Pelltech PK30 Installation And User Manual

PK160 Installation and user manual DK9803A7

Table of contents 1 General ......................................................................................................................................................... 3 Application ............................................................................................................................................ 3 2 Safety ............................................................................................................................................................ 3 Safety instructions for installation, use and service ................................................................................ 3 Warnings .............................................................................................................................................. 4 Safety devices ....................................................................................................................................... 4 3 Fuel ............................................................................................................................................................... 5 Pellet quality ......................................................................................................................................... 5 4 Technical data ............................................................................................................................................... 6 Measurements and main parts .............................................................................................................. 7 Control and monitoring devices ............................................................................................................. 9 Flue gas circulation in boiler .................................................................................................................10 Permitted usage ...................................................................................................................................10 5 Set of components .......................................................................................................................................11 6 Delivery ........................................................................................................................................................11 7 Boiler installation .........................................................................................................................................13 Boiler room requirements ....................................................................................................................13 Boiler room clearances .........................................................................................................................13 Combustion air .....................................................................................................................................15 Mains supply ........................................................................................................................................15 Heating systems water or liquid ...........................................................................................................16 Flue gas tube and chimney connection .................................................................................................16 8 Installation instructions ................................................................................................................................16 9 Installation of the PV-series burner ...............................................................................................................16 10 Initial start-up and operating instructions .................................................................................................16 Preconditions .......................................................................................................................................16 Filling the fuel container .......................................................................................................................17 Initial start up of boiler .........................................................................................................................17 11 Cleaning the boiler and burner .................................................................................................................17 12 Boiler’s everyday operation ......................................................................................................................18 13 Warranty and manufacturers liability .......................................................................................................18 14 Troubleshooting .......................................................................................................................................19 Annex 1 Connection diagram samples for connecting the boiler ............................................................................20 Annex 2 Wiring diagrams ......................................................................................................................................21 15 Installation protocol .................................................................................................................................25 Declaration of confirmity ......................................................................................................................................26 Energy label .........................................................................................................................................28

Manufacturer of pellet boilers PK: Pelltech OÜ Manufacturers address: Sära tee 3, Peetri, Rae vald, 75312 Harjumaa ESTONIA Name of product: Pellet boiler PK Ph.+3726775277 www.pelltech.eu [email protected] 1 General This manual is intended for all users and contains general information and handling with PK30, PK boiler. We recommend you pay great attention to the safety regulations. The owner / user shall read and understand this manual before installation and operation of the burner. Application Pellet boiler PK is a highly efficient 2-pass boiler for combustion of wood pellets. It can be used for heating a single or semi-detached houses or smaller public buildings. PK30 and PK50 boiler is specially designed to work with PV-series B-version burners. Such combination and integration ensures efficient, perfect and care free combustion of pellets and helps to save heating costs. The end-user is obliged to maintain the device according to the following manual in order to avoid any problems. The need for boiler’s maintenance depends on the quality of the fuel (pellets) and the output power (fuel consumption) and it varies throughout the year. 2 Safety Read and follow these directions carefully. Read the safety instructions carefully before installation. Always follow the safety instructions during installation and during maintenance. Follow the safety instructions on the warning and notice signs! Installation, operation, service, and other work must be carried out by qualified personnel in accordance with local codes and regulations. Always follow the instructions for operations and service. Safety instructions for installation, use and service The owner / user shall read and understand this manual before installation and operation of the burner. For proper function and to avoid accidents and damage, these instructions must be followed. Wrong handling and incorrect settings can result in injury and damage and / or malfunction of the equipment. • The room where the boiler is installed must fulfill all rules and recommendations in accordance with local codes and regulations. • All plumbing and chimney sweeping shall be done by certified and qualified personnel in accordance with local codes and regulations.

• Boiler and all accessories operate using 230VAC electrical current. Improper installation or repair can pose the danger of life-threatening electrical shock. • All electrical installation and service work shall be done by certified and qualified personnel in accordance with local rules and regulations. Do not perform electrical work unless you have the required qualifications. Perform a complete boiler shutdown and disconnect the power supply prior to performing any work on the device. Observe all guidelines with respect to installation, service, or cleaning. • Keep children away and do not touch the equipment during operation. • There is a risk of fire. Make sure that no flammable or liquid materials are stored in the boiler room or vicinity of the boiler. Do not use chemicals or fluids to start the burner fire. Do not burn garbage, gasoline, naphtha, engine oil, or other materials. • There is danger to life from flue gas poisoning. Make sure there is adequate combustion air under all circumstances in the boiler room. • It is recommended to wear a respirator while handling pellets. • Use only approved pellets as described in the section Error! Reference source not found.. Burning any other type of fuel voids the warranty. • Follow the manual carefully. Follow the recommended cleaning and maintenance. Proper installation of the boiler is necessary for safe and efficient operation. Contact your local building inspector to obtain any necessary permits or inspection guidelines before installing the product. Contact local building or fire officials about restrictions and installation inspection requirements in your area. Contact your local authority (such as municipal building department, fire department, fire prevention bureau, etc.) to determine the need for a permit. A working smoke detector is required and must be installed in the same room as the burner. This installation must conform to local codes and regulations. Warnings • Changing the construction of the boiler without written permission from the manufacturer is forbidden. • For personal and operational safety, use only spare parts provided or approved by Pelltech OÜ in order to avoid any damage to the burner and dangers resulting from it. Use of spare parts not provided or approved by Pelltech OÜ will void the warranty. • Manufacturer of burners has the right to make changes in construction of burner and its firmware. Safety devices The boiler is equipped with following safety devices: • Safety valve (overpressure relief valve): will apply when pressure in boiler exceeds 2,5 bar. There are several possibilities to mount the overpressure valve. Some examples are depicted in Annex 1. • Door switch: does not allow to start the burner when the door of boiler is open. When the boiler door is opened during work process the burner will automatically shut down and go to end burn state. By then closing the door burner continues normal burning. • Safety thermostat: interrupts boilers work when its temperature rises over 95oC. Safety thermostat has to be reset manually.

3 Fuel Only wood pellets only shall be used with PK-series boilers. Not only premium but also the industrial pellets can be used. Burning wood pellets according to recommendations and the specifications set forth will assure longer burner life and lessen potential maintenance issues. Pellets must be stored in a dry and ventilated room. PK boiler is foreseen to burn ENPlusA1, A2 ja EN-B wood pellets. Some key data for pellets is given in Table 1. Pellet quality Not all wood pellets make good fuel. It is always a good idea to review the pellet’s analysis and try some before committing to several tons. Higher pellet quality allows for more efficient operation. Many variables contribute to the quality of a wood pellet. Many of these have been identified and are regularly tested for by most pellet manufactures and distributors. Pellet material: Pellets should be made of softwood or hardwood or some combination of the two. Pellets should smell like wood. If not, then other materials may have been used in their manufacturing process. Examples are cardboard and paper that produce excessive ash and require chemical binders to hold the pellets together. All wood pellets (100% wood) don’t require binders and rely on the lignin in the wood to hold the pellets together. A few all wood pellets dropped in a glass of water should swell up quickly. If they don’t swell up, this may be an indication that the pellets are not entirely made of wood. The following table represents the pellet properies that are recommended by Pelltech. Raw material Sawdust, cutter shavings, stem wood, logging residues, bark, chemically untreated byproducts and residues Calorific value 4600-5200 kWh/tonne Bulk density > 600 kg/m3 Volume of 1 ton 1.5-1.6 m3 Diameter 6-8 mm Length 5 …40 mm Fines content (<3,2 mm) < 1 % Moisture content < 10 % Ash content < 2% Ash fusion temperature > 1100 OC Table 1 Wood pellets

4 Technical data Table 2 Technical data Model Unit PK30/31* PK50/51* PK100 PK160 Heat output range kW 11-24 18-42 26-90 40-140 Rated thermal load kW 30 50 100 160 Boiler class according to EN 303-5 - 5 Minimum return water temp. oC 55 Recommended heating water temp. oC 75 Permiss. working tempetature oC 90 Safety thermostat’s triggering temp. oC 95 Permiss. operating pressure bar 2,5 Test pressure bar 4 Dimensions WxLxH mm 600x600x1510 600x800x1510 785x995x1524 785x1175x1592 Combustion chamber’s dimensions WxLxH mm 330x400x700 330x600x700 430x840x710 430x969x710 In-take width (w.o side panels) mm 500 500 685 685 Boiler’s water volume l 125 150 275 300 Ash box volume l 38 54 97 115 Boiler’s weight kg 196 313 495 620 Mains supply 230V, 50Hz Electrical consumption at ignition W 400 300 Electrical consumption at stand by W 3 7 Electrical consumption average W 50 70 110 Electrical heating element* (option) kW 6 9 - Combustion air inlet hatch cm2 >200 >300 >600 >900 Number of turbulators pcs 4 7 14 22 Chimney’s diameter mm >100 >120 >150 >180 Flue gas outlet Ø mm 112 150 Burner’s fixing flange mm 90 130 Boiler top connections pcs 2xG1“ 2xG1,5“ 2xG2“ Distance between top connections mm 125 560 758 Boiler back connections pcs 2xRp1’’ 2xRp1,5’’ 2xRp2’’ Required safety valve connection pcs 1xDN20 1xDN25 1xDN32 Flue gas temp. at full load/min load oC 120 / 70 130/80 148/79 174/99 Flue gas mass flow at full load/min load g/sec 10 / 5 20/10 40/15 70/30 Efficiency at full load/min load % 93 / 93 92 / 92 92/94 90/92 CO (13% O2) mg/m3 95 / 59 232 / 148 157 / 119 185 / 49 Dust (13% O2) mg/m3 15 / 18 18 / 16 16,1 / 23,7 19,8 / 20,9

Measurements and main parts PK30 boiler’s main parts are similar to PK50. 1. Boiler main switch 12. Connection G1’’ outflow 2. Boiler thermostat 13. Connection G1’’ inflow 3. Temp. and pressure gauge 14. Pocket for thermostats Rp ½’’ 4. Safety thermostat 15. Heat exchangers tubes cleaning motor 5. Handle of furnace door 16. DIN rail for electrical connections 6. Furnace door 17. Heat exchangers tubes cleaning mechanism 7. Handle of ash box door 18. Connection Rp1’’ outflow 8. Ash box door 19. Flue gas outlet tube 9. Burner mount flange 20. Connection Rp1’’ inflow 10. Burners cable lead-out 21. Pocket for pressure cauge Rp¾’’ 11. Flue gas outlet tube Top view Front view Back view Side view Flange of flue gas outlet tube 21 PK50

PK100 boiler’s main parts are similar to PK160. PK100 PK160 Front view Side view Back view Top view Figure 1 Boilers’ main parts and measures

1. Boiler main switch 13. Flue gas fan 2. Safety thermostat 14. Connection fitting Rp1½’’ or Rp2’’ outflow 3. Safety thermostats signak lamp 15. Connection fittting for over pressure cauge G1’’ 4. Boiler thermostat 16. Connection fitting Rp1½’’ or Rp2’’ inflow 5. Temp. And pressure gauge 17. Flue gas fan 6. Boilers controller 18. Connection fitting G1½’’ or G2’’ outflow 7. Burner’s cable lead- out 19. DIN rail for electrical connections 8. Furnace door 20. Heat exchangers tubes cleaning motor 9. Handle of furnace door 21. Heat exchangers tubes cleaning mechanism 10. Handle of ash box door 22. Connection fitting G1½’’ or G2’’ inflow 11. Ash box door 23. Pocket for pressure cauge Rp¾’’ 12.Burners mounting flange 24. Pocket for thermostats Rp ½’’ Control and monitoring devices Boiler PK30, PK50 Boiler PK0031 and PK0051 Boiler PK30+, PK50+, PK100 and PK160 Boiler thermostat Main switch Temp. and pressure gauge ja rõhu mõõdik Safety thermostat Safety thermostat Main switch Boiler thermostat Temp. and pressure gauge El.heat element’s signal lamp El.heat element thermostat Main switch Safety thermostat Safety thermostat’s signal lamp Boiler thermostat Temp. and pressure gauge Boiler’s controller Figure 2 Control and monitoring devices

Main switch of boiler enables to turn boiler and burner on-off. Boiler thermostat controls burners work by switching it on-off according to pre-set temperature. Integrated temperature and pressure gauge shows actual temperature and pressure in boiler Safety thermostat switches boiler and burner off when bolilers temperature exceeds 95OC. You can reset it manually. Electrical heating element’s thermostat switches heating element on when boiler’s temperature drops down temperature set on heating element thermostat and off when temperature exceeds pre-set level. Orange signal lamp of electrical heating element is lit up when heating element is switched on. Red signal lamp is lit when safety thermostat is applied. Flue gas circulation in boiler Permitted usage Present device is a solid fuel boiler that produces low pressure warm water. Usage of boiler for other purposes is not allowed. 1. Flue gas fan 2. Heat exchanger’s tube 3. Stone wool 4. Connection 5. Ash box 6. Furnace 7. Water jacket 8. Connection 9. Connection 10. Connection PK0030/50 PK100/160 Figure 3 Flue gas circulation

5 Set of components The boiler is shipped with following components included: 1. Boiler PK 2. Safety valve (for PK30/31, PK50/51) 3. Screw fastened foot, 4 pcs 6 Delivery The boiler is delivered as a complete unit. Boiler is wrapped in card board sheets and packing-film and fixed with two metallic angle to wooden pallet. Angles must be removed before boiler’s installation. In order to remove the angles the side panels must be removed by lifting them up and pulling them to side. The boiler can be lifted and carried to the installation site by using a pallet truck. There is a welded hook on the top of boiler that enables to lift the boiler when needed. The taking-in weights and widths are given in Table 2.

PK30/PK50 PK100/PK160 Figure 4 Front, side and back views of boiler

7 Boiler installation Only persons holding necessary licences, knowledge, skills and equipment can be trusted with assembly of the boiler. Boiler room requirements Any room with normal air humidity and temperature is suitable for boiler’s installation. Room has to be provided with a chimney connection, sufficient draft and fresh air supply. It is not allowed to install boiler to room that is very dusty or humid. The boiler room should not be too small otherwise boiler’s heat radiation could overheat it. Boiler room has to satisfy all local statutory regulations and directives. Boiler, burner, external auger and pellet container form common system. The size and location of the pellet container depends on needs and construction of boiler room or boiler house. It is recommended to install the container to the left from boiler. In this case there is no need to remove augers hose while opening the boiler door. While choosing the pellet container keep in mind that: • if the pellet container is in the same room with the boiler then the size of the pellet container must not exceed 500 liters (appr. 350kg). • the container must be made of fireproof materials • the container must be positioned in a way that the raising angle of the feeding auger does not exceed 45°. Figure 5 Installation of pellet container, external auger and hose Boiler room clearances Position of the boiler has to be as close as possible to the chimney in order to avoid having a long flue connecting pipe. Boiler should be set on a non-flammable heat insulating pad or concrete floor. In order to enable safety installation and later maintenance, follow recommended clearance dimensions. Minimal clearance dimensions in centimeters are in brackets. See Figure 6. The boiler door opens to the left (PK30/50) or to both sides (РК100/160). In Figure 7, 8, 9 and 10 are depicted dimensions of burners farther edge in millimeters from boiler’s left side panel when boiler’s door is opened. 45o max 40-70 cm 10 .. 20 cm

120(100) 30 10(0) 10(5) 40(30) 10(0) 100(80) A C B A Container B Boiler C Burner Figure 6 Boiler room clearences Figure 7 Distance of PV20/30 burners Figure 8 Distances of PV50b burners

Combustion air An adequate supply of combustion air is nessecary for normal burning process. Air delivery shall take place through the non-closed hole. Mains supply The boiler is designed for supply voltage 230V/50Hz. TN-S earthing system is used. The boiler and burner are pre-wired in factory. Boiler has to be connected to mains supply with 3-core cable. It is recommended to protect burner and boiler against short circuit with 6A fuse or 6A C type MCB or RCD. It is recommended that boiler and boiler room lighting system have a different mains supply circuits. For elelctrical supply of electrical heating element, the heating elements have to be connected with 5- wire 5x2,5 mm2 cable. To protect heating elements 3x10A (boiler PK0031) or 3x16A (boiler PK0051) B- type MCB is used. Notice: Installation of electrical components may only be performed by a qualified technician. The regulations and specifications of local ordinances must be followed. In areas with increased power surge risk (e.g., lightning strikes in regions prone to storms) installation of an appropriate surge protector is reccommended. Electrial diagramms are depicted on Annex 2. Figure 9 Distance of PV100d burner Figure 10 Distance of PV180c burner

Heating systems water or liquid It is allowed to use in heating system: • ordinary drinking water (only minimal refilling!) • softened water • glycol dilution up to 50% Flue gas tube and chimney connection PK30 and PK50 boilers have 110 mm flue tube outlet for chimney connection. PK100 and PK160 have 150mm flue tube outlet. Flue tube is connected with boilers flue tube flange, which measures are depicted on Figure 3 . Connecting boiler with flue tube and connecting flue tube to chimney has to be made strictly according to local regulations. PK boilers have high efficiency, therefore outcoming flue gases have low temperature. If fluegas temperature in the top of chimney is below 80oC then pitch and water condensate will appear. With cold weathers they will damage chimney within few years. To protect chimney of the condensate a metal stainless tube has to be mounted into chimney. 8 Installation instructions To avoid scratching side panels it is recommended to remove side panels and upper thin of boiler before installation. In order to remove side panels lift them up and pull outwards. To boiler’s set belong 4 screw fastened feet that enable to adjust installation level. In order to mount the feet boiler has to slope slightly firstly to one side and screw feet to its nests. Then slope boiler slightly to other side and screw feet to its nest. By screwing feet up or down adjust suitable level of boiler. Boiler is lifted to planned place and connected to chimney and plumbing according to project by using specified materials. The volumes of PK boilers expansion tanks are given in Table 2. Some of boiler connections are depicted on Annex 1. After completing installation place side panels and upper panel back to place. 9 Installation of the PV-series burner Installation of the PV-series burners in particular is described in their user’s manuals. 10 Initial start-up and operating instructions Preconditions The following preconditions must be met before initial start-up: • boiler is installed correctly and connected to waterworks and heating system • central heating system is rinsed, filled and vented, heat consumption is provided • domestic hot water boiler is connected and filled • boiler is connected to chimney • no dampers in a fluegas duct • system is electrically wired up, burner and external auger sockets are connected firmly • sufficient quantity of pellets available in container

• external auger is connected to burner and auger is installed according to requirements • boiler’s doors and hatches are closed and all combustion air comes from the burner • boiler’s thermostat is set to lowest temperature • burner is installed correctly, the neck of burning chamber sits correctly in burner’s housing. • burners body and burning chamber are firmly fixed The initial start-up cannot be carried out if any of these points above is neglected. Filling the fuel container The fuel container must be filled before initial start up. Fuel can be added at any time during the operation. If the container runs empty, the burner stops working safely and turns itself off. In initial loading and in loadings after run out external auger must fill itself. It can take up to 20 minutes. Initial start up of boiler Before initial start up make sure that requirements by 13.1 are fulfilled. If so: • connect boiler to mains supply • turn boiler on from main switch • turn boilers thermostat to desired temperature. Usually it is +75oC If PV20b, PV30b, PV100b or PV180b burners are used, then • be sure that in main menu’s submenu PARAMETERS, PAR30 is set to “1” or “0” and PAR50 to “6”. Now motors of flue gas fan and self-cleaning mechanism are switched on. • turn burner on from BURNER menu by selecting ON or keep OK button down over 3 seconds. • burner displays WAITING, then TESTING and then LOADING. First loading may take about 20 minutes. • if there is enough pellets in the burner, the green LED will lit up • now follows IGNITING state where hot air coming from igniter ignites pellets in burning chamber • next state PRE-BURN assures existence of permanent flame, the yellow LED will lit on • BURNING is routine state of pellets combustion and heat production • if boiler has reached pre-set temperature the process will be completed by END-BURN and END- BLOW actions • after that burner goes back to WAITING state Read more about PV20b and PV30b burner’s actions from user manuals. All subsequent statuses are similar with above described ones. 11 Cleaning the boiler and burner Although the boiler has automatic self-cleaning system which is controlled by burner, maintenance and emptying the ash box need to be done manually. Boiler self-cleaning system rotates turbulators inside heat exchangers after time pre-set in PAR56 and PAR57 in order to remove ash from heat exchanger tubes. The ash is collected to ash box. It recommended to empty the ash box when it is filled up to 2/3. Depending on intensity of heating and quality of pellets the frequency of cleaning cycles may vary. It is recommended to clean boilers inner walls from deposited ash and non-burned residues at least once a month and every time after the end of heating season.

Before cleaning the boiler turn burner off from main menu. Let burner to finish burning procedure and wait at least one hour to cool boiler down before attempting any maintenance or cleaning works. Turn boilers main switch off. Only then you can open safely the boiler doors and start cleaning. Periodic cleaning helps to prolong life time of devices and improves burning quality significally. 12 Boiler’s everyday operation Boiler and burner work in fully automated mode and don’t need daily inspection. Boilers everyday work is controlled by boiler’s thermostat and burner’s controller. Thermostat switches burner on or off according pre- set temperature. Controller: • regulates fuel supply and quality of burning process • selects optimal power levels • cleans heat exchangers tubes • speed of flue gas fan according to underpressure sensor or pre-set power levels • ensures safety of whole system In danger situations or mains supply loss the burner will stop work of boiler and makes safety shut down. 13 Warranty and manufacturers liability The warranty protects user within 2 years from manufacturer’s defects under conditions that boiler is operated as assumed in present manual. Warranty starts from date in sales invoice unless not been agreed otherwise. Warranty is not valid when faults are caused by: • transportation and/or handling organized by user • incorrect installation by installer • misuse of device • unauthorized changes in construction of device • ignoring cleaning and maintenance instructions or leaving unattended • errors and interruptions caused by ambience

14 Troubleshooting Problem Reason and solution Boiler doesn’t switch on Boilers main switch is turned off • Turn boilers main switch on Boiler is overheated and safety thermostat has applied • Discover reason for overheating and eliminate it. Reset safety thermostat by removing its protective cover by turning it counter clockwise and pushing thermostates white button. Boilers thermostat is broken and doesn’t control burner • Check condition of thermostat. Replace thermostat when needed. Burners door is not closed and door switch is open. • Close the door properly. Boiler emits smoke or burns back Flue gas fan doesn’t work • Turn fan on by selecting PAR30 and „1“ (or „0“ when using underpressure sensor) Flue gas fan doesn’t rotate sufficiently • Add rotations PAR38>100%(PV20b/PV30b burners) Flue gas fan rotates hardly or makes uncommon voice • Replace fan Poor air supply of boiler room • Improve air supply. Make sure your boiler room has critical air supply by Table 2. Boiler’s ash box is full. Chimney or flue tube is full of soot • Empty ash box • Call qualified chimney cleaner Turbulators don’t rotate in self-cleaning process Turbulator turning motor is not turned on • Turn motor on by selecting PAR50 and „6“ Self-cleaning process of heat exchangers sounds quite noisy Usually it means no risk. In self-cleaning process metallic turbulators in heat-exchangers metal tubes are rotated slowly. Metal touches with metal and may make uncommon noise. This is not danger. • Lubrication of cleaning mechanism helps to reduce the noise

Annex 1 Connection diagram samples for connecting the boiler Figure 11 Heating systems with accumulator tank Attention! When using connection diagrams above assure that minimal temperature of boiler’s returning water would be 55oC. 3-way valve mixer with motor Heating circuit Check valve Expansion tank Pressure gauge Thermometer Safety valve Ball valve Circulation pump Thermostatic load valve 4-way valve mixer with motor Emptying tap Figure 12 Heating systems with 3-way valve mixer mxer Figure13 Heating systems with 4-way valve mixer

Annex 2 Wiring diagrams Boiler PK30 and PK50 Figure 14 Wiring diagram for PK30/50 boilers

Boiler PK31 and PK51 Figure 15 Wiring diagram for PK31/51 boilers

Figure 16 Wiring diagram for PK30/50 boilers controller

Figure 17 Wiring diagram for PK100 and PK160 with boiler’s controller

15 Installation protocol Burner serial number: Serial number, mark and modification Internet module: Cable or Wi-Fi, serial number Boiler mark: Fluegas fan: YES NO Producer, mark, serial number External auger: Mark, length power, rising angle Pellet silo: Mark, dimensions, distance from boiler Boiler room: Dimensions, material Chimney: Material, flue diameter, height, draught in Pa with cold chimney Air inlet hatch: Dimensions, location(outer wall, inner wall, door) Heating system Accumulation Tank: YES NO Radiator: YES NO Floor heating: YES NO Warm water: YES NO Remarks: Boiler installation specialities and remarks Client: Name/ Aaddress / Phone/ e-mail Installation date: Installer: Name / Company name / Phone/ e-mail/ Signature

Declaration of confirmity

Energy label