffer tank to it (according to wiring diagram)

- Summer Mode – Summer mode. Boiler works for heating of domestic hot water only.

If you have selected the (CH + DHW) option, upon confirmation of command via the

“F” button you may navigate to the next screen.

From this menu you can set up and adjust DHW pump activity periods. Use

the arrow keys to set time (HH:MM). Use “Enter” button to checkmark desired time period option. If no option is check-marked, the controller will maintain DHW temperature as a priority. Only when its preset value is reached, the CH circulation pump will start.10.2.3. Burner shut-down “Standby”

Pressing the “F” button will take you to the main menu and by using the navigation arrows

you can select the “Standby” menu and confirm the selection by pressing “F”. The burner goes into extinguishing mode.

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10.3. Installer’s menu (setting the combustion parameters in the burner controller)

CAUTION! We recommend that this menu be used only by an authorized installer/service shop in order to ensure efficient and safe operation of the equipment

To access the s e t t i n g s adjustment mode, s imultaneous ly press the “Enter”

and „F” buttons and hold them pressed for 4 /four/ seconds. This will display the controller hardware and software version on the screen. Press again button “Enter” and this will open the initial page for the burner settings.

For access to service settings menu you need a service menu code.The service menu comprises only and uniquely parameters with

direct impact on boiler combustion process, as well as on heating installation management (depending on the peripherals management capacity of the boiler digital controller unit).

Fuel switching and / or change the configuration of the heating installation must be performed by an authorized installer / service. Some of these reasons may affect the safe operation of the facility.

10.3.1. Cleaning setupThe burner performs automatic cleaning before each ignition and shut-down.

You can use this menu to adjust the running time of the main fan (FAN) and of the cleaning motor (Cleaner). Select the desired option using the navigation arrows. Use the „Enter” button

to open the next parameter. Use the button to open the next page of the menu.

In this submenu you can activate or deactivate the automatic cleaning of the burner in

Ignition (Start) mode or extinguished (Stop) mode. The checkmark in the box indicates that the automatic cleaning system is active.

10.3.2. Ignition setup

In this submenu you can set the number of attempts (Retries) to ignite the burner

and the time of the initial feed portion of pellets (Feed). Select the desired option using the navigation arrows. Use the „Enter” button to open the next

parameter. Use the button to open the next page of the menu.10.3.3. Cycle setup

Use this submenu to adjust the running time of the heater (Heater) and the running time and

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output of the main fan during the ignition of the initial portion of pellets. Principle of operation: After feeding the initial portion of pellets, the heater operates for 3 minutes , and the main fan is turned on at 20% of its capacity and operates for 4 minutes (the heater continues to work). If upon the expiration of that period the photosensor detects the presence of stable flame, the burner enters into operating mode. If no stable flame is present, the burner feeds in pellets again and repeats the process.

NOTE! Fan B/E 20/1 is a set up for the main fan at 20% and set up for the fan for fume gases 1% (if there is installed). Fan for the fume gases must be connected to termonal FSG (see scheme 11).

Select the desired option using the navigation arrows. Use the „Enter” button


10.3.4. Burn LevelThe burner has three main levels of burning (three main output modes of operation). Use this

menu to set the temperature differences at which the burner will shift from higher output mode to lower (step modulation).Example: We have set maximum temperature of 85°С. Upon reaching 77°С, the burner will shift down to lower mode of operation (two flames). Upon reaching 82°С, the burner enters into still lower mode of operation (one flame). Upon reaching 85°С, the burner enters into suspend mode (Suspend).

Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use

the button to open the next page of the menu.

10.3.5. Setup of burning LevelThis submenu allows you to adjust the parameters of the main mode of o p e r a t i o n

Maximum output of the burner. It is indicated by three flames .You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).Example: with the period set at 20 seconds, the pellet auger runs for 7,4 seconds feeding pellets in the burner, and is off for 12,6 seconds.Select the desired option using the navigation arrows. Use the “Enter” button


In this submenu you can adjust the parameters of the medium output mode of operation

of the burner.

It is indicated by two flames .We recommend to set at 50% of the main mode.You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).

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Example: with the period set at 20 seconds, the pellet auger runs for 4,2 seconds feeding pellets in the burner, and is off for 15,8 seconds.Select the desired option using the navigation arrows. Use the „Enter” button


In this submenu you can adjust the parameters of the lowest output mode

of operation of the burner. It is indicated by one flame .We recommend to set at 10÷35% of the main mode.You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).Example: with the period set at 20 seconds, the pellet auger runs for 1,5 seconds feeding pellets in the burner, and is off for 18,5 seconds.Select the desired option using the navigation arrows. Use the „Enter” button

to open the next parameter. Use the button to open the next page of the menu.Complete description of the output modes is provided in section 10 of this manual.

10.3.6. SuspendThis submenu allows you to adjust the parameters of the suspended mode of operation of the burner. You can modify the pellet quantity (Feed), time interval at which these pellets are fed (Cycle) and fan output as a percentage value (FAN).

Example: with the period set at 20 seconds, the pellet auger runs for 2 seconds feeding

pellets in the burner, and is off for 118 seconds. Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the button to open the next page of the menu.10.3.7. Suspend Time

In this menu you can adjust the time period for which the burner will remain in suspended mode

and the time can be set in minutes with a maximum duration of 180 minutes.If within a set time (20 minutes) the temperature in the boiler does not decrease, the burner enters into Extinguish mode – crossed-out flame .

10.3.8 . Cleaning set up in working modeIn menu Interm. Cleaing self-cleaning for the burner can be set. The main burner’s

fan turns on during certain cycle on higher power level for certain period of time. All parameters can be changed.

NOTE! This menu is valid only for pellet burners with model “ECO”

10.3.9. Auto Clean SetupYou can set time and number of engagements of the burner self-cleaning

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system.It is mandatory to have at least one self-cleaning session in 24 hours.Maximum number of self-cleaning sessions in 24 hours – six.Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the button to open the next page of the menu.10.4. Hardware Setup

Use this submenu to activate (with check mark) or deactivate a d d i t i o n a l peripherals.

CH PUMP – central heating pumpDHW PUMP – domestic hot water pumpThermostat .Select the desired option using the navigation arrows. Use the „Enter” button


From this screen menu you can choose the boiler o p e r a t i o n management mode.

This menu is valid only in the event of “CH only” option selected. By selecting the checkmark “Buffer” the boiler will be controlled according to temperature inside the buffer tank connected to the boiler. The setting of the temperature of the buffer tank circulation pump start and stop temperatures is done as described above. When selecting the boiler management via thermostat option the boiler will be controlled by the signal input from the thermostat, whereas the options are: thermostat normally open or thermostat normally closed. Its type is introduced at a later step on the controller

menu.Burner Feeder - internal burner auger /feeder/ Cleaner Motor Tstat NO -

Thermostat, normally open.There must be a checkmark on the internal pellet auger of the burner (Burner Feeder)Select the desired option using the navigation arrows. Use the „Enter” button


Example: If the external pellet auger runs for 10 seconds and feeds fuel in the burner, the internal

auger will run for 20 seconds, if the setting is (Duty 200% - see picture) Duty parameter can be changed from 0% up to 300%.Select the desired option using the navigation arrows. Use the „Enter” button

to open the next parameter. Use the button to open the next page of the menu.Use this submenu to activate or deactivate the additional peripheral components.

This submenu allows you to adjust the conditions under which the p h o t o s e n s o r

detects the presence of stable or unstable flame and signals the burner to shift to operating mode or be extinguished.Example: (see picture) If the light intensity in the burner is above 100 units over a period of more than 20 sec, the burner

33


will detect that there is a stable burning process going on and will shift from ignition to burning. If the light intensity in the burner is under 40 units over a period of more than 60 sec, the burner will detect that there is no stable burning process going on and will extinguish the burner and attempt to reignite.Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the button to open the next page of the menu.Use this menu to conduct fan operation test.

This menu allows you to select maximum boiler temperature. In

other words, the maximum temperature to heat the boiler on which the burner has been installed. The maximum value for this setting is 85°С. Select the desired option using the navigation arrows. Use the „Enter” button to open the next parameter. Use the button to open the next page of the menu.

You can control the fan in real time, without confirming anything, using only

the navigation arrows.

Important. This menu is for installers only and it is active and visible only if the controller is in „Standby” mode.

Test EFan Speed Use this menu to test the fan exhaust (if installed). You can control the fan in real time, without

confirming anything, using only the navigation arrows. Use the button to open the next page of the menu.

This menu allows you to check the operation of the various pellet burner components.

Using the navigation arrows, you can turn on and off the various components and each time the respective components is being activated a checkmark will appear in front of its name. Use the „Enter” button to select the individual components.

Description of components:1) FF – Fuel Feeder – main auger2) BF – Burner Feeder – internal burner auger / feeder3) CH – Central Heating pump4) DHW – Domestic Hot Water pump5) Ign – Ignition6) CM – Cleaning Motor

Important. This menu is for installers only. It is active and visible only if the controller is in "Standby".

11. SETTING OUTPUT MODES OF OPERATION OF THE PELLET BURNER

PELLUR

CAUTION! You must use gas analyzer when setting the burner.

The Pell pellet burner is equipped with three-step output adjustment and their setting depends on the boiler and heat requirements of the heating installation.

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11.1. Calibration of auger fuel feed rate.The auger fuel feed rate changes depending on the density and size of the fuel used. Therefore it is necessary to calibrate the main auger every time you change the type of the fuel used.

CAUTION! It is recommended to use the same fuel throughout the heating season.

Once you have installed the pellet auger according to the instructions in the manual, fill the hopper with fuel (pellets). Connect the power supply of the pellet auger directly to the power mains. The auger is now in operation. Wait about 15-20 minutes for the pellet auger to fill with pellets. The auger is filled with pellets when pellets begin to fall from the T-branch of the auger at the point where the flexible pipe is attached. Filling of the pellet auger is necessary when the fuel in the hopper has been depleted or when fuel has been changed.Once you have ensured that the pellet auger has been filled, take an empty plastic bag and fixed it securely on the pellet auger, at the place of the flexible pipe. Reconnect the auger to the power socket and measure the amount of pellets collected in the bag over a period of 15 minutes using scales/weighing scale. (In our example, the amount of pellets collected in the bag over a 15-minute period is 4320 grams (900 sec). We then divide 4320 by 900 and get 4.8 grams of pellets per 1 second. Repeat the measurement in order to obtain conclusive results .

11.2. Burner output adjustment.In the burner output settings menu you can adjust the running time of the main auger (Feed); main running interval (Cycle) and fan output (Fan).Example for Pell 25 model: we select mode Cycle = 20 sec. The heating value of your fuel is 4,8kWh/kg. (manufacturers indicate the heating value of the fuel on the packing – take it from there). We then employ the following formula to calculate the number of seconds for setting the operation of the main auger for these 20 sec.:tFEED= 25 000 / (4,8 x 180 x 4,8)hence tFEED= 6 sec.,where 25,000 is the desired output of the burner in Watts (W),4,8 is the heating value of the fuel in kWh/kg,180 is the number of burning cycles per 1 hour,4,8 is the amount of pellets in grams fed by the auger per 1 second. This way the output mode can be changed and instead the number 25,000 – 25kW, we input the desired kilowatts (40 kW=40000 W, 70 kW=70000 W etc.).Take also note of the fuel heating value which would change the value for the feed and the burner output.Using the above procedure, you can set any of the three output modes of the burner.

Mode : Maximum output mode – It is indicated by three flames.Pellet auger running time (Feed) – 7,3 sec. (25kW)Main combustion cycle (Cycle) – 20 sec. (recommended)Fan output (Fan) - adjust using gas

35


Important: For each of the output modes the optimal fan setting is tweaked by using gas analyzer to control the oxygen amount registered by the device (within the range 8% ÷ 10%, and for the lower modes up to 13%). The specific setting depends also on the internal resistance of the boiler combustion chamber on which the burner has been installed as well as on the chimney draught. Therefore it is not possible to provide here the exact value for the fan output and it must be entered by a competent installer or service technician using gas analyzer.

analyzer.

Mode : Medium output mode – It is indicated by two flames.We recommend to set value at 50% of the main mode.Pellet auger running time (Feed) – 3sec. (12,5kW; 6 х 50% = 3)Main combustion cycle (Cycle) – 20 sec. (recommended)Fan output (Fan) - adjust using gas analyzer.

Mode : Low output mode – It is indicated by one flame. We recommend to set value at 35% (0,35) of the main mode.Pellet auger running time (Feed) – 1,1 sec. (7,5 kW; 6 х 35% = 1,1)Main combustion cycle (Cycle) – 20 sec. (recommended)Fan output (Fan) – adjust using gas analyzer.

i

Important: You use a burner whose carbon footprint values are approximately (СО = 100 ppm), which is 2.5 times lower than the maximum allowed limits for harmful emissions in the EU Member States. Thus you can reduce the amount of harmful emission and contribute to environment protection.

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Controller parameters of pellet burnerpellet burner Pell Pell 25 Pell 30 Pell 40 Pell 70 Pell 90 Pell 150

Burner Mode Actuator Parameter value:Service code 00000012

Cleaning Setup Fan 180 secCleaner 20 sec

Use Cleaner Cleaner v On startv On Stop

Ignition Setup Retries 3Feed 30 sec 30 sec 35 sec 35 sec 35 sec 35 sec

Ignition SetupHeater 3 min

Fan B/E 2 min15/1

Burn Level

dt>8 dt>8 dt>8 dt>8 dt>8 dt>8



Setup Feed 6 sec 7 sec 10 sec 10 sec 6,2 sec 10,2 secCycle 20 sec 20 sec 20 sec 20 sec 20 sec 20 sec

Fan B/E 32/1 37/1 29/1 26/1 35/1 50/1

Setup Feed 3 sec 3,5 sec 5 sec 6 sec 3,1 sec 5,1 secCycle 20 sec 20 20 sec 20 sec 20 sec 20 sec

Fan B/E 20/1 23/1 20/1 20/1 22/1 32/1

Setup Feed 1,1 sec 1,8 sec 3 sec 3 sec 2,1 sec 2,7 secCycle 20 sec 20 sec 20 sec 20 sec 20 sec 20 sec

Fan B/E 25/1 20/1 17/1 17/1 15/1 17/1

SuspendFeed 5 sec 5 sec 5 sec 5 sec 5 sec 5 secCycle 60 sec 60 sec 60 sec 60 sec 60 sec 60 sec

Fan B/E 15/1 18/1 17/1 17/1 5/1 17/1Suspend Time - 5 min

Interm. Cleaning Cycle 30/0 30/0 30/0 30/0 30/0 30/0Fan B/E 50/1 50/1 50/1 50/1 50/1 50/1

Auto Clean Setup v 8:00 v 14:00 v 22:00□ 00:00 □ 00:00 □ 00:00

Addons Activacion v CH Pump v DHW Pump v Termostat

CH Mode v Thermostat Buffer

Hardware Setup v Cleaning Motor v Tstat NO

Vacuum Feeder v NO NC

Burner Feeder Duty 300%

Ir Level Setup Ign > 100/020 sExt < 040/060 s

Set Temperature Max 85oCUse „+“ button for fans ON/Test

Test Fan Speed 00Test EFan Speed 00

Activate a checkmark for appliance On (Test) Test Outputs

FF /Fuel Feeder – main auger/BF /Burner Feeder – internal burner auger / feeder/

CH /Central Heating pump 220V/DHW /Domestic Hot Water pump 220V/

Ign /Ignition/CM /Cleaning Motor/

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pass flue gas flow for improved heat exchange.

- Exchangeable metallic ash grate protects the pipe grid from the flame.

- Burner flange on lower door for fitting pellet burners.

- Safety devices:1) Elbow-shape feeder chute prevents backfire entry from burner into pellet hopper;2) Thermostatic protection (80°С).3) Fuse 10 А;4) In case of power interruption, all parameter settings are storedin the memory of the controller.5) Safety heat evacuator;6) Pressure relief valve 3 bar.

Diagram 14. Elemets of WBS Active - Pell1. Housing2. High efficiency thermal insulation3. Safety heat evacuator (exchanger)4. Three-pas flue gas flow5. Water mantle6. Combustion chamber

7. Metal ash grate8. Ash-and-soot tray9. Burner flange 10. Flue11. Air intake flap

12. WARRANTY TERMS

The warranty terms are described in the Service booklet included in the supply.

13. TECHNICAL PARAMETERS OF WBS ACTIVE - PELL

13.1. General features- Electronic control unit controls the

combustion by modulating the fan speed. Optional control of circulation pumps for central heating and domestic hot water (DHW).

- Combustion chamber with large heat exchanging surface and low chamber resistance.

- Ribbed chamber surface and three-

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13.2. Technical parameters of WBS Active - Pell

WBS - A 20 - Pell 25


Nominal heat output kW 17 22Minimum ÷ maximum heat output kW 5÷20 6÷25

Mass flow of exhaust gases, min.÷ max. heat ouput kg/s 0,004÷0,012 0,005÷0,013

Dimensions of boiler WBS Active + burner Pell

Height H mm 1235 1235Width L mm 540 540Depth D mm 1250 1315

Water mantle volume l 60 75Combustion chamber volume l 58 62

Mantle resistance, Δt=20, K Pa/mbar 8/0,08 9/0,09Required chimney draught Pa/mbar 10/0,10 10/0,10

Insulation BoilerDoors

high-efficiency thermal woolhigh-efficiency thermal wool

Average power

consumtion

Boler WBS Active W 60 60

Burner PellFiring-Up mode W ~ 400 ~ 400Operate mode W ~ 60÷70 ~ 60÷70

Self-cleaning mode W ~ 1300 ~ 1300Electric power supply V/Hz 230/50 230/50

Recommended fuel Pellets, class ENplus-A1; ENplus-A2; EN-BOperating temperature range °C 65 - 80 65 - 80

Operating pressure bar 3 3Weight: boiler, burner / fuel hopper kg 264/71 309/71

Cold water inlet A, mm R1¼''/232 R1¼''/232Hot water outlet B, mm R1¼''/1265 R1¼''/1265

Safety line sleeve (sensor or safety valve sleeve) К, mm G½''/1075 G½''/1075Safety heat evacuator inlet / outlet Е, mm R½''/1072 R½''/1072

FlueF ø

mm150945

150945

J, mm 270 270Flue chimney opening O, mm 150/70 150/70

Drain Y, mm G½''/232 G½''/232Ash-and-soot tray X P P

39







WBS - A 110 - Pell 90

25 30 35 52 60 807÷27 9÷32 10÷40 15÷65 18÷65 24÷90

0,005÷0,014 0,011÷0,025 0,007÷0,021 0,012÷0,032 0,010÷0,031 0,015÷0,038

1235 1235 1235 1385 1385 1385600 700 700 700 760 820

1315 1315 1375 1495 1495 149582 96 106 134 145 16273 84 97 120 133 160

10/0,10 12/0,12 14/0,14 26/0,26 20/0,20 25/0,2511/0,11 12/0,12 14/0,14 26/0,26 30/0,30 36/0,36

high-efficiency thermal woolhigh-efficiency thermal wool

60 60 60 110 110 110~ 400 ~ 400 ~ 400 ~ 400 ~ 400 ~ 400

~ 60÷70 ~ 60÷70 ~ 60÷70 ~ 70÷110 ~ 70÷110 ~ 70÷110~ 1300 ~ 1300 ~ 1300 ~ 1300 ~ 1300 ~ 1300230/50 230/50 230/50 230/50 230/50 230/50

Pellets, class ENplus-A1; ENplus-A2; EN-B65 - 80 65 - 80 65 - 80 65-80 65 - 80 65 - 80

3 3 3 3 3 3331/71 384/71 414/71 496/71 538/71 560/71

R1¼''/232 R1¼''/232 R1¼''/232 R1½''/232 R1½''/232 R1½''/232R1¼''/1265 R1¼''/1265 R1¼''/1265 R1½''/1420 R1½''/1420 R1½''/1420G½''/1075 G½''/1075 G½''/1075 G½''/1225 G½''/1225 G½''/1225R½''/1072 R½''/1072 R½''/1072 R½''/1222 R½''/1222 R½''/1222

150945

180930

180930

2001065

2001065

2001065

300 350 350 350 380 410150/70 150/70 150/70 150/70 150/70 150/70

G½''/232 G½''/232 G½''/ 232 G1''/ 232 G1''/ 232 G1''/ 232P P P P P P

40


Diagram 15. Dimensions of WBS Active - Pell

D

41


13.3. Elements of burner Pell

Diagram 16. Elements of burner Pell№ Part number Pell 25 Pell 30 Pell 40 Pell 70 Pell 901 82801300000002 х1 89081300000016 х1 82801300000003 х1 82801300000005 х х2 82801300000010 х2 82081300000036 x2 82801300000011 х2 82801300000012 х х3 89801300000006 х3 89081300000020 х3 89801300000024 х х х4 89800000000005 х х4 89080000000008 х х х5 89801381000001 х х5 89801381000002 х х5 89081300000023 х6 78801100000001 х х х х х7 83801200000001 х х х х х8 32800032000001 х х х8 32800032000007 х х9 89080000000006 х х х х х

10 89801200000006 х х х х х11 89800000000004 х х х х х12 32590000000092 х х х х х13 89080000000007 х х х х13 89080000000016 х14 32640000000002 х14 32640000000003 х х14 32640032000017 х14 32640032000020 х15 32800000000006 x(C130) x(C130) x(C130) x(C130) x(C130)

42


13.4. Technical parameters of fuel hopper FH 500-V2FH 500-V2

Capacity l 500Max /Min wood pellets load, ø 6÷8 mm kg 280÷300 / 15

Height H mm 1260Width L / Depth D mm 772 / 730

Foundation B, mm 53Auger mounting opening C, ø mm 76

Auger holder E PPellet-load hatch F, mm 400 / 772

Hinges G PInclination of guide plates P 45°

Leveling feet Z PWeight kg 71

14. RECYCLING AND WASTE DISPOSAL

Submit all packaging material for recycling according to the local regulations and requirements. At the end of life cycle of each product its components are due to be disposed of in conformity with regulatory prescriptions.According to Directive 2002/96/EC regarding electrical and electronic equipment waste, disposal thereof is required separately from the normal flow of solid household waste. Obsolete equipment shall be collected separately from other recyclable waste containing materials with adverse effect on

health and environment. Expired appliances must be collected separately from other recyclable waste containing substances hazardous to health and environment. Both metal and non-metal parts are sold out to licensed organizations for recyclable metal or non-metal waste collection. In any case they should not be treated as household waste.

12 Madara Blvd.,9700 Shumen, Bulgariat: +359 54 874 555f: +359 54 874 556e-mail: [email protected]

13 Chelopeshko Shose Str,1839 Sofia, Bulgariat: +359 2 903 97 80f: +359 54 874 556e-mail: [email protected]

www.sunsystem.bg

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